BULK BULK MATERIALS MATERIALS HANDLING HANDLING • POWDER • PACKAGING HANDLING • QUARRYING • QUARRYING • RECYCLING • RECYCLING & WASTE & WASTE MANAGEMENT MANAGEMENT
FEBRUARY APRIL 2017
JCB ensures uptimes for Stanton Recycling
Terex|Finlay adds MediMat to it’s network
Process Solutions for malt producer
Bobcat launches new excavator
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
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
14 BULK MATERIALS HANDLING 22 RECYCLING & WASTE MANAGEMENT BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: firstname.lastname@example.org email@example.com Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday
24 QUARRYING 28 HEALTH & SAFETY 30 FOOD & DRINK 32 PACKAGING 34
CIRCULATION To receive a copy free of charge, please send your details to firstname.lastname@example.org SUBSCRIPTIONS Subscriptions are available via www.bulksolidstoday.co.uk/subscribe No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements.
SOME MANUFACTURERS & SUPPLIERS HAVE MADE A CONTRIBUTION TOWARD THE COST OF REPRODUCING SOME PHOTOGRAPHS IN BST.
ISSN: 1365/7119 All contents Â© Abbey Publishing Ltd 2017
www.bulksolidstoday.co.uk Bulk Solids Today
RDS SHOWS LOADMASTER A50 AND PRODUCTIVITY DATA MANAGEMENT PORTFOLIO AT PLANTWORX 2017
n show at Plantworx 2017 on the RDS Technology stand J45 will be the LOADMASTER a50, LOADEX 100, LOADMASTER a100, iSOSYNC and WEIGHLOG a10. LOADMASTER a50, the enhanced colour touchscreen replacement for the LOADMASTER 8kiX, is an on-board weighing system for larger loaders designed to help increase loading efficiency, cut vehicle movements on site and ensure lorries are correctly loaded first time. LOADEX 100 is a retrofittable scale installed on both tracked and wheeled 360 degree excavators and material handling machines to weigh the amount of material in the bucket, grab or clamshell. LOADMASTER a100 is an onboard weighing scale for wheeled loaders. A CAN based system combining cutting edge sensor technology and signal processing techniques, the LOADMASTER a100 is designed to provide precise and consistent bucket weight information and to emphasise the gains in
productivity and profitability that can be achieved with such technology. LOADMASTER a100 is designed to operate within the fastest loading environments and toughest of conditions, to reduce cycle times and maximise tons per hour performance. iSOSYNC enables control of the loadout operation and inventory, productivity & traceability management. The software can be used with either LOADMASTER a100 or LOADEX 100 and allows the rapid transfer of job information from a central computer to the loader or excavator and the resultant load information is sent back to the PC upon completion. For smaller loaders and skidsteers, RDS offers the WEIGHLOG a10, which also benefits from a colour touch screen display. This instrument is designed to be a user friendly on-board weighing system which provides accurate and consistent bucket and total load results, meaning stock management and check-weighing operations can
be controlled more effectively. Additional information will be available at the RDS Technology stand J45 and online at rdstec.com. RDS Technology, (rdstec. com) a Topcon Positioning Group company, supplies over 100 original equipment manufacturers worldwide with custom solutions, as well as supplying standard ‘retrofit’ products through a network of specialist independent distributors in over 30 countries where customer service is the highest priority. Headquartered in Minchinhampton in the United Kingdom, RDS pioneered the use of electronics for agriculture and continues to lead in other sectors of mobile machinery.
ABBEY LOGISTICS APPOINTS NEW HEAD OF HR Abbey Logistics Group is pleased to announce the appointment of Marcia Findlay as Group Head of HR.
arcia will be responsible for the full range of HR functions, including employee relations, training and development, reward and recognition. Marcia’s appointment will support and strengthen the Group’s high calibre management team through a period of rapid growth. Abbey recently added more than 100 employees to the business as part of its acquisition of bulk liquid food tanker company Armet Logistics. Announcing the appointment, Steve Granite, Abbey Logistic’s CEO said: “Abbey’s transformation into a recognised National and European transport company will only be achieved through a strong, engaged 4
Bulk Solids Today
and highly-motivated workforce. With her successful track record of delivering HR and organisational change across a variety of complex businesses, Marcia has exactly the right experience, vision and energy to help us achieve this.” Marcia joins Abbey from Travelodge where she was the HR Projects Manager. She has significant experience of working in a variety of senior HR roles across a diverse range of businesses including Bibby Distribution and Asda. Marcia said: “This is an exciting time to be joining Abbey Logistics Group. The company has achieved a great deal in a short space of time and I look forward to working with
such a talented group of individuals and continuing to shape Abbey’s culture, by placing people and values at the heart of our business.” Visit www.abbeylogisticsgroup. com for more information about Abbey Logistics Group, on the road to a greener future.
LUDO GIELEN IS APPOINTED TO NEW TOP POSITION AT SCHOELLER ALLIBERT
udo Gielen, Chief Marketing & Innovation Officer at Schoeller Allibert since 2013 has been appointed to a new top position within the company. As Chief Strategic Growth Officer, the Limburg Entrepreneur is taking on the challenge of preparing the Schoeller Allibert Group for a strong period of growth. Schoeller Allibert is the European market leader in reusable plastic packaging and containers, offering sustainable alternatives to disposable singleuse packaging made of cardboard and wood. Last month, the construction of the brand-new Belgian Schoeller Allibert facility in Beringen started: a greenfield that will eventually employ about 70 people and in which Ludo Gielen himself is investing considerably. The Schoeller Allibert Group is facing a period of strong growth. In order to lift the commercial strategy to a higher level during this growth
period, Ludo Gielen, in the role of Chief Strategic Growth Officer, will link the innovation team, the sales department, Global Key Account Management and the marketing department to each other. The commercial strategy under the leadership of Ludo Gielen will mainly focus on the introduction of new products, the ‘routes-to-market’ strategy and the optimisation of the worldwide sales process. “I firmly believe in the future of reusable plastic packaging and containers, as well as in the possible growth of Schoeller Allibert,” says Ludo Gielen. “The market of ‘returnable transport packaging’ or reusable and sustainable packaging barely forms one percent of the worldwide production of all packaging products … which means that the growth potential of Schoeller Allibert is enormous. With our innovation team of 49 employees, we are continuously
working on the development of a wide range of new products that are aimed for optimising the workflow of our customers in a sustainable way. But it is not only our job to design and create innovative and sustainable C2C products (cradle to cradle) of the highest quality, we also have to mould them into a model that is financially feasible for the industry and acceptable to the consumer. Now I will be taking on a key role in that process of persuading the industry and the consumer. From this new position, I can ensure the connection, the coordination and the collaboration of our different departments, so that – together – we can achieve a strong commercial strategy.” www.schoellerallibert.com/be/nl
MILLINGTON APPOINTED MANAGING DIRECTOR OF VORTEX GLOBAL LTD.
ortex announces the appointment of Mr. Laurence Millington as Managing Director of the company’s operations in Darlington, United Kingdom. Mr. Millington will take over the role from Mr. Travis Young, who has overseen Vortex’s international operations since 2008. After nine years of managing the company’s business development in the EMEA and Asian markets, Mr. Young has accepted the position of Executive Vice President of Marketing and Global Strategy at Vortex’s corporate headquarters in Kansas, USA. “The appointment of Laurence was a straightforward decision. He understands how our business 6
Bulk Solids Today
works, the markets we serve, and the core values Vortex upholds”, commented Mr. Young. “Under his leadership, Vortex will continue to create winning relationships with our clients and distribution channels for many years to come.” Mr. Millington has been employed with the company since 2009 and was promoted to his most recent role of Sales Director, EMEA and Asia, in 2015. Mr. Young has been with the company since 2004. Founded in 1977, Vortex designs and manufactures valves and dustless loading equipment for handling dry bulk material in the food, chemical, and mineral industries. For 40 years, Vortex has
provided quality slide gates, diverters, iris valves and loading spouts designed specifically for handling dry bulk solids in gravity, vacuum, dilute, or dense phase applications. Vortex valves and spouts are engineered for dependability, durability, easy maintenance, and offer proven solutions to material handling and process efficiency problems. With an in-house team of engineers, Vortex products can be completely customized for individual applications or special installations. www.vortexglobal.com
TEREX|FINLAY ANNOUNCES THE ADDITION OF MEDIMAT TO IT’S GROWING INTERNATIONAL DEALER NETWORK
erex|Finlay is excited to presence in the South East, and announce the appointment it’s high reputation for customer of MediMat in France to service excellence, we are enhance it’s market coverage in confident that they will provide South East France. ‘Medimat’, the excellent sales, service, based in Juvignac near Montpellier, and parts support that the is now responsible for Sales and Terex|Finlay brand is renowned Aftermarket support across the for” commented Nigel Irvine, South East region of France. Sales and Marketing Director for MediMat has five Service Terex|Finlay. “Founded in 1979, Centres located around the region, MediMat has served the heavy specifically in Perpignan, Nimes, construction, mining, aggregate Toulouse, Albi and Montpellier. and recycling Industries within the Each Service Centre will provide region for many years. Their team customers with a range of Sales of professionals across their fulland Rental purchase options for service centres apply a customernew and used equipment, spare focused approach to maximize parts availability and full technical machine productivity and uptime”. service support for the entire range “We are very excited to of Terex|Finlay tracked mobile add Terex|Finlay crushing and crushing and screening products. screening products to our range,” “We look forward to building said Thierry Jacquot, MediMat and growing our partnership Sales Director. “Terex|Finlay has with MediMat. Given MediMat’s as being Filling and weighing (2016) Ad (134x178)_Layout a 1 reputation 19/08/2016 09:45 Pagea1 market
leader and innovator, producing high-quality equipment, which makes it a great fit for us.” Robert Pain, President of MediMat added, “We have a strong team in place to support the existing Terex|Finlay machine population in our territory, and are looking forward to promoting and increasing the sales of Terex|Finlay products among our current and prospective customer base.” www.terex.com
difference… …in hygienic filling and weighing systems Our accurate, weight controlled filling and weighing systems maintain the highest standards of hygiene, dust control and product integrity.
• • • • •
Accurate, stable repeatable weight readings of +/- 0.10g Hazardous area compliant Designed for filling containers of various sizes Can be integrated into laminar and downflow booths & isolators Interchangeable/fast change packing heads
Tel: +44 (0) 1928 755100 • E.mail: email@example.com • www.hosokawa.co.uk
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FPE STRENGTHENS SENIOR TEAM WITH GERICKE HIRE
pecialist engineering firm FPE Global has appointed exGericke Managing Director Peter Brickenden as Key Account Director to take lead on some of the firm’s highest-profile brands. He will join the business on 1st April 2017. With over 35 years’ experience in materials handling solutions, Peter joins FPE having built an industry-leading reputation within the international powder processing industry. He has previously held positions at Gericke, Californian Pellet Mill (CPM), Clyde Pneumatic Conveying, Solitec and one of FPE’s most established brands, Neu Engineering. As Key Account Director at FPE Global, Peter will work with some of the firm’s highest-profile clients across its target sectors of food and beverage and chemicals and
detergents. These include a number of major blue-chip brands, with the aim to deliver value added turnkey solutions, including bulk storage, size control, mixing, pneumatic conveying and process automation. Peter’s appointment follows a number of high-profile acquisitions for FPE. New staff welcomed to the firm in recent months include Gareth Durdin as Food and Beverage Sales Manager from Gericke, Sylvain LeMézec as Export Sales Manager from Matcon and Peter Slee-Smith as Technical Industry Expert. Dave Cooper, CEO at FPE Global, said: “Peter brings with him an exceptional level of technical and commercial credibility, as well as a mature network of high level contacts. His experience working with some of the largest brands
in the industry and familiarity with our existing clients will be a huge boost to us. The relationships he has built over the years will help tremendously as we aim to further expand our reach.” Peter Brickenden Key Account Director at FPE Global, said: “FPE has built a strong management team and continues to demonstrate ambition in competitive markets. My experience working with major brands will help fuel that ambition – strengthening valuable relationships with major brands both domestically and internationally. I am delighted to join FPE and look forward to working with its talented team to seize opportunities in growing markets.” www.fpeglobal.com
COMAU GOES TO BERLIN FOR THE “DIGITISING MANUFACTURING IN THE G20” CONFERENCE
he international conference, Digitising Tool Manufacturing in the G20 - Initiatives, Best Practices and Policy Approaches, started today in Berlin. Organized by the German Federal Ministry for Economic Affairs and Energy, it will run for two days. During the meeting, all member countries of the G20 will discuss ideas, strategies and programs aimed at driving the digitization of the manufacturing sector. Comau, which is part of the FCA Group, took part in the event by representing the Italian segment of the industry devoted to innovation and ready to welcome the opportunities and challenges of Industry 4.0. In particular, Mauro Fenzi, CEO of Comau, focused on Factories of the future - from global value chains to interconnected value networks, together with Susanto Irwan, Founder di Sensify Security, Jan Michael Mrosik, CEO of the Digital Factory Division di Siemens, 8
Bulk Solids Today
Karthikeyan Natarajan, Global Head Engineering Practice di Tech Mahindra and Stephan Reimelt, CEO di GE Deutschland. During the debate, Mr. Fenzi addressed the issue of digitization in the manufacturing industry, starting from Comau’s long-standing global experience within the industrial automation sector. He then focused on the major transformations brought about by the ‘digital revolution’ regarding the organization of work, production processes and the business models of companies. The concrete Comau
commitment to addressing these issues is seen by the innovative technologies such as AURA collaborative industrial robots. In addition, Comau is helping develop new skills for digital factory personnel through the activities of Comau Academy, conducted in collaboration with leading universities and international institutes. www.comau.com
TAKRAF WINS MAJOR CONTRACT IN AFRICA
AKRAF GmbH, a Leipzig based company, has secured a major contract for the turn key supply and installation of a bauxite handling plant in Guinea, West Africa. The contract value is approximately 100 mill Euros. TAKRAF, with roots dating back to 1725 and with more than 1,000 employees worldwide, is affiliated to TENOVA spa, a technology based group of companies based in Milan, Italy, which in turn belongs to the Italian engineering company TECHINT, a leading integrated supplier of technology and turnkey industrial plants. Guinea, situated on the west coast of Africa, boasts the worldâ€™s largest reserves in bauxite, a raw material utilized for the production of alumina, which is used in the smelting of aluminium, a metal important in the aviation industry, automobile fabrication, and many more durable goods manufacture.
Compagnie des Bauxites de GuinĂŠe (CBG), jointly owned by the international mining houses ALCOA, RIO TINTO, DADCO and the State of Guinea, mines and exports bauxite for more than 50 years and has put in place an ambitious program to increase their export capacity, for which TAKRAF supplies equipment for the unloading of rail wagons and crushing and conveying of the bauxite. A major challenge is the brownfield character of the works, which means that the new supplies and modifications to the existing plant have to be carried out whilst the installation is in operation. Very limited plant downtime and difficult conditions for logistics are a further challenge. TAKRAF is executing this contract in close cooperation with their subsidiaries in the USA, China and South Africa, whereas the project lead is based in Leipzig, Germany. TAKRAFs CEO Dr. Frank Hubrich
underlines the importance of this project for the implementation of the company in the important markets in western Africa and praises the good cooperation between the different entities of the company. The commissioning of the plant is scheduled for the 2nd half of 2018. Tenova TAKRAF is an integrated solutions provider to the mining, bulk material handling and minerals industries, offering innovative technological solutions as well as process and commodity knowledge along the industry value chains. With the integration of the well-known DELKOR brand of products into TAKRAF, the offered portfolio for the mineral beneficiation and processing sectors has been considerably enhanced. www.takraf.com. Tenova is a worldwide supplier of advanced technologies, products, and engineering services for the mining and metals industries. www.tenova.com
Bulk Solids Today
DEFINING DURABILITY IN INDUSTRIAL LABELS: WHY THE RIGHT LABEL MATTERS By Del Williams
urable labels can enhance safety, productivity, and prevent a host of problems caused by using standard paper labels that are not designed for industrial applications. Although standard “office” labels are more than sufficient for routine applications like filing, addressing envelopes, and shipping boxes, they are not designed to withstand the range of conditions and hazards found in harsh industrial settings such as warehouses, production lines, laboratories, or construction sites. Yet despite the availability of more durable offerings, many continue to use office-grade, “paper” labels for everything from warehouse racks and equipment to identifying chemical containers. This is often due to familiarity with such products from business settings, and perhaps an incomplete understanding of the significant differences in substrates, adhesives and other technologies used to design labels for specific applications. Fortunately, film labels are available that are engineered to withstand harsh industrial environments. Some are even tested and certified to meet existing safety and regulatory requirements. These self-adhesive labels can be utilized for everything from barcoded asset tags on machinery to location IDs on parts bins and affixed to a variety of surfaces found in industrial settings such as metal, wood (pallets), glass, plastic and ceramic. PAPER LABELS IN INDUSTRIAL SETTINGS There can be serious consequences to using standard paper labels in an industrial setting. For example, exposure to moisture, abrasion, chemicals, heat, and even sunlight can lead to torn, smeared, discoloured, unreadable labels, or labels that fall off. This can compromise safety, reduce productivity, and may 10
Bulk Solids Today
Fading label before Avery
lead to regulatory fines or legal consequences. For example, a missing or illegible label could not only result in an OSHA fine, but also serious injury and litigation if someone were to spill a bottle of a harsh chemical or worse, consume it. Similarly, equipment damage, unusable product, and downtime could result if the wrong solvent or lubricant is used in production. Even slightly damaged labels can be surprisingly costly, such as when inventory barcode scanning errors lead to misplaced equipment and inventory. Besides the cost of the label, estimates peg the labour costs to reprint the label at $10-$20, with up to $100 more to identify and fix any issues related to incorrect scanning. CHARACTERISTICS OF DURABLE LABELS Although standard paper labels and industrial film labels appear similar at a glance, a tremendous amount of R&D and testing goes into creating each product so that it works for its intended application. Because of this, it is much more cost effective to use the right label from the start. “There are significant differences between office labels and industrial film labels, including the materials and adhesives used,” says Tina Huff, a group product manager at Avery Products, a leader in printable,
Avery GHS label
self-adhesive labels. “For the best results, they should work with a trusted supplier that tests labels for their intended uses and provides specifications for resistance to water, chemicals, abrasion, UV, as well as service temperatures on request.” According to Huff, most selfadhesive labels are constructed of four key layers: a topcoat, substrate, adhesive, and liner. “The material characteristics of each of these layers determine how well typical paper, durable industrial, or any label, performs in its workspace,” she says. Since standard paper office labels are intended for an indoor environment, the topcoat is not waterproof, and the paper substrate tears easily and is not moisture or chemical resistant. In contrast, film labels can have a protective topcoat that is waterproof, even extremely chemical resistant in some instances. The substrate is a durable, scuff and tear-resistant film that can be made from materials like polyester and vinyl. The adhesive is high performance permanent that is also waterproof and chemical resistant. While the topcoat, substrate and adhesive can vary for an industrial label, each adds a level of strength to the entire label “sandwich” construction.
COMPANY NEWS To ensure products will perform properly in the field, companies such as Avery scientifically test and evaluate how the labels stand up to a host of potential situations found in industrial environments. These tests run the gamut, and can include exposing labels to a variety of common industrial chemicals such as isopropanol, and hydrochloric acid, as well as with cleaners, fuels, oils, lubricants, and salt water. In addition to increasing the durability of the label topcoat and substrate, additional innovations in label design and construction can improve performance further. Avery, for example, offers labels with technology which ensures that if a new label with TrueBlock® technology is placed over another label that has any printed information, the old information does not bleed through which could create confusion, cause incorrect bar code scans or simply make it difficult to read. Another innovation, SelfLaminating Labels, addresses a common work-around when using office-grade labels: covering them with clear tape in an attempt to increase longevity. By offering true lamination that can be easily applied by the user, these labels provide extra protection against abrasion, dirt, moisture, chemicals and UV. For Natalie Davis, a Product Design Drafter and Safety Coordinator at Itasca, IL-based Solberg Manufacturing, utilizing paper labels covered with tape clearly was not working. “Our previous labels on our acetone and alcohol dispensers in the production area kept rubbing off and had to be replaced,” explains Davis. “We tried putting see-through tape over the labels for protection, but the incompatibility of the tape with the harsh chemicals caused the tape to crinkle and the label was impossible to read.” When Davis switched to Avery Self-Laminating Labels, she found it resolved any issues of label readability and longevity. “I put the durable labels with clear self lamination on all our dispensers, and after weeks of use
and handling, it hasn’t really affected “The first time the labels came the labels,” says Davis. “The label out of our printer they worked information is easy to read and the perfectly,” says O’Connor. “The clear lamination is easy to clean if it labels are chemical resistant gets dirty. This has improved safety and are available in a number and saves the time and expense of sizes that accommodate all of having to print new labels and of our GHS labelling needs.” switch the labels every week.” These industrial labels are Global Harmonized compatible with laser or inkjet System (GHS) labels represent printers. Users can print in full another improvement in label colour using a printer they have durability that can be critical on hand, without having to to achieving compliance with purchase a specialized and costly new government regulations. thermal transfer printer, plus GHS labels, which are regulated multiple colours of ribbons. by OSHA and established by Armed with a better the United Nations to create a understanding of industrial labels, unified system for identifying safety and facility managers can now and communicating hazardous avoid the pitfalls of using officechemicals, are required on chemical grade paper labels in such harsh containers, including smaller settings. By doing so, companies not containers used in down packing. only eliminate the time and energy When Lani O’Connor, a Safety required for frequent replacement of Manager at Tollman Spring Co. could labels, but can also avoid potential not find any small GHS labels, “As a confusion and the additional temporary solution, I began printing hidden costs when labels become our GHS labels on regular paper unreadable, fall-off, or otherwise fail. stock,” she says. “Since they weren’t For more info, visit chemical resistant, the ink would www.avery.com/industrial. quickly smear and run. I was spending a lot of time printing and replacing labels.” After doing some research, O’Connor discovered Avery UltraDuty GHS The Bella dryer/cooler offers thermal Chemical Labels. These labels efficiencies to 80 percent or better were created to because air flows around material while withstand outdoor it is suspended in the weightless zone. use for up to two The result is a more consistent material. years, are tested to be waterproof for at least 90 days and resist a wide variety of chemicals while remaining difficult to tear. Due to the harsh environments these labels are used in, the products are typically rubDynamic Air Ltd. • +44 (0)1908 622344 tested with wet sandpaper. www.dynamicair.com
High Efficiency Drying or Cooling of Bulk Solids
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SANITARY TILT-DOWN FLEXIBLE SCREW CONVEYOR CLEANS RAPIDLY, ROLLS THROUGH DOORWAYS
anitary features include: a castor-mounted frame, support boom and hopper grate constructed of 316 stainless steel, sanitary quick-release clean out cap, quick-disconnect discharge box access cover, stainless control panel with stainless conduit, and liquidtight compression fittings, allowing wash down during changeovers and/or conveying of corrosive materials. HMI controls allow manual and automatic start/stop and speed adjustment. Material flows through the hopper into an adapter that charges the conveyor. As the flexible screw rotates in the material, it selfcentres within the tube, providing ample clearance between the screw and the tube wall to eliminate or minimise grinding. The flexible screw is top-driven beyond the point at which material exits the conveyor, preventing contact with bearings or seals. 12
Bulk Solids Today
New from Flexicon is a Sanitary Flexible Screw Conveyor that can be tilted down and rolled to serve multiple functions. Using a manual jack screw, the support boom and conveyor can be raised for discharging into vessels or other process equipment. Fully lowered, it can be rolled through doorways as low as 2134 mm in height, and aisles as narrow as 1067 mm. The conveyor transports bulk materials from sub-micron powders to large pellets, while the gentle rolling action of material prevents the separation of blends. The rugged inner screw is the only moving part contacting material, resulting in reduced maintenance and increased reliability. A broad range of screws with specialised geometries is available to handle free- and nonfree-flowing materials, including products that pack, cake or smear in other types of conveyors. The conveyor frame can be finished to sanitary of industrial standards, or constructed of
carbon steel with durable industrial coatings. Flexicon also manufactures numerous types of stationary flexible screw conveyors as well as tubular cable conveyors, pneumatic conveying systems, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, bag dump stations, drum/box/container tippers, drum fillers, weigh batching and blending systems, and engineered plantwide bulk handling systems with automated controls. For information contact Flexicon Europe Ltd, +44 (0)1227 374710, firstname.lastname@example.org, www.flexicon.co.uk
FIELD OPERATIONS MEET TERMINAL MANAGEMENT
he Implico Group has developed a software solution for handhelds that makes mineral oil loading faster, simpler and safer, enabling tank terminal operators to take the next step toward embracing the Internet of Things (IoT). The new, mobile solution connects employees in the field directly to the OpenTAS terminal management system to ensure that important information is immediately available everywhere. It also supports staff in the visual inspection of tank trucks and railcars. The digital transformation of business continues to progress – and downstream is no exception as demand is increasing for solutions that can replace the remaining paper-based processes. With its new software solution for handhelds, the Implico Group is now enabling digitalization in an area that was previously almost inaccessible: product loading in relation to railcars, ships and pipelines. Operations staff at refineries or tank terminals can digitally record incoming railcar and tank truck data using handheld devices and the new software, thus eliminating the need for subsequent entry of manual notes into the terminal management system. The solution is faster, more cost-efficient and avoids typical errors associated with manual data entry. The application uses a predefined checklist to guide employees step by step through the handling process. Since this checklist prevents staff from forgetting steps, it increases process safety. System-based visual inspection pursuant to specifications of hazardous materials legislation The checklist also supports the visual inspection of vehicles and loading, as prescribed by hazardous materials legislation for the transportation of dangerous goods. A history function in the application permits the entry of details such as earlier damage to a vehicle, enabling personnel to carry out targeted inspections of such areas. In many countries, vehicle compartments are sealed with special steel seals once loading is complete. Instead of painstakingly writing down complex seal ID numbers, employees need only a few seconds to scan in the numbers with the handheld application. This data is then stored immediately in the terminal management system. The new handheld application closes the previously existing digital gap between operations and the terminal management system. Refinery or tank terminal personnel can access the OpenTAS terminal management system during their work in the field,which results in substantial efficiency gains. For example, if the vehicle data is already stored in OpenTAS, it is shown to the employees as the default entry – so they do not need to enter the data again. Conversely, all data input by the operator is relayed back in real time, which means that the latest process information is visible immediately to the other
team members. The system can also be used to confirm which operator performed which tasks, and when. The solution’s unique real-time transparency and the soon-to-be-available background checking feature can also be used to prevent product contamination: since the system is always fully up-todate, it can report immediately if processes running in parallel may result in product contamination. The solution is compatible with any make of device, including those intended for use in explosion hazard areas. Backend functionality is provided by the OpenTAS Web Application Server. The handheld clients are connected in real time and access the solution via a browser. This enables true real-time transparency for logistics processes. www.implico.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. s s s s s s
,ESS FRICTION ,OW TORQUE ,OW MAINTENANCE ,OWER ACTUATOR COSTS ,ONGER VALVE LIFE -ORE RELIABLE Tel: +44 (0) 1908 622366
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BULK MATERIALS HANDLING
FIRST MERCEDES-BENZ DELIVERS MILES MORE SMILES FOR NIALL Truck-mounted crane hire and lifting specialist Niall Leitch has treated himself to a stunning 10th anniversary present in the shape of a highlyspecified, 8x4 Mercedes-Benz Arocs.
Bulk Solids Today
r Leitch, who founded Leitch Trans Lift, of Strabane, County Tyrone, in 2007, acquired the chassis from Newtownabbey Dealer Mercedes-Benz Truck & Van (NI). The high-riding Arocs is purposedesigned for construction-related applications. The first Leitch Trans Lift vehicle to wear a three-pointed star has a StreamSpace cab and is powered by an advanced, 12.8-litre straight-six engine which transmits its 375 kW (510 hp) output to the road via a smooth Mercedes PowerShift automated transmission. Resplendent in the operator’s metallic silver and blue livery with colour-coded bumper and roof-mounted light bar, it is fitted with a mighty 65 tonne/metre PM 65 SP crane. The truck’s platform body is by Nugent Coachworks, of Dungannon, as is the low-height tri-axle drawbar trailer which it pulls. Leitch Trans Lift works primarily for utilities companies, including Northern Ireland Electricity Networks and Electricity Supply Board (ESB), which is majority owned by the Irish Government. The Arocs has lined up alongside the operator’s five other crane trucks, a combination of rigids and tractor units, and
BULK MATERIALS HANDLING
BARTON’S HAT TRICK SILO SUCCESS AT SANKO GOSEI
T is now being inspected and serviced under a six-year Mercedes-Benz Repair and Maintenance Contract at the Dealer’s Dungannon worshop. Niall Leitch worked as a low-loader driver for an Omagh-based heavy haulage specialist, before launching his own business. Leitch Trans Lift handles pre-cast products, electricity transformers, wind turbines and portable offices, as well as other abnormal loads. Mr Leitch attended a roadshow staged by MercedesBenz Truck & Van (NI) at the Cabragh Filling Station, Dungannon. He recalled: “It was the Arocs cab that really impressed me. The moment I saw it, I thought to myself: ‘Mercedes-Benz have built something special here.’ The business has been going well so, having always purchased second-hand trucks in the past, I eventually decided to bite the bullet and order my first brand new one.” Mr Leitch continued: “I’d heard a lot of good things locally, about how the Dealer has been working hard to support operators out here in the west of the province. The response to my initial enquiry from its truck sales executive Paul McCrory was very professional. He took me seriously from the outset and brought an eightwheeler over for me to try – it was very different to the vehicle I ultimately purchased, but it was nice to get a run in a Mercedes-Benz, as I’d never driven one before.” He added: “My new truck and trailer represent a substantial investment. Through no fault of the chassis manufacturer or its Dealer, it took quite a time to get the combination on the road, but it’s been well worth the wait and money very well spent. “I love the way the Arocs looks, its power and its comfortable cab, while the ground clearance and excellent visibility mean the vehicle is ideally suited to work on rough sites. My drivers are also falling over themselves to take the Mercedes-Benz out. The transmission was a potential stumbling block initially, as none of them wanted an auto, but the PowerShift ’box makes the truck so easy drive that this has never been an issue. One guy, previously a die-hard fan of a Swedish brand, has been completely won over by the comfort and all-round usability of the Arocs.” http://www.mbtvni.com/
wo Barton Fabrications silos installed at Sanko Gosei Automotive Systems earlier in 2016 have delivered significant space savings, reduced raw material handling costs and enhanced safety. As a result, the company has just installed a further silo at its Skelmersdale site. The new 50 ton silo will be used to store polypropylene plastic granules and be bulk filled from tankers avoiding the need for manual handling of sacks and bins of raw material. www.bartonfabs.co.uk
BESPOKE SIEVING SOLUTIONS We offer innovative sieving equipment technologies for all industry sectors
Did you know we also offer a remesh service?
farleygreene.com Bulk Solids Today
BULK MATERIALS HANDLING
EXPLOSION PROOF C RAILS & LIGHT CRANE SYSTEMS J D Neuhaus, world leader in air hoists, cranes, trolleys and monorail hoists, is now introducing a range of C rail and light crane systems for operation with the companyâ€™s established and successful mini air hoist range. Both the C rail/ suspension tracks and the light crane systems are rated for use in explosion and hazardous dust-laden areas up to ATEX Zone 2, 22.
eaturing high quality standard elements, the modular C rail systems/suspension tracks make for simple assembly and smooth movement of loads in accordance with individual customer requirements. The units, which are ideal for flexible material transport applications, are purpose-engineered to offer high durability when deployed in challenging environmental conditions. Similarly, the light crane systems offer easy adaptation to load and operating conditions. Available in four standard profile sizes, design modularity again provides users with the opportunity for light and easy assembly, the result of which is smooth movement of the reinforced crane bridge and optimal space utilisation at low headroom conditions. Air delivery is facilitated via hose trolleys in the crane rail. To help maximise system life, users can pick from a range of surface protections for the crane rail and trolleys, including coated, zinc-plated or chromated, while stainless steel is available as an option for lighter capacities of 100 and 200kg. Both the light cranes and C rail/suspension tracks give provision for straightforward system extension to accommodate changing requirements over a working life. The crane track length is fully selectable in accordance with customer requirements, while the bridge length can be specified up to a maximum of 6000mm as standard, with larger sizes available upon request. Track width is dependent upon the bridge length, but typically, a system with a carrying capacity of 125kg 16
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would dictate a maximum track width of 4500mm. This rises to 5000mm for carrying capacities of 250, 500 and 980kg. The carrying capacities are of course determined by the choice of pneumatic hoist utilised. Here, JDN offers its mini 125, mini 250, mini 500 and mini 1000 models, which are not only offer lube-free operation for use in hazardous areas, but a price-competitive alternative in comparison with other types of powered hoist. Principal advantages of JDN mini air hoists include minimal components for ease of maintenance, a wear-resistant motor braking system and suitability for horizontal pulling (in addition to conventional lifting and lowering). Where fitted with an extremely sensitive lever control featuring an emergency shut-off valve, lifting heights of up to 8m can be specified. Tel: 01224 722751 Fax: 01224 729895 Email: info@jdneuhaus. co.uk www.jdngroup.com
BULK MATERIALS HANDLING
STAINLESS STEEL BUTTERFLY VALVE
osi-flate has introduced an inflatable seated butterfly valve with a highly polished 316 stainless steel housing and disc. The Series 486 inflatable seated butterfly valve from Posi-flate features a fully machined 316L stainless steel housing. The single piece disc and shaft is available in a number of materials including 316L stainless steel and hastelloy. The disc may be polished to a mirror finish or coated with PTFE, nylon or other high performance coating. The stainless steel valve is ideal for powders, granules, slurries and liquids and is available in sizes 2” (50mm) to 20” (500mm). Typical applications include loading and unloading of process material, sterile air control, and outlet valves for storage containers or hoppers. It is suitable for many applications, such as food, chemical and pharmaceutical. The inflatable seat design of the Posiflate butterfly valve provides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against the disc every time. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably. Because the Posi-flate disc only makes casual contact with the seat during opening and closing, torque requirements are substantially lower. This ease of movement also allows the disc to come to a perfect 90-degree position every time. Additionally, the smooth profile of the disc helps material flow easier and reduces build-up. For unique fail-safe monitoring, a pressure switch can be utilized to verify a perfect seal. Tel: +44 1908 622366 Email: email@example.com www.posiflate.com
VORTEX BOLSTERS SWEDISH SALES REPRESENTATION
ortex Global Limited has announced its recent partnership with LM Bulk & Materialhantering AB (LMB) to further the company’s sales in Sweden. Based in Helsingborg, Sweden, LMB possesses more than 25 years’ experience specialising in the sale of solids and bulk handling components. This collaborative effort will allow Vortex to further target the growing demand for powders and granulates among Swedish manufacturers. “We have not had a solid representative in the Swedish market for some years,” shared Laurence Millington, of Vortex Global Limited. “LMB has a proven track record in this market and comes highly recommended by other principles. They also see how the addition of Vortex products will strengthen their position in the Swedish dry bulk market.” Mr Millington explained that by partnering with LMB, Vortex will be in a position to quickly gain market share and further solidify sales in the Swedish market. He added that this market holds great potential for Vortex’s current range of engineered valve offerings, as well as future and up-and-coming Vortex products. www.vortexglobal.com www.lmbulk.se
Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof
Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: firstname.lastname@example.org • www.tuflok.com
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BULK MATERIALS HANDLING
HOSOKAWA’S PESTICIDE MILLING SYSTEM HELPS CONTRACT PROCESSOR GROW Hosokawa Micron Ltd recently beat stiff competition to win the order for a fine milling system to suit the rigorous demands of UK based contract chemical processing company, Exwold Technology Ltd.
ith an exacting requirement for a pesticide formulation milling system able to achieve throughput rates of 900kg/ hr and a particle top size limitation of 15 microns the customer awarded the contract to Hosokawa based on their technical expertise, project management capability and most appropriate equipment supply to meet the target requirements. ‘The customer specialises in formulation and processing for the Crop Protection and Speciality Chemicals markets, providing toll processing services on a worldwide basis. We were happy to support through extensive product trials carried out at the Hosokawa Alpine test centre to ensure correct mill selection and operating parameters to meet the customer’s needs,’ explained John Buck, Area Sales Manager, Hosokawa Micron Ltd. Hosokawa Micron supplied a 630 AFG Fluidised Bed Jet Mill with integral 315 ATP Classifier which is capable of producing the top size requirement with extremely tight particle size distribution. This configuration gives the customer highly efficient and accurate particle sizing across the high volume throughput. Product is fed to the mill by screw feeder via a double flap valve to ensure an accurate, modulated flow of material and maintaining the integrity of the 10 Bar containment. Once milled the product is collected in a filter. As standard within an agrochemical plant the stainless steel construction milling system is fully ATEX compliant and built to 10 Bar pressure resistant design. The crevice free design of the mill and integral classifier helps ensure full product evacuation whilst the WIP nozzles allow easy cleaning for 18
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contamination free production between batches. John confirms, ‘When the system was installed a few months ago, Hosokawa Micron engineers provided installation assistance and full commissioning services. The system is now fully operational with expected throughput and particle distribution targets achieved.’ Kevin Martin, Managing Director, Exwold Technology Ltd. commented, ‘This new milling system is highly efficient and enables us to produce high volumes of powders to exacting particles size to meet the demands of new and existing customers. We have been extremely pleased with the service we have received from Hosokawa Micron and their sales and engineering teams. The ability to undertake prepurchase tests ensured we were able to buy the right machine for the job.’ Tel: +44 (0) 1928 755100 Email: email@example.com www.hosokawa.co.uk
BULK MATERIALS HANDLING
DYNAMIC AIR OFFERS 16 DIFFERENT PNEUMATIC CONVEYING CONCEPTS • Four different vacuum conveying systems • Twelve different pressure conveying systems.
ach system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is extremely critical to match the system operating characteristics to the material to be conveyed in order to achieve the most desired conveying performance and to provide the best value to you, the customer. Dynamic Air’s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. Dynamic Air can convey many materials with conveying velocities as low as 50 feet per minute (0.25 m/sec) using the HDP 6000 dense phase pneumatic conveying system and, using the LDP 2000 dilute phase pneumatic conveying system, Dynamic Air can convey at velocities well over 7000 feet per minute (35 m/ sec). Plus Dynamic Air’s conveying capacities range from just a few hundred pounds (100 kg) of material per hour up to 400 tons per hour and conveying distances exceeding 5000 feet (1500 m) in length. In addition, Dynamic Air’s pneumatic conveying systems become highly efficient when they employ the unique patented DC-5™ Air Saver technology and are unmatched for performance and reliability. These systems can handle even the most difficult of materials, plus they significantly reduce the energy requirements and convey material at much lower conveying line velocity with higher conveying line densities and reduced dynamic loading. When Dynamic Air’s DC-5 Air Saver technology is employed on lower pressure systems using less than 15 PSIG (1 barg), in many applications the conveying line velocity can be lowered well below the normal
saltation velocity. Depending on the material being conveyed, energy requirements can be reduced and system performance and reliability drastically improved.
Gentle handling of heavy abrasive and nonabrasive materials that cannot tolerate degradation. For many fragile crystalline and granular materials there is no finer material handling process. Dynamic Air’s 16 different pneumatic conveying concepts can offer a more gentle treatment of system components as well. Because of lower velocities, system wear and related breakdowns are minimized.
DYNAMIC AIR PNEUMATIC CONVEYING SYSTEMS ARE:
• Energy and labour efficient • More reliable, because of our DC-5 Air Saver technology • Flexible to design in tight plant environments • Easy to install with minimum disruption to existing plant production • Clean - because the system totally contains the material conveyed • Friendly to the environment • Equipped with fewer moving parts • Lower in initial investment costs • Lower in maintenance http://www.dynamicair.com/systems.html www.dynamicair.com Email: firstname.lastname@example.org Phone: +44 1908 622344 Bulk Solids Today
BULK MATERIALS HANDLING
VORTEX GLOBAL PROVIDES PROCESS SOLUTIONS FOR MALT PRODUCER
ortex Global Limited recently consulted with British malt producer Simpsons Malt to provide process solutions for its white malt barley operations. Based in Berwick-Upon-Tweed, Northumberland, Simpsons Malt is a familyowned company providing premium malt to the brewing, distilling and food industries worldwide. In 2016, Vortex Global was asked to provide a solution for the transfer of white malt barley from one silo into two sieve units at a rate of 20-40 tonnes/hour, while also minimizing dust. In order to disperse white malt barley between the two outlets, a solution was necessary so that material flow rates could be variably controlled. Such results were achieved by installing a Vortex Gravity Vee Diverter valve into the existing 200mm square ductwork at Simpsons Malt, where the valve is controlled by a programmable logic controller (PLC) interface. The valve’s dual actuators can be used to divert or stream material flows, and can also be used to restrict flow in either or both directions. The Vortex Gravity Vee Diverter valve made Simpsons Malt’s operations more efficient, as traditional diverters require material flow to be shut off before redirecting material, often requiring an additional knife gate valve to be installed above a diverter. The sliding blade action of the Gravity Vee Diverter valve serves as a self-cleaning mechanism, removing material and eliminating the problem of material sticking, which is typical of traditional diverter blades. By selecting the Gravity Vee Diverter valve, Simpsons Malt has eliminated the flow areas where materials can lodge or become trapped in production, thus minimizing their risk of material cross contamination and spoilage. Vortex Global was also asked to supply Simpsons Malt with a retractable Loading Spout. The application loads white malt barley into open trucks at a rate of 60 tonnes/ hour for transport to Simpsons Malt customers. Simpsons Malt was particularly interested in the retractable Loading Spout’s four-cable hoist drive system. Vortex Global is so confident in its cables – which incorporate custom, CNC-machined three piece cable pulleys and heavy duty idler rollers with sealed bearings – that they offer a 10-year warranty 20
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to account for cable wear and tear. If for any reason a hoist cable should break, Vortex’s clever design allows the loading spout to continue functioning with the three remaining cables until repairs can be made. In order to meet Simpsons Malt’s dust reduction requests, Vortex equipped the auto-retractable Loading Spout with a vinyl-coated polyester dust sleeve. The sleeve assists a discharge skirt, made of neoprene rubber, in containing white malt barley dust at the point of loading. The dust is then suppressed by a pre-existing remote dust collection system through a spigot on the body of the loading spout.
ABOUT VORTEX GLOBAL:
For almost 40 years, Vortex has provided quality slide gates, diverters, iris valves and loading spouts designed specifically for handling dry bulk solids in gravity, vacuum, dilute, or dense phase applications. Vortex valves and spouts are engineered for dependability, durability, easy maintenance, and offer proven solutions to material handling and process efficiency problems. With an in-house team of engineers, Vortex products can be completely customized for individual applications or special installations. Tel: +44 (0) 1325 728 577 Email: email@example.com Web: www.vortexglobal.com
ABOUT SIMPSONS MALT:
Simpsons Malt teams employ the long-standing principles that have passed from generation to generation to make the best possible malt. Like the heritage behind the brand, every delivery that leaves its maltings is fully traceable. From the agronomic studies that match certified seeds to their partner farmers’ lands, to the time spent training their hand-picked distributors in the qualities and attributes of their malt, service and quality are all important to Simpsons Malt. Tel: +44 (0)1289 330033 Email: firstname.lastname@example.org www.simpsonsmalt.co.uk
BULK MATERIALS HANDLING
FARLEYGREENE’S DEDICATION TO R&D
ith 41 years of design and manufacturing experience, Farleygreene provide state of the art sieving equipment to a wide variety of customers and industry sectors, as a result of this they are constantly developing their technology to meet the demands across the sectors they service. Their dedicated R&D engineers strive to innovate and bring simple cost effective solutions across the vast machine portfolio that caters for almost every type of sieving application. This dedication to R&D has been illustrated with a recent design change on the already successful SIEVMASTER Easilift product, the ‘Sievmaster Easilift’ dispensing station can be used as a simple means of check sieving into containers, convey systems and even directly into mixers, it therefore makes an ideal arrangement to sieve dry powders in small or large volumes to ensure product reliability. Similar units on the market required an operator to lift off the hood manually to gain full access to the sieve unit, the Easilift has a flip top hood which is powered so it is a single operator task and there is no lifting required to open the unit, the hood is also designed to take a sack across its length making it easier to split and tip the sack into the sieve below. Units can be configured to suit the customer installation and is compatible with the Slimline 550 & 950 sieve units depending upon throughput requirements. With such a strong product you might ask why there is a need to change it, the simple answer is that Farleygreene have total dedication to their customers’ needs by offering solutions to their problems. Standard machines are constantly being re-designed, modified and standardised - the Easilift is a perfect example of this. The project example for an SM950 Easilift below shows how Farleygreene responds to their customers’ needs, it speaks volumes and highlights that offering bespoke solutions is their passion.
BESPOKE TO CUSTOMER NEEDS:
• WIP system added to dusthood and sieve to protect operators when opening machine for cleaning. • Solution for compacting empty sacks so operators are not exposed to dust on completion of the dispensing process – the transfer must be directly from the hood to a compactor next to the unit. • Ultrasonic deblinding to mesh assembly. • Continuous removal of oversize particles.
NEW MACHINE STANDARDS:
• Upper frame new design to make it even easier for operators to remove the top gallery and mesh for quick and easy cleaning and maintenance. • Baseplate modified to allow for oversize outlet option if requested.
NEW OPTIONS NOW AVAILABLE:
• Ultrasonic systems can now be easily incorporated. • Integrated bag compaction system. • Oversize removal and collection. • WIP/CIP integration. • Combined dust extraction to hood assembly electric and pneumatic versions Farleygreene support their machines with a 24 month warranty, 12 months longer then the industry standard. They also offer a full spare parts support, and re-meshing services for all types of rings and frames no matter who the original supplier or manufacturer. Visit www.farleygreene.com for their full product range and services. Bulk Solids Today
RECYCLING & WASTE MANAGEMENT
JCB ENSURES UPTIME FOR STANTON RECYCLING Just 15 minutes off the M1 near Derby, lies a 50-acre hub of recycling on Crompton Road in Ilkeston. The variety of companies here can between them recycle just about anything. At the centre of this hub is Stanton Recycling’s 5-acre site.
tarting out 35 years ago as a skip hire business, the family owned company is today a fully focused waste transfer and treatment plant. The waste is predominantly municipal, from Stanton’s domestic and small commercial waste contracts with local authorities. The volume of waste imported on to the site has grown year-on-year, leading Stanton to develop its infrastructure from a single small building to process it, to three buildings. Mick Clifton, Operations Manager at Stanton Recycling said: “People notice when you do something good and that’s how our waste import has increased. Waste is an industry that will never go away and we are getting busier year-on-year with more business from our existing contracts. We have to look after them and provide the service they want.” This, of course, places greater demand on its materials handling machines. “Having machinery running all of the time is the best thing we can wish for,” says Mick. Fulfilling this wish is Stanton’s fleet of materials handling machines comprising a JCB JS145 tracked excavator and three JCB 560-80 Wastemaster Loadalls – its newest arrival. Stanton processes the municipal waste inside its three buildings, which calls for a manoeuvrable materials handling vehicle. “We’ve tried loading shovels but they don’t offer the same manoeuvrability as the Loadalls, which also have a comparable capacity,” says Mick. “The 560-80s are the best machines for this environment. We don’t have a lot of room inside our buildings for large waste moving machines so JCB’s Loadall fits the bill for our compact site. They are ideal.” The versatile machines are used for most jobs on site. “One minute it can be a forklift, the next it can be a loader. Some loading shovels, can do this but changing attachments is not as easy,” says Mick, adding that all of Stanton’s JCBs multitask. “They can all do each others’ jobs with their universal attachments. This means that if one of our machines needs servicing, we can swap over to another in a matter of minutes so production never stops.” Outside the buildings, Stanton uses its JS145 to handle green waste brought in by the local council. Stanton shreds this waste to create compost for selling to 22
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commercial companies. Like the Loadalls, the JS145 can be quickly reassigned with a switch of an attachment. “JCB’s Wastemasters are far in front of any other machine that we’ve had on site because they are built for the waste job,” says Mick. “We have looked at other machines but they are not a patch on the JCBs. Our drivers love them because of the great visibility from the cabs and they get to work in a very comfortable environment. That’s particularly important because they don’t get fatigued while working six to seven hours a day.” Safety has always been paramount on Stanton’s site, which has an impressive health and safety record – reporting over 4600 (and counting) working days without any accidents. “That’s very good for the waste industry,” says Mick. “During a recent routine inspection, the HSE were impressed with the JCBs’ reversing cameras, visibility and white noise sirens.” Having invested in materials handling machinery, waste and recycling sites will want to get the most out of them. Stanton is maximising the productivity and uptime of its machines using JCB’s LiveLink telematics system. This gives Stanton regular reports via email showing a break down of a machine’s daily operation, including work hours and fuel consumption. Time not running is illustrated in grey while running time is shown in orange. Stanton gets clear visibility of the machine’s utilisation – and there are few grey areas on Stanton’s site. “A Loadall may be loading lorries and moving waste around. We can see clearly what work it’s doing and what work it has actually done. We can monitor which machines are doing the most hours and working the hardest and we can rotate the machines on to an easier job and let the new machines get the harder work. LiveLink also tells us when a machine is due for maintenance and will flag up any issues a machine may have.” For Stanton, reliable back-up is crucial. “There’s no machine that won’t break down eventually, so it’s all
RECYCLING & WASTE MANAGEMENT
about how quickly it can be fixed,” says Mick. “We have had machines in the past from other suppliers where we couldn’t get parts for two to three weeks but with JCB, if we do have a problem it will be fixed within 24-48 hours. This is vital for machines operating in a rugged environment such as waste transfer site. “In the event of a breakdown, the service we receive from our JCB dealer, TC Harrison JCB, is second to none.” TC Harrison has a depot in Alfreton near Derby and head office in Chapeltown, Sheffield. “If I ring JCB up, somebody will turn up the same day or at least first thing the next morning. Its service is over and above that of any other machinery supplier. Plus, I don’t think there’s any other manufacturer that offers a similar connection with the people who supply the kit.” Stanton purchases its machines using finance. “It’s not just that you get a new machine with all of JCB’s features that make it fit for purpose on a waste and recycling site such as ours, you also get a competitive rate from JCB Finance. With the warranties and servicing contracts we have a fixed monthly cost, which makes budgeting easier – that works for any business,” says Mick. Stanton normally exchanges on a three-year cycle – sometimes four years, depending on the hours they do. The machine’s solid tyres won’t have to be replaced during its lifespan on the site. “The oldest machine on site is coming up to 4500 hours – that will be the next machine to be traded in for a like for like JCB replacement. Mick concludes: “For us, the whole package around the machines is important. We will stay with JCB as long as they keep providing us with what we want.” www.jcb.com Bulk Solids Today
BOBCAT LAUNCHES NEW E17Z ZERO TAIL SWING EXCAVATOR
obcat has launched the new 1.7 tonne E17Z Zero Tail Swing (ZTS) canopy model, completing the company’s 1-2 tonne range of compact excavators. The E17Z provides an unmatched combination of features for a machine of this size, from ZTS and the roomy and comfortable operator area to the ease of transport thanks to a shipping weight close to 1.6 tonne; its impressive digging forces and working range; the smoothness of the workgroup functions; the fast hydraulic performance in terms of low cycle times and its reliability, durability and easy service access. In the new E17Z, the ZTS functionality is taken a level further using Bobcat’s Zero House Swing (ZHS) design, in which the front upper structure is also fully protected by ensuring the front corners are kept within the swing circle when the tracks are in the fully expanded position. As a result, the ZHS functionality on the E17Z provides the peace-of-mind of 320° of free rotation when working close to walls and other obstructions, without sacrificing on operator comfort or performance.
Bulk Solids Today
ROOMY AND COMFORTABLE OPERATOR ENVIRONMENT
The uncompromised operator environment on the E17Z in combination with excellent visibility, provides unmatched operator comfort and safety. In fact, the E17Z is built around the operator, providing optimal ergonomics for operators of all sizes with easy access to the pedals and controls. The large canopy and entry/ exit space provide the driver with plenty of room to get into and out of the operator’s seat and this is further helped by the left hand control console lifting completely out of the way. In addition, when not in use, the pedals can be folded away to increase room for the operator’s feet, leaving a large flat floor area that is easy to clean. The E17Z has a standard operating weight of 1749 kg and a maximum digging depth of 2249 mm. Many of the well accepted features in the current 1-2 tonne range such as the retractable undercarriage, upperstructure tie-down points and advanced diagnostics are available as standard on the E17Z. The compact size combined with great stability and a transport weight
QUARRYING close to 1.6 tonne makes this machine the perfect choice for applications in confined areas. The hydraulic system on the E17Z makes the best possible use of the engine power. Fast cycle times, combined with smooth control of class-leading breakout forces, provide maximum productivity. Boom and arm cylinder cushioning – unique in this class – enhance the overall smoothness of the workgroup. The E17Z incorporates the architecture of the hydraulic system on the larger Bobcat E20 model with a combination of variable piston pumps and a gear pump. With its optimised stability and lifting capacity, the E17Z also offers the highest versatility in operating a wide range of attachments.
In accordance with European transport regulations, the maximum towable weight for a BE license is 3500 kg. With a transport weight of less than 1.65 tonne, the E17Z is towable on trailers for 2200 kg of total weight. Transportability is made even easier with the integrated upper-structure tie-down points. An automatic slew brake helps facilitate safe parking and transportation. The premium control panel ensures all the vital information for the machine is easily accessible by the operator [auto engine shut-down, auto glow plugs countdown, auto cab lights switch-off, audible alarm (in case of malfunction) and the RPM meter]. The E17Z also offers keyless ignition for optimal safety and a battery kill switch to help prevent battery drain when storing the machine as well providing an effective way to prevent theft. The impressive dump height on the E17Z allows it to load trucks easily, while the reach at ground level means the machine does not need to be repositioned as often when digging. When fully retracted, the undercarriage allows the excavator to go through narrow spaces; and when fully expanded, provides optimum stability for the excavator, especially when working over the side. Expansion/retraction is a simple process via an electric switch on the control panel. Stability is essential for making maximum use of the digging forces and lifting capacities. Optimum stability is achieved by fully expanding the retractable undercarriage and using the optional long dozer blade. As well as helping in dustpanning work, the long dozer blade significantly improves the front stability enabling the operator to use the full breakout
forces the machine can deliver. As standard, the E17Z has easy-to-operate durable blade extensions. With stability on a par with other ZTS machines in this class, the E17Z is ideally suited to picking up and placing heavy items with safety. In addition, the E17Z can be supplied with an optional certified ‘object handling device’, which consists of:a boom load holding valve, arm load holding valve, hooking device and overload warning device.
DURABILITY AND RELIABILITY
The use of highly durable materials ensures the Bobcat E17Z model is hard-wearing, robust and easy to repair. The design features have been tested under extreme conditions – the heavy steel gauge covers and tailgate ensure class leading durability and peace of mind while working. The rear tailgate is protected by a casted counterweight. Other features include openable or bolted on covers; two-piece blade cylinder hoses to simplify replacement in case of damage; wrenchless hydraulic hose technology helping to prevent leakages; proven boom and dipper-stick design; the protected top-mounted boom cylinder; oversized long lifetime cylinders; a new paint and surface treatment process for added durability and residual value and a reinforced expandable undercarriage to maximise rigidity. Thanks to the large steel tailgate and openable side cover, all components for daily maintenance are easy to access, reducing downtime to a minimum. Daily maintenance and service points are conveniently located for easy and immediate access. Side-by-side coolers are easy to clean. The E17Z also provides simple diagnostics for service work, thanks to the error codes displayed on the control panel and service tool connection. Floor panels can also be rapidly removed for service purposes. For more information about Bobcat and Bobcat products, visit the website www.bobcat.com
Bulk Solids Today
ALLU TRANSFORMS AT CONEXPO/CONAGG
LLU Group presented at CONEXPO/ CONAGG 2017 it’s new, customer focused technology brand: ALLU TRANSFORMER. This positive and radical change reflects the transformation of ALLU screener crusher products and from world class manufacturer to customer driven communication and solutions. ALLU has for many years provided an equipment range that has helped businesses across the globe with their material handling, separation and sorting requirements. Even with great global success it has been a challenge to clearly communicate the benefits it delivers to the customers. During the press conference at CONEXPO/ CONAGG over 50 members of the International and US press, ALLU was pleased to announce the rebranding of the technology. The branding enforces the real benefits of the ALLU range, and what it actually achieves for ALLU customers. “Through the rebranding ALLU is now sending a clear and concise message that our equipment is able to transform the businesses of our customers and 26
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improve the profitability and value addition in their businesses,” says Mr Ola Ulmala, President of ALLU. “We were able to identify that our equipment not only provides solutions that produce higher levels of profitability, but leads to changes that totally transform the way businesses are able to operate. Examples may be ‘waste to value’.” Mr Ulmala concludes.
THE SOLUTION WHATEVER YOUR MATERIAL
Some applications and benefits include: • Landscaping and Agriculture: The DL Transformer Series makes the perfect attachment for landscaping and agricultural applications. From composting to aerating, top soil screening to waste and debris processing, all can be carried out on site. This truly mobile solution provides the versatility and flexibility to let you work more efficiently in the most challenging environments. • Earth Moving and Demolition: Through using a Transformer attachment excavated soil and rubble will not need to be transported away and replaced with fresh soil. Not only does
QUARRYING this result in substantial savings in material and transport costs, but no time is lost when waiting for replacement material. Additionally, binders can be mixed if the material handling includes additive requirements or stabilization. â€˘ Mining processes, Quarrying and Aggregates: Crushing and loading of raw material (e.g. soft lime stone) can be completed in one cycle. The process change reduces the need for buffer storage and extra material transportation, with capital expenditure being lower than for large stationary processing stations. This speeds up the transportation from one site to another and in some cases even eliminating the need for electricity thus delivering further cost savings and flexibility. The ALLU Transformer Series comprises of an excavator/ loader/ tractor mounted processing bucket which screens, pulverizes, aerates, blends, mixes, separates, even crushes, feeds and loads materials. This results in the feed material being effectively transformed into highly valuable products, making your business more efficient, and more profitable.
Catering for applications of all sizes, and capable of processing any material that can be screened and sorted, the ALLU Transformer Series comprises of the compact DL & D Series as well as the truly massive M Series. All are designed to transform the way in which construction businesses are able to improve their efficiency, profitability and value added. www.allu.net
RDS OFFERS EXTENDED PRODUCTIVITY DATA MANAGEMENT PORTFOLIO FOR QUARRY AND GRAVEL PIT APPLICATIONS
he RDS Technology product portfolio for Quarry and Gravel Pit productivity management offers a suite of high-precision measuring and productivity tools which allow the Productivity Manager to maximise the efficiency and profitability of his site. THE RDS LOADMASTER ALPHA 100, LOADEX 100 and iSOSYNC pc software (also available as a downloadable app) increase the efficiency of the load-out operation, batching and blending and stock movement. RDS iSOSYNC allows the excavator operator to directly transfer information on the volumes of material loaded to a remote office (e.g. face to primary crusher) iSOSYNC also allows the Productivity Manager to send jobs via the LOADMASTER ALPHA 100 onboard weighing system in real time from his or her remotely located office using GPS/ 3G/ Wi-Fi and to receive back the resultant load information. When the customer trucks arrive on site, the loader operator has immediate visibility of the job information on the screen of his LOADMASTER ALPHA 100. He knows from the screen which product he has to load, which product bay to get it from, how many tonnes or kilos of product he has to load and the numberplate of the truck into which the product needs to be loaded. He also knows which customer the product is going to. The site manager also has visibility of the operatorâ€™s screen from outside the vehicle, using the iSOSYNC App on his mobile device.
While the operator is loading the truck, his LOADMASTER screen tells him the weight of product loaded, the remaining target and number of buckets. The unique tip-off feature allows him to whittle the final bucket volume down to exactly the right amount so the truck is loaded accurately the first time. Saving time and money. Once the driver has completed his job, he presses the Clear button on the LOADMASTER to submit the load data directly to the office. Immediate data transfer. The truck driver takes his ticket from the ICP300 in cab printer and drives away with minimal delays, secure in the knowledge that the LOADMASTER ALPHA 100 is trade approved for commercial transactions. For more information on how we can help optimise your Productivity Data Management, call 01453 733300 or visit rdstec.com. Bulk Solids Today
HEALTH & SAFETY
BRITISH SAFETY COUNCIL – THE PAST, PRESENT AND FUTURE The British Safety Council launches its 60th anniversary celebrations using the medium of film to reflect on the organisation’s past, present and future
he British Safety Council held a gala film night, hosted by eminent film critic Mark Kermode, to demonstrate the contribution it has made to improving health and safety over the last 60 years. In the grand setting of the Regent Street cinema, the charity and membership organisation showcased on 23 March, in a film festival style, its 60 years history, recent achievements and plans for the future.
The film British Safety Council at 60 launched the evening of celebrations. It tells the story of the creation of the British Safety Council in 1957 and its growth as a significant campaigning organisation that transformed health and safety. Using long lost archival footage, the film focuses on the life and work of James Tye, the organisation’s charismatic, and sometimes controversial, founder as he tried to improve health and safety at a time when hundreds of people were being killed at work each year and when laws to protect workers were inadequate and piecemeal. The film includes footage of James at work and his campaigning and training activities, as well as photographs with celebrities, such as Barbara Windsor. Guests at the event were also presented with a book, Beware! Watchdog with fearsome bark, which features historic posters and other documents commissioned by the British Safety Council in all their colourful and vibrant glory. The tile of the book refers to an article written for The Financial Times by James Tye in 1978. Authored by Mike Esbester, senior lecturer in History at the University of Portsmouth, the book shows how this material both reflected the values of British society and tried to change them.
Since 1957, the British Safety Council has been advising on risk, helping both employers and the general public to understand and manage its consequences in pursuit of the charity’s vision that “no-one should be injured or made ill at work.” To mark its 60th anniversary, the British Safety Council launched a competition challenging young filmmakers to share their understanding of risk in a short film format. The competition attracted nearly 50 entries from young people in Britain and around the world. The films were judged by a panel of filmmakers and critics, including Richard Bracewell, a film director 28
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best known for the feature film Bill, and the deputy editor of Sight & Sound, Kieron Corless. The winning film Me, Miphone & I, by Juan Cruz-Hernández, a student and camera operator from London, is a powerful warning against a very modern phenomenon - the alienating effects of mobile technology. Equipped with boxes of popcorn, the guests also watched the four other competition finalists: Inertia, by Nikhil Sudersanan, a film-editing student from Kerala, India; Flight Risk, by Scottish independent filmmaker Sean Hall; Let’s Plan a Holiday, by English independent filmmaker Shanil Kawol and Risk, by Kate Haley, a student of English Literature at Trinity College, Dublin.
“It’s difficult to predict how we will live and work in the future,” said Mark Kermode, introducing the next film: Future risk: the next 60 years. “However, it’s important that we try, as the way we work have a profound impact on our health and wellbeing. If we understand these changes, we will be better prepared to deal with them.” Reflecting a wide-ranging debate between thought leaders and academics, including Professor Cary Cooper, PwC’s Michael Rendell and the International Labour Organisation’s Deputy Director General, Deborah Greenfield, the film explores the impact of automation, the rise of the gig economy and an ageing workforce. It concludes with the ultimate question: does work itself have a future? The 60th anniversary celebration night was also an opportunity to raise funds for Labour Behind the Label, a charity campaigning to improve the working conditions of garment workers worldwide. Talking at a press conference before the event, Caroline Lewis, Director of Fundraising at Labour Behind the Label, reminded how poor conditions can lead to a tragedy, such as the Rana Plaza factory collapse in Bangladesh in 2013, in which 1,100 workers died. She also spoke about the responsibilities of organisations to guarantee health and safety standards through their supply chain. Reflecting on the evening, Mike Robinson, Chief Executive of the British Safety Council, said: “The British Safety Council has a great spirit. Today’s celebrations clearly demonstrate that we have a lot to feel proud of, as well as many challenges and opportunities to address as we look forward to the next 60 years.” www.britsafe.org
HEALTH & SAFETY
CUSTOMIZED PHARMA SIEVE PROVIDES SAFE REMOVAL OF CONTACT PARTS Sanitary sieve designed with clamping system to provide contained removal and transferral of contact parts
hen processing active pharmaceutical ingredients (API’s), containment is imperative. Not only does this protect the product from contamination, this also ensures operators are protected from exposure to the highly hazardous materials. Due to the nature of the pharmaceutical industry, where product quality and hygiene are the absolute priority, it is necessary to use equipment that is easy to clean. When processing active pharmaceutical ingredients, this is often done in a contained environment. When a leading pharmaceutical manufacturer sought a solution for transferring API processing equipment to a containment isolator, an innovative solution was manufactured. Previously, to clean sanitary powder screeners, operators would have to enter the production area wearing a ventilated protective suit to avoid potential contact or inhalation of the pharmaceutical powders or dust. This, however, does not absolutely guarantee sanitation, as the equipment is still exposed to the surrounding environment, and contamination could be carried to other areas by the suit. To eliminate this risk, the manufacturer required a pharmaceutical sifter, customized for easy cleaning in a containment isolator. It was agreed that the most user-friendly solution would be a Russell Compact Sieve® with an additional customized clamping system. This would allow transferral of all potentially hazardous
contact parts to a containment isolator quickly and easily, with no risk of exposure to the operator. Additional clamps were added to the contact parts in question. When closed, the clamps keep the underpan, mesh screen and lid sealed together, and all parts can be carried jointly to a containment booth for cleaning. As the Russell Compact Sieve® is inherently an enclosed sieve to provide contained sieving during operation, these are the only parts that would be in contact with the API’s. Therefore, sealing these components together effectively contains the harmful material, meaning the exterior surfaces are safe to handle, and the sealed unit can be carried by the operator to a containment booth. Once inside the containment booth (or glovebox as commonly known in the pharma industry), the equipment can be easily dismantled by simply opening the clamps. As with all versions of this pharma sieve range, each component is easy to clean and re-assemble, meaning minimal production downtime. These compact vibratory screeners can fit easily into existing production lines and a wide range of sizes and options are available. To find out how a customized upgrade such as this could optimize your maintenance or production, contact Russell Finex today. http://www.russellfinex.com/en/contact-russell-finex/
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FOOD & DRINK
ECO VIBRATORY SEPARATOR IMPROVES PRODUCTIVITY & PRODUCT QUALITY AT ECO TREASURES Vibratory grader separated seeds and dust from frozen juice product at fruit juice production plant
ow, more than ever, sustainability and waste reduction have become concerns for many manufacturing companies. Eco Treasures recognize that natural resources should be used in a sustainable and economical way. In 2006 this Belgium-based company set up a pilot installation especially designed to utilize processing activities aimed at reusing or recycling product back into the production process. One of Eco Treasures’ main production activities is the ecological extraction of essential oils from residual vegetable feedstock and fine fruit seeds. The seed oils, such as raspberry and pomegranate, are those with the most organic forms of rich, unsaturated fatty acids and vitamins and are mainly supplied to the food and cosmetics industries. Since the introduction of the Eco Treasures pilot plant, the company has been constantly looking for ways to enhance its manufacturing process. Having previously used a very simple sieving process, delivering consistency of product quality was proving difficult. To meet high quality standards, and ensure the best production efficiency, the company trialled a vibratory grading machine at their pilot plant. The extraction of seed oil from residual frozen pulp begins by separating the seeds from the juice pulp. To separate the seeds, the frozen pulp is first melted and then dried. Once separated the seeds then go into a press to extract the oil. The issue the company was facing was that there was too much dust from the dried juice pulp attached to the seeds after the drying process, which resulted in a lower quality of extracted oil. Therefore, the company decided to separate
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the product into two fractions (fine dust and seeds) before the seeds were passed to the press. With the Russell Eco Separator® Eco Treasures could separate the two fractions enabling them to send the seeds through the press free of dust. Not only did the machine eliminate the dust from the seeds, it also saved them time by reducing the amount of labour previously involved in manually sieving the product. These two factors contributed to the reduction in manufacturing costs for Eco Treasures, an increase in productivity, as well as improved product quality for their customers. Production Manager at Eco Treasures, Stefan Ongena, said: “We were able to run tests with the Russell Eco Separator both at our site and at the Russell Finex test facility. As a company with a pilot production plant it was very useful to benefit from Russell Finex’s experience in sieving. They were willing to think ahead with us and offered us the solution we needed.” www.russellfinex.com
FOOD & DRINK
THE COST OF FUNCTIONAL SAFETY FOR FOOD PROCESSING How neglecting functional safety can have serious consequences
n 2014 in the UK, a large food manufacturer had to pay a £800,000 fine after a serious industrial accident. An engineer was trapped by the machinery while examining a conveyor belt and suffered major injury and ongoing nerve damage. An investigation revealed that this dangerous accident could have been prevented if a guard was in place on the machine. Here, Jorgen Saxeryd, safety products and functional safety advisor to ABB’s food and beverage program explains how safety procedures must be developed in food processing plants. Across the globe, there are a variety of different regulations for food processing plants. In particular, North America and Europe have strict regulations for safety in these potentially dangerous environments. This also applies to the safety of employees in the processing plants and employers who fail to make adequate safety considerations can face large fines. Not only can these authorities enforce these in the case of accidents, they can also be enforced during regular inspections. In Europe, the Machinery Directive 2006/42/ EC requires machinery to be designed and built so it can be used safely. In food processing plants, there are many dangerous machines for which plant managers should follow safety regulations, or the plants may face closure or high fines. Machines such as decanters operate at high centrifugal forces and it is not unknown for the machine’s g-forces to reach more than 2000 times gravitational force. This is clearly a dangerous environment for employees to work in, however as these machines are essential for use, the key concept is the management of risk. In the 1970s, the increase in heavy machinery such as the creation of the steel press led to increased safety guards. Since then, many safety conscious companies undertake a risk analysis in the initial stages of machine development. In the case of decanters, it is not possible to remove the risk, but it is possible to mitigate the risk to an acceptable level by putting safety guards
such as enclosures or emergency stops into place. Often, companies find it too difficult to manage the complex world of safety regulations alone. In this case, it is always better to consult professional services rather than to not comply with the regulations, as this will work out to be a costly mistake. ABB’s experts can provide specific advice on regulations, which also takes into account the needs of food processing plants. As companies become more knowledgeable about regulations and regulations become more stringent, the need for retrofitting old equipment with additional safety measures may arise. Although it may seem instinctive, where there is a dangerous moving machine, the safest answer is not always to shut it away behind an enclosure or barrier. In the food processing industry, companies should consult functional safety experts who have experience in the sector. The experts will for example suggest equipment such as light grid, which perform an emergency stop on a machine when a light grid is broken by an object. These devices are more appropriate for the food processing sector than using physical guards or barriers as they allow easier access for maintenance and washdown, which is essential for hygiene in food processing plants. Managers of food processing plants in all countries, regardless of the country’s regulations, should consider safety as a priority in their plant. From the safety of single pieces of equipment to line safety and then plant safety, plant managers need to be aware of what they can do to mitigate risks. Plant managers not only have a responsibility to put in place an accurate safety strategy to protect their employees, but they also need to protect their businesses from costly infringements of worldwide safety regulations, as proven in the many cases gone by. http://new.abb.com/food-beverage Bulk Solids Today
BEKUM: ECONOMICAL ALTERNATIVES IN THE MATERIALS USED FOR EXTRUSION BLOW MOULDING
EKUM will be focusing on the latest trends and production processes for extrusion-blown packaging at the Interpack 2017. Of crucial importance are the current machine and system solutions for the economic and ecological production of bottles, containers, cans, drums and IBCs made of plastic. On the material side, we focus on three aspects: the newly developed EPET IV materials, the processing of calcium carbonate (chalk) and the resource-saving recycling of materials. A further highlight of our exhibition at the trade fair will be on the importance of spiral distributor blow head technology to increase performance. As a pioneer in the industry, BEKUM has intensively devoted itself for years to the material aspects of extrusion blow moulding. This has been in order to meet the requirements of the target group. The packaging industry continuously tries to keep the costs on the material side under control, as fluctuations in the prices of materials can greatly affect unit costing. Likewise, functionally convincing packaging, which has been developed in a resourcesaving manner, provides scope for sustainability, added value and setting itself apart from the competition through product differentiation. Michael Mehnert, CEO of BEKUM Maschinenfabriken Traismauer GesmbH: â€œAs a pioneer and technology leader in blow moulding, the requirements and desires of the packaging industry are of crucial importance to us. It is well known that the cost of materials has a decisive influence on the calculations of manufacturers. Our energy-efficient, flexible, high-performance machine and extrusion solutions of the latest generation grant manufacturers the opportunity of improving their added value through the intelligent and resource-saving use of materials, increasing the quality of their articles and, at the same time, achieving the ambitious sustainability targets.â€?
FULLY TRANSPARENT EPET PACKAGING WITH HANDLE FUNCTION
A key concept in the packaging industry is product differentiation. Accordingly, suppliers are constantly looking for innovative or recyclable materials for new product ideas. The fully transparent, newly introduced EPET class IV material, capable of being extrusion blow moulded, is an interesting candidate. This material has sufficient stability for extrusion blow moulding. 32
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The HYBLOW 407 D, with the C-frame clamping unit patented by BEKUM, enables the reliable production of EPET bottles with flash removal and directed bottle transfer integrated in the machine
Brilliant and elegant: The high transparency of glass-clear EPET IV container convincing at the point of sale
The parameters of the improved class IV are higher than the 1.0 PET recycling stream launched on the market. The typical challenges of PET blow moulding are exceptionally well mastered by the high-quality EPET class IV materials. EPET IV has a comparatively high resistance to wear. The material can be completely melted in the extrusion unit without causing excessive wear. In respect of the machine, special requirements must be met to provide a robust, reliable, fully automatic production in a 3-layer operation. Blow-moulding
SUBSTITUTION BY RECYCLED MATERIAL
Significantly more performance in extrusion blow moulding due to high-tech spiral distributor blow heads from BEKUM
machines from BEKUM, such as the HYBLOW 407 D, have been specially designed for high performance in these demanding EPET applications. The HYBLOW 407 D allows the reliable production of EPET bottles with flash removal and directed bottle transfer integrated into the machine. The current 07 series of machines with the C-frame clamping unit, patented by BEKUM, is perfect for EPET processing due to the high closing force per cavity, uniform force distribution and extremely quick force generation. Michael Mehnert: “BEKUM has numerous references in extrusion blow moulding of the most demanding PET and co-polyester materials. Customers accordingly have access to a comprehensive knowledge base on blow moulding PET materials. This is particularly true in respect of attractive handle containers made of transparent EPET IV for innovative new product ideas for our global customers.”
TWO OPTIONS FOR REDUCING THE COST OF MATERIALS
In order to reduce the cost of materials, two methods are available to the packaging manufacturer. The use of calcium carbonate (CaCO3 = chalk) and recycled material as a substitute in the middle layer. The proven multilayer co-extrusion technology from BEKUM provides the flexibility required and also offers advantages in the processing of both material strategies. Even the combined introduction of chalk and PCR material as a multilayer system is possible and has already been successfully implemented by BEKUM.
CALCIUM CARBONATE FOR EFFECTIVELY CUTTING COSTS
The use of calcium carbonate (chalk) displays excellent barrier properties. The improved UV protection function is also attractive for packaging manufacturers. However, it is in respect of its extremely high cost effectiveness that the use of calcium carbonate (chalk) is decisive. Michael Mehnert: “With a 20 l canister for the packaging of cooking oil, 24% of the HDPE, based on a total weight of only 900 g, could be replaced by chalk at a far lower price. The cost difference between HDPE and chalk in this specific case was about USD 1,000 per tonne. At a machine output of 210 items per hour and 6,000 production hours per year, this results in possible savings of more than USD 270,000 per year. These are very exciting prospects for a packaging manufacturer.”
The use of recycled materials (PCR = post consumer recycled) as a substitute in the middle layer is the other ideal route. The tri-extrusion technology from BEKUM is the right solution for the smooth and efficient production of multilayer systems. It provides the opportunity of including inexpensive, but varied, recycled polymers (old plastics) and their different rheology in the processing between the material layers of the new material. This option was presented to professionals in the industry as part of the launch of the new electric blow-moulding machine EBLOW 37 at the K 2016. A three-layer 20 l canister with a combined material layer distribution made of chalk and PCR was shown. The production parameters in figures: an output of 240 20 l canisters/h (918 g net weight, 1,188 g gross weight) has a flash waste of 23%. The potential savings for packaging manufacturers are enormous. The flash waste generated during the production process is 100% reused in the production and processing. In addition, 20% of the HDPE new material can be replaced by the less expensive combination with chalk. There are also advantages when adding colour. The 2% proportion of colour pigments in a single-layer design can be reduced to 0.5%. The more expensive colour pigments (master batches) only need to be applied to the outer layers. The hidden core no longer needs to be coloured.
HIGH EXTRUSION QUALITY WITH HIGH-TECH SPIRAL DISTRIBUTOR BLOW HEADS
At the Interpack 2017, the focus of our exhibition will once again be on the spiral distributor blow head technology from BEKUM. The unique spiral distributor blow heads are characterised by an excellent, uniform wall thickness distribution in the parison and in the end product. This results in a significant potential for packaging manufacturers to optimise the singlelayer parison quality. However, the spiral distributor blow heads from BEKUM are even more impressive in respect of items with a multilayer structure. In this regard, manufacturers of packaging products do not need to dispense with user friendliness. The heads can be easily adjusted by the operator from the front of the machine. In addition, the head design enables faster colour changing times than conventional designs. The consequent significant increase in machine productivity is of enormous interest to packaging manufacturers in regard to flexibility and profitability. The consumption of change material for cleaning can also be reduced to a minimum by means of spiral distributor blow head technology. The compact design of the spiral distribution blow heads is a further advantage. Their smaller surfaces mean considerably less energy is required to heat them. All in all, the high-tech spiral distributor blow heads from BEKUM provide packaging manufacturers with interesting options to increase the quality of the items, save time and costs during production and a general improvement in adding value. www.bekum.de Bulk Solids Today
BUYERS GUIDE Aero Mechanical Conveyors
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Tel / Fax: 01270 651611
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Bulk Storage & Handling
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FIBC/Big Bag Filling
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Tel: 01608 662878
BUYERS GUIDE Sieves & Sifters Contâ€™d
Manufacturers of semi/fully automatic weighing and filling machines into valve/open mouth sacks.
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INDEX TO ADVERTISERS Bella 11 Dynamic Air
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Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706
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Sieves & Sifters
Valves 22/10/2013 14:56:57
Tuf-lok 17 Vortex Valves
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Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions
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Intelligent Drivesystems, Worldwide Services
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NORD Gear Limited
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