BULK MATERIALS HANDLING • CONVEYING • MIXERS BLENDERS DRYERS • RECYCLING • SIZE REDUCTION
The Smart Way to Unload, Convey, Weigh & Mix ®
MODU-KLEEN BIN VENT FILTER
BLENDCON SILO BLENDER
BULKBUSTER BULK BAG UNLOADER
VIBRA-JET BIN AERATOR
GYRO BIN ACTIVATING FEEDER TM
DYNA-SLIDE HIGH PRECISION AIR-ACTIVATED FEEDER
BAGBUSTER BAG BREAKER ®
BELLA TWIN SHAFT FLUIDIZED ZONE MIXER
BLENDCON AIR BLENDING HEAD
TRANSPORTER MANUAL HOSE SWITCH
Move your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear.
Our high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation and maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation.
Proven capability Dynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from less than a hundred kilograms per hour to 400 tonnes per hour, over distances exceeding 1500 metres.
Sixteen concepts Each Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises.
BellaTM Twin Shaft Fluidized Zone Mixer
GYRO EXTM Bin Activating Feeder
Write or call us today with your questions, or for detailed information on our system applications. Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: email@example.com
Dense Phase Transporter, J-Series
BulkBusterTM Bulk Bag Unloader
CONTENTS 4 NEWS 17
24 BULK MATERIALS HANDLING 38 FEEDERS BST TEAM Sales Director: James Scrivens Creative Director: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley Printing: Mixam Print BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Bulk Solids Today 17 Whitley Close, Irthlingborough, Northants, NN9 5GN Tel: 01933 316931 Email: firstname.lastname@example.org email@example.com Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday
39 CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS
42 SIZE REDUCTION 44
MIXERS, BLENDERS & DRYERS
46 RECYCLING & WASTE MANAGEMENT 50 BUYERS GUIDE 32
CIRCULATION To receive a copy free of charge, please send your details to firstname.lastname@example.org SUBSCRIPTIONS Subscriptions are available to non-qualified readers for £30 per annum (postage incl.), £35 (Europe), and £45 (rest of the world) Cover Price: £5.00 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 2016
www.bulksolidstoday.co.uk Bulk Solids Today
SHEFFIELD ENGINEERING FIRM DEVELOPS INNOVATIVE SAFETY SOLUTION FOR TESCO
Sheffield engineering firm has developed a bespoke maintenance solution for Tesco which aims to make working at height safer. PCT, a sub contract engineering firm employing 70, collaborated with safety specialists HCL Safety to develop a modular access system for Tesco which enables safe access from one roof-top to another allowing maintenance and cleaning. Engineers at PCT were challenged to design and manufacture a companionway ladder system which could be adjusted to accommodate different heights. In addition to meeting stringent safety standards, the ladder also needed to be extremely light to allow for manual handling. James Harding-Terry, managing director of PCT, said: “We thrive on a challenge at PCT and this project allowed us
PCT staff manufacturing bespoke safety solutions to make working at height safer.
PCT’s aluminium companionway ladder system.
to demonstrate both our design expertise and fabrication skills. “It’s important to get working at height right. Trips and falls whilst working at height account for 40 deaths and 4000 injuries each year.
We’ve developed a range of working at height products over the past few months and we’ve also seen an increase in demand for bespoke projects like the one for Tesco.” PCT, which is based at Holbrook, Sheffield, was founded in 1926 and has survived war, recession and numerous steel crises, to mark its 90th anniversary this year.
The family-run business operates in a range of sectors including the construction and automotive industries and manufactures around 50,000 towbars each year. PCT has a turnover of more than £5m and also specialises in profiling, metal fabrication, tube manipulation and including prototype development. www.pct.eu.com
DIMERCO CELEBRATES SUCCESS IN CHINA
lobal logistics & transportation specialist Dimerco Express Group celebrate 25 years of success in the Greater China region as two of its subsidiaries are ranked by CIFA (China International Freight Forwarders Association) in both the 100 Top China Forwarding & Logistics Enterprises as well as the 50 Top China Air Cargo Enterprises lists for the tenth consecutive year. The achievement of the Taiwan headquartered group also coincides with the 20th anniversary of the founding of Dimerco Zhongjing International Express Co. Ltd in China and the launch of the company’s Beijing Office 20 years ago, which was marked with a special celebration dinner in Beijing on September 26th 2016. China International Freight Forwarders Association (CIFA), which is a national organization of the international freight forwarding industries, ranks
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companies based on sales volumes. Dimerco Zhongjing International Express Co., Ltd. has been ranked 69th of top 100 China Freight Forwarders and 23rd of top 50 China Air Cargo transporters, while Dimerco International Transportation (Shanghai) Co achieved rankings of 76th and 28th on the respective lists. In recognition of the company’s ten year track record, Dimerco has been presented with a prestigious ‘Steady Business Growth’ Award” by CIFA, which was received on behalf of the company by Mr. Alexander King, Sales Director of Greater China North District. Mr. Edward Lin, CEO of Dimerco Express Group, commented, “Recognition by CIFA is a valued reflection of our continued success and strong growth in this key market for Dimerco as well as demonstrating our capabilities and achievements
Dimerco Zhongjing International Express Co., Ltd., a subsidiary of Dimerco Express Group, celebrates its 20th Anniversary on September 26, 2016 in Beijing.
in the Greater China Region. We are particularly delighted that this comes at a time that we are marking several important milestones in our journey to become the most competitive global logistics and transportation provider.”As part of Dimerco Express Group, Dimerco Zhongjing International Express Co., Ltd., which is an Authorised Economic Operator (AEO) in its Beijing and Shenzhen office,
manages air freight gateway operations in Shanghai, Beijing, Xiamen and Guangzhou both for import and export. All gateway offices have Class A license for Customs Brokerage as well as for international and domestic transportation. Currently, Dimerco Express Group owns 73 service outlets in the Greater China region. For more information about Dimerco, please visit: www.dimerco.com/
THE UK’S MATERIALS HANDLING EXHIBITION AND CONFERENCE
HARROGATE INTERNATIONAL CENTRE 5-6 OCTOBER 2016
COME AND EXHIBIT Showcase your products and services to key decision makers across the bulk materials handling industry. New for 2016 is Speaker’s Corner, bringing the programme of high profile speakers and presentations into the heart of the exhibition hall. Those wishing to make an extra impact can take advantage of a range of sponsorship opportunities to suit all budgets.
REGISTER NOW Tickets for BULKEX16 are free. Register to attend at: www.mhea.co.uk/bulkex-2016/attend-bulkex-2016/
To exhibit at the event, find out more about sponsorship or to register for your free ticket, contact the BULKEX events team. 01787 226995 www.mhea.co.uk/bulkex-16/
PETER SLEE-SMITH JOINS FPE GLOBAL’S SENIOR MANAGEMENT TEAM
PE Global has appointed Peter Slee-Smith as a Technical Industry Expert to focus on new product development as the materials handling firm gears up for significant growth in the bulk handling space. Slee-Smith has over 25 years’ experience in materials handling and powder processing and has held a number of senior positions at Matcon, B&W, Portasilo and Clyde Bergemann. He has a strong track record of helping to grow companies at all stages in their development and has been responsible for leading projects in locations such as Russia, China, Korea and Czech Republic. He has previously worked with FPE’s CEO David Cooper when they both served on the
board of directors for Matcon, where they delivered significant growth to the firm through the supply of integrated IBC systems for the food and pharmaceutical industries. In his new role, Peter will work closely with the company’s senior management team to drive new product development and help to develop the operational side of the business to provide higher value services to its customer base. Slee-Smith said: “It’s an exciting time to be joining FPE Global. The firm has a clear strategy and I am delighted to have the opportunity to help drive accelerated focus on the strategic plan and develop technical solutions that provide added value to customers across the firm’s core industry
sectors. The business now has a solid management team in place and is in a stronger position than ever before to provide a true alternative to some of the bigger players in the industry.” David Cooper, CEO at FPE Global, added: “Peter is a highly regarded figure in the materials handling industry and we are delighted to welcome him to the team at FPE Global. His appointment is further demonstration of the investment we are making in developing the firm’s overall offering to its customer base. Peter is an exceptional engineer and his leadership in customer centric innovation and overall operational capability will be a fantastic asset to FPE
Global. The business has seen excellent growth over the last 12 months and, as we look to manage the company through its next phase of organic and in-organic development, Peter’s technical expertise in process improvement and product design will help the company to strengthen its offering as well as bolstering operational capability.” www.fpeglobal.com
NEW HGV BUNKER REFUELLING SITE PLANNED FOR PORT OF LIVERPOOL Planning permission has been granted for a new 24 hour HGV refuelling facility at the Port of Liverpool, thanks to a partnership between Certas Energy and Peel Ports Group.
he Port of Liverpool is one of the largest, busiest and most diverse ports in the UK. Its current traffic and anticipated growth through investment make it the perfect location for the new HGV refuelling site.
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Ground works and construction will begin imminently on this significant investment to develop a state-ofthe-art refuelling facility for up to eight HGVs at the same time. High speed pumps combined with advanced data collection,
fuel monitoring equipment and filtration systems will ensure the best service offering at all times. Located at the main entrance to the Royal Seaforth Container Terminal and adjacent to the new Liverpool2 deep-water container terminal, which is part of Peel Ports’ £750 million investment programme across the North West, the bunker site will add convenience for current port users as there will be no need for drivers to divert off route to refuel; they can refuel on entering or leaving the port, saving time as they proceed to their onward destination. Paul Williams, Director, Certas Energy commented, “This is an exciting opportunity for Certas Energy and we are really pleased
to be working with Peel Ports Group on this development. Our long-term lease not only demonstrates our continued investment to expanding our national refuelling network, but also highlights our commitment to supporting the continued economic development of the city of Liverpool. We look forward to the HGV refuelling site opening in early 2017”. David Huck, Port Director, Peel Ports Group said, “This new facility will add value to our customers and provide a convenient and cost-effective location for HGV drivers to refuel their vehicles. Planning permission is a key milestone and we look forward to working with Certas Energy to provide a convenient new service to our port users.” http://www.peelports.com http://www.peelgroup.global
FLEXICON OPENS NEW OFFICE IN GERMANY
lexicon (Europe) Ltd has opened a new office to provide factory-direct engineering services and technical sales support to customers throughout Germany, it was announced by Keith Bourton, Managing Director. “The Aschaffenburg location will fuel Flexicon’s rapid growth in the region by providing a dedicated German-language staff with full access to corporate resources,” explains Mr. Bourton. The Aschaffenburg office is headed by Christian Löchler, Regional Sales Manager. He holds an Engineering degree in Plastic Processing Technology from Fachhochschule Darmstadt (University of Applied Sciences), and possesses 20 years of experience in plastics processing, compounding and recycling, most recently as a Sales/Project Engineer for a consultancy specialising in gravimetric and
volumetric dosing for granulates, powders and liquids. At Flexicon he will be responsible for building relationships with plant engineers, managers and other equipment specifiers in facilities that handle bulk solid materials across the food, pharmaceutical, mineral, plastics and general chemical industries. “The Aschaffenburg office will have full access to Flexicon’s engineering resources, including details on more than 20,000 installations of Flexicon bulk handling equipment and engineered systems worldwide,” notes Mr. Bourton. Flexicon is a world leader in bulk handling equipment including: flexible screw conveyors; tubular cable conveyors; pneumatic conveying systems; bulk bag filling, unloading and conditioning machinery;
box, drum and container tippers; manual dumping stations; weigh batching systems; and automated plant-wide bulk handling systems integrated with new or existing process equipment. Flexicon (Europe) Ltd is located in Whitstable, Kent, England, and is a fully owned subsidiary of Flexicon Corporation of Bethlehem, Pennsylvania, USA. In addition to the Kent manufacturing location, Flexicon
Corporation owns and operates manufacturing facilities in Brisbane, Australia and Port Elizabeth, South Africa, and maintains factory-direct sales offices in Barcelona, Spain; Santiago, Chile; and Singapore. For information contact Flexicon Europe Ltd, Matthäusstrasse 13, 63743 Aschaffenburg, GERMANY, +49 170 8 187 613, www. flexiconeurope.de, Email: email@example.com
FPE LAUNCHES WORLD-CLASS TEST FACILITY AND MANUFACTURING FACTORY
pecialist engineering firm FPE Global has launched its new state of the art test facility and manufacturing operation to strengthen its services to a growing international customer base. Located at the company’s UK headquarters close to Manchester Airport, the 30,000 sqft facility is one of the largest and most advanced in the country. The test facility covers 3,500 sqft and offers a full spectrum of materials
Bulk Solids Today
handling technology, including a multi-phase 500m pneumatic conveying system, which is the only one of its kind in the UK. The new facilities have been built with the sole purpose of helping customers to reduce risk with capital investments associated with materials handling infrastructure. Unlike other test facilities that offer only pilot or lab scale capability, the array of materials handling technology on offer at FPE Global allows customers to
conduct full scale material handling trials prior to final specification and purchase order placement. The manufacturing facility has been specifically designed to enable lean and efficient materials flow, as well as providing separation between mild steel and stainless steel production to ensure the highest quality standards are met. The new facility also provides full scale assembly and test capability to ensure that new products and systems are fully built and tested prior to despatch. This will allow for a ‘vertical start up’ when products arrive to customer’s facilities. David Cooper, Chief Executive at FPE Global, said:“The launch of the new manufacturing and test facility is another key step on our growth journey as we enhance our services to clients around the
world. With one of the largest and most advanced facilities in the country, we are now able to provide a world class service to our customers from initial concept through to on site delivery, start-up and throughout the life of the installation. This full scope capability is what sets us apart from our competition and enables FPE Global to guarantee maximum efficiency and return on investment for our customers.” FPE Global was backed by private equity firm NorthEdge Capital in 2014 and is on track to achieve sales of £16m by the end of 2017. www.fpeglobal.com
NEW SALES MANAGER FOR RDS MME
ASSOCIATED BRITISH PORTS ORDERS FIVE NEW GRABS
o facilitate an expansion in trade, Associated British Ports (ABP) at Ipswich has placed Orders for the Supply of Five New Grabs from pALM Bulk Solutions Ltd, the UK Dealer for MRS Greifer GmbH in Germany. The Grabs are all of high close, Clam shell design, the largest of which will have a capacity of 13.0 m³ and is designed for handling a wide range of Bulk Materials with a bulk density upto 1.0 t/ m³ including Fertilizer, Grain, Soya, Animal Feeds and similar materials. With a Grab self-weight of nearly 8.0 tonnes, it is suitable for connection to ABP’s dockside crane with minimum 21.0 tonnes lifting capacity. A powerful 37.5 kW integral hydraulic power pack ensures rapid opening and closing rates to achieve high levels of performance, critical to minimise the amount of time in unloading vessels where excessive delays can generate high level of demurrage cost. The second Heavy Duty Hydraulic Grab of 3.5 m³ capacity is designed for handling material, upto 1.5 t/m³ including Sand and Aggregates and is provided complete with an adaptor plate to suit ABP’s dockside material handler.
The remaining Three Grabs ordered, range in capacity from 4.0 to 5.0 m³ capacity and are suitable for materials with bulk density upto 1.0 t/m³ and again provided with an adaptor plate to suit ABP’s dockside material handlers. Each of the Grabs incorporate a unique design of Fork Lift pick up point, high close shells rated for zero degrees repose angle and close tolerance spill free Pantanax wear resistant lower and side knives, the design of which has been developed in conjunction with ABP on several previous Grab Orders during recent years where Grabs have been supplied to ABP at Ipswich, Kings Lynn, Garston, Newport and Ayr. Video of a typical MRS Clamshell Grab operating at ABP Port of Kings Lynn can be seen on the following YouTube link https://www.youtube.com/ watch?v=19iB0FLAeek This brings the number of MRS grabs supplied in the UK to 99, for sure there will be a big celebration when number 100 is ordered, if that could be you, then for further details or information, please Contact Andrew Mitchell at pALM Bulk Solutions on 01353 665030, mobile 0780 1024578 or email firstname.lastname@example.org
imon Harrison has been appointed as the new Sales Manager for RDS MME in the North East of England. RDS MME, a distributor for RDS Technology, is pleased to report the addition of their latest team member. Simon has extensive knowledge of the mobile machinery sector, including many years spent selling forklift trucks in the UK. John Evans, sales director for MME, said, “We are delighted to have Simon on board and are looking forward to some great results in the North East.” Simon Harrison, sales manager for MME, said, “Our LIFTLOG range of forklift weighing and load monitoring products are just what the forklift market needs to increase safety and productivity in warehouse operations. I am
Simon Harrison, Sales Manager for RDS MME North East
really looking forward to seeing these products make a real difference to this sector.” For more information about RDS Technology and RDS MME on-board weighing systems for forklift trucks and other mobile machinery, contact RDS on: 01453 733300 or email email@example.com. For enquiries from the North East, South East and South West of England, call RDS MME direct on: 01249 472446 or email: firstname.lastname@example.org.
ROTECH FOR RELIABILITY! ROTECH motion sensors can be used whenever information on shaft speed, position, completed revolutions, etc, is required, for indication, control, interlocking, alarm initiation, etc.
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Bulk Solids Today
IAA NEWS: TRUCK PARKING EUROPE IN THE FLEETBOARD STORE FOR APPS Daimler FleetBoard GmbH offers truck parking app
n its FleetBoard store, Daimler FleetBoard GmbH offers apps from partners in the sector, now including the Truck Parking Europe app, Europe’s largest free platform for truck parking spaces. With over 250,000 downloads, over 24,000 parking areas and over 400,000 parking spaces across Europe, Truck Parking Europe is the most successful truck parking app. At IAA Commercial Vehicles 2016, telematics provider Daimler FleetBoard will present the new FleetBoard store for apps. It was deliberately conceived as an open platform
to offer partners in the sector the opportunity to contribute useful apps for everyone involved in the transport industry, thereby improving the overall efficiency of road freight transport. Here, customers will now be able to find Truck Parking Europe. The app shows truck drivers across Europe the best, most secure and available parking areas for trucks along their route. This saves time, enables efficient planning of rest periods and improves truck drivers’ safety. The parking options can be rated by the community of over 250,000 European truck drivers.
TEREX CONSTRUCTION APPOINTS PRODUCT SPECIALIST
lobal equipment solutions provider, Terex Construction, has appointed Adam Phillips to the role of Product Specialist at its UK manufacturing facility in Coventry. With several years’ experience at Terex, working in engineering and product development roles, Adam has a detailed understanding of the Terex compact portfolio and construction equipment marketplace, both in the UK and internationally. In his new role, Adam will work closely with Terex distributors worldwide, providing in-depth training on the company’s latest range of backhoe loaders, site dumpers and compaction rollers. Moving forward, he will also be responsible for the development and delivery of all online distributor training programmes. Paul Macpherson, Sales and Marketing Director at Terex Construction’s Coventry facility, commented: “With a global distributor network operating in more than 60 countries
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worldwide, providing access to comprehensive, one-to-one product training is a key corporate priority. “We are delighted that Adam has taken on this new role. With excellent product knowledge and a thorough understanding of the Terex business, we’re confident that his capabilities will help to keep our global network upto-date with the latest product innovations and equipment operation instruction.” Commenting on his appointment, Adam added: “I’ve grown up as an end user of Terex products, working within the agricultural and construction sectors, so have first-hand experience with a number of models. This new role is an excellent opportunity to utilise this knowledge and help to keep distributors up-to-date with the latest product operation information.” www.terex.com
FleetBoard customers can simply search for the Truck Parking Europe app from their work station and send it “over the air” to their fleet – to individual trucks, multiple trucks or the even the entire fleet, as they wish. The truck driver accesses the available apps using the driver tablet, the FleetBoard DispoPilot.guide. “With Truck Parking Europe, we support truck drivers every day. The collaboration with Daimler FleetBoard takes
us further in increasing the efficiency of the logistics sector,” comments Niels de Zwaan, Managing Director Truck Parking Europe. All apps offered in the Fleetboard store undergo a quality assurance process, ensuring that they meet FleetBoard’s high security standards. www.ptvgroup.com
SETTING A NEW STANDARD FOR WAREHOUSE MANAGERS
n collaboration with Logistics Learning Alliance (LLA), the UK Warehousing Association (UKWA) has developed and launched a new Warehouse Manager Certificate of Professional Competence (CPC). The study programme involves both guided learning hours and distance learning and, once successfully completed, leads to a qualification which is equivalent to Level 4/5 of the Qualifications and Credit Framework. The UKWA Warehouse Manager CPC was officially launched in September with a pilot programme at LLA’s training centre at Coalville near Leicester. Peter Ward, UKWA’s CEO, commented: “The course is focused, relevant and designed to meet the needs of the industry and our aim and expectation is for the UKWA Warehouse Manager CPC to become the recognised industry standard of achievement for Warehouse Managers.”
LLA’s Managing Director, Peter Jones, said: “The course will not only set the UK standard but will also meet global standards for the future. It will be an on-going programme for anyone aspiring to become a Warehouse Manager or Warehouse Managers looking to achieve a recognised standard and gain a qualification.” In addition to the Warehouse Manager CPC qualification, Logistics Learning Alliance is working with UKWA to provide a standard for warehouse supervisors. This course will be introduced in spring 2017. For further information regarding UKWA’s Warehouse Manager CPC visit www.ukwa.org.uk
VEGA TEAM STEPS UP TO THE PLOD CHALLENGE! VEGA support crew who worked in shifts through the night to rendezvous at the check points all along the route. They were the ‘unsung heroes’, providing sustenance, support and plasters! The hike went very well, with team ‘Challenge 64’ completing the course in a very respectable 14 ¾ hours. There were a few blisters and a bit of sunburn, especially from the last stages across Seven Sisters and Burling Gap! “It was a great achievement, experience and team building event, not just for the team doing the walk and their support crew, the whole company got behind us”. Said Ray Tregale, Managing Director of VEGA Controls. The challenge was in aid of Action Medical Research for children, you can find out more about their fantastic work on their website. Fundraising donations came from all areas
The VEGA Controls team just after completing their 40 miles. From left: Doug Anderson, Ray Tregale, Agnieszka Sielaszuk, Tom Foreman, Matt Westgate and Peter Lewis
of the company, staff, family and friends, suppliers and customers, fundraising events – including a cream tea day where 200 cream teas were distributed on behalf of VEGA by AMR, enjoyed across the country in offices and homes on special VEGA yellow picnic cloths! You can still donate, www.action.org.uk/sponsor/ vegacontrols, the page will be open until the 15th October. After which, one lucky donator will be drawn to win a 2ft
high Paddington Bear, who is currently celebrating 40 years of being the mascot of Action Medical Research! Ray concluded, “On behalf of the VEGA team and company, we would like to express our deepest thanks to all those who donated and supported us, and with a total currently approaching £4000, all the money raised has gone to a great cause.” www.vega.com/uk Email: email@example.com
Strengthen your process When handling abrasive materials, the use of abrasion resistant rotary and diverter valves reduces the downtime for replacement or re-adjustment of worn parts, the refurbishment costs and thus the cost of ownership. Also the valves have a more predictable and reliable performance, making preventative maintenance schedules easier to establish. DMN-WESTINGHOUSE abrasion resistant ceramic coated or Ni-hard rotary valves and the specially designed, rugged BTD ball diverter can help you strengthen your process.
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COMPONENTS FOR BULK SOLIDS OLIDS HANDLING
n the 16th July, staff from VEGA Controls took part in The ‘South Downs Plod’, a 40 mile/64Km night and day hike across The South Downs of England, from Devils Dyke, North West of Brighton to Beachy Head, Eastbourne. It involved a team of 6 navigating and walking through the night and finishing the following day on Sunday 17th July, via a series of check points along the way. The event was to raise funds for Action Medical Research, a children’s medical charity. The ‘Plod’ started at midnight on a (thankfully) warm and dry summers evening, the VEGA team ‘Challenge 64’ set off amongst a tide of headtorch lights with almost 300 walkers involved. However, along with the 6 walkers from VEGA participating in the event, there was also an indispensable
DMN UK Ltd. T +44 1249 818 400 firstname.lastname@example.org
www.dmnwestinghouse.uk Bulk Solids Today
SPORTS DIRECT COVERAGE MUST NOT BE BAD NEWS FOR THE LOGISTICS INDUSTRY, SAYS UKWA CEO
he negative publicity surrounding Sports Direct’s treatment of its warehouse staff, must not be allowed to tarnish the reputation of the logistics industry by making firms in the sector appear unattractive employers, says Peter Ward, chief executive officer of the UK Warehousing Association (UKWA) – the leading trade body for the supply chain sector. Sports Direct has featured prominently across the media throughout the summer months after the working conditions at one of its warehouses were described as being closer to “that of a Victorian workhouse than a
modern High Street retailer.” “It would be easy to conclude that the media storm surrounding Mr Ashley and the treatment of the workforce at his company’s distribution centre, will have negative ramifications for the whole logistics industry,” Peter Ward comments. He goes on: “While no doubt there will be some people who now perceive logistics to be a poorly paid, low-skilled industry where people spend their days being mistreated in cold, dirty warehouses, the reality is quite the opposite. “The pay, working conditions and long term career prospects of staff across all levels of
the industry compare very favourably with other markets and the truth is that the logistics industry is a dynamic place to be at the moment. “Logistics is the ‘new retail’ and the rapid growth of e-commerce (and Amazon in particular) and the transition of traditional warehouses to fulfilment centres are just two of the factors impacting on the way the sector operates. “It is essential that logistics grabs the attention of our brightest school and university leavers and UKWA is working hard to encourage more young people to enter the industry as a conscious career move.
“There are positive signs that our efforts are paying off and the Sports Direct debacle will not de-rail this progress.” www.ukwa.org.uk
BEAM GRAB ATTACHMENTS SUPPLIED TO LYNX PRECAST
stablished in January 2014, Lynx Precast is a specialist in the design, manufacture and installation of precast concrete flooring systems. Based near Ashington, approximately 10 miles north of Newcastle upon Tyne, Lynx Precast has currently invested over £2 million in its T Beam and Hollowcore manufacturing plant, which is the only facility in the North East of England to produce both products. The concrete flooring company supplies a complete range of products, including traditional beam and block, insulated beam and block, hollowcore slab, stairs and landings. The company supplies its products to all sectors of the UK construction industry including housebuilders, main contractors, groundworkers, civil engineering contractors, builders merchants and self-builders. Lynx Precast understands that each site and customer has different delivery
Bulk Solids Today
requirements and expectations, and that when delivering its products, vehicles and material handling attachments must be specified to suit. To further excel in its customer service offer, Lynx Precast contacted B&B Attachments, the leading supplier of forklift attachments and specialist bespoke material handling solutions, to supply it with beam grab attachments. The grabs fitted to Lynx Precast crane delivery vehicles, assist in the smooth delivery process of beams where “supply only” customers do not require the aid of mechanical offloading facilities on site. Each Beam grab, with optional lifting hooks and a rubber pad gripper arrangement, is designed to pick up a range of different sized beams and profiles. Lifting either 4 or 6 beams at once, the beam grabs supplied to Lynx Precast also have individual ball lock valves fitted, which enables single beams to be clamped
and released when required. The universal crane mounting plate enables the attachment to suit various adaptors, and the quick release couplings allow a quick change over to alternative attachments when required. Andy Teasdale, Managing Director at Lynx Precast comments “Our customers are our priority. We wanted to make our delivery process as smooth and as safe as possible. The Beam Grabs supplied and manufactured by B&B Attachments have helped us to achieve this. The ease of use and reliable operation of the attachments when moving our products has also helped improve daily productivity.” Established for over 35 years, B&B Attachments Ltd is the leading fork lift truck attachment
company in the UK and Ireland. B&B prides itself on providing the most comprehensive range of attachments available from one provider. This includes solutions for ancillary systems, such as cameras and weighing systems from leading manufacturers, such as KAUP, Liftek and MoTec, whilst also designing and manufacturing bespoke, specialist attachments in-house for customers with unique requirements. Information on B&B Attachments products and services can be found on www.bandbattachments.com.
HOPPECKE MOVES INTO FOURTH QUARTER WITH MORE GOOD NEWS
oppecke Industrial Batteries goes into the fourth quarter of 2016 full of confidence after an excellent year to date and the promise of much more to come. The leading specialist in industrial battery systems and the largest battery manufacturer in European ownership, Hoppecke has seen its sales soar throughout the year and has just finished a highly successful IMHX 2016 exhibition where it saw visitor numbers much higher than on previous occasions and genuine enquiries at a record high, especially for the company’s lead acid, fibre nickel cadmium (FNC), lithium-ion (LiOn) and explosion-proof batteries. Hoppecke also received a huge number of enquiries relating to its chargers, its service contracts and its green energy solutions using renewable energy sources.
At the same time, the company has invested in a fleet of brand new service vans with contemporary livery that enhance the image of the company and ensure customers receive the best quality of service throughout the UK. This follows on the back of the recent announcement by Hoppecke that it has taken on two new regional service managers and strengthened its entire senior management team. The company has also introduced an improved fiveyear warranty service for all its motive power customers and signed long-term service agreements with such major rail companies as Bombardier, Siemens and Alstom. On the personnel front, Jason Howlett, already Managing Director of Hoppecke UK and Ireland, has been given the position of
Regional Managing Director of Western & Northern Europe while Lynne Morris has been appointed as Hoppecke UK’s new Human Resources Manager. Lynne brings with her significant experience of working at very senior levels in a number of organisations, with particular skills in organisational development and transformational management. Says Jason Howlett: “This
year has been an incredibly exciting time for Hoppecke and the team has worked wonders in expanding our markets and improving the level of service we deliver to existing customers. I am also delighted that I will now be able to play a central role in transforming the wider northern/ western European business and building an even greater future for our company.” www.hoppecke.co.uk
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PROCESS INDUSTRY – WHAT’S THE ENERGY AND EMISSION SAVINGS POTENTIAL?
he process industry has a lot in common with the construction sector in terms of ways of reducing energy consumption and CO2 emission. In both cases a key to sustainability lies in viable solutions that lower the operating costs by minimising heat transfer and therefore – the final energy demand. How much can a single factory save with proper insulation? According to Energy Savings Opportunity Scheme (ESOS) regulations, organisations that qualify as large undertakings must choose one or more routes to compliance that cover all areas of significant energy consumption and are bound to carry out ESOS assessments every 4 years. These assessments are audits of the energy used by their buildings, industrial processes and transport to identify cost-effective energy saving measures. Unfortunately, the savings potential is not always recognised. “The level of insulation applied may be based on a minimum investment decision following requirements regarding the maximum surface temperature to avoid personal injuries, minimum process needs or based on generic maximum heat loss rates only” says Craig Treanor, Technical Support Manager at Paroc Ltd and certified TIPCHECK engineer. “There is a recognised gap between current and cost-effective insulation levels” he adds. RECOGNISING THE POTENTIAL How much could we save? The answer to that question can be found in the European Industrial Insulation Foundation report “Climate Protection with rapid payback – Energy and CO2 savings potential of industrial insulation in EU-27”. According to the non-profit organisation, the share of equipment without insulation or with damaged insulation in EU is conservatively estimated to
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be 10%, 6% and 2% for lowmiddle- and high temperature surfaces respectively. There is a significant energy saving and CO2 mitigation potential related to improved thermal insulation in industry. This potential is currently untapped, despite being cost-effective to implement. The report covers several case studies where TIPCHECK energy audits were performed. In a chemical plant in France, 30 valves and 35 storage tanks rooftops were uninsulated, generating a total of 12.600Mwh of unnecessary heat loss per year. – An investment of €100,000 which covered audit, insulation instalment and material costs, allowed to achieve approximately €405,000 of energy cost savings in the first year and €505,000 in the following years. Payback? Merely two and a half months – explains Craig Treanor from Paroc Ltd. BENEFITS FOR EUROPEAN INDUSTRY The study goes the extra mile to describe the potential of energy and emission savings for all European Trading System members, including the UK. EIIF estimates that if the plant managers in EU-27 would consider economically viable solutions such as insulating bare surfaces to cost-effective levels and repairing damaged insulation in industry, we could save approximately 620 PJ of energy and cut the emission of CO2 by 49 Mt yearly. This energy savings potential is equivalent to the energy consumption of all Dutch industry, while the annual CO2 reductions potential is equivalent to 18 million medium-sized cars each running 12,500 kilometres per year. In order to tap into this potential, the assessors at EIIF estimate a one-time investment of €900 million is required. At current prices, it would help reduce industry production costs
Europe-wide by €3.5 billion every year and diminish the gas import from Russia by up to 12.5% The average payback period of industrial insulation improvements is 1-2 years and it is easy to achieve compared to other Best Available Techniques. It can be even shorter depending on energy prices, energy losses and insulation costs. The complete study can be found on European Industrial Insulation Foundation’s website. TIPCHECK YOURSELF! TIPCHECK (Technical Insulation Performance Check) is laid out in conformance with article 8, Annex 6 of the Energy Efficiency Directive, and with EN 16247 and ISO 50001/50002, as a contributing industrial process energy survey – and supports the requirement for auditing every 4 years, working to reduce energy consumption to reach the -20% target in 2020. The aim of the TIPCHECK Programme established by the European Industrial Insulation Foundation is to provide industry with a standardized, high quality thermal energy audit tool focusing on the thermal performance of technical insulation systems. TIPCHECKs quantify the amount of energy and money an industrial facility is losing with its current insulation system (including uninsulated parts). Payback on insulation investments can be clearly demonstrated by industrial site temperature and heat flow measurements, calculations and thermal imaging. Paroc has trained a number of TIPCHECK Engineers in order to serve the industrial insulation sector and lead assessors with better energy saving advice. For more information contact
Paroc’s Product and Technical support at www.paroc.co.uk. Paroc is one of Europe’s leading manufacturers of energyefficient insulation solutions for new and renovated buildings, marine and offshore, acoustics and other industrial applications. Throughout its over 75-year history, the Finnish supplier has built a reputation for innovation, product performance, technical expertise and sustainability. Paroc aims to remain an innovative and trusted partner for a sustainable built environment. Paroc employs around 2,020 people in its production plants in Finland, Sweden, Lithuania and Poland and Russia and in sales offices in 14 European countries.
NARROW AISLE RAISES FUNDS FOR TRANSAID
embers of the Narrow Aisle team took time away from the company’s hectic stand at the recent IMHX to compete in the Transaid ‘Lift to Save Lives’ challenge. The challenge aimed to raise funds for the charity as well as awareness of the logistical difficulties faced by Transaid when delivering vaccines in Sub-Saharan Africa. Exhibitors were pitted against one-another to find out who could generate the most power on a ‘Ski-Erg’ exercise machine and, in doing so, move the most vaccines
G Left to right: Scott Whittlestone, Chris Newton and Pete Lancaster
and ‘save the most lives’. The challenge raised £5375 for Transaid throughout the course of IMHX. The winning team was Zonzini, whilst Toyota Materials Handling was top of the pile in the forklift truck division. Congratulations to both teams! www.flexi.co.uk
FPE STRENGTHENS TEAM WITH CFO APPOINTMENT
pecialist engineering firm FPE Global has appointed Tim Hines as Chief Financial Officer (CFO) to support its continued growth strategy. Tim joins FPE with over 11 years’ experience in senior financial management positions. He has spent the past two years as finance director at mining solutions firm Joy Global, and has held other senior roles at Manchester Airport, HJ Heinz, Kellogg’s and KPMG. In his new role, Tim will be responsible for driving the company’s financial strategy as the Manchester-headquartered business continues to target growth in overseas markets. An expert in bulk materials handling and pneumatic conveying, the company has already doubled order intake in 2016 and sales are forecasted to grow to £16m by the end of 2017. Tim’s appointment comes after a period of investment in FPE’s senior management team. The company introduced Dave Cooper as CEO in March this year and has appointed a number of industry experts as
SUPPLY CHAIN DEAL IS A HEALTHY OPTION FOR ZERO NOODLES
it shifts its focus to a number of high growth sectors. This includes specialist materials handling, food and beverage, pet foods, detergents and chemicals and renewables. David Cooper, CEO at FPE Global, said: “We’re delighted to have Tim on board as we target further growth on an international scale. Tim’s experience in capital goods businesses coupled with his knowledge of our core markets will be a great asset to the team as we look to build on recent successes and get more deeply engrained with our core markets and key customer base. Tim Hines, Chief Financial Officer at FPE Global, added: “FPE has a clear growth strategy and with increasingly strong sales figures the role represents an exciting opportunity. The company has the right team in place to offer a best in class service to customers and I am confident that we can cement our position as a global leader in the bulk handling space.” www.fpeglobal.com
low Nutrition Ltd has appointed Walker Logistics to manage the UK supply chain for its Zero Noodles brand of diet food. Hugely popular across Asia, Zero Noodles are eaten as a replacement for rice and pasta and contain only 4 Calories per 100g serving. Sales of Zero Noodles, which are sold mainly through specialist health food retailers such as Holland & Barrett and Boots, are increasing across the UK and this growing demand prompted Glow Nutrition to seek a dedicated logistics partner for the product. The contract will run from Walker’s 230,000 sq.ft. multi-user ambient foodgrade storage facility in
Berkshire and will involve the receipt, storage and dispatch of full pallet loads. Outgoing shipments will be delivered using Walker’s own vehicles to the DC network of Zero Noodles’ stockists across the UK. William Walker, sales director of Walker Logistics, commented: “The client had previously been fulfilling orders from their own warehouses but, by outsourcing, will save money and improve supply chain efficiency.” www.walkerlogistics.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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Company showcase W
elcome to the latest edition The companies featured of the Bulk Solids Today in this edition are: Company Showcase. This • Dynamic Air Ltd. special feature has been designed to • Flexco Ltd. highlight companies who excel and • Process Link Ltd. provide outstanding service within • Hosokawa Micron Ltd. their respective industries. We believe • VEGA Controls Ltd. each company in this showcase to • Vortex Valves be a leader in their own markets. Europe, Ltd.
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Specialists in conveying, mixing and drying of dry bulk solids
Dynamic Air Ltd., Milton Keynes, UK
Dynamic Air Ltd. test facility
Corporate Description Dynamic Air is a manufacturer of pneumatic conveying systems, vibratory equipment, and process equipment. We provide manufacturing, sales, technical, and service support to customers and representatives worldwide with offices in: • St. Paul, Minnesota U.S.A., • Milton Keynes, England, • Brazil, • China,
Full Scale Test Facilities Our state-of-the-art full-scale test facilities are available to perform: • • •
Full pneumatic conveying testing Blending Mixing
• • • •
Agglomerating Coating Bin discharging Dust collection
• • • • • • • • • • • • • • • • • • • •
Cement Ceramics Chemical Dairy Feed Food Foundry Glass Mining Petrochemical Pharmaceutical Plastics Power Pulp & paper Railroad Refinery Refractory Rubber Steel Wastewater
Air blending and pneumatic conveying system
Dynamic Air provides: • • •
Complete electrical and mechanical design Engineering Start-up services
Sixteen Conveying Concepts: We offer sixteen different pneumatic conveying concepts • Four different vacuum conveying systems • Twelve different pressure conveying systems. Each system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Our 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. Capabilities include the handling of difficult abrasive to very fragile granular materials at capacities exceeding 400 ton per hour and distances exceeding 1500 m in length.
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Preassembled bag breaking and pneumatic conveying system
Dynamic Air Ltd. 26 Peverel Drive, Milton Keynes, United Kingdom Phone: +44 (0)1908 622344 Email: firstname.lastname@example.org www.dynamicair.com
Effective Solutions for Maximising Productivity
or more than 100 years, Flexco has been providing belt conveyor operators around the world with efficient, safe products and solutions for their bulk materials handling systems. Flexco products range from mechanical belt fasteners to controlled flow transfer chutes all designed to maximise your belt conveyor productivity. As an industry leader, Flexco understands that belt conveyors play a critical role in a bulk material handling operation’s productivity. When conveyors run efficiently, they make a real impact on an operation’s bottom line. Flexco takes a holistic approach to belt conveyor systems, recognising each system as a whole and working to address challenges and develop solutions. That’s why Flexco goes beyond manufacturing fasteners, cleaners, and maintenance products to develop real solutions to bulk material handling challenges. Flexco makes products that help maximise belt conveyor productivity including: Belt positioners and trainers • Impact beds and skirting systems • Belt cleaners and plows • Controlled flow transfer chutes • Mechanical belt fastening systems • Ceramic and rubber pulley lagging • Portable belt splice presses • Belt maintenance, safety and installation tools Our most recent product launches include the PTEZ™ and PT Pro™ Belt Trainers, Modular Impact Beds, ATEX certified Cleaners, Slide-out Cartridge Cleaners, FDA/EU 1935 compliant FoodGrade Cleaners. The recently-introduced PTEZ™ Belt Trainer and PT Pro™ Belt Trainer are high-performance tracking idlers designed with the Flexco “Pivot and Tilt” feature. Both may be used in any application that requires tracking to prevent damage to the belt or conveyor structure, including single-direction and reversing belts. Flexco Modular Impact Beds are engineered with maximum capacity in mind, while ensuring full containment. The beds are
designed with universal components that offer effective and affordable load zone protection and feature a 600 mm sectional design, which allows the user to choose the layout of their load zone, depending on application-specific performance requirements. ATEX compliance is demanded by facilities handling materials such as biomass where airborne dust presents an explosion risk, the Flexco EZP1 and MSP Belt Cleaners are accredited by CSA as fully ATEX compliant, with further models to follow. Flexco views its role as more than a manufacturer of products, but rather the provider of belt conveyor solutions for splicing, cleaning, tracking, spillage and belt slippage. As a result, company representatives and distributors meet with customers, analyze conveyor operations and offer solutions designed to reduce downtime, accelerate belt repairs, and help achieve maximum productivity. To support the needs of its customers, Flexco has developed a worldwide network of distribution partners who know Flexco products inside and out. The company ensures that our partners understand not just what its products do, but how they are constructed, and how they are best suited for their customers’ applications. The Flexco team of field representatives and global distributors are always at your service. They can help you evaluate your system’s performance, identify opportunities for improvement, and implement complete solutions. It’s all part of our commitment to being your most valued partner on the job. The company serves customers in a variety of industries – including bulk handling, mining, quarrying, and recycling – on six continents through a global network of subsidiary offices, sales representatives, and distributors. Flexco operates subsidiaries in Australia, Chile, China, Germany, India, Mexico, Singapore, South Africa, and the United Kingdom, marketing its broad line of products through a worldwide network of subsidiary offices, sales representatives, and distributors. Tel: +44 (0) 1274 600 942 www.flexco.com/
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Hosokawa Micron Ltd
osokawa Micron Ltd has an extensive heritage in supporting particle and powder processing activities across a wide range of industries. With a comprehensive equipment portfolio, from laboratory and pilot plant through to full production machines Hosokawa Micron can provide processing solutions that include milling, mixing, powder processing, agglomeration and compaction, classifying, drying and containment. Hosokawa Micron offers customers a single source supply for integrated processing systems and component machinery to meet individual requirements and deliver significant competitor advantage with a philosophy not just to offer a standard machine but to work alongside customers and their engineering teams to provide value added solutions to processing problems.
Choosing Equipment with Added Benefits Choosing the right equipment can provide tangible added benefits for manufacturers and is where a specialist equipment and systems manufacturer, like Hosokawa Micron, with extensive processing knowledge, can assist. As ingredient blending can impact on end product and downstream processes it is important to make the right choice – here we consider how choosing the right mixer for food applications, with the challenges of ingredient variety, complex processing combinations and hygiene and quality, can meet and exceed customer expectations by accurately mixing multiple ingredients, coating, wetting and agglomerating. The first step in making the right mixer choice is to understand the nature of the ingredients to be mixed and what you need as an end result.
Batch or Continuous Historically batch mixing is the most frequently used in food manufacturing with the whole batch identified and traceable for quality control. However continuous mixing offers advantages for volume production. Often the two modes of mixing are used - minor ingredients premixed in a batch blender for introduction alongside a major ingredient to a continuous mixer.
Batch Mixing Systems
Mixing, Coating, Drying – Vrieco Nauta Conical Mixer This conical mixer can carry out 3 processes in 1 machine; blending; coating - efficiently blending small quantities of liquids, waxes or chemicals into the main powder bulk; drying - by applying a vacuum modification to the vessel so that mixing and drying can be carried out in the same vessel thus reducing product transfer issues.
Fast, Intensive Mixing and Agglomeration of Sensitive Ingredients - Cyclomix This smaller, highly efficient conical mixer delivers an intensive yet gentle mixing action without product damage and in short mixing time. When fitted with a cooling jacket it is suited to mixing heat sensitive products. Agglomeration can also be carried out within the Cyclomix.
Powders, Pastes and Slurries – Vitomix For lump free mixing of cohesive and non-cohesive powders, the Vitomix delivers high speed and intensive mixing results. It is ideal for volumes from 500 to 10,000litres and can also be used for moistening of powders, granulating, colouring, heating
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and cooling and homogenisation of sensitive products like brittle granules or freeze dried products.
Intensive Mixing Without Product Deformation – Intensomix This compact mixer has been developed for processes where high shear leads to product deformation and low shear to inadequate mixing. Admixing of liquids can be carried out without undesirable lump formation and the need for a separate de-lumping process. Mixer sizes up to 25,000 litres.
In-line Mixing and Delumping – Hosokawa Micron In-line Disintegrator For manufacturers looking for effective transportation of liquid products between batch processes where sedimentation or settling may occur, the In-line Disintegrator offers effective mixing and de-lumping of thick suspensions or slurries and can readily be installed in pipe systems operating at up to 10barg. There is no need for additional strainers with their associated blocking and cleaning problems.
Continuous Mixing Systems
Hosokawa Micron engineers suggest that to ensure mixing homogeneity in continuous mixing systems that attention is paid to the accuracy and control of the feed system for the powders, solids and liquids – particularly where the residence time in the blender unit is very small.
Pastes and Slurries – Schugi Flexomix The unique Schugi Flexomix mixer/agglomerator is ideal for use in the production of instant products such as soups, beverages and sauces as well as chemical and pharmaceutical products. The Flexomix achieves excellent product uniformity due to the avoidance of demixing in the almost instantaneous blending of all ingredients and can be applied to efficiently disperse small amounts of liquids or solids to a bulk carrier.
Homogenous Mixing and Extrusion – Hosokawa Micron Extrudomix This is a low to medium pressure extruder which can be used to generate very homogeneous pellets up to 5-6mm. The final product can be a paste, plastic mass or extrudate. Email: email@example.com Web: www.hosokawa.co.uk
UniTrak Powderflight Ltd
niTrak Powderflight Ltd is a is a manufacturer of high quality conveying equipment for a large number of products including: powders, granules, pellets, pastilles, fruit, confectionery and many more. The company has over 30 years knowledge & experience within the dry bulk handling industry allowing us to always be prepared and proficient in providing our customers with excellent service and equipment. UniTrak Powderflight was originally called Angus Powderflight and was founded by Bill Angus in 1982, providing Powderflight aeromechanical conveyors and Bulk Bag Unloaders. Bill retired in 2000 and a company called UniTrak Corporation Limited purchased the company from Bill. With the takeover in place this meant that UniTrak Corporation could add their unique TipTrak™ bucket elevator to the Powderflight equipment family. Our Powderflight aeromechanical conveyors are a versatile and cost-effective means of moving a wide range of free flowing materials. They are dust-tight, have low power consumption, have high throughput capabilities, small footprint and are ideal for dedicated batches. The TipTrak is a gentle handling bucket elevator that operates horizontally and vertically from a single drive. Rubber “chains” provides the quietest possible elevation of friable products. Interlocking buckets that never separate eliminate product waste from spillage and lowering maintenance costs. Our Flexible Screw Conveyors are simple to install and operate. With only one moving part it means that maintenance requirements are minimal – achieving longterm production reliability with unsurpassed versatility. The Bagstander bulk bag dischargers is a frame built of heavy-gauge stainless or carbon steel which is finished with a durable Steel-It paint. The frame is formed in upper and lower sections. Our Bagstanders ensure no leakage and zero dust escape during any unloading operation. It’s not only our equipment that makes UniTrak Powderflight such a reputable company, but our experienced, dedicated and loyal staff who keep pushing the boundaries on what can be achieved. We only manufacture high quality equipment and this is proven with our ISO9001 certification and principles. This is kept every year by our excellent customer service, operating systems, equipment and companywide policies & procedures. UniTrak Powderflight attaches high priority to testing at the design stage. With a number of existing and potential customers coming up with new materials to convey UniTrak Powderflight has its own dedicated testing facility that demonstrates the capabilities of Powderflight conveyors, TipTrak bucket conveyors, UniFlex & Bagstander equipment for a specific project. Finding the solution for a difficult product is what we do best, proving that our equipment operates effectively on the most challenging of bulk material, products and ingredients. When our customers place an order, we want them to have 100% confidence that UniTrak Powderflight has the best solution for their project. For this reason we prefer where possible to have had the opportunity to test materials beforehand in the
industrial environment of its dedicated testing facility. Here different conveyors are installed together with FIBC handling equipment to identify the suitability of the equipment based on flow rate, damage to the product (if any) as well as abrasiveness of the product and how that my impact on wear. This also helps determine what optional accessories may be required. Customers or potential new customers are invited to bring a sample of the material they would like to be tested. They are given the option of witnessing first-hand how the equipment performs. Customers (potential or existing) are also welcome to submit a sample if they prefer. A live test video of the product along with a full detailed report and any recommendations will be provided. The test plant is available to both existing and potential customers and is free of charge. It is used not only by UK companies but from others overseas as well. UniTrak Powderflight conveying equipment are in operation all over the world and are backed up by our quick spare parts and service team. In doing so offering an excellent after sales service which we pride ourselves on. For more information contact UniTrak Powderflight on 01457 865038, email: firstname.lastname@example.org or visit wwww.unitrakpowderflight.com
Bulk Solids Today
VEGA Controls Ltd VEGA manufacture a range of level pressure sensors and switches for bulk solids processing, handling and storage (and liquids too). Employing wide ranging (contact and non-contact) technologies combined with their expertise, means that they can provide a solution in even the most arduous and demanding applications.
adar level sensors are already a proven a success story for bulk solids level. In some industries they have superseded electromechanical and ultrasonic measuring devices. This is due to their proven immunity to in-flight dust, air movement, pressure, temperature, delivered by good focusing and no loss of echo – even during pneumatic filling – so the areas of application are extended. Although users are increasingly adopting microwave technology, a level sensor which truly covers all applications has still not yet been realised. With a higher frequency and performance capability of 80GHz, the new VEGAPULS 69 radar designed for bulk solids comes a big step closer to this ideal. This new 80 GHz contactless radar level device is changing bulk level measurement forever. Its much higher operating frequency enables a much tighter focusing of the transmission signal, so it easily avoids all interference from internal structures or build up inside vessels. Also using latest generation microwave components, even the tiniest of reflection signals can be measured and it can ignore even the heaviest of build up. This means previously difficult to measure products with very poor reflective properties, such as high purity plastics, fine ash, cement powders or wood chips, can now be measured with confidence both during filling and emptying, with long term reliability. This ability makes even the ‘everyday’ applications really simple to measure, as it has so much performance in reserve. VEGAPULS 69 also offers versatility over a wider application range. It has a measuring range capability to work over one or two metres... right up to 120 m, a speed of response of less than 1 sec and an accuracy of ±5 mm, offering solutions for the more ‘unusual’ assignments, such as fast response positioning for conveyor car systems and stockpile cranes.
Bluetooth Technology To add to this, VEGA engineers came up with something special. They have developed a Bluetooth communication system for all ‘plics’ transmitters in the VEGA product range, along with a free App to wirelessly communicate and set up the device with Bluetooth from smartphone, tablet or PC. This makes it ideal for the more remote, inhospitable, high level or inaccessible areas of the plant. The Bluetooth set up and communication option is backward compatible for every VEGA plics transmitter made since 2002. Inspired by the spirit level Apps on smartphones, there is even an App tool to make sensor aiming or alignment in the silo easy. The main benefits all these new technologies provide is the cost savings and reliability right from the start. Quick 22
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delivery, simple installation, small transducers for easy handling, easy wiring, intuitive and simple to set up, even from your smart phone if preferred. Aim the sensor with the most highly directional of signals, (use the free App if it’s easier for you) to measure from top to bottom, with smooth analogue measurement, not a series of jumps, while being immune to filling dust and antenna deposits. VEGAPULS 69 is delivering a higher level of confidence from plant engineers and managers to process operators about their sensor performance, stock availability, process control and improves efficiency.
Solutions for bulk solids, liquids and gases, including: • • • • • • •
Level and Contents measurement Inventory Control – local and remote High and Low point level detection with SIL conformance Interface measurement and switching Pressure measurement Remote inventory systems and web based software Density, mass flow measurement and switching
Instrument technologies manufactured by VEGA : • • • •
Radar level Transmitters Guided Wave Radar (TDR) Pressure and DP Transmitters Nucleonic gauging for non contact level, density and weighing • Admittance/Capacitance • Vibrating point level switches for solids and liquids • Microwave barrier level switches • Conductivity point level switches • Wireless communication systems Approval portfolio includes ATEX dust and gas, mining, safety and environmental to SIL 2/3. VEGA provide peace of mind to users with direct, expert advice on level and pressure solutions followed by great after sales service. All VEGA products have a 3 year warranty; combining quality, product design and years of experience. www.vega.com/uk Email: email@example.com
Solids & Dry Bulk Handling Solutions A Global Business Partner Founded in 1977, Vortex specialises in the design and manufacture of components to transport and control the flow of solids and dry bulk material. Vortex’s design philosophy is to develop products that compensate for wear, require minimal spare parts, have in-line maintenance capabilities, and provide a longer service life than market alternatives. Throughout the world, over 15,000 companies in the chemical, food, plastic, grain, minerals, and power industries rely on Vortex’s innovative slide gates, diverters, iris valves, and loading solutions to improve process efficiency.
World’s Leading Expert in Handling Dry Bulk Solids Vortex clients can be assured they are getting the best solutions available on the market. By listening to their needs and relying on Vortex’s in-depth knowledge of dry solids, Vortex engineers can develop the right solution to meet the most demanding applications. The result is a product that will out-perform and out-last typical components found on the market today. Vortex’s knowledge of dry bulk solid processing is unprecedented. For almost 40 years, Vortex has delivered innovative solutions to a wide range of industries, handling thousands of dry bulk solids.
Quality Assurance and Customer Service Quality assurance in manufacturing is the most important prerequisite for the optimal performance of Vortex products in the field. Vortex’s client-focused quality management system is registered to ISO 9001:2008 and covers every aspect of product quality and technical services, from initial inquiry to product performance. With a customer service network that covers over 40 countries, Vortex can deliver global solutions at a local level. Specialists are available to contact at any time and can be quickly on site.
Innovative Products for Process Improvement Vortex offers a wide range of solids handling components that suits most materials and applications. Selecting the right piece of equipment is critical to the success of any dry bulk material handling system. Misapplied and design deficient components add unexpected costs and inefficiencies in process. The characteristics of dry bulk solids are endless, so there is no all-encompassing solution for every application. This is why Vortex offers the world’s widest range of valves and loading solutions for handling nearly any type of dry solids, from fine powders to heavy ore.
QUANTUM SERIES Valves for Dry Bulk Processing & Conveying Vortex Quantum® Series slide gates and diverters are the valves Vortex customers have been using for decades to shut off, meter, and divert their dry bulk material. It’s Vortex’s traditional line of valves for dry bulk processing and conveying through gravity flow or pneumatic (pressure or vacuum) conveying. Some of the industries that use Quantum valves include, but not limited to: agriculture, chemical, coffee, dairy, foods, milling, pet food, petrochemical, pharmaceutical, plastics, rubber, textiles, tobacco, and wood.
TITAN SERIES Gates & Diverters for Heavy-Duty Applications Vortex Titan Series slide gates and diverters are engineered for heavy-duty material handling applications. These applications include materials that pose excessive abrasion or wear issues, situations that call for extremely large sized valves / diverters, and conditions that warrant additional considerations that will allow these valves to be as successful as possible in extremely harsh environments. Some of the materials handled with Vortex Titan valves include, but not limited to: alumina, bauxite, cement, clinker, coal, fly ash, gravel, glass cullet, lime, limestone, metal powders, potash, rock, and sand.
LOADING SOLUTIONS Dustless Loading Spouts and Equipment Loading Solutions offer a complete line of telescopic loading chute systems for the loading process. Vortex also custom engineers any loading spout system to meet the most demanding loadout application requirements, including corrosive or hazardous materials, long distances, low and high temperatures, etc. Vortex fully assembles, factory tests and packages every loading spout system before shipping it to a facility to provide ease of installation and to ensure optimal performance once in use. Vortex spouts include a 10-year warranty on any of its cables that breaks due to friction. Some of the materials handled with Vortex Loading Solutions include, but not limited to: petrochemical powders, plastic granules, wood pellets, cement, grains, sand, gravel, or coal. Vortex spouts can be used in open, semi-enclosed and closed vessels: trucks, railroad cars, tankers, ships, barges, and open-stockpiling.
ENGINEERED SOLUTIONS Solids & Bulk Handling Components Built for Application Engineered Solutions for handling dry bulk material have always been a part of Vortex. Their application engineers listen to the customer’s needs and match the right valve to the application parameters. Material characteristics, environment, and valve requirements all must be considered to properly modify the valve to fit the application. Because the combinations are nearly endless, a commodity valve or off the shelf valve will not be enough. Vortex offers literally millions of variations of slide gates and diverter valves to meet almost any dry bulk processing application. Vortex can sometimes take a standard valve and make some minor modifications to fit the customer’s application. Other times the only thing left standard on the valve is the famous black and silver Vortex sticker.
Vortex Global Ltd. Building 1-J, Enterprise House, Darlington, County Durham, DL1 1GY - United Kingdom. Tel: +44 (0) 1325 728 577 Email: firstname.lastname@example.org www.vortexglobal.com
Bulk Solids Today
BULK MATERIALS HANDLING
THE MOVING OF SIEVED DRY INGREDIENTS FROM LOW CARE TO HIGH CARE ENVIRONMENTS IS BECOMING A MUST FOR FOOD MANUFACTURERS SUPPLYING CONSUMER GOODS
he days of throwing a bag of food product through an open sieving machine and collecting it in a bin on the floor, with the hope that it would not get contaminated further whilst waiting for it to be introduced into the process system are numbered. Today hygiene and quality control are of paramount importance to all manufacturers, the risks involved when leaving product within an unclassified area are not acceptable in today’s high consumer demand and quality production. Due diligence must be seen to be carried out when any ingredients are being used especially when dispensing ingredients from possibly dirty pallets and bins. The consequences of mishandling and contamination can be catastrophic to all concerned – the manufacturer – the retailer – and the consumer. Health, wealth and happiness can all be affected!! Litigation can be very expensive and the loss of a big retail purchaser can be disastrous. To overcome the possibility of cross contamination between a ‘dirty area’ and a ‘production clean area’ has become a very necessary requirement. Segregation between the unloading and dispensing area and the manufacturing and processing area has required special consideration to how ingredients can be properly handled and sieved; in addition operator safety becomes a special requirement. Health and Safety demands that dust levels are maintained down to an acceptable level, and, the requirement in most instance to comply with the ATEX regulations all add to the issues which need resolving. When sourcing equipment to carry out this task, it is often difficult to find items which will easily fit together and will suit the space available – a bespoke design being required in nearly all cases. Farleygreene Ltd has now designed a number of suitable options for processors. Available for the small to larger producer, each system provides a simple, effective and clean solution to segregate your ingredient loading and meeting your audit requirements.
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Where small quantities of product are handled the simplest means of total segregation between areas is to locate the sieving machine to the outside of an enclosure protruding from the wall of the clean area. This allows the clean bin to be filled through the enclosure top. By using specially moulded diaphragm seals and sleeves Farleygreene can provide a completely isolated sieving arrangement. In addition when combined with the ‘553-STS’ and ‘Easilift’ sack tip stations, the need to clean all contact components becomes a simple and effortless job, requiring only a few seconds of downtime and just a single operator. Where larger quantities of product are involved, and especially where space is at a premium or distance of product transfer required it is possible to incorporate a vacuum transfer conveyor within the system. The sieve unit can be located up to 40 Meters away from the discharge point thus allowing enormous flexibility within a building. This arrangement provides wide scope of system design. In addition it is possible to charge a number of process points directly without the need for bins or storage hoppers. A system can be designed to suit almost any rate of throughput, and can be incorporated within any type of Farleygreene sieve. For those requiring higher throughputs of multi ingredients a sack tip counter is very often the best option. Comprising a counter located to the segregated area wall with individual sieves mounted upon it to allow one product to each sieve. Using
the unique sealing system between sieve and clean area this arrangement serves the high rate throughput user many benefits. Speed of cleaning without any tools, faster dispensing time, operator comfort. Each system can be supplied with a full dust extraction system, stairways and work platforms. Farleygreene are noted for their ability to provide answers to difficult processing needs, their portfolio includes many blue chip companies who use their services for not only standard sieving machinery but also to problem solve their quality needs. Coupled with this they can provide full certification of all parts within the system as well as spares and service packages to ensure traceability and optimum performance. If you have a need for integrity and segregation of your products to suit audit specifications, Farleygreene can certainly provide the system to suit your requirements. Visit www.farleygreene.com to view the vast range of sieving equipment Farleygreene can provide.
Intelligent Drivesystems, Worldwide Services
A complete range of geared motors rated at 0.12...200kW provides the optimum solution for all drive requirements. For convenient control combine with our decentralised inverter range to 22kW.
NORD Gear Limited
11 Barton Lane, Abingdon, OX14 3NB Tel. No.: +44 (0) 1235 534404 Email: GB-Sales@nord.com
Member of the NORD DRIVESYSTEMS Group
BULK MATERIALS HANDLING
STS MC11 TWIN SCREW EXTRUDER DESIGNED FOR MASTERBATCH PRODUCTION
o make handling even easier, Coperion GmbH, Stuttgart, is presenting an STS Mc11 extruder especially designed for masterbatch production at K 2016. The STS Mc11 twin screw extruder features a specific torque of 11.3 Nm/ cm3 and features a series of improvements including a new manifold with coaxial solenoid valves, improved heat covers, quick-release clamps for the simple, quick replacement of the feed hopper as well as the CSpro basic control system. At its booth at K 2016 (booth B19 in hall 14), Coperion will be presenting the new STS Mc11 with a screw diameter of 35 mm. The STS 35 Mc11 on the booth features a die head specifically developed for masterbatch applications and is equipped a volumetric twin screw feeder from Coperion K-Tron. NEW DEVELOPMENTS FOR SAFER WORKING AND IMPROVED CLEANING Coperion has equipped the STS Mc11 twin screw extruder with a new manifold with coaxial solenoid valves. The result is a highly reliable twin screw extruder. To make it even simpler to work at the machine, Coperion revised the heat covers in a way that enables easy access to the processing section and easy cleaning as
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well. In addition, quick-release clamps facilitate easy feed hopper replacement. To prevent vibrations during operation, the STS Mc11 series has been equipped with an innovative, torsion-resistant base frame like the one in the ZSK series. This base frame supports smooth operation and increased reliability, which ultimately increases the extrusion system’s service life. STS MC11 IDEAL FOR COLOR MASTERBATCHES Color masterbatch processing makes great demands on the compounding process. The pigment and additive parts must be mixed into the base polymer 100% homogeneously to yield optimal product quality. Because of their excellent mixing properties, an operating mode that conserves the product and easy-clean properties, the co-rotating twin screw extruders from Coperion are particularly suitable for this compounding task. The STS 35 Mc11 extruder that will be showcased at K 2016 is engineered for producing color masterbatches. Coperion is exhibiting the extruder with a new die head that was specially developed for compounding colour masterbatches. It allows the strands to flow evenly, with virtually no dead zones.
The twin screw extruder is equipped with the user-friendly CSpro basic control system, which Coperion has used with its ZSK high performance extruders since 2010. Over the years, the CSpro basic has proven to be a reliable, user-friendly control system. In order to feed the pigments simply and precisely, the STS 35 Mc11 has been equipped with a T35 volumetric twin screw feeder from Coperion K-Tron. It yields feeding rates of 1.25 to 2,500 dm³/h, which are ideal for powder and materials that are difficult to feed or sticky. The feeder is mounted on a turntable above the gearbox for simple, flexible handling, easy accessibility and quick cleaning. Coperion (www.coperion.com) is the international market and technology leader in compounding systems, feeding technology, bulk materials handling systems and services. Coperion designs, develops, manufactures and maintains systems, machines and components for the plastics, chemicals, pharmaceutical, food and minerals industries. Within its four divisions – Compounding & Extrusion, Equipment & Systems, Materials Handling and Service – Coperion has 2,500 employees and nearly 40 sales and service companies worldwide.
Dust and buildup on the antenna? No problem! The future is 80 GHz: a new generation of radar level sensors
VEGAPULSÂ 69 is designed specifically for level measurement of bulk solids. Even in dusty conditions, it always provides precise readings. Dust in the silo or buildup on the antenna have no effect. This radar sensor also features unrivalled focusing at a frequency of 80Â GHz. Simply world-class! www.vega.com/radar
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WHICH ACTUATOR DO I NEED FOR DRY BULK SOLID PROCESSING VALVES? Deciding what is the best actuator type to use on a dry bulk processing gate or diverter needs significant consideration. Selecting the correct type of actuator can eliminate costly mistakes and provide optimal performance over the life cycle of the valve. Acquisition costs, running expenditures, maintenance frequency, spare parts, safety, environment, torque, and accuracy all play into the decision-making process.
alve manufacturers need to carefully review each application to ensure the actuator used on any valve is fit for purpose. This is accomplished assessing the following: 1. How much force and in what directions (push, pull, vertical, and/or horizontal) will the actuator need to move? 2. What stroke length is required for a given valve design and bore size? 3. How fast will the actuator need to move the valve blade or flap? 4. How many actuations are required in a given time period or “duty cycle”? 5. What is the desired life cycle for a particular actuation package? 6. How will the actuator be mounted to the valve? 7. Does the application suggest particular safety mechanisms, such as “manual overrides” for use in a power supply failure? 8. Will environmental factors (temperature variations, moisture, vibration, or product degradation) impact the performance of the actuator? 9. Is there space available within the installation area to accommodate the actuator? 10. What type of power supply is available at the plant location? 11. Is feedback required for speed and/or position? Depending on the answers to these questions, it is necessary to decide the best actuation package for application. There are three primary type of linear driven actuators used on dry bulk solid processing valves: pneumatic, hydraulic, and electric. Here are some of the general advantages and disadvantages of each. PNEUMATIC ACTUATORS Double acting pneumatic linear actuators consist of a piston inside a hollow cylinder. Air pressure from an external compressor moves the piston inside the cylinder. As pressure increases, the cylinder moves along the axis of the piston, creating a linear force. The piston returns to its original position by air pressure being supplied to the other side of the piston.
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ADVANTAGES • The design of a pneumatic actuator is quite simple, which usually translates to easy maintenance. Ring seals and seats are generally reliable and can be easily replaced if needed. • In case of electrical supply failure, a pneumatic air cylinder can use solenoid valves to default to close or in the last position. An electric actuator must include a manual override or have alternative power sources for safety issues. • Torque requirements needed for most dry bulk material handling applications can be covered through the use of pneumatic actuators. • By utilising the correct configurations of solenoids, sensors, and PLC programming, pneumatic actuators can provide accurate intermediate positioning. • By using compressed air, pneumatic actuators do not require hazardous materials to operate. • The unit cost of pneumatic actuators is significantly lower compared to other actuators. DISADVANTAGES • In the case of an air supply failure, there is no way to move the blade or flap position of a valve unless there is a Fail Safe compressed air tank in place. • Pressure losses and maintaining clean dry air through the system can make pneumatics less efficient than other linearmotion methods. A compressor will run continually at operating pressure even if nothing is moving. • Even though air is readily available, it can be contaminated by dirt, oil, water, or lubrication, leading to downtime and maintenance. • To operate efficiently, pneumatic actuators must be sized correctly for a specific application. Improper bore size selection can result in slow actuation and potential failure to close off material flow. • Accurate positioning control can be achieved; however, the necessary components to accurately hit intermediate
BULK MATERIALS HANDLING positions can raise costs and complexity. • Pneumatic actuators are not practical on large equipment that require large bore cylinders due to compressed air consumption.
on the direction of rotation of the lead screw. By connecting linkages to the nut, the motion can be converted to usable linear displacement.
HYDRAULIC ACTUATORS Hydraulic linear actuators operate similarly to pneumatic actuators, but an incompressible liquid from a pump rather than pressurised air moves the cylinder. The diagram below outlines the basic design and function of a hydraulic actuator.
ADVANTAGES • Hydraulic actuators are robust and suited for high-force applications. They can produce forces up to 25 times greater than pneumatic cylinders of equal size. • Hydraulic motors have higher horsepower-to-weight ratio than pneumatic actuators. • A hydraulic actuator can hold force and torque constant without the pump supplying more fluid or pressure. • Hydraulic actuators can have their pumps and motors located a considerable distance away with minimal loss of power. DISADVANTAGES • Hydraulic actuators and the power packs required to operate them can have a higher unit cost versus pneumatic or electric actuators. • No matter how much prevention is used, hydraulics will leak fluid. The loss of hydraulic fluid leads to less efficiency, cleanliness problems, potential environmental contamination, and safety issues. • Hydraulic actuators require many companion parts, including a fluid reservoir, motors, pumps, release valves, and heat exchangers, along with noise-reduction equipment. This makes linear systems large and difficult to accommodate. ELECTRIC ACTUATORS Electric actuators are driven by a motor that is connected to rotate a lead screw. A lead screw has a continuous helical thread machined on its circumference running along the length. Threaded onto the lead screw is a lead nut or ball nut with corresponding helical threads. The nut is prevented from rotating with the lead screw (typically the nut interlocks with a non-rotating part of the actuator body). Therefore, when the lead screw is rotated, the nut will be driven along the threads. The direction of motion of the nut depends
ADVANTAGES • Linear electric actuators can be modified to work in lower temperature environments, where pneumatics may have issues with elastomer gaskets and potential frozen water in the lines or cylinder. • Electric actuators offer the highest precision-control positioning. Their setups are scalable for any purpose or force requirement, and are quiet, smooth, and repeatable. • Electric actuators can be networked and reprogrammed quickly. They offer immediate feedback for diagnostics and maintenance. • Electric actuators provide complete control of motion profiles and can include encoders to control velocity, position, torque, and applied force. • In terms of noise, they are quieter than pneumatic and hydraulic actuators. Because there are no fluids leaks, environmental hazards are eliminated. DISADVANTAGES • In case of an electrical power failure, an electric actuator requires a type of manual override or alternative power source to shut off the gate or Fail Close. • The initial unit cost of an electric actuator is higher than that of pneumatic actuators. • A continuously running motor will overheat, increasing wear and tear on the reduction gear. The motor can also be large and create installation problems. • Electric actuators are not suitable for all environments, unlike pneumatic actuators, which are generally safe in hazardous and flammable areas. • The chosen motor limits the actuator’s force, thrust, and speed to a fixed setting. If a different set of values for force, thrust, and speed are required, the motor must be changed. Talk to your valve manufacturer who can help select if a pneumatic, hydraulic, or electric actuator is right for you. By covering all relevant questions and discussing the advantages and disadvantages of the choice actuator, your valve manufacturer can help select the best actuator for your specific situation. www.vortexglobal.com Email: email@example.com Tel: +44 (0) 1325 728 577
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BULK MATERIALS HANDLING
PORT OF SUNDERLAND UPGRADES FLEET AND REINFORCES PARTNERSHIP WITH COOPER
ne of the UK’s largest municipallyowned ports is strengthening its partnership with Cooper Specialised Handling, the UK’s only independent and dedicated provider of specialised heavy lifting solutions, as it enhances its materials handling capability. Port of Sunderland has taken delivery of a new Konecranes 32-1200C, the second heavy duty forklift that Cooper has supplied to the port, which has seen its fortunes change in recent years, with millions of investment into redevelopment and new equipment. Both the new truck and existing Konecranes 32-1200B, which is already well-established as a vital resource within the port, will be serviced and maintained by Cooper’s own fully qualified, ISO-accredited engineers. The port, which covers 106 hectares (264 acres), is looking to grow its extensive trade portfolio comprising imports of forest products, non-ferrous metals, steel, aggregates and refined oil products, plus exports of agricultural limestone and chemicals. With a reputation for achieving rapid turnaround times while also delivering a high quality service, improving its cargo handling capabilities is key to maximising business development opportunities. The partnership with Cooper helped the port to find the most appropriate and
cost-effective way to upgrade its equipment fleet to achieve this aim. Ian Craig, Engineering Manager at Port of Sunderland, said: “When it comes to reliability, we know from experience that Konecranes forklifts will serve us well. However, a reliable piece of equipment is only part of the solution. “The expertise and high level of service that we receive from Cooper Specialised Handling is key to making sure that our fleet operates at peak performance, especially so as we see our handling figures rise each year, and with the addition of this latest machine we look forward to strengthening this important business relationship.” The new Konecranes 32-1200C features a powerful, low emission Euro 4 Volvo tad-871-ve engine and ZF transmission and has been specified with a 5metre mast to improve versatility and facilitate easy handling of a wide range of loads. It is also equipped with an individual fork positioner, since the ability to hydraulically change fork position and carriage width from inside the cabin plays an important role in speeding up the loading/unloading process thereby helping to improve productivity. A dedicated filter kit with the requisite number of original equipment transmission, hydraulics, engine and cabin air filters
will keep the forklift running for 4,000 hours, while additional silencing has been incorporated around the engine and exhaust. The machine specification also includes a seatbelt, warning beacon and reversing alarm to meet regulatory requirements and improve safety for both truck driver and others operating in the working environment. The new Konecranes truck is an important addition to Port of Sunderland’s fleet of forklifts, which range in capacity from 4t to 29t. It will be put to work at the port’s East Quay site on the North East coast. www.cooperhandling.com
CEMEX PLACES FURTHER ORDERS FOR NEW BOBCAT TELEHANDLERS
EMEX representatives visited Bobcat’s plant in Pontchâteau (LoireAtlantique, France) this summer to place further orders for eight new Bobcat telehandlers. The visit followed the delivery of eight machines to various production sites belonging to the CEMEX Group at the beginning of the year. The CEMEX orders once again demonstrate Bobcat’s ability to meet the needs of major clients, including this world-famous producer of ready-mixed concrete and aggregates. CEMEX operations make full use of the versatility of Bobcat telehandlers, which have been supplied with a range of attachments such as pallet forks, buckets, jibs and manplatforms. CEMEX uses the TL range of telehandlers from Bobcat with lifting heights of 6 and 7 m for a range of tasks including handling large bagged loads and the Bobcat T
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series of telehandlers with lifting heights of 14 and 18 m as part of maintenance operations using manplatforms. Based on good experience with the new Bobcat telehandlers at the start of the year, CEMEX followed this with an order for two 14 m telehandlers and a third order in July for a further six telehandlers to complete its fleet. The CEMEX France teams chose Bobcat for several reasons: • The specifications and options offered by Bobcat were particularly suited to the needs of CEMEX operations teams. • The total cost of the equipment and the finance solutions were highly favourable. • The French made equipment is fully in line with CEMEX’s policy of corporate responsibility, particularly in terms of responsible purchasing.
CEMEX is the world’s third largest producer of ready-mixed concrete, the fourth largest producer of aggregates and the seventh largest producer of cement, and is active in over 50 countries. In France, CEMEX is a leader in ready-mixed concrete and aggregates and operates over 330 sites around the country to be as close as possible to all of the company’s customers. www.bobcat.com
BULK MATERIALS HANDLING
RISING TO THE SEASONAL CHALLENGE
n the run up to Christmas, firms that rely on materials handling equipment can be faced with a wide range of challenges that have the potential to impact on both health an safety and productivity. To help business meet these challenges, Allan Parsons, National Rental Manager at Briggs Equipment, has put together these six top tips that will help firms avoid unexpected costs in the run up to Christmas. 1. Carry out a thorough review of your current materials handling capability. Trucks can be damaged if they are used for loads they are not designed to carry and health and safety could be compromised. 2. Donâ€™t leave it late before making any decisions. By planning ahead you will be able to secure the most appropriate equipment for the task at hand. 3. Ensure you have enough staff and equipment to cope safely with demand. Just as machines can be pushed beyond their limit, so can people. 4. Make sure that all temporary staff are fully familiar with both the work environment and the equipment they are using, perhaps by introducing a thorough induction process if one is not already in place. 5. Hold a brief workshop or seminar to remind longer-serving staff of their obligations. This is also a good opportunity to find out, first hand, from operators of any potential problems. 6. Be prepared for the unexpected, keep one eye on the forecasts and have plans in place to deal with bad weather, including snow! www.briggsequipment.co.uk
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BULK MATERIALS HANDLING
STOPPING TANK CORROSION IN THE TRANSPORTATION SECTOR In truck, rail tankers and beyond, Chemically Bonded Phosphate Ceramics can stop corrosion, improve safety, extend equipment life and minimize maintenance and downtime.
housands of chemicals, petroleum products, and corrosive elements like salt water brine are transported by tanker truck, railcar and distributors, as well as processed in chemical tanks at facilities and refineries every day. In these venues, carbon steel corrosion can require early tank replacement and maintenance, as well as pose a safety risk in terms of potential leaks, spills, and even fire and explosion, so effective corrosion protection is a must. “We clean just about any tank hauling product or waste on the road or rail,” says Joe Svehlak, Facility Manager at DFW Tank Cleaning, a Dallas-Fort Worth, Texasbased full service tank cleaning facility that specializes in chemical cleaning. “Protecting against corrosion is vital in such tanks, as it is in our facility flush tanks.” According to Svehlak, effective corrosion resistance is essential in the flush tanks because they hold the wastewater from the first flushes of tanks that the company cleans, which can include residual chemicals, until it is treated. This amounts to thousands of different residual chemicals held in the flush tanks annually – from petroleum products and salt-water brine to fluoride, caustic soda, and a variety of acids. Against such tank corrosion challenges, traditional polymer paints and rubber type coatings have long been used as physical barriers to keep corrosion promoters such as water and oxygen away from steel substrates. This works until the paint is scratched, chipped, or breached and corrosion promoters enter the gap between the substrate and coating. However, truck or rail tankers hauling waste, including sand and sediment, can be particularly prone to scratches, chips, or breaches. Then the coating can act like a greenhouse – trapping water, oxygen and other corrosion
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EonCoat application on tank
promoters – which allows the corrosion to spread. While stainless steel can be used for tanks to resist corrosion, it can be up to six times more costly than carbon steel, as well as challenging to weld, fabricate, and maintain. Now a new generation of anticorrosion coating, called Chemically Bonded Phosphate Ceramics, is poised to stop such corrosion, improve safety, and extend tank life in the transportation industry and beyond while minimizing maintenance and downtime. RUGGED ANTI-CORROSION PROTECTION “Our corrosion protection for our 10,000-gallon flush tanks has to be particularly rugged because we mix the wastewater so it does not stratify, and sand, rocks, and even metal shavings can be present from the waste trailers we service,” says Svehlak. “The corrosion protection also has to withstand the high-temperature, high-pressure water we often work with.” To control corrosion, the tank cleaning facility chose to have Ennis, Texas-based DC Metal Construction, a privately owned company specializing in steel construction and industrial plant building projects, coat the inside of two flush tanks. The flush tanks were coated with a spray applied inorganic coating called EonCoat® from the Raleigh, N.C.- based company of the same name. EonCoat represents a new category of tough, Chemically Bonded Phosphate Ceramics (CBPCs) that can stop corrosion. In contrast to traditional polymer coatings that sit on top of the substrate, the corrosion resistant coating bonds through
a chemical reaction with the substrate, and slight surface oxidation actually improves the reaction. An alloy layer is formed. This makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. The corrosion barrier is covered by a ceramic shell that resists corrosion, fire, water, abrasion, chemicals, and temperatures up to 400 °F. Although traditional polymer coatings mechanically bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge. By contrast, the same damage to the ceramic-coated substrate will not spread corrosion because the carbon steel’s surface is turned into an alloy of stable oxides. Once the steel’s surface is stable (the way noble metals like gold and silver are stable) it will no longer react with the environment and corrode. Visible in scanning electron microscope photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical. Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel. The only spot that can corrode is the scribe line itself, which eliminates the possibility of the corrosion migrating. “Unlike traditional methods, the corrosion resistant coatings for mild steel have a double layer of protection,” says Bobby Hobbs, a DC Metal Construction job foreman. “The tough, outside ceramic coating will not chip like paint and takes sandblasting
BULK MATERIALS HANDLING
to remove. The chemically bonded layer stops corrosion and will not allow corrosion promoters to spread.” “EonCoat has stood up really well to everything from chemicals and salty brine to abrasion, high-pressure water and heat,” adds Svehlak. “I believe it will double the life of our tanks while significantly lowering maintenance costs and downtime.” According to Svehlak, the coating’s rugged anti-corrosion properties could also benefit a wide range of transportation-related businesses. “Tanker truck and rail operations can benefit from the anticorrosion coating’s reliability,” says Svehlak. “Its abrasion resistance would be a big plus to wastewater haulers or super sucker truck operators with vacuum tanks that may encounter metal chips, glass shards, etc. when cleaning out sumps. It would also resist tank corrosion when transporting petroleum products or even used restaurant waste such as oil, fat, or grease.” For transportation companies looking to reduce costs, there are additional advantages to CBPC coatings beyond corrosion resistance. This includes quick return to service that minimizes equipment downtime, as well as no VOCs or HAPs, and a flame spread rating of zero which improves safety. For corrosion protection projects using typical polymer paints such as polyurethanes or epoxies, the cure time may be days or weeks before the next coat of traditional ‘three part systems’ can be applied, depending on the product. The cure time is necessary to allow each coat to achieve its full properties, even though it may feel dry to the touch. In contrast, a corrosion resistant coating for carbon steel utilizing the ceramic coating in a single coat requires almost no curing time. Return to service can be achieved in as little as one hour. This kind of speed in getting a tank, tanker truck, or railcar operating again can save significantly in reduced downtime. “After appropriate tank preparation, we found that if we spray EonCoat in the morning the tank can be returned to service the same day because it applies in one coat and dries quickly,” says Hobbs. EonCoat consists of two, non-hazardous components that do not interact until applied by a plural spray system like those commonly used to apply polyurethane foam or polyurea coatings. Since the coating is inorganic, there are no VOCs, no HAPs and no odour. This means that the coating can be applied safely, even in confined spaces. “Since the corrosion resistant coating has no VOCs, HAPs or odor we were able to spray during work hours, so work next to the tanks could continue while we coated them,” concludes Hobbs. “For any tank, facility, or transportation-related operation with corrosion issues, it is well worth considering.” For more info, call 754-222-4919; or visit www.eoncoat.com.
NUMBER ONE FOR PIPEWORK SYSTEMS Modular pipework systems Stainless Steel, Galvanised or Powder Coated (inside and out) 60 - 800 mm diameter sections as standard 1 - 3 mm thickness Easy to fit Quick Connect Jacob (UK) Ltd T: +44 (0) 1694 722841 E: firstname.lastname@example.org W: Jacob-uk.com
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WIDE-INLET BULK BAG FILLER HANDLES CHUNKS, SEMI-SOLIDS
new Wide-Inlet Bulk Bag Filler from Flexicon allows rapid filling and passage of large, moist or dense chunks and semi-solid materials into open or duffle-top bulk bags. The unit features powered height adjustment of the cantilevered fill head to accommodate all popular bag heights, pneumatically-adjustable bag hooks, a roller conveyor, automated vibratory densification/deaeration deck and load cells with automated controls. Material passes through a hopper equipped with a slide gate valve positioned above the filler, and through the filler’s inlet chute that tapers from 660 to 508 mm square before discharging into an open-top bulk bag. A vibratory deaeration deck activated at timed intervals during the filling cycle densifies the bulk material, stabilising the bag. When load cells signal that the bag is approaching target weight, a controller shuts the slide gate valve, releases the bag straps and activates a
powered roller conveyor to remove the filled bulk bag from the filling area. Constructed of carbon steel with durable industrial finish, the system is suitable for sludge-like materials, disparate-sized scrap, mulch, stone, coal, wood pellets and other bulk material containing pieces, chunks, agglomerates, clumps and other materials too large or non-free-flowing for conventional bulk bags and fillers. The unit is also available in stainless steel for filling of potatoes, cassavas, turnips and similarly sized crops. The company also offers patented TWIN-CENTREPOST™ bulk bag fillers for low volume, low cost filling applications, and patented SWING-DOWN® bulk bag fillers that lower and pivot the fill head to the operator at floor level for safe, rapid bag connections. In addition, the company also manufactures flexible screw conveyors, pneumatic conveying systems, tubular cable conveyors, bulk bag conditioners, bulk bag dischargers, drum/box/ container tippers, bag dump stations,
weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. For information contact Flexicon Europe Ltd, Tel: +44 (0)1227 374710, Email: email@example.com, www.flexicon.co.uk
SICK DEVELOPS EASY-FIT, ALL-IN-ONE MEASURING WHEEL SOLUTION
ICK has developed the DBV50 Measuring Wheel for ‘plug and play’ precision measurement of continuous and sheet fed materials on roller and conveyor belts that is easy to retrofit to existing conveying lines in an easy-mount unit. In a competitively-priced all-in-one unit, the DBV50 comprises a SICK encoder, measuring wheel and patented spring assembly for measuring the passage of a moving material to resolutions of better than 0.1mm. The DBV50 can be combined with vision inspection for product tracking, picking and rejection applications. It can be integrated simply with printing, registration and cut to length systems and is easy to retrofit to existing production lines. Encoder technology specialists at SICK value-engineered the DBV50’s combination of wheel, encoder, arm and mount for a leading logistics integrator. The DBV50 has already undergone hundreds of hours of in-use trialling to ensure its robustness and performance. The key is the patented, spring-loading mechanism that adjusts the spring to the
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correct 15N tension for the degree of vertical travel every time. It can easily be reset for different material thicknesses. Darren Pratt, SICK UK’s Encoder Product Manager explains: “Setting up an encoder mounted on a separate spring-loaded friction-wheel with the correct degree of vertical travel poses many difficulties for the plant engineer that the DBV50 now completely avoids. “With separate components, selecting the right balance of encoder, spring and moving arm can be a matter of trial and error. Then it can be difficult to achieve the right force on the wheel for non-slip contact; it’s all too easy to over-weight it so that the encoder bearing is overloaded and soon burns out. “Over-tensioning of the spring to achieve down force, or poor arm travel adjustment, soon weakens the spring so it needs replacement. The DBV50 overcomes all that in a precision-engineered package.” The SICK DBV50 is a compact measuring wheel system with 63.5mm
centre distance and a 200mm circumference wheel. The encoder and wheel have a resolution of down to 0.08mm and, for convenience and ease in mounting, the encoder can be mounted in 300 steps, on both sides, with the wheel located top or bottom. The maximum spring travel is 14mm, with integrated limits to prevent over stretching, and the patented adjustable pre-tensioning mechanism ensures quick adjustment to the optimum 15N load/10mm travel. The measuring wheel system is available with a high number of electrical interface and electrical connection options, as well as resolutions for different applications. A demonstration video is available on SICK’s You-Tube channel to show just how easy the DBV50 is to set up https://youtu.be/e30oN7FJsfc. For more information on the SICK DBV50 measuring wheel, please contact Andrea Hornby on 01727 831121 or email firstname.lastname@example.org.
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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.
AUMUND BUILDS NEW 100,000 T SILO FOR VASSILIKO CEMENT WORKS
nder the technical leadership of AUMUND Fördertechnik GmbH, the Cypriot cement producer, Vassiliko Cement Works, is constructing over the next 18 months an additional clinker silo with a capacity of around 100,000 tonnes, at its works close to the coastal town of Limassol. Vassiliko Cement has made considerable investments over the past ten years, installing a cement grinding plant with vertical mill, a kiln line with a capacity for 2 million tpa of clinker, and a clinker silo with a capacity of 100,000 tonnes. The plant was first established here in 1963, and Vassiliko has been operating it since 2011 with a kiln capacity of 6,000 tpd. Approximately 50 percent of the production is exported through its own port. Under a semi-turnkey contract covering the construction of the additional clinker silo, complete with conveyor bridges, transfer towers, superstructures, loading silos and supports, AUMUND is responsible for the technical organisation and coordination. Back in 2008 AUMUND had already won the order to supply conveying equipment for clinker. KZB pan conveyors with a capacity of up to 600 t/h are used for the transportation of clinker from the kiln to the clinker silo and from the clinker silo to the loading silos. Material chutes and feed points are equipped with filters to keep the plant substantially dust-free. AUMUND’s scope of supply and services also includes all drive units and instrumentation as well as the complete plant design and the supervision of all installation work on site up to commissioning of the clinker transportation and silo system. The earthworks and concreting for the silo foundations will be carried out by local companies. “We are delighted that we were able to convince Vassiliko with our complete package of machine supply, integrative design and site supervision”, according to AUMUND Sales Director Cement, Martin Dalbert. Site work is due to begin this month (September 2016) and the commissioning of the complete clinker transportation and storage system is planned for the end of 2017. www.aumund.com
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: email@example.com • www.tuflok.com
Bulk Solids Today
BULK MATERIALS HANDLING
EXTENSIVE HANDLING EQUIPMENT RANGE FEATURES EXPLOSION PROTECTION AS STANDARD The J D Neuhaus extensive range of handling equipment, including hoists and cranes are all engineered for extremes, providing safe operation in dust laden atmospheres or other explosionhazardous areas such as the chemical manufacture and processing environments. All the JDN products, which include both compressed air and hydraulically operated units are Explosion Protected as Standard.
his ensures that all JDN products are safe for continuous and long-term operation in potentially explosive chemical atmospheres as well as the more insidiously dangerous conditions where high levels of airborne dusts exist. This can include combustible dusts, high concentrations of airborne dusts, or wherever a dust cloud is confined with an oxidant present (ie typically atmospheric oxygen) and particularly where there is an ignition source. The oxidation of other commonly known materials such as coal and sawdust can also be the source of a dust explosion. However, many other normally inactive materials such as grain, flour, sugar, powdered milk and even powdered metals can form potentially explosive dust cloud suspensions in a busy working atmosphere. The easy to use Profi TI hoist range is the workhorse of the industrial and commercial world, and the operating air supply can be set at 4 or 6 bar pressure, with a standard load lift height of three metres being provided throughout. Other
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A hydraulic JDN crane system with an 80 tonne carrying capacity, shown in an offshore location
optional lift height requirements can also be specified and accommodated as required. Their Profi TI range of air operated hoists includes a total of 19 models providing lift capacities from 250kg up to an impressive 100 tonnes. These incorporate many years of design and development, and have successfully proved their versatility and universal reliability following installations within a wide range of light, medium and heavy duty industrial workplaces. Their compressed air power supply is also utilised for control functions. It does not initiate sparks, so providing an unbeatable advantage when hoists are operating in potentially explosive atmospheres. Even greater safety can be achieved by the prevention of sparks generated by static discharges or metal to metal friction contacts. Standard versions of JDN hoists and crane systems (which utilise Profi TI hoists for lift operations) have the explosion protection / classifications and markings EX II 2 GD IIA T4 / II 3 GD IIB T4. Increased spark protection can be achieved, which involves copper galvanisation plating of the hoist bottom block and load hooks, together with fitting brass safety catches to achieve a rating of EX II 2 GD IIB T4.
With even further increased spark protection for explosion group IIC, the hoist horizontal movement trolleys incorporate running wheels and travel gearing which are manufactured in bronze for an impressive EX II 2 GD IIC T4 rating. All Profi TI hoists incorporate a top suspension hook, with optional overhead trolleys also available to accommodate lateral movement of suspended loads. Three trolley options incorporate load traverse movements combined with precise load A Profi 2 TI positioning. One trolley hoist from the is manually operated for J D Neuhaus horizontal movement range featuring a motorised trolley of the suspended load. drive, providing a A second trolley has a 2 tonne lift and full manually operated reel pendant control chain mechanism for lateral load movements. The third motorised trolley provides traverse as well as load raise and lower
BULK MATERIALS HANDLING
A J D Neuhaus air operated Profi 1 TI with a one tonne lift capacity, suitable for operation in typical hot and dust laden atmospheric conditions
movements, together with precise load positioning, utilising compressed air power. All trolley systems can negotiate overhead rail curvatures, with trolleys optionally fitted with rack and pinion drives for safe load handling on offshore platforms and sea going vessels. For installations with overhead space constrictions, a low headroom trolley option is also available, suitable for loads up to six tonne. The hoists are all 100% duty rated with unlimited duty cycles, so minimising any downtime conditions. Their compact modern design eliminates any protruding control hoses or similar external parts susceptible to damage, emphasising the suitability of the Profi range for even horizontal pulling. These standard hoists are also insensitive to atmospheric dust or humidity and can withstand working temperatures ranging from 20°C to +70°C. Their patented, low maintenance vane motor brake systems ensure fail-safe starting and positive braking, while also being low maintenance as well as providing lube-free operation. Various pendant controls can be fitted for sensitive, single speed, multi-function or remote control operation. These design-led hoists also provide strong, fast and silent operation combined with high performance efficiency and reliability even when operating at high lifting and lowering speeds. The compact hoist designs ensure minimum product dead-weight, and when operating with loads from one tonne upwards also feature overload protection as standard. Selected models from the range of air operated hoists and trolleys can be supplied with nickel plated components for clean room operations and other specialist applications that also require
Hoists from the J D Neuhaus Mini range being used to handle aircraft components
hygienic working conditions or washdown facilities. These include chemical and pharmaceutical production establishments, together with the food and drink industries covering all aspects of both handling and product manufacture. The models currently available in the nickel-plated range include: the Profi TI hoists with 0.5 and 1 tonne lift capacities, together with a big-bag handling unit with a rated 1 tonne lift. A low headroom trolley hoist of 1 tonne capacity is also available, which is designed for operation in areas subject to low headroom capacity. Where Profi hoists are utilised with trolleys for overhead rail mounting, both manual operated (type LN) and motorised (type LM) trolleys can be provided which have also been subject to appropriate nickel-plating treatment for use in hygienically critical areas. For less severe operations the JDN Mini hoist range is available for light – medium lifting requirements. These cover four models for individual lift capacities of 125/250/500 and 980kg, with manipulator variations available for single handed operation during lift/lower/traverse and even final load positioning operations. Hydraulically operated versions of the JDN Profi range can also be made available, together with hoists specifically designated for operation within unique working conditions. These include hoists available with compressed air or hydraulic operation, which are suitable for underwater work. These specialised hoists have been utilised in subsea conditions to provide weightless underwater movements of suspended loads. Typical operations have
included the replacement of a 45 tonne replacement rudder blade for a cargo ship while remaining at sea. Overhead monorail air hoists having air A J D Neuhaus mini hoist, or hydraulic shown handling a submersible pump in a potentially drives can hazardous area operation also be supplied with 11 models in the range covering lift capacities from 10 to 100 tonnes. Further ultra low headroom versions are also available for lifting operation up to 100 tonnes including specialised products available for BOP handling up to 200 tonnes. Hoists for specialised lifting in cryogenic conditions down to temperatures of -45°C are also now available. Full crane systems together with self assembly crane kits can be provided for onshore/offshore operations with optional compressed air/hydraulic drives. These products can be supplied to suit individual customer requirements including jib cranes, plus top running and underhung overhead travelling cranes. All JDN products are covered by a worldwide service for annual checks, inspection and repair together with complete overhaul and installation facilities. Tel: 01224 722751 www.jdngroup.com Email: firstname.lastname@example.org
Bulk Solids Today
SCHENCK PROCESS LAUNCHES HIGH-PERFORMANCE, HIGH AVAILABILITY DF704 EXCITER Latest directed force exciter on view at MINExpo in Las Vegas
igh performance, high availability, long service life and low maintenance are the characteristics that operations engineers look for in an exciter mechanism to drive linear motion vibrating screens and feeders in quarrying, mining and steelmaking. Once again Schenck Process has raised the bar across all of these dimensions with the launch of its DF704 exciter model. With the highest exciter force output on the market at 1,000kN, the DF704 not only delivers exceptional performance but is highly economical. The largest Schenck Process vibrating screens and conveyors will now typically need only two exciters rather than three. High availability makes the DF704 ideal for continuous flow operation. The use of spherical roller bearings allows for shaft bending and reduces single-edged bending loads, providing a long service life and extremely smooth operation. The bearing life of the DF704 is at least 20,000 hours
at the intended operation speed. Moreover, serial production has cut the delivery lead time for new machines, while the Schenck Process exciter exchange and refurbishment service eliminates the risk of prolonged downtime. Maintenance is limited to an oil change or an oillevel check at the prescribed intervals. “The Schenck Process directed force exciter model series has a long pedigree dating back to the late 1930s. They are now in use around the world,” commented Gordon Ashley, Chief Engineer, Screens, Schenck Process Australia Pty Ltd. Over time, screens have become larger and exciter force output was limited by shaft bending. Then in 2004, Schenck Process launched the breakthrough DF504, rearranging segments into four per shaft to
deliver 20% more force with less bending. “The DF704 is the latest development, taking advantage of the roller bearings from well-known suppliers such as FAG and SKF. It is the largest exciter in the directed force range, which now covers forces outputs from 43kN all the way up to 1,000kN / 112.3 tons, fulfilling expectations in even the toughest mining environments,” added Gordon Ashley, Chief Engineer, Screens, Schenck Process Australia Pty Ltd. www.schenckprocess.com/uk
APPLICATION FLYERS DEMONSTRATE CAPABILITY: DRIVE SOLUTIONS FOR ROTARY FEEDERS
s part of a wide selection of application flyers that are available for download from the NORD DRIVESYSTEMS website, ‘Drive Solutions for Rotary Feeders’ is an overview of drive technology that can be costeffectively applied to flow control tasks for bulk materials. The two-page flyer describes how single-source intelligent frequency inverter and gearmotor drive solutions from NORD can be applied to precisely control dosing or discharging as well as clear inhomogeneous material blockages without relying upon an external PLC or other plant controls. NORD SK200E series frequency inverters include an onboard PLC that can be programmed with an overload reversing function activated through a combination of speed monitoring inductive sensors on the gearbox input shaft and a torque-limiting clutch between the motor and gear unit. An extensive choice of integrated fieldbus systems, including EtherCAT, POWERLINK
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and Profibus, can report to higher level plant controls. Furthermore, as the SK200E frequency inverter is a motor-mounted decentralized solution with plug and play power and bus system connectors, simplified machine wiring and zero signal interference is assured. Drive Solutions for Rotary Feeders is part of a series of application flyers available as PDF downloads from the NORD website – or on request as printed versions. Other applications areas explored include conveyors and bucket elevators, bottling plant technology, beverage industry, grain industry, and more. ABOUT NORD DRIVESYSTEMS A developer and manufacturer of drive technology for over 50 years, NORD DRIVESYSTEMS employs more than 3,200 people and is one of the world’s leading suppliers of full-scale, comprehensive drive solutions. NORD’s portfolio ranges from standard drives to customized solutions
for demanding application requirements, e.g. based on energyefficient or explosionprotected drives. Gross sales amounted to EUR 540 mn in the 2015 business year. Subsidiaries in 36 countries around the world and an extensive distribution and service network ensure minimal lead times and provide customeroriented services wherever needed on short notice. NORD’s wide variety of gear types covers torques from 10 Nm to 250 kNm and more. The company also supplies motors with outputs from .12 kW to 1,000 kW and manufactures frequency inverters up to 160 kW. www.nord.com
CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS
UPM CONVEYORS ANNOUNCE INVESTMENT IN NEW STAFF & MANUFACTURING EQUIPMENT
o cater for the increased order intake achieved by UPM Conveyors during the past six months, significant investment has been made in additional manufacturing equipment. Owner Roy Fowler, who has worked in the manufacturing industry for over 40 years, has purchased a smaller router to allow the existing 3m x 2m router to machine conveyor main side frames, plus a new lathe, as well as a new vertical milling machine and pillar drill. The increase in demand has also resulted in a recent employment drive by the company, with more engineering personnel now employed at the Sussex site. This follows the success experienced by UPM Conveyors in attending exhibitions in the UK and Europe via their network of European Agents. “As we enter another positive stage of our ongoing expansion, it’s important that we lead the way in innovation and continue to create new and improved solutions within the industry”, states Roy Fowler. UPM remain optimistic for the foreseeable future and exhibited at the PPMA show on Stand D36 during 27-29th
September at the NEC displaying their latest innovations. These included automated product handling systems, ways to improve the efficiency of the packaging operations in a variety of applications utilising high care access belt cleaning conveyors and radius plus incline / decline conveyors complying with full wash down procedures. In addition, the team were also on hand to discuss accumulation systems and a 360 degree carousel incorporating metal detection and product cooling. http://www.upmconveyors.co.uk/
uf-Lok ring grip couplings are low cost, heavy-duty self-aligning couplings for either high pressure, to 150 psig, or full vacuum rated applications. Utilized in all industries where pipe ends need to be connected, they are ideal for pneumatic conveying systems as well as gas and liquid applications. These couplings install quickly and easily, reducing installation costs. They are available in 2-inch (50mm) through 10-inch (250mm) pipe sizes and are made for use on plain end pipe or tube, regardless of pipe or tube wall thickness. Other features include self-grounding, vibration resistant, leak-proof, with an extremely high end pull for difficult applications. No machining or grooving is required to maintain pipe integrity. Every coupling becomes a union, providing easy, low-cost maintenance when piping components need replacement. Standard gasket materials are available to meet special design conditions, such as food grade, higher temperatures or special chemical resistant applications. www.tuflok.com/primary/products.html Phone: +44 (0) 1706 822512 Email: email@example.com
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CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS
UNITRAK POWDERFLIGHT SOLUTION HELPS THE GARAGE BEER COMPANY MEET BARCELONA’S NOISE REGULATIONS
he Garage Beer Company is described as a brewery with a tasting room and a 7.5 barrel plant. The company directors looked at various sites for the company until they found the present building. The name “Garage Beer Company” came from when the directors looked at a former garage as a possible site, but this turned out to be too small, however they liked the name so much they decided to use it. When the Garage Beer Company took the decision to set up in Barcelona, the owners did not foresee the problems they would have in adhering to strict city regulations relating to noise disruption. The regulations specified that sound insulation had to be applied not just to the ceiling of the brewery but also the brew house floor. In effect the business was losing 45cm of ceiling height due to sound insulation, which left little room for the brewery plant. At this point the owners had already formalised the agreement for the brewery plant so they had to work within the boundaries they were given.
This meant they needed to find a way to transport malt into the mash tun without handling it too roughly, and without the conveyor taking up too much space. David Welsh (the brewery consultant for Garage Beer) contacted Phil Booth from UniTrak as he had dealt with Phil before on another project. David explained the issues he was having and asked Phil if he could help. Phil recommended the M75 Powderflight as it maintains low noise levels during operation, has low power requirements, small footprint, minimal headroom required and is cost effective to use.
If David hadn’t discovered the M75 Powderflight Conveyor, the Garage Beer Company would have had problems conforming to the noise regulations, as the remaining space would have been insufficient to function as a brewery. For more information contact UniTrak Powderflight on 01457 865038, Email: firstname.lastname@example.org or visit wwww.unitrakpowderflight.com
SPIROFLOW’S CONVEYING SOLUTIONS ON SHOW IN DUBAI
ood and drinks manufacturers seeking solutions for optimising plant production are being urged to visit Spiroflow Ltd’s stand for the latest in conveying and weighing technology at the Gulfood exhibition in Dubai in November – the largest food and beverage processing industry event in the MEASA region. Industry professionals from all over the world will be attending the show and can see for themselves how Spiroflow’s conveying, weighing, filling and discharge systems can make a difference for the food industry. It will be promoting cost-effective solutions for handling bulk ingredients where the most rigid standards in hygiene and containment need to be met and maintained. The award-winning global business will be demonstrating working models of a Bulk Bag Discharger and Flexible Screw Conveyor, while Spiroflow’s technical team will be on hand to discuss the full range
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of flexible and totally secure conveying solutions that can negotiate lengthy and tortuous routes through factories to hygienically transfer materials. The company’s model T2 bulk bag discharger is a market leader, installed by major food processors worldwide for dustfree and controlled discharge of ingredients. Options include loss-in-weight product feed, patented massage systems to promote flow from bags, hygienic bag spout sealing device, integral hoist and other features to ensure hygienic emptying of 1-2 tonne bags. The main advantage of Spiroflow’s flexible screw conveyor is its simplicity, which results in short installation times and low maintenance – the whole system can be stripped down for cleaning in minutes. It can transport powdered, granular and flaked materials with a bulk density up to 2.5kg/1 and carry material to a maximum distance of 20 metres, although multiple units can extend to greater distances as required.
Whether equipment is required for efficiently conveying food ingredients like cereals and coffee granules to mixers and packaging machinery, or accurately controlling the flow of difficult materials like chocolate crumb, which has a tendency to smear, Spiroflow can show Gulfood visitors that its wide range of standard equipment or customised systems provide optimum performance and offer value for money. Food manufacturers and processors visiting Gulfood – possibly agonising over which conveyor not only best suits their product but also meets the stringent regulatory safety requirements – need look no further than Spiroflow’s stand Z2 – C45. For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525.
CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS
SANITARY DRUM TIPPER WITH ROLLER CONVEYOR
new TIP-TITEÂŽ Sanitary Drum Tipper allows dust-free transfer of bulk materials from drums to downstream equipment, and rapid sanitising between changeovers. Constructed of stainless steel and suitable for wash-down, the tipper is pneumatically powered and certified for use in areas with hazardous conditions. A hydraulic cylinder raises and seats the drum against a discharge cone, after which a second hydraulic cylinder tips the drum to an angle of 45, 60 or 90 degrees with a motion-dampening feature. At full rotation, the outlet of the discharge cone mates with a gasketed receiving-ring fitted to the lid of any receiving vessel, creating a dust-tight seal and allowing controlled, dust-free discharge through a pneumatically-actuated butterfly valve into the vessel. The hydraulic power unit enclosure with sight glass to check gauges and valves, is located on the frame exterior for accessibility during set-up, inspection and maintenance, and houses a pneumatic motor to drive the unit. It is equipped with a roller conveyor that can be fed by an optional or existing infeed conveyor, allowing drums to roll into place by gravity. Other Flexicon drum tippers are available constructed of carbon steel with durable industrial finishes, or with material contact surfaces of stainless steel. The company also manufactures high-lift drum tippers, drum
Double flap valves
fillers, box/container tippers, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, flexible screw conveyors, tubular cable conveyors, pneumatic conveying systems, bag dump stations, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. For information contact Flexicon Europe Ltd, +44 (0)1227 374710, email@example.com, www.flexicon.com.co.uk
Ibis Intergrid Ltd. Materials Handling Engineers
Suppliers, manufacturers & distributors of bulk handling equipment worldwide for 25 years
Tel: 01539 731900 Fax: 01539 731910
Email: firstname.lastname@example.org Web: www.ibis-int.co.uk
Area Sales Agents Required Bulk Solids Today
DOES SAVVY SIZE REDUCTION MAKE SMART BUSINESS SENSE?
In the modern business environment, bulk handlers understandably have a keen eye on the activities that will improve their bottom lines. But how many are overlooking the wealth that lies in waste? Jonathan Oldfield, managing director of Riverside Waste Machinery outlines the key environmental and commercial arguments for the savvy size reduction of ‘rubbish’… 42
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ith the business environment constantly evolving there’s often enough on a bulk handler’s mind – warehousing, logistics, the supply chain, overheads. The list goes on. Inevitably, in many cases, waste management falls to the bottom of the list of priorities. It’s ‘rubbish’ after all. But this mindset, whilst understandable, is becoming increasingly unwise. From a compliance perspective, organisations that handle 50 tonnes of packaging materials in a year, and that have a turnover in excess of £2m, are regulated by The Producer Responsibility Obligations (Packaging Waste) Regulations 2007. This means they have a legal duty to reduce packaging and how much waste packaging goes to landfill, whilst increasing the amount of packaging that is recycled and recovered. The goal, of course, is to ensure producers of packaging waste take responsibility for their environmental impact and pay a proportion of the costs associated with the recovery and recycling activity. So, does this render organisations that
don’t fall into these parameters, exempt from their waste management duties? Strictly speaking, no. In January 2015, new European legislation called for the separate collection of paper, plastics, metals and glass where technically, environmentally and economically practicable (TEEP). The aim was to encourage continued sustainability progress across the continent, but a lack of TEEP definition, certainly in England, has left much open to interpretation. It therefore hasn’t had the impact it perhaps could have, which is a shame because, like it or not, legislation does drive change. We only have to look at the progress that has been made since the UK’s continued hike in landfill taxes, to see that. However, look a little closer at the waste management landscape and there are far more reasons to reduce the size of bulky wastes such as cardboard packaging and IBC drums, as well as other mixed rigid plastics, and materials such as plastic film and PET bottles. On a simplistic level, devising a waste reduction strategy can improve on-site cleanliness, which is particularly important when space is limited. So, bale waste rather
SIZE REDUCTION than disposing of it loosely, and a tidy warehouse or depot won’t just look better – it will protect the safety of operatives too. Smarter waste handling can also have time saving benefits. In some organisations, cardboard packaging, for example, is handled three or four times before it is collected for recycling. Surely that operative’s time would be better spent focusing on the task at hand. But then there’s the commercial advantage of recycling the types of ‘wastes’ highlighted above. Why pay to dispose of these materials, via costly skip charges, when they can be collected for free? In some instances, the value is such that recycling contractors will even pay the waste producer, which generates an additional revenue stream. How? Much depends on the geographical vicinity of a recycling partner, and the volume and quality of the waste being prepared for recycling. However, in simple terms, once waste streams are segregated and pressed into neat, compacted bales, they become easier and more cost effective to transport. They’re often even viewed as a commodity. Recycling firms will therefore collect them willingly. Size Reduction (2016) Ad (134x178)_Layout 1
So rather than throwing bulky, cardboard boxes into a skip which may cost £400 to get emptied, bulk handlers can produce bales of anywhere between 40 and 650kg, that are then taken off their hands at no cost. These savings alone – when coupled with the benefits outlined above – would mean waste handling technologies have paid for themselves in 12-24 months. The larger bales – mill size bales of 400kg and above – are those that usually attract a rebate of anywhere in the region of £50 per tonne. An ROI will be recouped even quicker, if such a yield can be generated. This commercial rationale doesn’t just apply to cardboard of course. Steel drum recycling fees are usually charged according to volume rather than weight. So, if these barrels can be compacted at a ratio of 6:1, for example, bulk handlers will be able to get rid of six times the amount of material, for the same price. There are special considerations to make when handling more complex wastes such as confidential documents or hazardous substances, of course. But technology is smart and there are ways to do this safely, compliantly and without breaking the bank. 27/09/2016 11:53 Page 1
‘Green thinking’ was once just a focus for organisations with strong corporate social responsibility (CSR) principles, who perhaps wanted to stand out for their environmental stance. But, not only do sustainable practices protect the world in which we live – they can boost bulk handlers’ bottom lines too. www.wastemachinery.co.uk
difference… …in innovative size reduction We have one of the largest ranges of size reduction equipment on the market and provide a single source supply of comminution equipment and expertise: from <1g to multi-tonne.
• From lump crushing and coarse grinding to micronizing, fine grinding and nano-milling
• Wet and dry milling equipment and systems • Unique equipment for small batch milling <1g • Accurate, repeatable particle size reduction Milling systems contained within an isolator/glovebox can operate to meet OEB 6. Hosokawa Micron size reduction equipment can be designed specifically for installation within an isolator for a more bespoke solution.
Tel: +44 (0) 1928 755100 • E.mail: email@example.com • www.hosokawa.co.uk Bulk Solids Today
MIXERS, BLENDERS & DRYERS
SANITARY, HIGH-INTENSITY CONTINUOUS BLENDER A new sanitary, highintensity continuous blender, Model HIM124-S316, from Munson Machinery provides low to high shear as required for high speed blending and/or homogenising of dry solids, agglomerates, slurries or pastes when processing food, chemicals, pharmaceuticals or other contaminationsensitive materials.
omogeneous blends can be achieved in as little as 20 seconds residence time depending on material characteristics, at throughput rates to 5.7 m3/h. Liquids can also be added in small to large amounts through optional injection ports for de-dusting and agglomerating of dry materials, as well as for producing pastes, emulsions and slurries. The unit’s horizontal, cylindrical vessel with a single high-speed rotating agitator is supported by externally-mounted bearings with sanitary type seals. Large radius welds joining the largediameter, solid shaft to blending paddle standoffs allow rapid cleaning and sanitising. For wash down, water or cleaning solution can be introduced through the injection ports and retained by an optional gate at the outlet of the discharge chute before running the machine to dislodge any solids adhering to interior surfaces. A flanged outlet on the side of discharge chute allows draining of the liquid. Constructed of #316 stainless steel and finished to USDA, FDA or pharmaceutical requirements, the blender is available with an insulated low-pressure jacket, or high-pressure jacket constructed to ASME code that can be heated or cooled, as processes dictate. The blender and motor are mounted on a common support base. The standard blender drive is a multiple “V” belt and sheave arrangement. Agitator speeds range from 100 to 2500 RPM depending on the application. Optional gear drives are available for reduced speed, high-torque requirements. All drives are furnished with totally enclosed guards. For non-sanitary applications, threaded 180° adjustable paddles
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for varying degrees of blending intensity are offered as standard. Other high-intensity blenders can be fabricated of carbon steel, #304 stainless steel, abrasion-resistant steel or exotic alloys, and the paddle faces can be hard-faced for extreme wear conditions. Other mixing and blending machinery offered by the company includes Rotary Batch Mixers, Ribbon/Paddle/Plow Blenders, Vee-Cone Blenders, Fluidised Bed Mixers, and Rotary Continuous Mixers. Size reduction equipment includes Screen Classifying Cutters, Pin Mills, Attrition Mills, Lump Breakers, Rotary Knife Cutters, Hammer Mills, Crushers and Shredders. For information contact Munson Machinery Company, Inc., Tel: +1-315-797-0090, Email: firstname.lastname@example.org, http://www.munsonmachinery.com/
MIXERS, BLENDERS & DRYERS
IMPROVED METHOD FOR COOLING AND DRYING POWDERS, GRANULATES AND FILTER CAKES
he Bella Series 543 mixer/ dryer/cooler by Dynamic Air Inc. offers an improved method for drying or cooling powders, granulates and filter cakes. The Bella dryer can be used for drying, mixing, spraying, agglomerating and cooling in the same unit without additional equipment or costs. Operation is extremely efficient because air flows around material while it is suspended in the weightless zone of the mixer. This maximizes the total surface which is exposed to the air, increasing the desired effect. The drying process will go through an adiabatic evaporation with thermal efficiency at about 80 percent. Only small air volumes are required compared with other fluidizing dryers. Benefits include better air distribution which increases drying / cooling efficiency; homogeneous mixing during drying / cooling process; low air volume reduces filter requirements, rotating paddles prevent material lumping and air channels; increased air contact creates better thermal efficiency; random material/air movement reduces drying /cooling time; gentle paddle motion creates low shear and low energy usage due to high thermal efficiency. www.dynamicair.com/products/dryer.html Corporate Headquarters Dynamic Air Inc. St. Paul, MN USA Tel: +1 651 484-2900 Email: email@example.com www.dynamicair.com
UK Office: Dynamic Air Ltd. Milton Keynes, UK Tel: +44-1908-622344 Email: firstname.lastname@example.org
High Efficiency Drying or Cooling of Bulk Solids The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone. The result is a more consistent material.
Dynamic Air Ltd. â€˘ +44 (0)1908 622344
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RECYCLING & WASTE MANAGEMENT
IRELAND’S FIRST ELECTRIC FUCHS MATERIALS HANDLER GOES TO RIVERRIDGE RECYCLING RiverRidge Recycling has just taken delivery of Ireland’s very first electrically powered Fuchs MHL820 long-reach materials handler from appointed distributors Blue Ireland.
iverRidge Recycling is a wellestablished waste management company based in Northern Ireland, operating from four sites. As part of the company’s continued investment in modern, efficient waste processing machinery and materials handlers and following intensive appraisal of the equipment market, RiverRidge opted for the electric Fuchs MHL820 from Blue Ireland and this versatile materials handler is now hard at work at their state-of-the-art Materials Recovery Facility (MRF) in Coleraine. The Fuchs MHL820 has an operating weight of 20 tonnes, a reach capability of up to 10.4 metres and, in this case, is equipped with an Arden S1102B grab. With a total power output of 95kW, there is power to spare even for heavy loads and the four point hydraulically operated outriggers provide total stability for stationary operation. The MHL820 is quick and agile around the working area and the electric cable feeding power to the machine has a generous range. The hydraulically elevating cab provides an excellent raised line of sight for the operator which is particularly important for maximum load and site visibility and enhances safe operation. Controls, including the familiar CAN BUS system, are almost identical to the diesel version, so operators can easily transfer without having to learn to work the machine afresh. The electric drive not only reduces operational costs but the exceptional ease of maintenance also allows good savings on running costs as well. RiverRidge’s MRF at Coleraine is capable of segregating high value products found in the waste streams to a high quality for recycling or reuse. The MRF is also
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capable of recovering and refining Refuse Derived Fuel (RDF) which is exported to Europe for use in waste-to-energy plants. The company’s new Fuchs machine is fully occupied handling MSW and C&I delivered by RiverRidge’s large and varied fleet of skips and specialist waste collection vehicles. It is stockpiling the waste and feeding it into a Doppstadt DW 3060 for pre-shredding before it is fed into the MRF, which is housed in a tailormade building. Being used under cover, the zero emissions of the electrically powered machine, coupled with its extremely quiet operation and minimal heat output, are highly beneficial features which contribute considerably to the working environment. Additionally, since RiverRidge Recycling has taken the prudent and self-sufficient step to capture the landfill gases on the site to generate its own electricity, the running costs of their new materials handler are fairly insignificant! In fact, RiverRidge estimates that the comparative operational saving on the new Fuchs machine over a conventionally powered materials handler is around £20,000 per annum. In choosing a Fuchs materials handler
from Blue Ireland, RiverRidge Recycling is drawing on their past dealings with Blue, having purchased a Fuchs 331 materials handler and a Doppstadt DW 3060 – another of Blue Ireland’s distributorships – for their Portadown site back in February this year. “Our first experience with Blue Ireland earlier this year proved they provide a good service” said Tony Kirkpatrick, Operations Director at RiverRidge, “and Blue’s commitment to excellent spares availability and a first rate warranty cover were also major factors in making the purchasing decision; additionally, their field service engineer is local to us so the response time is good should the need arise. Couple that with the proven build quality, reliability and productivity of the plant and machinery Blue Ireland has to offer and our choice was comparatively easy.” www.blue-group.com/ie/
RECYCLING & WASTE MANAGEMENT
CDE GLOBAL PARTICIPATE IN MAJOR C&D WASTE RESEARCH PROJECT - RE4 On Thursday 15th September CDE were delighted to attend the first meeting of the, EU funded, RE4 Project in Brindisi, Italy.
ver the next three and a half years CDE shall contribute to this group to develop new technologies to increase the reuse and recycling of construction & demolition waste material in energy efficient prefabricated elements for building refurbishment and construction. Speaking about the project, CDE Representative Sean Kerr, Head of Engineering, says, “To be involved in the first Horizon 2020 funded research project in this area is an exciting prospect and a great opportunity to make significant advancements in reducing the environmental impact of construction and demolition activities.” “CDE are a key member of the consortium and through our competence and experience in this area we aim to provide innovative strategies and processes for construction & demolition waste
recycling to produce recycled products for new and high value applications – taking construction & demolition waste recycling to the next level!” Having delivered over thirty turnkey C&D wet processing recycling projects throughout UK, Europe, Scandinavia, South America and India, CDE bring a wealth of experience. CDE have been working in the construction & demolition waste recycling sector for over 14 years, and have developed technology that ensures the production of the highest value recycled
sand and aggregates. The company also has the highest number of wet processing C&D waste processing projects delivered by and single supplier in the world. Adapting to unique customer needs, these projects process between 80 and 300 tonnes per hour each and combined divert more than six million tons of C&D waste from landfill each year. CDE also delivered the world’s largest wet processing C&D waste recycling project in Norway which processes 300 tonnes per hour. For further information on CDE please visit www.cdeglobal.com.
PLASTIC WASTE CRISIS UNITES DESIGNERS AND PLASTICS EXPERTS AT LONDON FORUM
ow can product designers help in reducing plastics waste, in a world where less than 15% of all plastic ever produced gets recycled today? This was the question at the heart of the Plasticity Forum, held as part of the London Design Festival. The goal was to help bring the design community into the big discussion on the future of plastic sustainability, giving designers the tools and know-how to become part of the solution in reducing plastics waste. The discussion has also been taking place in cities such as Rio, New York and Hong Kong. Designers are one of the missing links to solving some of the complex solutions related to materials, designing for recycling, and societal process flow in terms of resource recovery. Those who know the issues will be better able to drive expansion of the Corporate Social Responsibility (CSR) and UN Sustainable Development Goals (SDGs) that the brands and clients they work for should be striving to meet. Plastics pollution may be one of
the biggest looming challenges of our time, but it also offers one of the exciting opportunities when it comes to creating new design solutions that can be scaled across industries. France’s recent announcement to ban all disposable plastic plates, cups and cutlery, and the first country to do so, is evidence of the recognition of the ills that plastic pollution creates. The Plasticity Forum in London included a unique range of global expert speakers on the topic of plastic sustainability, with challenges and opportunities that included the manufacturing needs for an innovative single-material shampoo bottle, the use of calcium carbonate from large volumes of egg shells as a filler for any types of polymers which can benefit from its inclusion. Guilio Bonazzi, chairman and CEO of Italy’s Aquafil Group, spoke about his firm’s unique fiber recycling capacities from carpet tiles and used fishing nets. Aquafil has a growing program with carpet maker Interface, which sources fishing nets from local communities in the Philippines
and Cameron. Mr. Bonazzi, and Miriam Turner from Interface said that “over 100 tons of nets have been collected, with over 55,000 families impacted by a cleaner environment, and over 600 families now having access to micro finance as a result of the Net-Works program.” This was the sixth international Plasticity Forum, with previous forums held in a new city each year so that more businesses, government officials and members of each community can learn about the logjams and dynamics of creating larger scaled new materials, recycled content, and process flows to reduce waste and create value. www.plasticityforum.com. Bulk Solids Today
RECYCLING & WASTE MANAGEMENT
LINDNER’S NEW RAFTER: EFFICIENT PRE-WASHING OF HIGHLY CONTAMINATED POST-CONSUMER PLASTICS As a washing system for pre-shredded highly contaminated postconsumer plastic waste, the new Rafter takes its place in the recycling line between the Micromat WS wet shredder and a downstream Loop Dryer. All three systems form part of the new washing machine concept for plastics presented by the Austrian Lindner Group.
ith its new Rafter system, Lindner washTech presents a gentle yet highly efficient solution for the thorough cleaning of highly contaminated, pre-shredded plastic waste – e.g. packaging, bottles or film – by removing extraneous material and prewashing the charge in one single step. In conjunction with another Lindner novelty, the wet shredder Micromat WS, this machine marks the rise of a new generation of plastic washing equipment of more compact design and superior economic efficiency. The cleaning process performed in the Rafter comprises three phases. First, a special conveyor screw pulls the contaminated material under the water surface so that heavy contaminations such as metals, stones or glass can precipitate in a calm initial step. In a second phase, particles adhering to the plastic such as sand, soil or other contaminants are removed by a paddled rotor. The rotor’s rotational speed (r.p.m.) can be adapted to the degree of contamination, thus providing direct control of the cleanliness achieved. This step is performed in a stationary drum,
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with floating and precipitated particles being separated by means of plate screens. Upon completion of the washing cycle, the pre-cleaned waste rises to the surface again from where it is delivered to the following process steps by a feed screw. The separated extraneous materials and removed contaminants are discharged by an optional chain-type scraper conveyor. With a nominal throughput of 1,500 to 2,500 kg/h the Rafter matches the capacity of today’s recycling lines. It thus supports continuous in-line reconditioning of plastic waste all the way to the finished granulated recyclate or recycled film, respectively. The machine’s actual throughput can be adapted perfectly to the pace of upstream and downstream equipment by means of a frequency converter. Moreover, the Rafter is particularly cost-efficient to operate thanks to its energy-optimized drive system and a water demand of only 3 to 10 m³/h. Harald Hoffmann, Managing Director at Lindner washTech, comments: “By integrating the Rafter into a recycling line to pre-wash the plastic waste, operators gain an effective and also economical method of reducing wear in downstream
reconditioning equipment and hence, boosting the line’s cost efficiency as a whole. Moreover, all systems in Lindner’s innovative washing system portfolio are distinguished by a characteristic, exceptionally rugged design. This feature, in conjunction with the use of stainless steel for water-wetted parts, contribute to a high long-term system availability and low maintenance needs.“ The Lindner Group headquartered at Spittal/Austria was established in 1948 as a mechanical engineering and equipment construction company and has evolved into a competent supplier of shredding technology for industrial applications. Employing around 300 people, the Lindner Group specializes in the development, manufacture and sales of shredding systems for plastics, waste materials and wood. Lindner washTech GmbH is based in Großbottwar/Germany. The company develops and builds high-performance washing equipment for the plastics industry. In recent years it has established itself globally as a reliable supplier of complete washing lines. www.lindner-washtech.com
RECYCLING & WASTE MANAGEMENT
QUALITY ASSURANCE IS KEY TO MAXIMISING CORRUGATED RECYCLING RATES The Confederation of Paper Industries (CPI) Corrugated Sector is urging the waste industry and local authorities to do more to achieve greater collection consistency to help reverse the rise in recycling rejection rates, due to cross contamination.
PI believes that the increasing use of co-mingled collections has contributed to the increase in household waste in England that had been rejected from materials recycling facilities – 338,000 tonnes in 2014/15 compared to 184,000 tonnes in 2011/12 – according to a recent BBC report following a Freedom of Information request. The Corrugated Industry is proud of its recycling heritage – every year, over 80% of the material is recycled, which if laid flat would cover an area the size of Greater London three times over – but if corrugated, a valuable and reusable material, is contaminated through councils’ collection process it can end up being treated as waste and lost to the industry. There are those in waste management that insist co-mingling can be justified providing there is a sorting mechanism in place, however CPI considers source separation as the most effective process to maintain material quality. Director of Packaging Affairs, Andy Barnetson, says that the rising reject rates partially reflects a “growing impatience” among paper mills about the quality of the material they are
receiving and then having to shoulder the cost burden of contamination. He said: “The vast majority of the material recovered from the back of retailers’ stores is Corrugated, and that’s pretty clean. The core area of concern for us is post domestic where there’s been a lack of clarity and consistency over methodology for household collection which has led to a decline in quality. “Increasing energy, water, sorting and waste disposal costs have focused reprocessors on the impact of poor quality recycled corrugated. The Corrugated Industry favours separation at source but a clear and consistent approach to collection, such as that being advocated by WRAP, would provide clarity and simplicity for councils and the public.” He added: “While the declining quality of secondary fibre for recycling post domestic is impacting on the Corrugated Industry there are encouraging signs of initiatives to rationalise collection systems technologies throughout the country, such as the WRAP Consistency Programme, which suggests that the direction of travel may be changing.”
Not only is recycling corrugated beneficial to the environment and to the nation’s carbon footprint, it has a commercial value and is essential to the Corrugated Industry. Even though the UK corrugated sector is already surpassing Government and EU targets, recycling it ensures that fibres, which would otherwise be lost, can be reused on secondary packaging. From a domestic perspective, awareness of the benefits of recycling is generally on the increase, but around 50% of English authorities employ a co-mingle system when councils should be encouraging more households to separate corrugated from other recyclables, particularly glass and plastic. Rising quality issues and flat-lining recycling rates pose big challenges. Even though CPI argues that the advent of co-mingled collections effectively cross-contaminates everything, the Corrugated Industry’s resolve to continue to reduce its impact on the planet and further boost recycling is unwavering. For facts on the UK’s Paperbased Industries please visit: http://www.paper.org.uk.
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We offer processing solutions for Aggregate, Recycling and Bulk Handling industries in the UK and overseas.
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Our Partners Our position as a leading supplier of Washing, Water and Silt Management,Crushing and Screening,Dry Recycling and Enviromental Waste Processing plant is directly linked to the quality of our partners. Our partners have been carefully selected so that whether its individual pieces of equipment or turn-key installations, we are able to offer industry leading equipment from experienced European and American O.E.M’s.
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Call us to discuss your specific Washing, Crushing and Screening, Aggregate Processing and Bulk Handling requirements DUO Group, 4 Rye Hill Office Park, Birmingham Road, Allesley, Coventry, CV5 9AB, UK.
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