Cider production generates large amounts of natural byproducts that, while highly biodegradable, cannot be simply discarded into the environment, posing significant challenges. That’s where the XRipper grinder comes in—optimising sludge handling and ensuring smoother operations for further processing.
At C&C Group (Bulmers) in Clonmel, Co. Tipperary, Ireland's leading cider producer transforms locally sourced apples into the iconic beverage enjoyed worldwide. The cider-making process generates significant apple waste sludge, a byproduct that presents tough processing challenges, including clogged transfer pumps and costly downtime.
To solve this, Campion Pumps, with their extensive 30+ years of experience in the Irish pump industry, partnered with Vogelsang Ireland to deliver a reliable and efficient solution: the Vogelsang XRipper XRP136-200Q. Since its installation in May 2019, the system has optimised sludge handling, reduced maintenance, and ensured smoother operations.
Apple processing industries, like cider production, creates significant quantities of byproducts in the form of solid and liquid sludge. These residues, consisting of a mix of apple skin, pulp, and seeds, are natural remnants of the cider-making process.
However, due to their highly biodegradable nature, these byproducts cannot simply be discarded into the environment. Proper processing and management of this waste are essential to avoid environmental harm and ensure smooth production operations.
At this site, transferring sludge to a pump station had become an increasingly problematic task. The high solid content and viscous nature of the sludge frequently clogged the existing pump, leading to excessive wear, costly operational delays, and maintenance expenses. As Ireland’s trusted provider of water and wastewater pumping solutions, Campion Pumps quickly stepped in to assess the issue.
Drawing on their expertise and skilled engineers, they worked closely with Bulmers to identify the root of the problem and develop an effective solution. Partnering with Vogelsang, they delivered a robust, long-term fix tailored to meet the site’s specific challenges.
Their preferred solution was the two Vogelsang XRipper XRP136-200Q grinders, specifically designed for sludge applications. These grinders proved to be the perfect answer to the plant's needs, offering unmatched performance and reliability.
Campion Pumps understood the need for a grinder capable of handling heavy, debris-laden sludge reliably. Vogelsang recommended two robust XRipper grinders purpose-built for challenging sludge applications. Since its installation, the Vogelsang XRipper has proven itself as a future-proof addition to the overall operations mix.
"We partnered with Bulmers to identify the best solution that would ensure uninterrupted sludge flow while also enhancing their overall processing operations. The Vogelsang XRipper grinder quickly stood out as the ideal choice for its efficiency, durability, and ability to meet the plant's demanding requirements.”
Martin Campion, Managing Director at Campion Pumps
Designed to crush sludge into a manageable consistency, the XRipper ensures smooth operation of downstream pumps without the risk of clogging. The plant has not experienced a single instance of clogged pumps where the XRipper is installed— a testament to its exceptional efficiency and durability.
"The XRipper has drastically reduced our maintenance needs and operational headaches. It’s a reliable, robust piece of engineering that simply works,” commented a member of the Bulmers team.
The XRipper has delivered far-reaching improvements to the Bulmer’s facility, enhancing plant reliability and operational efficiency:
"The high-quality and tough—truly tough—components of the XRipper make it an incredibly robust unit. From the monolithic Ripper rotors, made from high-quality steel blocks, to the shafts and rotors designed to be structurally rigid and resistant to blockages, every part is built to last. The XRipper comes in a range of models to meet the unique needs of our customers and their specific applications.”
Dan Maunsell, Vogelsang Ireland Technical Consultant
What sets the XRipper apart? Its innovative design and robust construction make it a trusted choice for sludge handling. The unit is easy to install, service, and repair, giving teams confidence in its performance. Building on the success of this installation, Campion Pumps has since deployed additional XRippers across several projects.
The strong collaboration between Campion Pumps and Vogelsang Ireland has ensured seamless installation, reliable servicing, and access to genuine Vogelsang parts, which have been key to sustaining the XRipper’s performance.
Campion Pumps’ local expertise combined with Vogelsang’s advanced technology ensures that even the toughest challenges—like apple waste sludge—are overcome efficiently and cost-effectively.
Campion adds, “Vogelsang offers a great product backed by excellent support. Dan Maunsell, our representative, has played a pivotal role in strengthening the relationship between Campion Pumps and Vogelsang. We look forward to growing this partnership further.”
The XRipper has proven to be more than just a piece of equipment—it’s a critical component in maintaining smooth operations during the seasonal cider production periods. For this plant reliability is non-negotiable, and the XRipper delivers every time.
From its exceptional durability and ease of maintenance to its cost-saving benefits, the XRipper has exceeded expectations and reinforced Vogelsang’s reputation as a leader in innovative engineering.
All about our grinding technology
All about the XRipper