Monster Stack — The Right Cutter at the Right Location

The debris in wastewater varies. There are hard, abrasive materials such as rock and sand that are pushed along the bottom of the waste stream, and then there are materials that float in the waste stream, such as stringy wipes and food scraps. And above the wastewater, the air is often high in hydrogen sulfide, which creates a corrosive environment.

Choosing a single cutter type for a grinder often addresses one operational challenge while ignoring others. This leads to dissatisfaction with grinder performance and operational life when the grinder does not address all the needs of the installation.

The Monster Stack is JWC’s solution to this problem — a customized cutter stack with individual cutters to address the specific challenges of your installation. A Monster Stack will mix and match the right cutter at the right location to optimize grinder performance and unit longevity.

Individual vs. monolithic cutters

Individual cutters can be machined to very tight tolerances as the whole cutter surface is accessible for the machining processes necessary to achieve extremely flat cutter surfaces. These finishing techniques cannot be used on the cutter surfaces of a monolithic cutter stack.

So why is it important for the cutter surfaces to be very flat? It has to do with shearing action. Think about how scissors perform. When the scissor pivot screw is tight — such that the blades have minimal distance between them — the shearing action between the blades results in a clean cut. But when the pivot screw is loose, increasing the distance between the blades, the scissors can no longer effectively shear, resulting in poor cutting. The blades need to pass close to each other to shear effectively without touching each other as interference could cause damage.

The effectiveness of a grinder’s shearing capability follows the same principles. To achieve minimal spacing, cutters need to be manufactured to consistent and precise dimensions to realize the required spacing without making contact. Individual cutters can be manufactured to tight tolerances that are not possible with a monolithic design.

Crushing tough solids

Does your waste stream have a high level of rocks, grit and other heavy debris at the bottom of the waste stream? The Monster Stack solution is a seven-tooth cutter configuration to crush these tough solids.

Are the cutters at the top of your grinder exposed to a high level of hydrogen sulfide? The Monster Stack solution installs corrosion-resistant stainless steel cutters in the region from the expected water line to the top of the grinder. The stainless steel will not be as susceptible to corrosion as a typical alloy steel cutter.

Why not select an all stainless steel stack when operating in an acidic environment? With a Monster Stack, you have the ideal cutters to address the specific challenges above and below the waterline — stainless steel for the exposed cutters in an acidic environment above the waterline and alloy steel for the cutters grinding solids in the waste stream.

Monster Stack can solve your unique waste stream challenges. If you have a problem with wipes, the Wipes Ready cutter is specifically designed to shred wipes into pieces that will not reweave. For small particles, a thin high-tooth-count cutter can shred solids into small particles. For plants with a variety of solids, a general purpose cutter can serve well.

JWC Environmental is a world leader in solids reduction, removal systems and product destruction for municipal and industrial applications. JWC Muffin Monster sewage grinders protect vital sewage pumping stations and sludge system equipment, and JWC headworks screens protect essential treatment plant equipment from debris in wastewater. Plants globally turn to JWC systems like Auger Monsters and Screening Washer Monsters for unique all-in-one packaged solutions for solids separation and dewatering. Founded in 1973, the company has built and shipped more than 40,000 Monster grinders, shredders and screens to customers worldwide.



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