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‘Reuse, recycle, repeat’ advises leading plastic pallet supplier




Greater process efficiency through smart mesh design


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Issue 131



14 BULK MATERIALS HANDLING 19 SPECIAL FEATURE BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk advertising@bulksolidstoday.co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday





CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk SUBSCRIPTIONS Subscriptions are available via www.bulksolidstoday.co.uk/subscribe No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements. SOME MANUFACTURERS & SUPPLIERS HAVE MADE A CONTRIBUTION TOWARD THE COST OF REPRODUCING SOME PHOTOGRAPHS IN BST.

ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2019

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SEE THE TECHNOLOGY THAT IS RESHAPING WAREHOUSING AT IMHX 2019 Visitors to IMHX 2019 - the UK’s largest intralogistics and supply chain event - will be able to see the developments in automation and robotics technology that are reshaping the way orders are picked, packed and dispatched, says event director, Rob Fisher


he relentless rise of e-Commerce is forcing retailers and logistics operators to adapt the design of their facilities to keep pace with the demands of today’s technologyenabled consumer who is demanding ever-faster and more efficient delivery of goods. As a result, traditional storage warehouses are being transformed into massive highvolume order-fulfilment centres with higher racking and narrower aisles to ensure that every square inch of the site is optimised. The technology deployed within these facilities is evolving too. Developments in intralogistics systems are advancing more rapidly than ever before as operators search for greater reliability and higher efficiency. Changes in the ways modern e-fulfiment warehouses operate are, not surprisingly, being driven by developments in automation and robotics.  For decades, automation has been used to complete various processes – including storage, inventory control, transport, picking, packing and loading – in more efficient and cost-effective ways: but, until recently, the robots used in warehouses have largely been employed to assemble pallet loads ready for dispatch. Now, however, robotics is closing in on the logistics ‘Holy Grail’ - order picking for e-commerce fulfilment. The growing role of artificial intelligence and technology within modern supply chain operations will be reflected at IMHX 2019: 4

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with over a third of exhibitors showcasing some form of automation, robotics, autonomous vehicles or new tech, visitors to the show will be able to discover exciting technology for themselves and get a greater understanding of how it can deliver operational benefits and competitive advantages. Dematic is among the leading suppliers of advanced automated materials handling solutions that will be exhibiting at IMHX 2019. The company offers an extensive range of ground-breaking warehouse technology as well as the all important software that manages and controls it. Dematic’s suite of high-intelligence iQ software, for example, ranges from a top-level Warehouse Management System, through Warehouse Execution and Control Software to a cloud-based Asset Performance Management platform which offers live-updates on KPIs across multiple distribution sites. Visitors to IMHX 2019 will also be able to see the latest innovations from Bito Storage Systems. Bito has recently introduced a driverless container transporter which helps to reduce travel times for returns and other tasks within e-Commerce warehouses. The transporter links workstations and handles transport from the returns department or processing point to other stations for repairs, disposal, packing or returning the item to the warehouse. Meanwhile, on KNAPP’s stand, visitors will be able to discuss technology such as the OSR Shuttle automated storage and retrieval system (ASRS) – technology which not only achieves up to six times the rate of totes in/out than a

traditional ASRS, but also requires about 20 per cent less footprint and consumes only some 5 per cent of the energy of other solutions. Swisslog will highlight a range of robot-based picking and palletising solutions. The company’s systems feature KUKA robots and are designed to reduce operational costs and improve warehouse efficiency. For example, the ItemPiQ robot-based automated solution allows item picking to be fulfilled rapidly and accurately. The robot cell – which is operational 24/7 and can pick and place products from a source into a target bin or carton – is designed to handle repeated piece picking, error-free. Picking and palletising are the most time consuming processes in the warehouse and make up around 60% of a warehouse’s operational costs. With workers to carry out these tasks becoming harder to find too, there is a growing realisation that automation and self-learning smart-data systems can meet today’s diverse and growing demands and, with some 400 leading companies exhibiting, IMHX 2019 represents an unmissable opportunity to see live and dynamic demonstrations of the latest technological developments that are shaping the modern logistics industry. In addition, across the four days of the show, visitors will have the opportunity to access a high quality programme of educational seminars and conferences featuring leading speakers from the supply chain world, completely free of charge. To register for your free IMHX 2019 visitor pass, go to https://www.imhx.net/ en/visiting/register.html




t its recently held Annual Conference UKWA (the United Kingdom Warehousing Association) announced that it will mark its 75th anniversary – which it is celebrating throughout 2019 – by raising £75,000 for industry charity Transaid. Transaid’s work includes the MAMaZ Against Malaria (MAM) programme which works to tackle severe malaria in Zambia by improving drug supply chains and access to health facilities. UKWA CEO, Peter Ward, commented: “The money raised by UKWA will help reduce depressing mortality rates from malaria by funding development of the country’s supply chain and logistics infrastructure to reach remote Size Reduction (2016) Ad (134x178)_Layout 1

communities and deliver effective treatment and vital medicines. “UKWA adopted Transaid as its official charity in 2013 and since then our members have raised significant funds in support of various key Transaid projects. Transaid is the logistics industry’s charity, so our two organisations are a perfect fit.” With match funding coming from a consortium of donors including major contributions from the Canadian Government, Medicines for Malaria Venture (MMV) and the Bill & Melinda Gates foundation funds raised by Transaid’s MAM campaign during 2019, if UKWA is successful in reaching it £75,000 target the donation will, in fact, be worth £150,000 to the charity. UKWA was launched in 1944 when representatives from 27/09/2016 11:53 Page 1

warehousing companies formed a committee to discuss the storage and distribution of food and materials in wartime Britain. Today the organisation is the leading trade body dedicated to serving the needs of the UK’s logistics industry and has over 700 members who, between them, control nearly 100 million square feet of warehousing space from nearly 1300 locations across the UK. Transaid, which was founded by its Patron, HRH The Princess Royal, along with Save the Children and the Chartered Institute of Logistics and Transport, transforms lives through safe, available and sustainable transport solutions across subSaharan Africa. www.ukwa.org.uk

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GKD: GREATER PROCESS EFFICIENCY THROUGH SMART MESH DESIGN Specialized consulting leads to tailor-made products


ith a focus on groundbreaking, intelligent mesh designs made frommetal and all other industrially weavable materials, GKD – Gebr. Kufferath AG (GKD) is presenting itself at the Techtextil fair in Frankfurt. As a leading global manufacturer of high-performance mesh that is developed on an application-specific basis for applications in industry and architecture, as well as process belts, GKD offers the entire added value chain - from mesh production, all the way up to ready-for-installation systems - from a single expert source. This integrated solution expertise for cost and usage-optimized developments makes the company an internationally sought-after contact when it comes to tackling exacting challenges. With smart mesh designs that combine material properties with one another at the physical level and thereby furnish the basic material with additional benefits, GKD is developing innovative solution options for users. At the leading international trade fair for technical textiles and nonwovens from May 14 to 17, the company will be demonstrating this integrative consulting and process expertise on its trade fair stand (Hall 3.1, Stand D79) based on examples that have been proven in practice and in discussion with customer-specific issues. Ever shorter technology and demand cycles, coupled with the strictest requirements in terms of efficiency, hygiene, and product safety, require innovative solutions. Whether increased end customer expectations, demand for greater productivity, or stricter legal 6

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stipulations: its unparalleled portfolio of materials used, material combinations, and weaving technology make GKD a soughtafter solution partner. The company has a large number of engineers with many years of experience and profound knowledge of a very wide range of customer processes and systems. GKD is therefore able to combine its capabilities to create tailor-made products through a correspondingly specialized consulting approach. The basis for this is the diverse portfolio of weavable materials made from metal, special alloys, polymer, and other non-metals such as ceramic or glass as wire, cable, or fiber. Through applicationspecific material combinations, weave types, web technologies, and refinements, GKD transforms mesh into a smart product, whose range of potential applications far exceeds conventional alternatives. HIGH-PERFORMANCE MESH MADE OF GLASS AND METAL The company’s highly developed weaving equipment plays a key part in this. The heavy looms that were

developed in-house can weave all materials either individually or as combinations and in all directions – i.e. both warp and weft. GKD processes up to ten material components – both monofilament and multifilament, as well as fibers – to create innovative mesh designs. Glass hybrid belts, which combine a monofilament metal shell with multifilament fibers in the warp, or forming belts with metal fibers in the warp and monofilament polymer in the weft are good examples of this weaving expertise. The weaving experts process monofilaments made of polymer and metal as weft wires from 13 micrometers to five millimeters - a thickness spectrum that is unsurpassed in the market. This intelligent weaving technique also

COMPANY NEWS facilitates partial and selective integration of materials chosen for the specific application – no matter whether thick, thin, monofilament, multifilament, or even various materials. This for example allows mesh designs with electrodes, heating wires, memory-effect alloys, or even placeholders interwoven in certain sections, as is the case with the Mediamesh architecture system. GKD combines these opportunities with the optimum application-specific weave type – single-layer or multilayer. With targeted control of the various material parameters, such as stretching, tensile strength, or Rp0.2 (yield strength), the high-tech looms create the highperformance meshes with secured reproducibility. TRUE GREATNESS THROUGH INTERACTION Examining the heavy process belts, the interaction of webs measuring up to eight meters wide and 170 meters long, as well as the range of refinement options – coating, heat setting or drawing – also serves to underline the exceptionally high manufacturing expertise of GKD. In the field of process and architectural belts, this spectrum is also supplemented by complete inhouse manufacture of spiral belts. Depending on the process, GKD produces these from flat or round wires and furnishes them with process-related properties. For example, metal spirals with innovative polymer filling allow usage-optimized air permeability rates to be established. The pronounced innovation expertise of the mid-sized enterprise, which is now in its third generation of owner management, can also be seen in the development of a mini spiral made of metal, which is significantly smaller than all others in the market. Owing to the wide range of weave types, material combinations, and production technology used, GKD is able to tap into often unimagined opportunities for users and equipment manufacturers. Perfectly matched and coordinated physical properties, for example, improve abrasion resistance, electrical or heat conductivity, (high) temperature resistance, tensile strength, transverse stability, cleaning, tracking stability, as well as non-stick or traction effects. Thanks to their recyclability and durability, as well as their cleaning resistance, metal meshes also comply with ever stricter sustainability requirements. This integrated expertise makes the company a sought-after partner to equipment manufacturers and research projects for groundbreaking product developments. At the Techtextil event, GKD will be 4 showcasing the potential of smart, woven structures on the basis of solutions proven in realworld applications. In conversation with the visitors, the experts will also be answering concrete questions on moving the boundaries in terms of performance limitations or substituting materials/processes. You can find GKD – Gebr. Kufferath AG at Techtextil, Messe Frankfurt, May 14 – 17, 2019, Hall 3.1, D79 www.gkd.de



icromeritics Instrument Corporation has announced the appointment of ATS Scientific Inc. as Canadian distributor and service provider for Micromeritics’ full product line with the exception of its line of particle size measurement products. ATS’ products are used in the following industries: Powders, Materials Science and Engineering, Environmental Science, Food and Feed, Mining and Earth Sciences, Pharma/Nutraceuticals, Petroleum and Energy, and Cannabis Testing. Micromeritics Instrument Corporation is a global provider of solutions for material characterization with best-in-class instrumentation and application expertise in five core areas: density; surface area and porosity; particle size and shape; powder characterization; and catalyst characterization and process development.  “ATS Scientific shares the same core values as Micromeritics and meets the exacting standards of every company we partner with,” said Micromeritics Preston Hendrix, President of Micromeritics. For additional information go to www.micromeritics.com

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HUNTSMAN TECNOELASTOMERI LAUNCHES NEW ENGINEERING URETHANE ELASTOMERS FOR EXTREME WORKING CONDITIONS Huntsman Tecnoelastomeri announced the availability of a new range of customizable, high performance, MDI-based hot cast elastomers. The TECNOTHANE® VTER family of engineering elastomers is an innovative portfolio of exceptionally resilient polyurethane materials for the manufacture of wheels, castors and industrial parts, which need to be equipped to perform in extreme working conditions.


asy to process compared to NDI-based technologies, Huntsman Tecnoelastomeri’s TECNOTHANE® VTER range includes six elastomer solutions with customizable features, which can be adapted to match customer-specific requirements. As standard, products in the new range of engineering elastomers offer outstanding tear and cut resistance plus high rebound and very low hysteresis properties. Wheels made with TECNOTHANE® VTER elastomers are less inclined to generate heat and because of the material’s very low hysteresis require less energy to operate. This makes them ideal for high speed, high frequency applications and heavy-duty, high load tasks where friction can be a problem. Castors, wheels and parts based on TECNOTHANE® VTER elastomers will also perform well in cold storage warehouses where the temperature is frequently sub-zero - giving supply chain managers the confidence that moving components of stock transfer, stacking and picking equipment will stay reliable, even in very cold environments. The six products available in the TECNOTHANE® VTER range are: • TECNOTHANE® VTER N: Designed to satisfy various end-use applications, this multi-purpose product


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is based on a threecomponent system and has hardness properties that can be adjusted according to the mix ratio. • TECNOTHANE® VTER V: This elastomer is ideal for the production of bumpers and can be used in other applications where high frequency stress is the norm. It can also perform exceptionally well at low temperatures - remaining elastic down to -40°C. • TECNOTHANE® VTER R: This three-component system is well suited to the production of large wheels. Easy to process and handle after curing, this elastomer offers outstanding physical and mechanical properties including excellent tear resistance and rebound. • TECNOTHANE® VTER E: Developed with the production of high performance wheels in mind, this three-component elastomer offers very low hysteresis and outstanding tear resistance and rebound properties. • TECNOTHANE® VTER H: This two-component system is a high hardness material that copes very well in high load situations

and is recommended for the development of wheels used on automatic guided vehicles and in automated warehousing applications. • TECNOTHANE® VTER M: Capable of withstanding high load and high-speed operating conditions this easy to process, high performance elastomer performs best in very heavy load wheel applications e.g., on monorails.  Simone Breviglieri, TechnoCommercial Manager, at Huntsman Tecnoelastomeri, said: “When we developed our TECNOTHANE® VTER family of elastomers we had a very clear vision in mind. We knew the market was looking for an alternative to NDI-based hot cast elastomer systems that could offer comparable performance properties. Combining the best of our MDI chemistry with our hot cast elastomers expertise, we’ve created a range of products, which are available globally, and are designed to withstand extreme working conditions across a range of markets and applications.” For more information about Huntsman Tecnoelastomeri and its work on the development of high performance hot cast elastomers, please contact: info@tecnoelastomeri.com www.tecnoelastomeri.com




omau, a global leader in advanced industrial automation, is taking a quantum step forward in digital-enabled solutions for lightweight vehicle manufacturing with its new robotic roller hemming process. Fast, flexible and extremely precise, Smart Hemmer is a highly compact, symmetrical roller hemmer able to hem any complex joint. It is the perfect solution for the new generation of electric, hybrid and traditional lightweight vehicles as it is designed to allow automakers to join dissimilar materials using a cold process that grants complete control throughout the process. Smart Hemmer addresses the dual market requirements of increased efficiency and accuracy. Its innovative design features two flexible rollers in which the linear roller can automatically disengage when encountering obstacles or a curved path and avoids the costly and inflexible fixed anvil, apparent in all traditional roller hemming processes. As a result, Smart Hemmer can perform curved path hemming and manage complex angles as part of a single, continuous process. Smart Hemmer is also able to maintain a constant hemming thickness even when encountering multiple layers of dissimilar materials The result is an Industry 4.0-compliant hemming head, jointly developed by Comau and a world-class automotive manufacturer, offering high reliability, inherent flexibility and complete process control while ensuring the geometric uniformity of the assembled parts. “Comau’s newest hemming solution features a revolutionary design that renders it extremely fast and efficient for lightweight and e-vehicle manufacturing, while eliminating the costly attributes of the product as well as the associated production process,” explains Giovanni Di Stefano, Head of Process Technologies, “The Industry 4.0 compliant solution lets automakers to innovatively join components together with full in-process monitoring of the joint.” Field-tested and validated by major European automakers, Smart Hemmer is a standardized product that can be applied to all vehicle architectures and compliments the complete array of similar technologies developed by Comau in the cold joining environment. It is available immediately at a global level. ABOUT COMAU: Comau, a member of the FCA Group, is a worldwide leader in delivering advanced industrial automation products and systems. Combining innovative engineering

solutions with enabling technologies, Comau helps companies leverage the full potential of digital manufacturing. In addition to a vast range of modular, flexible and highly-configurable products, Comau offers interconnected digital service solutions able to transmit, elaborate and analyze important machine and process data, thereby increasing efficiency for smart manufacturing. The full portfolio includes: joining, assembly and machining solutions for traditional and electric vehicles, robotized manufacturing systems, a complete family of robots with extensive range and payload configurations, autonomous logistics, and asset optimization services with real-time monitoring and control capabilities. The offering also extends to project management and consultancy, IoT services, and maintenance and training for a wide range of industrial segments. www.comau.com

Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof

Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: sales@tuflok.co.uk • www.tuflok.com

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riez Magnetics Europe recently sold a Metalarm Metal Detector to MMD (Mining Machinery Developments). The Metalarm Metal Detector was then donated to The HALO Trust (Hazardous Area Life-support Organisation) to speed up anti-personnel landmine clearance in Zimbabwe and to help support the global Landmine Free 2025 campaign. MMD designed a mobile Demining Sizer rig to donate to The HALO Trust to help reach this commitment. Eriez Europe was tasked with designing a metal detector for the mobile rig to detect larger mines prior to them entering the crusher chamber. Working with MMD’s design team, Eriez provided a special metal detector allowing smaller contaminates to be ignored while still detecting larger pieces – this prevents unnecessary belt stoppages but still stops any larger pieces damaging downstream machinery. Eriez advised on the installation requirements for the metal detector ensuring a successful installation and commissioning at MMD’s site in Derbyshire. The HALO Trust ran a number of successful tests with dummy anti-personnel landmines. Both Eriez Europe and MMD are world leaders in the manufacturing industry. Eriez Europe is recognised for their extensive knowledge and experience in separation technologies and last year, celebrated 50 years of manufacturing excellence in Europe. MMD celebrated a landmark year in 2018, celebrating 40 years in business in the design, manufacture and supply of mineral processing solutions and associated machinery serving the mining, quarrying and recycling industries. The HALO Trust is a humanitarian mine clearance organisation registered as a charity in both the UK and US. Its mission is to protect lives and restore livelihoods for those affected by conflict by removing landmines and other debris of war. HALO employs over 9,000 deminers worldwide, including 350 national staff in Zimbabwe, one of the most highly mine-impacted countries in the world. Highly dense belts of landmines (reportedly 5,500 mines per km) were laid along the borders with Zambia and Mozambique 10

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during the Liberation War of the 1970s and HALO has been demining there since 2013, with a clearance rate of approximately 500 mines per month. The metal detectors on the rig will make a significant difference to HALO’s clearance rate. The MMD Demining Sizer rig was officially handed over to The HALO Trust at Hillhead 2018 and is currently in transit to Zimbabwe, where local management have said it will ‘make a real difference to tens of thousands of people’s lives.’ Paul Hale, Metal Detection Sales Manager, at Eriez Europe comments, “Eriez is very proud to work with MMD on this project and to support the incredible work of The HALO Trust. It is fantastic to know that our Metalarm Metal Detector will help towards eliminating mines in Zimbabwe and make a difference to so many people’s lives.” For more information on Eriez Metal Detectors or product range, contact Tel: +44 (0)2920 868 501 or email: info-europe@eriez.com ABOUT ERIEZ EUROPE: Eriez Magnetics is recognized as world authority in separation technologies. The company’s magnetic lift and separation, metal detection, materials feeding, screening, conveying and controlling equipment have application in the process, metalworking, packaging, plastics, rubber, recycling, mining, aggregate and textile industries. Eriez manufactures and markets these products through 12 international facilities located on six continents. Eriez Europe Ltd. has its head office in Caerphilly, South Wales, UK. For more information visit www.en-gb.eriez.com




CB’s new JCB 30-19E is the first electric powered model in Teletruk range – and its launch opens up new opportunities for a machine which has revolutionised operations in builders merchants, ports, recycling centres and industrial facilities around the world. Until now JCB’s Teletruks have been powered by diesel and LPG and used predominantly in outdoor applications. With the launch of the new electric model, the Teletruk now becomes suited for a wealth of tasks inside buildings as well as outside – offering a new generation of customers the cost and space saving advantages enjoyed by users over the past two decades. Because it is battery-powered, the JCB 30-19E is supremely quiet and produces zero emissions – making it suited to tasks inside a building, while its fully sealed, weather-proof body protects the machine’s driveline and other key components from the elements when the Teletruk is required to work in the yard. Power is provided by an 80-volt lead acid battery which can work a full eight hour shift on a single charge. The battery compartment is positioned at the rear of the truck and has been designed to allow quick and easy battery changeover. Using a single point hoist or another lift truck, the battery can be swapped in around 2 minutes – ensuring truck uptime is maximised. Thanks to its electric driveline, the new JCB Teletruk can climb a 21% gradient or ramp with ease and productivity is further enhanced with full free lift of 1575 mm as standard. Like all Teletruk models, the JCB 3019E features a side-mounted boom and using the unique telescopic forward reach, it has a lift capacity of 1900 kg at 2 metres, meaning palletised loads weighing can be loaded to the far side of a curtainsided trailer. In addition, the forward reach functionality eliminates the risk of material and vehicle damage - as well as the potential for injury to personnel - when loading or unloading pallets to and from light goods vehicles, especially vans. The Teletruk can place a 1600kg load 3 metres into a van – allowing full utilisation of extended wheel-base vehicles. For ultimate efficiency, the Teletruk can load three Euro pallets into a van easily and safely within two minutes. Safety also comes as standard as all machines are fitted with Load Motion Control. This patented JCB innovation alerts the operator when reaching full lift or reach capacity with a simple green, amber, red light system and will not allow a load to be used outside of the load capabilities of the machine, aiding the prevention of forward tip. The JCB 30-19E features the JCB ‘Command Plus’

cab, which has been designed to ensure that the operator remains comfortable and, therefore, productive, throughout the course of his or her working day. The cab is just 2.2 metres high, allowing the 30-19E to operate within the height constraints of shipping containers. It is spacious and clutter-free with all hydraulic functions, as well as direction and speed of travel, controlled via a single joystick, which offers easier and safer operation. Additionally, important truck performance information such as battery life, speed and Load Motion Control is relayed to the operator via an easy-to-read electronic display positioned at eye level. The JCB 30-19E Teletruk’s ability to operate both inside and outside a building brings a number of benefits to the user. For example, working inside a building, the JCB 30-19E can enter a container that has been reversed in to a sealed loading dock and use its telescopic boom to safely stuff and de-stuff loads far more time – and space – efficiently than is possible with a conventional counterbalanced forklift or stacker. This increases utilisation of vehicles, aisle trucks and goods in/out infrastructure. www.jcb.com

Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. • • • • • •

Less friction Low torque Low maintenance Lower actuator costs Longer valve life More reliable Tel: +44 (0) 1908 622366


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yster Europe has announced that its forthcoming Stage V compliant Big Truck range for European customers will be powered by Mercedes-Benz/ MTU engines. “Our heavy industry and port customers in Europe who will require a Stage V driveline, can continue to expect highly efficient trucks with low fuel and DEF consumption, benefiting from high productivity levels and fast operations with the power available.” says Jan Willem van den Brand, Director Big Truck Product Strategy & Solutions at Hyster Europe. Hyster® lift trucks over 8 tonnes, Container Handlers and Reachstackers will be equipped with the Stage V-compliant Mercedes-Benz/ MTU Series 1000 and 1100 engines. The exact availability varies per series and will be communicated in due course. The engines have been specially designed for industrial applications such as material handling and further developed to meet EU Stage V regulations. They are based on commercial vehicle engines from Daimler. Lars Kräft, Vice President Industrial Business at MTU, said: “We are very pleased, that Hyster, one of the leading global brands of materials handling equipment, decided to power its new vehicles with our engines.” The Mercedes-Benz/ MTU engines will support the well-known durability of Hyster® Big Trucks. They are proven to deliver reduced Total Cost of Ownership (TCO), great reliability and outstanding performance in tough, heavy-duty applications. 12

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“Mercedes-Benz/ MTU engines have a highly successful track record in both on-road and offroad applications such as forestry or agriculture. They are also particularly suited to intermittent applications like our business serves,” says van den Brand, explaining that the power ratings range from 129kW to 280kW depending on model. “With the optimal match of engine sizes to the trucks and applications, customers can handle the heaviest of loads all day long, with quick turnaround times,” he says. “Customers can expect to boost productivity with more power available for faster operations whether it is handling containers in the Swedish winter or steel pipes in the hot Italian summer.” Produced at the Mercedes-Benz plant in Mannheim, Germany, the engines are known for their robustness and durability up to very high running hours. The engines have been optimised to work well in intermittent duty applications, resulting in lower engine temperatures, less component wear and reduced noise levels. Sufficient power reserves also result in less stress and parts wear. With long service intervals of 1000hrs, good access to main service parts and outstanding durability, the Mercedes-Benz/ MTU engines are expected to help reduce service costs. Hyster Europe will work in close cooperation with MTU to ensure its dealer network will be fully trained and equipped for service support, meaning that end users will receive optimum support throughout their entire product life-cycle. For more information, www.hyster.eu.


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erex Trucks’ 28-tonne upgraded TA300 articulated hauler is making its first international trade show appearance and taking pride of place on the company’s stand at bauma Munich 2019. The recently updated Terex Trucks TA300 articulated hauler is making its first international trade show appearance on the company’s outdoor stand: FN 720/9 at bauma in Germany. Representatives from Terex Trucks are at the event, which runs from April 8th to 14th, showing visitors how the company’s two articulated haulers – the TA300 and TA400 – deliver low total cost of ownership and high productivity on jobs including large-scale construction projects, infrastructure developments, quarries and mines. “Bauma is the biggest trade fair for our industry,” says Paul Douglas, Managing Director of Terex Trucks. “It attracts all kinds of equipment from around the world, but for us, it’s all about robust articulated haulers – that’s the only product Terex Trucks manufactures. This gives us the luxury of being able to focus all our attention on this machine. We are the experts in all-things articulated hauler, and have been for many decades.” “Terex Trucks has been investing in and making improvements to both the TA300 and TA400 articulated haulers,” continues Paul. “Both of these machines are robust, reliable and productive. Our articulated haulers have never been better and Terex Trucks has never been stronger.” Since August, the TA300 has incorporated the new EP320 transmission, which comes with two additional forward gears – eight in total – as well as four reverse gears. This helps to ensure smoother gear shifting and thereby superior operator comfort. In addition to this, the TA300 now delivers a 5% improvement in fuel efficiency, as well as enhanced performance, productivity and operator comfort. It also now comes with long life transmission fluid, which has helped to increase the length of time between oil maintenance intervals from 1,000 to 4,000 hours. The hauler’s maximum speed has also increased to 55 km/h (34 mph), up from 50 km/h (31 mph). Ultimately, this means that customers can achieve faster cycle times, reduce the cost of operation per tonne and minimize their fuel consumption. www.terextrucks.com

Non-contact, 80 GHz radar level sensors mean simpler installation and set up, handles dust, no loss of echo, works over any range up to 120m. In a word: reliability. Don’t take our word for it, trial one yourself. For an application demo: info.uk@vega.com More information: www.vega.com/radar

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he rapid development of sensor technology provides cement producers with a toolbox of solutions that optimise performance potential and strengthen market presence. Non-contact volume flow measurement of conveyed materials can help to optimise the material handling process from quarry to final product. Bulkscan® flow measurement technology, introduced by SICK Automation several years ago, had its portfolio broadened in latter 2018 with the introduction of its Bulkscan low cost LMS111. Both versions provide non-contact maintenance-free measurement of volume flow more accurately than mechanical belt scales. They also minimise errors in mass and volume flow rate calculations. BACKGROUND Felix Bartknecht and Michele Savino of SICK AG, Germany, explain that the movement and material handling of bulk materials like raw materials from quarries, additives, fuels, or clinker and packaged cement, are tasks mainly carried out by conveyors. “In many established cement plants this movement is unsupervised due to physical limitations as well as a lack of labour resources to watch, monitor and adjust material flow.” They add that the need for lower production costs, improved quality, reduced downtime and enhanced tracking accuracy, while ensuring environmental protection, requires cement plants to keep up with modern sensor technology. “This technology provides automated monitoring and process control from quarry to end product.” The cement industry can learn from Industry 4.0-leading sectors, and adopt best practices and technology where applicable. One of the key components of Industry 4.0 is the ability to take data from process sensors to a centre that can evaluate this information and recommend closed-loop process changes. Data collected from process sensors can be stored and evaluated over time to spot patterns and determine trends. Attaining this level of ‘Big Data’ and cloud accessibility in the ‘Internet of Things’ (IoT) increases the potential for process 14

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improvements, as well as opening up opportunities to quickly assess and respond to consumer trends and environmental correlations.

MONITORING FLOW IN CEMENT PLANTS Knowing how much raw material is in the yard is a challenge. It is essential that conveyors provide a nonstop flow of raw materials, additives, fuel, clinker and cement upstream and downstream of the pyroprocess. Mechanical scales measure mass and the volume of material transported is calculated using an average material density. This process is hindered when material density




changes and when a conveyor belt is not properly maintained. Material density is used to convert mass from the weigh scales into volume and vice versa. “When the density is incorrect, the volume and mass calculations are also incorrect,” Bartknecht and Savino concur. THE SOLUTION Bulkscan® flow measurement technology enables the yard manager to directly measure the contour, volume, height and material distribution through the use of LiDAR (light detection and ranging)-based technology. The sensors can be mounted over conveyor belts, onto cranes and reclaimers. Inside the Bulkscan® sensor, high-pulse laser beams create a profile of the material on the conveyor which, in combination with belt speed, represents volume flow and calculated mass flow. This measurement principle is based on a laser beam that is deflected internally across a rotating mirror. The sequential order of the laser pulses is synchronised with the rotation frequency of the motor and the desired angular resolution. Generally, the motor rotation speed is determined by the maximum emitted pulse frequency of the laser source and the desired angular resolution. The laser beams scan the surface area of the material on the conveyor and send this information to the measurement device, which compares the data with an empty reference conveyor belt. Bulkscan® allows plant operators to directly measure volume flow on conveyor belts, bucket elevators or drag chain conveyors outdoors in harsh conditions as well as inside the cement plant. The scanner can be mounted above the conveyor, measuring volume flow without any material contact, making it virtually maintenance free. The collected data can either inform manual processes, or act as an input to fully-automated systems to drive changes in material flow and composition. When large objects are detected, the plant operator is alerted and an automated stop process is triggered.

The benchmark for accuracy in difficult conditions and terrains

T: +44(0)1453 733300 | info@rdstec.com | www.rdstec.com

OPTIMISING PROCESSES Bulkscan also helps plant operators to optimise conveyor operation and reduce unplanned downtime. The same laser beams used to measure the bulk flow rate also provide information about the exact height and distribution of the bulk material on the conveyor. In addition, the centre of gravity of the load and the distance between the bulk material and the conveyor edge is measured and provided to a closed-loop system to adjust material distribution on the belt. This process automation helps increase belt life and decrease one-sided roller wear and downtime. Bulkscan can also be used in conjunction with a weigh scale. The actual bulk density can be determined in real time as the device measures the volume while the weigh scale measures mass. When these values are known, density can be calculated. www.sickautomation.co.za Bulk Solids Today





yster Europe has announced it is developing a zeroemission reachstacker featuring a hydrogen fuel cell for the Port of Valencia, as part of the European Horizon 2020 programme and H2Ports project. The port will be the first in Europe to incorporate hydrogen energy in its operations. “An on-board Hydrogen fuel cell will charge the battery on the forthcoming fully electric Hyster® ReachStacker,” says Jan Willem van den Brand, Director Big Truck Product Strategy and Solutions at Hyster Europe. “The technology will help evolve this industry into a low carbon and zero-emission sector.” The demonstration site for the H2Ports project will be the MSC Terminal Valencia (MSCTV) in Spain, that can receive today’s biggest container ships and has 260,000 m2 of container stacking space. The reachstacker is expected to enter operation in 2021, where it will undergo thorough testing handling laden shipping containers alongside several existing reachstackers. “As the first of its kind, we expect the new Hyster® ReachStacker will be able to support continuous operations while providing zero emissions and achieving comparable full shift performance to a conventional IC reachstacker,” says Van den Brand. The truck architecture incorporates electricity as the main energy source at high voltage to power fully electric motors. Noise levels will be low, and users can expect a reduction in energy costs. The company also expects reduced vehicle maintenance costs thanks to the elimination of the engine, transmission and other mechanical-driven components. “It has the potential to effectively support port applications with a heavy-duty cycle,” he says. “We plan to maximise uptime, minimise refuelling requirements and help applications to manage power consumption while complying with relevant environmental regulations and incentives.”


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Jan Willem van den Brand

Hyster-Yale Group is participating in the H2Ports project alongside the Port Authority of Valencia, the Valenciaport Foundation, the National Hydrogen Center, MSC Terminal Valencia, Grimaldi Group, Atena, Ballard Power Systems Europe and ENAGAS. The project has received funding from the Fuel Cells and Hydrogen Joint undertaking (FCHJU) which also includes the development of an electric yard tractor and the installation of a mobile hydrogen supply station. “Achieving zero emissions for container handling equipment at seaports is a substantial challenge,” says Van den Brand. “The highly demanding and varied duty cycles in these intense operations make battery recharging time a critical factor. These and other technical limitations have obstructed the electrification of container handlers or large lift trucks until now.” The H2Ports project follows a similar development in the Port of Los Angeles and the electrification of a Hyster® laden container handler. For more information, visit www.hyster.eu.




une 2019 will see the opening of a highly anticipated brand-new division of the business, “welcome the Plantforce Compact Range”, with a new state-of-the-art depot based in Bristol backed by a massive 2.8 million investment into new highly specked compact machinery ranging from 0.3 ton to 5t cabbed excavators, telehandlers, trench compactors, hi tip dumpers and an industry specific small tools range. The new division of the business opening follows a very busy couple of years for Plantforce, who have over the past three years invested 35 million in new plant equipment and last year alone introduced a bespoke rail ready division of the business, in addition, expanded services to also include a highly advanced GPS ready range of excavators backed up with an industry leading operator training program. COMPACT EQUIPMENT RANGE! With special focus on the utilities, SME ground working and landscaping sectors which have also seen a massive growth in the South West over recent years, Plantforce Compact will now be offering a one stop shop which will include the “ready to go range”, teaming up with industry suppliers like Geith, Kobelco, Thwaites, Indespension, Daemo attachments, Ammann, Dieci, the new compact range will consist of excavators, dumpers, attachments and trailer packages backed by a small range of specific tools including hand held whacker plates and rollers, “everything a SME will need to get the job done”, one contract one supplier and as always a top notch service. We’re committed to offering our customers the widest choice of services and best customer experience possible. This includes providing the most advanced fleet of plant equipment, a diversely skilled workforce and supporting these with excellent customer service from the minute a client gets in touch.

is facing an impending skills shortage, and we hope these apprentices will pave the way for many more here at Plantforce. Operations director Sam Mercer, said: “The opening of this new, specialist division of the business is hugely exciting for Plantforce. Every aspect is of the highest quality to support the already fantastic service we deliver to our customers. “The culmination of major investment, planning and development, it underlines our commitment to customers and our belief in the potential for growth in this key area of the southwest”. “The scale and the calibre of the facilities here will deliver tangible improvements to the availability of equipment and the speed and quality of the experience we provide to our customers. The purpose-built new depot, sales office, training room and yard for equipment storage gives us the ideal location for the business. “We are currently recruiting staff for the new business venture with all enquiry’s to be made with our Operations Director Sam Mercer on Sam@plantforce.com”

THE NEW DEPOT The 0.6-acre new depot in Bristol comprises of a fully operational plant & small tool Hire depot with all the latest innovations in parts storage, repair, inspection and maintenance facilities. An initial 5 jobs will be created at the new depot in Bristol which will also see the provision of two apprenticeship places, in collaboration with Weston College. Like many industry sectors, ours Bulk Solids Today



NEW BUSINESS SECTOR FOR AWARD WINNING SUMMIT SYSTEMS Multi award winning Summit Systems, a UK distributor of plastics industry ancillary equipment and solutions based in Tamworth, is proud to announce a significant new division focusing on Internet of Things (IoT) solutions including sensors for monitoring energy, conditions and fixed assets managed by long distance Wireless Radio Frequency transmitters, control tools and dashboards.


or almost 30 years Summit System’s strategic goal has been to provide solutions to the Plastics Manufacturing sector that drive greater efficiencies and less wasteful production. Combining their extensive plastics industry knowledge with market leading IoT technology aligns firmly against their strategic goal. By offering IoT solutions specifically tailored for plastics manufacturers, they are empowering customers to take a step change in how they can collect and anlayse data to support the universal quest to reduce costs and improve productivity. Jem Hudson, newly appointed Head of all things IoT at Summit Systems said: “IoT has a wide and varied scope, from the smart home to smart car and smart city. But we need to ask what does IoT really mean to plastics manufactures facing global competition, tighter regulation and increasing energy costs?” Jem continues to explain that, “IoT in plastics manufacturing really comes into play when the manufacturer is asking questions that begin with ‘I’d really like to know when or if or what …’ capturing and utilising data that isn’t readily accessible is the key to providing the answers to help improve production processes, identify issues and pre-emp failures that cause unscheduled downtime” Summit Systems’ customers have two recurring areas of focus with their first phase IoT deployments: 1. Developing a detailed understanding of power consumption at a machine, ancillary equipment, or production line level At this level of granularity of power monitoring the customer can: • get an immediate view on the ongoing power cost per cycle/per shot of a production process • compare energy efficiencies of a mixed estate of production systems • use detailed historical data to support new energy saving investment decisions.


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2. Condition Monitoring and Alerting Using a variety of sensors feeding data to central dashboards Summit is able to: • Alert maintenance teams when a motor exceeds pre-set vibration levels • Provide alerts when water pressures move out of normal operating parameters, eg on heat exchangers and water filtration units. • Identify amp levels that exceed normal operating levels for preventive maintenance. e.g. vacuum pumps working harder than normal can indicate vacuum issues to investigate before system failures. Or a granulator with an upward curve on its amp readings suggest blade health issues. These examples are starting points. Summit have sensors to measure just about anything in the plastics factory from temperatures, pressures, vibrations, and power consumption through to buildings management, asset tracking, weather stations, legionella control and even people monitoring. For further information contact our IoT product manager Jem Hudson; Email: jem.hudson@summitsystems.co.uk Tel: (0) 7890 751925


AB MAURI PROTECTS SOYA MILLING PROCESS FROM METAL CONTAMINATION WITH 9 MAGNETIC SEPARATORS FROM ECLIPSE MAGNETICS AB MAURI UK & Ireland has invested in 9 Pneumag magnetic separators from Eclipse Magnetics to meet the very latest food safety standards in its soya milling processes. Fitted into pipelines that feed the soya beans into the process, the Pneumags provide protection against ferrous and paramagnetic contamination of dry powders and granulates, making them perfect for AB MAURI’s processing lines.


s a global family of yeast and bakery ingredient companies, AB MAURI is one of the largest producers and distributors in the world. AB MAURI must, therefore, ensure that the soya they process is free from any contamination that may be introduced into the process from the raw material, or during the milling process itself. As a company with exceptionally high standards, AB MAURI is always vigilant regarding contamination issues, and therefore made a cautionary decision to replace the existing magnetic units in the milling system with upgraded units meeting the very latest food safety standards. A solution was required to protect the plant at the very beginning of the process, in addition to the replacement of 9 magnets further down in the processing line to eliminate contamination. Adrian Seeley, Production Supervisor at AB MAURI UK & Ireland said: “Our pipelines are angled, so the units supplied by Eclipse provide the perfect solution to replace the existing magnets. Our operatives have commented on how much easier these new units are to clean and inspect each week”. During milling, the soya beans are processed to a uniform particle size to produce flour. This is achieved by a sequence of breaking, grinding and separating operations. 9 Pneumag high intensity magnetic separators ensure that even the smallest ferrous contamination particles are extracted from pneumatically fed lines. Each Pneumag unit contains a double row high intensity magnetic cartridge, and is secured into its housing

by quick release toggle clamps, which ensure even pressure is generated around the unique silicon-based metal-detectable seal. The Pneumag was perfect for this application due to its ability to be installed at any angle, from vertical to horizontal. A lockable tamper proof cover plate was also provided to ensure only authorised personnel have access to the unit. Adrian continued: “We were delighted with the service provided by Eclipse Magnetics; from the initial site survey, right through to delivery.” AB MAURI is Associated British Food’s (ABF) most globally represented business, employing over 7,000 people across 52 plants with a presence in 32 countries, and sales in over 90 countries. The businesses boasts a heritage of 150 years in the bakery industry, and uses its intimate knowledge of bakery ingredients and yeast to support and enable the world’s bakers. AB MAURI UK & Ireland is committed to supplying bakers with yeast and technical bakery ingredients to meet strict quality standards, performance criteria, and cost parameters. www.eclipsemagnetics.com

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reat Tew Ironstone Quarry in North Oxfordshire in the UK has purchased a new top-of-the-range Doosan DL580-5 wheel loader to increase production of Ironstone products from the quarry. The DL580-5 carries huge 14-16 tonne blocks of Ironstone from the quarry face to a new £1 million stone processing plant that has recently begun production at the top of the quarry. Great Tew Ironstone has a striking brown and blue vein and is only available from this Oxfordshire quarry. The quarried block is often up to 30 tonne, which opens up a wide variety of uses, including building and walling stone, architectural details, mullion windows, copings, quoins and flooring. Smaller quarried block is suitable for rockery stone and one-off garden features. The quarry lies on the historic Great Tew Estate, which always quarried block for its own use and in 2000, the quarry was opened further to satisfy a wider demand for this unique product. Great Tew is part of Johnston Quarry Group, the largest supplier of quarried and mined block stone in southern England. As well as Great Tew, the Group owns and operates Sarsden Quarry in Oxfordshire, Creeton Quarry and Ropsley Quarry both in Lincolnshire and Oathill Quarry in Gloucestershire. The Group also runs three Bath stone mines. With the wide choice of building stone and masonry products available, the Group supplies over 60,000 tonne of stone block and 300,000 tonne of aggregates per year. Paul Keyte, Operations Director at Johnston Quarry Group, who is responsible for overseeing the Great Tew, Sarsden and Oathill sites, said: “We are delighted with the boost in productivity provided by the new DL580-5 and the processing plant, which allows us to process up to 100 tonne of stone a day. The arrival of the DL580-5 and the opening of the new plant are both timely and are enabling us to meet a significant increase in demand for our Ironstone products in the UK.” Equipped with specially matched pallet tines, the DL580-5 brings the large blocks from the base of the quarry to the top and along a short road, at the end of which it loads them on to the sawing machines in the processing plant. Previously, the 20

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quarry was only able to move blocks weighing up to a maximum of 10 tonne, so the arrival of the DL5805 has made this a much more efficient process. DESIGNED FOR HEAVY LIFTING To take on heavy material handling jobs like this, the DL580-5 features robust structural components and an advanced double circuit axle cooling system to provide an ideal solution for heavier work. This ensures the DL580-5 is ideal not only for block lifting in quarries and mines, but also heavy-duty applications in industrial, construction and recycling operations. The overall size of the DL580-5 is almost the same as the DL550-5, the next model down in the Doosan range, but it has an operating weight of 36030 kg and higher static tipping loads (straight/ full turn 40°) of 29700 and 26200 kg, respectively. In addition, the new model is equipped with a series of features that make the machine extremely reliable and durable. For example, the front structure is more rugged, with greater rigidity and strength. The DL5805 has reinforced Z-bar kinematics for heavier lifting with few moving parts. This design also helps stabilise the loader, enables rapid bucket movements and keeps the bucket at the right angle position at all times. The DL580-5 was supplied by Doosan dealer, Filtermech Plant Sales Ltd, based in Wakefield in West Yorkshire, in conjunction with another DL5805 supplied last year to Creeton Quarry. Filtermech provides back-up for the DL580-5 along with the

QUARRYING & MINING other Doosan wheel loaders, crawler excavators and articulated dump trucks at Creeton but the DL5805 and the other Doosan machines at Great Tew are supported by Murley Construction, another Doosan dealer, based more locally at Stourport-on-Severn. Established in 1959, Murley Construction, has been providing machinery sales and support for over 50 years to the Midlands community. Like Filtermech, Murley represents the full range of equipment from Doosan that also includes wheeled excavators, providing full servicing, repairs, warranty and parts back-up from the company’s modern and well equipped premises, with Doosan-trained technicians and advisors. ADDITIONAL FUEL SAVINGS The DL580-5 is powered by the Scania DC13 6-cylinder engine producing 283 kW (380 HP) of power at 1800 rpm. Providing a generous maximum torque of 1765 Nm at 1300 rpm, up to a 10% reduction in fuel consumption and excellent response, the Scania DC13 engine meets Stage IV emission regulations without the need of a diesel particulate filter (DPF), through the use of cooled exhaust gas recirculation (EGR) and selective catalyst reduction (SCR) after-treatment technologies. The engine Auto Idle system when activated saves further on fuel costs by lowering the idle level from 950 to 750 rpm – when the operator does not give any input to the steering wheel, arm and bucket for more than 10 seconds (ideal for applications where there is a lot of waiting time such as truck loading which can be up to 8% of the time). In all DL-5 loaders, the Engine Auto Shut Off shuts down the machine after it has been idling for a specified amount of time (3-60 minutes, configurable by the operator via the control panel). This feature saves on fuel and reduces operating costs. As well as the powerful Scania DC13 Stage IV engine, the DL580-5 also features automatic 5-speed powershift transmission, heavy duty cooled axles, a high comfort cab, smooth and responsive hydraulics and auxiliary hydraulic connections, together providing a solution for the heaviest jobs that need to be done. As with all other Doosan DL-5 wheel loaders, most of these features are standard on the DL580-5 unlike other machines on the market where they are options and many have been developed to optimise fuel efficiency. HIGH COMFORT CAB The cab demonstrates how Doosan has placed operator comfort at the very centre of its design priorities. Offering generous headroom and an ultra-comfortable, fully adjustable, heated Grammer air suspension seat, the DL580-5 cab features a novel steering column design giving more clearance for the operator’s legs and knees. The steering wheel can also be tilted and moved telescopically to match the operator’s preferred position. Electric joystick steering is incorporated to ensure operator driving comfort and improve productivity.

Many of the new features on the cab in the large DL-5 wheel loaders such as the DL580-5 are aimed at increased safety and visibility in and around the operator’s cab. For example, a new handrail has been installed around the cab roof with three holding points, allowing operators to move very safely all around the cab to clean windows and to perform other tasks. A new large step and access platform has also been added on the front of the cab and a change in the wiring routing has allowed the horn to be repositioned below the road light. Together these changes ensure maximum safety and confidence, with very safe and faster movements around the cab (without any obstacles) during daily maintenance. INCREASED SPACE AND VISIBILITY The increased space, better visibility and plentiful storage space in the cab allows operators to work for hours without fatigue or discomfort. Meeting ROPS/FOPS regulations, the cab also offers a wide emergency exit (located on the right hand side) to provide fast and easy evacuation in critical situations. The 5.7 inch full colour LCD panel is suitable for day and night work. The user-friendly monitor has two customisable screen displays to suit the operator’s preference, giving a full readout of machine settings and maintenance data. The rear-view camera greatly enhances visibility and safety. The screen in the cab shows the operator what the camera sees and includes several lines to help judge distances; it also has other functions, including light intensity control, viewing angle control, language setting and power on/off setting. The DL580-5 incorporates all of the new safety and ergonomic features recently announced for the other six large Doosan wheel loaders from the DL280-5 to the DL550-5. It also features the latest restyling common to all models in the Doosan wheel loader range. The styling scheme involves a change of colour (from orange to dark grey) for the front lift arm, front frame and front and rear axle components on the machines. The more dynamic curved lines of the new styling are designed to reinforce the robustness and power of the Doosan wheel loader range. www.doosanequipment.eu Bulk Solids Today



KENT WASTE FIRM PUTS ON THE STYLE WITH JCB ORDER Privately-owned waste recycling business, Countrystyle Recycling, has further improved on-site handling efficiency at its flagship facility at Sittingbourne, Kent, with the introduction of four JCB 457 wheeled loaders.


ountrystyle provides specialist waste recycling, haulage and recovery services for a range of industrial products, including plasterboard, wood, general waste, dry mixed recyclables and organic green and food wastes. Two of the new JCB models will be deployed within the facility’s dedicated plasterboard recycling building; the remaining two units will operate within the wood yard at Ridham Dock, near Sittingbourne. As part of Countrystyle’s ongoing commitment to promoting health and safety within the waste sector, the dedicated JCB machines working within the plasterboard processing plant have been supplied with BMAir cabin air filtration technology. The BMAir system prevents polluted


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air entering the cabin and allows air quality within the operator’s working space to be continuously monitored. In addition, the new wheeled loaders have been supplied with automatic dual agent fire suppression systems, supplied by Fireward, LED lighting and foam filled tyres to ensure on-site safety and machine uptime are optimised. Featuring a powerful MTU diesel engine that meets Stage IV/Tier 4 emissions, the JCB 457 wheeled loader is designed to work at sites where large volumes of materials need to be handled. It is available in a variety of model configurations – all built with safety, efficiency, ease of use and maintenance, productivity, performance, reliability and comfort in mind. Neil Webb, Countrystyle’s Engineering & Project Manager, says: “The build quality of the JCB machines is second to none. We already operate a number of JCB machines including telehandlers and excavators at our Sittingbourne site so we had no hesitation in turning to JCB for our new wheeled loaders.” JCB dealer, Greenshields JCB, supplied the new equipment and will also provide ongoing full maintenance support. www.jcb.com


TATA STEEL GOES FROM PILOT TO PERMANENT WITH SILTBUSTER Siltbuster Process Solutions (SPS) has designed, built, installed and commissioned a new effluent treatment plant for Tata Steel’s Shotton Works, doubling the treatment capacity at the site. Following the process optimisation, the turnkey solution can now treat up to 40 m3/hr, removing at least 80% of the total Zinc.


ata Steel invited SPS to tender for the project after the water treatment experts successfully delivered a full-scale treatment pilot plant to the Shotton site in 2015. This pilot enabled Tata to test the chemical treatment process it had in mind for its effluent and scope the ideal permanent treatment solution for its needs. According to Rich Matthews, General Manager at Siltbuster Process Solutions, this ‘pilot to permanent’ approach is a growing trend: “Companies are increasingly using our modular plant to test out ways of optimising the processes and chemistry behind their effluent treatment by running our pilot system in parallel (or as a side stream) with their existing plant. During the pilot, companies not only refine their treatment processes, but they also become familiar with our technology, team and approach.  The fact our test plant can then be scaled-up to a permanent solution makes the transition so much easier for the customer.  It de-risks the plant upgrade process; clients know our system and know it will work.” In the case of Tata, the SPS pilot plant worked so well during the trial that Tata was able to wind down its current, ageing treatment plant, rather than running the two in parallel. This, together with the way the modular solution worked – it was energy efficient, could cope with varying effluent in terms of volume and type, and minimised waste - made SPS an obvious candidate when Tata was ready to install a permanent solution. Occupying a quarter of the footprint of the old plant and yet doubling the treatment capacity, the permanent treatment plant which SPS has designed and built for Tata consists of modular process stages, including a 4-stage mixed reaction tank, a lamella clarifier, pre-packaged chemical dosing plus housing for a motor control centre panel, with associated instrumentation and pumping stages. Tata operates three production lines at Shotton, manufacturing approximately 600,000 tonnes of pre-

finished steel per year in the form of coated strip for building envelope, domestic and consumer applications. Tata’s effluent at the site has a variety of heavy metals present predominantly zinc but includes other trace metals too. When treating this effluent previously Tata’s treatment plant generated Gypsum (calcium sulphate) which is problematic to equipment and both difficult and expensive to remove.  With the new SPS system, Gypsum is no longer formed, during effluent treatment, so processing costs are reduced. Instead, the dissolved metals are precipitated by chemical reactions during the mixed reaction tank stages before being settled out and separated by the lamella clarifier. The treated water can then be safely discharged to watercourse. The new plant, which was delivered on time and within budget, works on every front as Bill Duckworth, Tata Shotton Works Manager, says: “The new treatment plant will increase the volume of effluent that can be treated, it will reduce waste, reduce our energy consumption, and it will make the process more efficient and controlled.” Richard Sidebottom, Tata Shotton Director Engineering Downstream Operations recently visited the treatment plant and commented: “I found it particularly encouraging to see the new technology that has been introduced which will support our production plans well into the future.” The project presents another example of modular standard products, supplied by Siltbuster, being used to treat a variety of effluent streams. The deployment of a smaller system as a pilot, optimised the process selection and provided certainty to the project. For further information about Siltbuster Process Solutions please visit the website, call 01600 772256 or email enquire@siltbuster.com Bulk Solids Today



‘REUSE, RECYCLE, REPEAT’ ADVISES LEADING PLASTIC PALLET SUPPLIER Goplasticpallets.com – The Responsible Plastic Pallet Company – is urging customers to reuse their plastic pallets and boxes, recycle them, and then repeat the process to help create a circular economy.


his pertinent advice comes following what’s been a difficult last year for plastic pallet’s biggest rival ‘the wooden pallet’ with timber shortages and price rises affecting availability and causing serious concern amongst pallet users. Jim Hardisty, Managing Director for Goplasticpallets.com, said: “Not only do we stock the largest range of plastic pallets, pallet boxes and small containers in the UK, all of our products are available in large volumes – our customers need not worry about supply shortages. “Our plastic pallets and boxes can be reused time and time again; recycled once they reach the end of their working life; then the recycled plastic can be fed back into the manufacturing process to create new, high quality, reusable plastic pallets and boxes – closing the loop and creating a circular economy.” Following the company’s pledge last month to recycle all of its customers’ plastic pallets and boxes, Goplasticpallets.com has had a lot of interest in its recycling scheme. But a question they’re frequently being asked is how exactly does it work? Jim explained: “We’ve tried to make it as simple as possible for our customers to recycle their plastic pallets and boxes. Depending on the volume that customers wish to recycle, they can choose from one of our two recycling solutions. “For volumes in excess of 1500kg, customers can take advantage of our hassle-free collection service, where we will arrange a collection and transport the products straight to our partner’s recycling facility in Belgium. Customers can arrange for smaller loads to be dropped off at our warehouse at their own convenience, where once consolidated we will


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The life cycle of a recycled plastic pallet

Plastic pallet granules ready to be used to create new, reusable plastic pallets and boxes

transport in full truck loads to Belgium – ensuring our trucks are running at their maximum efficiency. “Our partner’s recycling factory in Belgium is one of only three in Europe with a pallet recycling facility adjacent to the manufacturing plant, and is the closet one to the UK. By recycling our customers’ plastic pallets and boxes in Belgium we guarantee that they will not only be ethically recycled by a fully licensed facility, but also that the recovered material will be reused to make the next wave of high quality, long life plastic pallets and boxes.” Call 01323 744057 for help recycling your plastic pallets and boxes. For further information visit www.goplasticpallets.com




pecialist roofing and cladding company, Thornton Roofing has completed a two-year recycling project at Oakleaf Farm Recycling. Thornton joined Architects WDR & RT Taggart to construct a waste processing building on an impressive five-hectare site in Stanwell Moor. Located on an official green belt, the factory’s close proximity to residential housing developments, the Staines Reservoirs and Heathrow Airport made it a project with a broad range of stakeholders. The roofing and cladding experts installed the Euroclad Elite 2 acoustic roofing system and Euroclad Elite 55 acoustic wall cladding system, both designed with specialist absorption qualities to control noise emissions from the factory. The revolutionary roofing system designed by Thornton has been built with an insulation gap between the outer and inner lining sheet in order to curtail possible noise emissions. In addition to this, the double skinned walls prevent unwanted noise reverberations in the green belt. Paul McErlane, Contracts Manager at Thornton Roofing said of the project: “We are particularly proud to have worked on this unique project. Certain requirements of the project meant that specialist skills were necessary to deliver on site objectives.

It was fantastic that we at Thornton are recognised as being able to deliver specialist requirements and execute them with a calibre of high degree. “Ensuring that strict noise (laws) were met were of paramount importance, ensuring that these standards were met was a key consideration when selecting products for the project. The Thornton team were consistently proactive in building positive relationships with the entire team on-site and always delivered on requirements to an impeccable standard. Competence levels displayed by the team were impressive and had a positive ripple effect across the entire team on-site.’ To find out more visit: www.thorntonroofing.com

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COOPEROSTLUND ANNOUNCES COOPERATION WITH VAISALA REGARDING WORLD’S FIRST 3-IN-1 BIOGAS MEASUREMENT INSTRUMENT Biogas plants can now extract more value from waste following the launch of the world’s first in-situ 3-in-1 biogas measurement instrument.


eveloped by Finnish technology provider Vaisala, the MGP261 multi-gas instrument provides accurate readings for the methane, carbon dioxide and humidity content of biogas produced from anaerobic digestion, industrial and municipal waste, and wastewater treatment. The novel instrument can also be used for CHP engine monitoring and heat exchanger optimisation with humidity measurement. CooperOstlund, the leading provider of gas engine specification, installation and maintenance services, contributed to the development of the new instrument by organising a field trial campaign at one of the company’s existing customer sites. CooperOstlund personnel also provided professional insight regarding any process changes observed during the trial. “When installed directly into the gas line, the MGP261 provides real-time data for operators and engine manufacturers on the quality and consistency of the biogas they produce,” explains CooperOstlund CEO Duncan McPherson. “Not only does this provide greater oversight of product quality and plant performance, but it also helps engineers to spot problems early and improve efficiencies, thus potentially achieving significant cost-savings over the long-term. “At CooperOstlund, our focus is on installing, maintaining and improving CHP solutions,” Duncan says. “We will now offer the MGP261 to customers with both new and existing CHP installations to help improve the efficiency and effectiveness of their sites.” The partnership between CooperOstlund and Vaisala began in 2017 after the two companies met at an Anaerobic Digestion & Bioresources Association (ADBA) exhibition. “Vaisala told us what they were working on, and we knew we needed to be involved,” Duncan explains. “We’re always looking for new technologies that will help our customers reap the full potential of their sites, which is why we chose to support Vaisala in developing this product.” In addition to providing technical expertise, CooperOstlund helped Vaisala source a UK site in which 26

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to install a prototype of the MGP261. One such field trial took place at a Gloucestershire-based anaerobic digestion plant, which was able to use the MGP261 to check whether moisture was being removed from the biogas produced by the plant. This not only validated that its gas chillers were operating successfully, but also ensured that the business maintained a consistently high quality of biogas, which it could then sell to the National Grid. “We made contact with an existing customer, who kindly let us install the product at their site,” Duncan says. “At the time, they were modifying their gas pipework in preparation for the installation of a gas chiller, so we used the MGP261 to check that the chiller was working properly. Results from this trial have been very positive, which enabled us to take the project forward, ready for launch.” Antti Heikkilä, Product Manager at Vaisala, added: “With CooperOstlund’s expertise, we were able to trial the technology in real-life customer applications, which ultimately led to the validation of the product’s performance. We look forward to working with CooperOstlund on future projects that can improve the effectiveness and efficiency of CHP installations.” For more information on CooperOstlund’s installation, maintenance and improvement services for CHP sites, please visit https://cooperostlund. com/. For product options and specifications, please visit: www.vaisala.com/MGP261




rom the highpoint of the 1960’s when nearly 70 per cent of all lift trucks sold had IC engines, the ICengine-powered forklift has seen its share of the global forklift sales market steadily eroded by the growing popularity of battery-driven trucks. And LP Gas-powered truck sales have been hit particularly hard. “Sales of LP Gas-powered warehouse trucks have been declining for a while for several reasons,” says John Maguire, managing director of Narrow Aisle Ltd – manufacturer of the Flexi range of articulated forklift truckbased intralogistics solutions. He continues: “Compared to battery electric power, the cost of LP Gas is costly and linked to global oil prices, and from an operational point of view the time taken to change and store each gas bottle means that truck downtime can be a problem for some high utilisation customers unless a bulk tank can be justified. “In addition, the control systems and catalytic converters required to reduce the risk of carbon monoxide emission from LPG engines add significantly to a truck’s operating costs. There are many differing emission control and safe operational noise level standards and rules across the world which make the supply and operation of engine powered tracks more and more difficult in many markets.” With developments in electric truck technology – such as the development of LithiumIon batteries – John Maguire believes the trend towards battery power is set to accelerate. “Make no mistake,” he says, “the age of electric vehicles has arrived and many people feel that Lithium-Ion batteries are the future of industrial truck power.” “It is more than 10 years since the first Lithium-Ion powered forklift appeared, and now some

With developments in electric lift truck technology – such as the development of Lithium-Ion batteries – the trend towards battery power is set to accelerate, says John Maguire, managing director of Narrow Aisle Ltd of the biggest names in industrial equipment manufacturing are using lithium power to replace fossil fuels. “Take-up of Lithium-Ion technology was initially quite slow, but now more and more truck users understand the many benefits that Lithium-Ion battery technology offers.” These benefits include greater energy efficiency and higher levels of operational performance. “The higher energy efficiency of Lithium-Ion batteries leads to notable savings in energy costs and allows rapid payback times to be achieved. Furthermore, thanks to their fast charging capability, Lithium-Ion batteries eliminate the battery exchange process which can mean less truck downtime,” explains John Maguire. Since the launch of the Flexi LiTHiON articulated reach truck range at Cemat 2018, all the models across the LiTHiON range are available with integrated Lithium-Ion battery-power. Flexi LiTHiON trucks require virtually no battery maintenance - the truck monitors the battery function constantly and reports the battery status real time, while the fact that the Flexi LiTHiON range’s batteries can be fully charged within one or two hours, even if the battery is fully discharged – ensures that truck uptime is optimised. In addition, the Flexi LiTHiON has the ability to distribute consistent power levels each hour, which means maximum warehouse throughput efficiency is achieved even during the busiest multi shift operation. “When it comes to running a

modern warehouse around the clock, productivity is key which is why lift truck users appreciate the benefits of Lithium-Ion battery technology,” says John Maguire. Narrow Aisle is offering a free consultancy service to users of all makes of LPG-powered articulated forklift trucks to allow the benefits of switching from LPG to Flexi LiTHiON battery power to be compared. The company has also launched a scrappage scheme that gives operators of LPG-powered articulated trucks the chance to make significant savings should they choose to upgrade their old LPG forklifts to new Flexi LiTHiON electric models. “Our scrappage scheme means we’re offering companies the chance to take older less efficient forklift trucks out of their fleets and replace them with the latest ultra-efficient Flexi technology in the most cost-effective way possible,” added John Maguire. John Maguire likens the logistics industry’s move away from icengine power to battery technology to the changes taking place in the global automobile sector. He says: “The number of electrically-powered vehicles has always been high in the warehousing industry, this trend is now increasing in the whole logistics sector as it is in the automotive industry and, with the advantages that modern Lithium-Ion battery technology offers, Lithium-Ion is increasingly regarded as key to a clean, quiet and cost-effective power source for the future of all industrial trucks in the industry.” www.flexi.co.uk Bulk Solids Today


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Bulk Solids Today April 2019  

Bulk Solids Today April 2019