Twin-Shaft Channel Grinders & Sewage Macerators
The Ultimate Defense for Pump Stations: Inline Pump Protection & Solid Waste Reduction
Solving the "Flushable" Crisis in Wastewater Infrastructure
The Problem: The High Cost of “Ragging” Modern wastewater systems are heavily overwhelmed by fibrous materials, “flushable” wipes, and synthetic rags. These materials easily bypass standard pretreatment, intertwining inside submersible pumps to cause severe “ragging”. Furthermore, traditional bar screens leave behind foul-smelling “screenings” that must be manually hauled away. The result is high maintenance costs, frequent pump failures, and hazardous manual cleanouts.
The Loway Solution: In-Situ Solid Waste Reduction Instead of extracting and transporting this waste, the Loway Channel Grinder utilizes dual-shaft, low-speed, high-torque shearing technology. By shredding debris into uniform 8-10mm particles in-situ, we eliminate the need for waste disposal and protect your pumps from the source. These particles safely pass through downstream pumps, valves, and heat exchangers without causing blockages.
Working Principle: Total Capture & Precision Shearing
Unlike standalone grinders, Loway’s integrated system uses a multi-stage process installed directly into the wastewater flow path to ensure zero bypass.
Mandatory Interception:
Wastewater enters the vertical rotating drum. The fine mesh ensures that 99%+ of solids are captured—no bypass, no escape.
Guided Shredding:
Two counter-rotating shafts equipped with interleaved, hardened steel cutters grab and pull the captured debris inward.
Differential Shearing:
Operating at different speeds, the alloy steel cutters create a severe tearing and slicing action, effortlessly reducing textiles, wood, and plastics to uniform 8-10mm particles.
Safe Flow:
The shredded effluent flows harmlessly downstream, maintaining your system's hydraulic efficiency and keeping biological processes undisturbed.
Built to Outlast: Engineered for Zero Downtime
We don’t just build equipment; we engineer long-term reliability for headworks pretreatment and pump station protection.
Hexagonal Shaft Design:
We utilize high-tensile strength hexagonal shafts rather than traditional keyed round shafts. This provides superior torque transmission and completely eliminates the risk of keyway shearing under heavy loads.
Heat-Treated Alloy Cutters:
Crafted from high-grade alloy steel, our blades are heat-treated to a surface hardness exceeding 50 HRC. This allows them to handle soft textiles and hard wood alike, offering a service life 2x longer than standard cutters.
Intelligent Auto-Reverse (Anti-Jam):
The advanced PLC system features a high-sensitivity torque monitor. If a non-grindable object (e.g., a solid metal bar) enters the cutters, the system triggers an auto-reverse sequence to clear the jam, protecting the motor and gearbox.
IP68 Submersible Drive:
Equipped with an IP68-rated amphibious motor, the unit ensures continuous operation whether fully submerged in a flooded wet well or exposed in a dry pit. Triple-level protection (overload, moisture, and seepage) guarantees the motor is never compromised.
Technical Specifications & Sizing
Comparison | No-Drum (Basic) | Single-Drum (Standard) | Double-Drum (High Flow) |
Capture Rate | Low (Bypass risk) | ≥ 99% (Full-stream) | ~ 100% (Dual protection) |
Particle Size | Variable | Uniform 8-10mm | Uniform 8-10mm |
Flow Rate | 500 – 20,000 m³/h | 100 – 3,000 m³/h | 2,000 – 50,000 m³/h |
Ideal For | Large storm flows | Prefabricated pump stations | Critical municipal WWTPs |
Custom dimensions, motor sizing, and cutter profiles are available upon request to match your specific application.
Modular Integration & Drop-In Replacements
Upgrading an existing facility shouldn’t require major civil works. Loway Equipment specializes in manufacturing custom adapter frames and guide rails, allowing our grinders to serve as exact drop-in replacements for older, failing grinders from other brands.
Whether your site requires open channel, pipeline (flanged), or wall-mounted installation, we provide a customizable mounting system to fit your specific civil works. Every unit passes a rigorous 72-hour factory run test before shipment and arrives in thickened, fumigated wooden crates worldwide.
Industrial Applications
Municipal Infrastructure:
Protect raw sewage pumps in remote underground wet wells where manual screening removal is impractical. Ideal for WWTP inlets and stormwater overflow.
Heavy-Duty Industries:
Food processing, paper mills, and slaughterhouses to reduce fiber and organic waste.
Institutional Facilities:
Prevent deliberate blockages in prisons, hospitals, and nursing homes where clothing, bedding, and medical waste are frequently flushed.
Sludge Processing Lines:
Precondition sludge prior to centrifuges, belt presses, or digesters to prevent mechanical damage and improve dewatering efficiency.
Septage Receiving:
Shred compacted solids from vacuum trucks before they enter the main treatment plant.
Technical FAQ: Twin-Shaft Channel Grinders
Have More Questions? Our technical team is ready to provide detailed, personalized guidance.
Q1: When should I specify a Channel Grinder instead of a traditional Bar Screen?
Traditional bar screens physically remove solids, which is ideal when you need to reduce the organic load and have the facility to wash, compact, and haul away the screenings. Channel Grinders are the perfect solution for remote, unmanned, or space-constrained lift stations where handling and disposing of solid waste is logistically difficult, unsafe, or cost-prohibitive.
Q2: What happens if a heavy metal object or large stone enters the cutting chamber?
Our intelligent PLC control panel continuously monitors motor amperage and torque. If an ungrindable object causes a sudden spike, the controller instantly triggers an auto-reverse sequence to clear the jam. If the obstruction remains after programmed attempts, the system safely shuts down and sends an alarm to your SCADA network, completely protecting the motor and gearbox from damage.
Q3: Will the shredded particles (8-12mm) negatively impact downstream biological treatment?
No. The uniform particles safely pass through standard centrifugal pumps, valves, and heat exchangers without “re-weaving” or causing secondary blockages. The grinding process only changes the physical size of the waste; it does not alter the wastewater’s chemical or biological properties.
Q4: What is the typical lifespan of the cutter blades, and how are they maintained?
Cutter lifespan depends heavily on the grit and sand content of your specific effluent, but they typically last 3 to 5 years in standard municipal sewage. When maintenance is required, our modular design allows for the replacement of individual cutter discs or complete pre-assembled cutter cartridges, significantly minimizing downtime.
Q5: Do you offer models for pressurized sludge pipelines?
Yes. Alongside our open-channel models, we manufacture In-line (Flanged) Grinders. These bolt directly into your existing pipe network to precondition sludge before it enters dewatering equipment, ensuring they operate at peak efficiency.
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