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BULK MATERIALS HANDLING • CONVEYING • PACKAGING • QUARRYING • SEPARATORS

AUGUST 2016


The Smart Way to Unload, Convey, Weigh & Mix ®

MODU-KLEEN BIN VENT FILTER

SWITCH RECEIVER

CONVEYING LINE

®

BLENDCON SILO BLENDER

TM

BULKBUSTER BULK BAG UNLOADER

STORAGE SILO

STORAGE SILO

STORAGE SILO

TM

VIBRA-JET BIN AERATOR

BULK BAG

®

GYRO BIN ACTIVATING FEEDER TM

DYNA-SLIDE HIGH PRECISION AIR-ACTIVATED FEEDER

WEIGH HOPPER

®

BAGBUSTER BAG BREAKER ®

BELLA TWIN SHAFT FLUIDIZED ZONE MIXER

®

BLENDCON AIR BLENDING HEAD

TRANSPORTER MANUAL HOSE SWITCH

Less degradation

Cost effective

Move your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear.

Our high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation and maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation.

Proven capability Dynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from less than a hundred kilograms per hour to 400 tonnes per hour, over distances exceeding 1500 metres.

Sixteen concepts Each Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises.

BellaTM Twin Shaft Fluidized Zone Mixer

GYRO EXTM Bin Activating Feeder

Write or call us today with your questions, or for detailed information on our system applications. Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: sales@dynamicair.co.uk

www.dynamicair.com

Dense Phase Transporter, J-Series

BulkBusterTM Bulk Bag Unloader


Issue 115

CONTENTS 4 NEWS 18 BULK MATERIALS HANDLING 30 QUARRYING 36  CONVEYORS, ELEVATORS, BST TEAM Sales Director: James Scrivens Creative Director: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley Printing: Mixam Print BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Bulk Solids Today 17 Whitley Close, Irthlingborough, Northants, NN9 5GN Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk advertising@bulksolidstoday.co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday

TRANSMISSIONS & COMPONENTS

40 SIEVES, SIFTERS, SEPARATORS & SCREENING 42 RECYCLING & WASTE MANAGEMENT 44 SPECIAL FEATURE 46 PACKAGING 50 BUYERS GUIDE 24

CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk SUBSCRIPTIONS Subscriptions are available to non-qualified readers for £30 per annum (postage incl.), £35 (Europe), and £45 (rest of the world) Cover Price: £5.00 No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements. SOME MANUFACTURERS & SUPPLIERS HAVE MADE A CONTRIBUTION TOWARD THE COST OF REPRODUCING SOME PHOTOGRAPHS IN BST.

ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2016

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COMPANY NEWS

ADVANCED MATERIAL HANDLING TECHNOLOGIES FROM CROWN AT IMHX 2016 Crown, one of the world’s largest material handling companies, will showcase a full line-up of products and forward-thinking technologies on stand 10J61 at IMHX 2016, being staged at the NEC Birmingham from 13th to 16th September 2016.

Now available with a broad range of Crown trucks – the magic glove of Quick Pick® Remote order picking technology

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n modern material handling, the constant need for improved productivity, connectivity and cost control leads to increased efforts to integrate modern technologies into logistics and warehousing processes. On Crown’s 440 square metres stand, visitors will get a deep insight into the company’s latest developments in terms of semi-automation, energy and fleet management technologies. Quick Pick® Remote – Crown’s proven and award-winning Quick Pick® Remote Order Picking Technology improves workflow efficiency, whilst reducing time, effort and costs by enabling the truck to be advanced remotely to the next picking position. Introduced on Crown’s GPC 3000 order picker series at the end of 2013 and followed by its success at various European customer applications, the system is now available on all the company’s order pickers as well as its MPC multi-purpose lift trucks and TC tow tractors. Functionality has been further enhanced with the ability to remotely control lift/lower functions on nearly all Crown stacker models – all via the wrist-mounted “magic glove”. Auto Fence and Auto Positioning Systems – Crown has

The new generation Wave Work Assist® Vehicle from Crown

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Bulk Solids Today

raised the bar in semi-automation with its new RFIDbased Auto Fence and Auto Positioning System technologies for its TSP Series turret trucks. Being launched on the UK market at IMHX 2016, the Auto Fence system controls truck operation near a hazard or where greater caution is required and the Auto Positioning System automates travel and lift functions for the most efficient path between the truck and its destinations. Li-Ion ready range extended – In addition to Crown’s 24-Volt trucks, Lithium-Ion ready variants are now available on 48-Volt machines, including the SC 6000 counterbalance and ESR 5200 reach truck series. The new Wave® – IMHX 2016 will see the UK debut of the new WAV 60 Work Assist® Vehicle from Crown. Designed to bring greater safety, efficiency and flexibility to applications where ladders are typically used to reach up to five metres, such as in retail and manufacturing, the applications for this versatile machine are virtually limitless. The new generation of the Crown Wave features powerful and reliable AC technology with travel speeds up to 8 km/h, as well as the comprehensive on-board Access 1 2 3 system for optimum performance and control. ABOUT CROWN EQUIPMENT CORPORATION Crown is one of the world’s largest material handling companies with a reputation for award-winning product design, advanced engineering and technology supported by superior after-sale service. Crown’s business philosophy utilises vertically integrated processes to design, manufacture and distribute forward-thinking, innovative solutions that improve customers’ productivity and operating efficiency. Crown develops, produces and sells a broad range of forklifts as well as automation and fleet management technologies. The company’s global headquarters is located in New Bremen, Ohio, USA, with regional headquarters in Australia, China, Germany and Singapore. Its employees number 13,200 worldwide. Crown operates a service and distribution network that exceeds 500 retail locations in over 80 countries. To learn more about Crown’s ideas for helping customers advance the productivity of their operations, visit crown.com. You can also visit our online newsroom at news.crown.com.


COMPANY NEWS

ANDREW MCNALLY JOINS CMS CEPCOR TO DEVELOP THEIR AFRICAN BUSINESS.

EURTEAM WELCOMES QUALITAIR&SEA AS NEW PARTNER

xpanding their international sales team further, CMS Cepcor™ have recently been joined by Andrew McNally who will take up the role of Business Development Manager – Africa. Re-locating to Leicestershire from South Africa, Andrew joins with experience of the global comminution industry, with a focus on the African mining market. 20 years of previous capital sales experience within the African market includes the sale of OEM crushing equipment along with aftermarket service and solutions for primary gyratory, cone, jaw and impact crushers. Andrew commented, “CMS Cepcor™ has numerous large accounts in Africa but I know there are some big opportunities in this market for the company. I can see that the service levels are very high and I know that together with the vast product range and huge stocks, covering a wide range of models CMS Cepcor™ can respond very quickly and satisfy the demands of the market easily.” “I’m keen to develop and increase the market confidence further and with a big customer base in the quarrying industry and also huge opportunities in the mining industry, specifically in regions where we don’t yet supply, there are lots of opportunities that I will explore.” Based in Coalville, Leicestershire UK, CMS Cepcor™ is Europe’s leading aftermarket manufacturer and supplier of crusher spare parts, premium manganese crusher liners and crusher service to mining, aggregate production and the crushing industry globally. Exporting to over 100 countries CMS Cepcor™ were awarded The Queen’s Award for Enterprise: International Trade 2012, for outstanding export sales. www.cmscepcor.com

unique alliance of European transport and logistics specialists for the chemical sector has significantly bolstered its market proposition with the appointment of a new partner. QualitAir&Sea International Logistics, the leading independent freight forwarder in France, has joined Eurteam bringing in-country knowledge and client focused expertise to the alliance. Established in 1986, the company is a dynamic niche player in the pharmaceutical, oil and gas, aviation and automotive sectors with a growing reputation for managing hazardous and dangerous products. Luis Cleminson, CEO of Asta Logistik and President of Eurteam, said he was extremely pleased to welcome QualitAir&Sea to Eurteam. He said: “QualitAir&Sea’s reputation as a leading independent freight forwarder in France with a dedicated team and considerable industry experience made them a natural fit for Eurteam.” Eurteam is an alliance of market leading European logistics and freight forwarding companies, providing solutions on a global scale for the chemical sector. It includes Leschaco in Germany, Belgium, the Netherlands and Switzerland, Del Corona Scardigli in Italy, Asta Logistik in Spain and Warrant Group in the UK. Eric Hennet, Managing Director of QualitAir&Sea, which employs 200 people based at 14 locations throughout France, said they were excited to join the chemical alliance to enhance their customer portfolio through Eurteam’s global coverage of chemical expertise. “Joining Eurteam is a great step forward for QualitAir&Sea. We bring detailed knowledge and widespread coverage of the French market to the collaboration. “QualitAir&Sea is located at all the major French ports and airports and with a customer-focused approach, we have invested significantly in our teams to deliver exceptional expertise and dedicated resource.” www.eurteam.com www.qualitairsea.com

E

A

RDS TECHNOLOGY SHOWS LIFTLOG RANGE AT IMHX 2016 At the upcoming IMHX 2016, RDS Technology will be exhibiting their range of on-board weighing systems for Forklift trucks - the Liftalert, Liftlog 100+ and the NEW LIFTLOG 1000.

T

hese systems offer load monitoring and weighing functions with an internal alarm to warn when load threshold is approached and at the overload point. The Liftlog products on show also offer a totalising feature, making it ideal for applications where multiple pallets are to be checkweighed or loading storage systems where weight limits are to be adhered to. Negating the need to travel to a floor-mounted platform scale often sited in a remote part of the warehouse, the Liftlog range provides a time-efficient means of check weighing. A hydraulic load sensor is used to measure the increase in system pressure and the LIFTLOG unit displays the weight to the operator. Also included is an overload alarm that will sound when the overload threshold is approached and at the overload point to further inform

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Bulk Solids Today

the operator of load status. This helps the driver to avoid potential tip-over, increasing the safety of the forklift and surrounding warehouse. The NEW LIFTLOG 1000 is the latest product in the LIFTLOG range, offering ±0.5% accuracy for forklift trucks operating in the fastest loading environments. It is a costeffective weighing instrument that reduces loading cycle times and maximises tons per hour performance. For more information on how on-board weighing and data handling be used to help improve your operations, visit RDS on stand 11P25 or visit www.rdstec.com.


Dust and buildup on the antenna? No problem! The future is 80 GHz: a new generation of radar level sensors

VEGAPULS 69 is designed specifically for level measurement of bulk solids. Even in dusty conditions, it always provides precise readings. Dust in the silo or buildup on the antenna have no effect. This radar sensor also features unrivalled focusing at a frequency of 80 GHz. Simply world-class! www.vega.com/radar


COMPANY NEWS

DOOSAN HOSTS THE DOOSAN GLOBAL BUSINESS FORUM 2016 IN SCOTLAND

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he Rt. Hon. Lord William Hague, former British Foreign Secretary, Professor Joseph Stiglitz and other distinguished speakers and guests gathered to assess the world economy and discuss geopolitical risks. Presentations were also delivered on the infrastructure development outlook in Asia and implications of the new climate regime on the infrastructure sector. Prominent speakers included Lord William Hague, a former British Foreign Secretary; Joseph Stiglitz, a Professor of Economics at Columbia University; and Chang Yong Rhee, Director of the Asia and Pacific Department of the International Monetary Fund (IMF); Juan Miranda, the Managing Director General of the Asian Development Bank (ADB); Sir Danny Alexander, Vice President of the Asian Infrastructure Investment Bank (AIIB); and Amitabh Kant, CEO of NITI Aayog and former Secretary of the Department of Industrial Policy and Promotion in India; H.E. Felipe Calderón, Chair of the Global Commission on the Economy and Climate and former President of Mexico; Arun Majumdar, a former Undersecretary of the U.S. Department of Energy. In his special remarks, Lord William Hague shed light on geopolitical risks that particularly require global attention and their impact on the world economy. In the first session, Professor Joseph Stiglitz, a Nobel Prize-winning Economist, and Dr. Chang Yong Rhee, IMF director, presented their prospects for the global economy and discussed the short- and long-term global economic trends highlighting North America, Europe and Asia. In the following session on the Asian infrastructure industry, AIIB Vice President Sir Danny Alexander and ADB Managing Director General Juan Miranda spoke about the challenges and opportunities that the infrastructure businesses are facing in Asia. NITI Aayog CEO

Amitabh Kant also touched upon India’s reforms and innovations to improve the infrastructure. The last session dealt with the implications of the Paris Agreement on industries in the era of the new climate change regime. H.E. Felipe Calderón, Chair of the Global Commission on the Economy and Climate, and Professor Arun Majumdar shared their prospects for the future low-carbon energy economy and the implications of the new climate change regime on the infrastructure business. Founded in 2012, Doosan Global Business Forum has become an annual event in which global leaders including eminent economists and CEOs of multinational enterprises gather to gain valuable insights on the global business environment. Previous participants include politicians such as The Rt. Hon. Tony Blair, former Prime Minister of the United Kingdom; Lawrence H. Summers, former U.S. Secretary of the Treasury; Condoleezza Rice, former U.S. Secretary of State; and Angel Gurria, Secretary-General of the Organization for Economic Cooperation and Development (OECD). Visit Doosan at the IMHX Exhibition, 13 – 16 September at the Birmingham NEC. For more information please call 01604 825 600 or email salesadmin@doosan.com www.doosan.com

SPACIOTEMPO ANNOUNCES EXHIBITION FIRST FOR IMHX

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his year’s IMHX show will be marked by an exhibition-first as temporary building specialist Spaciotempo installs its own temporary building as its stand, from which it will reveal its latest product developments for premier structures. As part of its biggest and most interactive exhibition to date, Spaciotempo will install its own temporary structure to welcome visitors to IMHX at Birmingham NEC between September 13-16. The business, which is the only temporary building specialist to manufacture its own raw materials, is confident that by installing one of its lightweight and durable aluminium frame structures, visitors to the show will be able to experience for themselves the durability, safety, and high quality aesthetics that temporary structures can provide. It will also demonstrate how quickly the company’s structures can be installed and removed, with just days to set the stand up. The company is also using this year’s exhibition to unveil the latest new products to come out of its R&D department, which enable Spaciotempo to deliver a complete fit out service to businesses in need of urgent and affordable extra space. This can include racking, LED lighting, improved door and window fittings, and interior fixtures. Scott Jameson, Managing Director at Spaciotempo, said that visitors to this year’s IMHX will be left in no doubt regarding the quality and durability of using temporary structures for warehousing, extension projects, distribution hubs, motor vehicle dealerships, retail refurbishments, and much more. He commented: “We spend a lot of time telling visitors at exhibitions how suitable our temporary structures are for a range of different projects, and how quickly and conveniently they can be installed, extended, and removed. This year, we’ve decided to

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Bulk Solids Today

let our products do the talking for us, and will be inviting people to have a look around our temporary structure and learn about some of the new materials and products in our most recent range. We’ve been planning to do something like this for a while and can think of no greater stage on which to showcase our quality structures than IMHX, our most important UK exhibition.” IMHX brings together various parts of the supply chain to give delegates the perfect opportunity to meet suppliers face to face, discuss their challenges and find solutions. Spaciotempo will be exhibiting on stand 11N11, where it will also be handing out its new white paper, which explores the benefits of temporary solutions to the UK and Ireland at a time the two nations are experiencing a critical warehouse shortage. www.spaciotempo.co.uk


COMPANY NEWS

VORTEX (UK) MOVES INTO ANOTHER DECADE OF HANDLING BULK SOLIDS

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s you walk through the entrance of Vortex’s newly renovated offices in Darlington, United Kingdom, you might think you’ve entered a local supermarket. There are shelves full of familiar every day products; Yorkshire Tea, Lavazza Coffee, Daz Washing Powder, Pringles Crisps, Jacobs Biscuits, Dunlop Tyres, Guinness, Wrigley’s Chewing Gum, and the list goes on and on. “It is sometimes hard to describe what we do,” explains Vortex’s Managing Director Travis Young. “This display essentially shows the range of materials and brands our equipment handles. It helps connect the dots for those unfamiliar with Vortex and the dry bulk handling industry as a whole.” Vortex, which was founded in the USA almost 40 years ago, specialises in a wide range of valves and components for handling bulk solids. The company’s Darlingtonbased operations is celebrating its ten year anniversary this year and is responsible for the corporation’s business activities in Europe, Asia, and Africa. In April 2016, the company moved into a newly renovated industrial building near Darlington town centre to house its primary offices and distribution centre. “The new premises not only provides a great work environment for our employees, but offers a lot more room for growth,” commented Mr. Young. “We routinely host many agents and clients for training courses from all over the world, so the large conference room and product demonstration area are a welcome addition.” According to the company’s website, Vortex has contracted with 40 sales agents that cover over 75 countries throughout the world. Its clients include many blue chip companies like Dow Chemical, Nestle, DuPont, Sabic, BASF, Kraft Foods, P&G, Rio Tinto, Cargill, and InBev. “The range of processes we are involved with is staggering,” remarked Andrew Davies, Vortex’s Application Engineering Manager. “One day we’ll be working on a cement project in the Jordanian desert, the next day spent on a Dutch factory that produces whole bean roasted coffee.” A TEN YEAR MARATHON Sir Richard Branson has been quoted as saying “There are no quick wins in business – it takes years to become an overnight success.” The same is true for Vortex’s business expansion outside of the Americas. According to Laurence Millington, Vortex’s International Sales Director, it has been more of a marathon than a sprint. “Ten years ago Vortex had a huge mountain to climb. When we started (in the UK) we had only a handful of customers throughout Europe, Asia, and Africa. Despite this, we knew if we could assist our customers by solving their processing problems, whilst striving to delivering excellent service and response, Vortex would find its place in these new markets.” The proverbial mountain mentioned by Mr. Millington involved a wide range of challenges, which included offering products that were certified in accordance to EU Directives and developing products that conformed to metric versus imperial standards. “The first three

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Bulk Solids Today

Vortex’s Managing Director Travis Young says the new premises offers more room for hosting its many global agents and clients in the dry bulk solids industry.

years were more about investing in the future than turning over profits,” commented Mr. Young. The move in April marks Vortex’s third relocation in ten years to accommodate more staff and warehousing space. Prior to its move to Enterprise House in Darlington, the company was located in the Morton Park Industrial Estate. “Much of our growth can be attributed to Vortex’s employees,” mentioned Mr. Young, ”We have a great team of people that maintain our company’s core values of Respect, Humility, Integrity, and Passion in both the UK and the US.” Vortex’s UK office is located at Building 1J, Enterprise House, Valley North Street, Darlington, DL1 1GY in the United Kingdom. To find out more information, the company’s website is www.vortexglobal.com. Tel: +44 (0)1325 728577 Email: global@vortexglobal.com


COMPANY NEWS

MOTAN COLORTRONIC TEAM COMPLETE

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eil Watton has recently joined Team Motan Colortronic as Technical Project Engineer. Neil, with over 14 years’ experience in ancillaries for the Plastics Industry, will work alongside the Engineering Team and interact daily with clients to prepare, schedule and coordinate engineering installations and projects. “We are delighted to welcome Neil to our extensive engineering team� states Dave Sturgess, Technical Manager of Motan Colortronic From left – Dave Sturgess, Limited “and we are sure, with his Neil Watton considerable experience he will further enhance our engineering capabilities�. Tel: 01246 260222 Email: sales@motan-colortronic. co.uk www.motan-colortronic.co.uk

High Efficiency Drying or Cooling of Bulk Solids The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone. The result is a more consistent material.

BARTON’S SPACE SAVING SILOS

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anko Gosei Automotive Systems has saved considerable warehouse space and significantly reduced raw material costs by installing two aluminium, plastic granule storage silos supplied by Barton Fabrications. The two 3.5m x 12m high silos are used to store polypropylene granules used in the company’s automotive parts moulding processes. The 50 tonne storage vessels are bulk filled from road tankers and replace large plastic sacks and cardboard Octobins previously used on-site. As part of the installation, the two Barton silos were fitted with load cells and telemetry system. This allows real-time visibility of stock levels and usage by both Sanko Gosei and the raw material supplier, which in turn simplifies management of the company’s plastic granule consignment stock. Commenting on the benefits of the decision to move to silo storage, James Bradley Sanko Gosei’s Production Engineering Manager said: “As part of our Kaizen process, we were tasked with removing waste from our warehouse. We identified two materials as high use with good potential for improvements in materials handling and storage. The decision to install two storage silos has allowed us to save significant warehouse space. Additionally, we have reduced both fork lift truck movements and the need to dispose of plastic storage sacks & cardboard Octobins. “We have also lowered direct materials costs by buying in bulk and our surcharge / transport costs are less. We are absolutely delighted with the new Barton silos and were very happy with the whole installation process.� The Sanko Gosei project is the latest Barton Fabrications installation that supports the supply of plastic moulded parts for the UK’s automotive industry. Tel: +44 (0) 1275 845901 Email: sales@bartonfabs.co.uk www.bartonfabs.co.uk

$YNAMIC!IR,TDs  

www.dynamicair.com

ROTECH FOR RELIABILITY! ROTECH motion sensors can be used whenever information on shaft speed, position, completed revolutions, etc, is required, for indication, control, interlocking, alarm initiation, etc.

Less? Why Accept Anything

Speed monitoring Safety interlocking Rotation control

Polypropylene Body Stainless Steel Body

Rotation/Vibration monitoring solutions for your equipment  using our wide range of sensors. • Self Contained, Easy to Fit Aluminium Body

• Maintenance Free for Life • Pulse rates from 1 to 1000

Vibration Sensor

Speed Relay

• Range of AC/DC signal outputs • All Industrial Applications •

Tel: +44 (0)151 356 2322

ATEX

Website: www.rotechsystems.co.uk

Monitoring the world since 1983

Bulk Solids Today

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COMPANY NEWS

IMPACT TO UNVEIL NEW CARER HEAVY DUTY ELECTRIC FORKLIFT AT IMHX Stand 10H27, OS2, IMHX, NEC, Birmingham, 13-16 September 2016

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mpact, the UK’s sole distributor for Cat® Lift Trucks, will return to IMHX this year to showcase its comprehensive product line-up – including the UK show debut of a new 8-10 tonne Carer heavy duty electric forklift range. The company will feature 12 trucks on its stand, as well as displaying a Konecranes 45-tonne container reach-stacker outside the hall, welcoming delegates as they enter the exhibition. Nine forklifts from Impact’s extensive Cat® lift trucks product line will be on display, including examples from both the warehouse and counterbalance range. Impact will also reveal a suite of enhancements to its Cat product line at the show, including details of a new cold-store cab for Cat reach trucks, and enhanced cold-store protection for its 48V electric forklift range. The company will also detail the new Tier 3b and Tier 4-interim diesel engines now available for its 4- to 16-tonne Cat diesel forklifts, which were developed to comply with the latest European emissions legislation. Equipped with a passive diesel particulate filter, these new engines do not require downtime for regeneration purposes, or additional maintenance requirements. A 4-tonne unit fitted with this engine will be displayed at the stand. Italian manufacturer Carer – for which Impact is also sole UK distributor – will display its new A80 electric truck at IMHX. Designed to help companies cut their greenhouse gas emissions by switching to electric power, the A80 will be available in 8-10 tonne models, and is already garnering significant interest from UK industries – especially paper and packaging firms.

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Bulk Solids Today

ROCLA AND SPIJKSTAAL JOIN PRODUCT RANGE Impact is using the show to further cement its new role as an official distributor for Finnish automated guided vehicle (AGV) manufacturer Rocla, by displaying one of the company’s ATX16 units. The AGV on display – one of 1,000 Rocla variants Impact can offer UK companies – will be tasked with serving drinks throughout the exhibition, moving safely and steadily around its own display zone on the Impact stand. AGVs manufactured by Rocla – which has been part of Mitsubishi Nichiyu Forklift group since 2009 – share many common components with Cat lift trucks, meaning Impact is ideally placed to supply and support the advanced products, and help UK companies adopt, optimise, install and operate the time-saving technology. Meanwhile, joining Cat and Rocla on the stand will be another new addition to Impact’s stable – a three-wheel tow tractor from Spijkstaal; one of many specialist vehicles now available from the Dutch manufacturer through its relationship with Impact. For more information about Impact visit www.impact-handling.com.


COMPANY NEWS

TEREX CONSTRUCTION APPOINTS NATIONAL ACCOUNTS RELATIONSHIP MANAGER

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lobal equipment solutions provider, Terex Construction, has appointed Jon Beckley to the role of National Accounts Relationship Manager for its UK manufacturing facility in Coventry. With 17 years’ experience in sales and customer development within the Terex group, Beckley has considerable expertise within the compact equipment marketplace; both in the UK and internationally. In his new role, Beckley will manage Terex Construction’s national client portfolio, with a principal goal of developing strong relationships with existing accounts and supporting their equipment requirements. Going forward, Jon will also play a leading role in further expanding the company’s national and international presence with major fleets. Paul Macpherson, Sales and Marketing Director of Terex Construction’s UK manufacturing facility in Coventry, commented: “As we continue our ambitious growth, we are delighted that Jon has taken on this new role, which will help us to consolidate relationships with existing customers and further develop opportunities with new partners. “As a highly experienced professional with meticulous product knowledge, I’m confident that Jon’s commitment to delivering exceptional customer service will be second to none.” Beckley, who has spent the past eight years as Global Product Manager – Backhoe Loaders, has also worked as Dealer Manager, Development Manager and Product Manager at Terex Construction.

He begins his new role immediately and will be based at the company’s manufacturing facility in Coventry. Commenting on his new role, Beckley added: “Thanks to continued R&D and a number of new product launches over the past six months, Terex continues to build on its reputation as a leading manufacturer of heavyduty plant equipment – both in the UK and internationally. “Moving to my new role as National Accounts Relationship Manager is an excellent opportunity, allowing me to develop existing customer relationships and forge new ones with leading construction businesses right across the industry.” www.terex.com

Toll Processing (2016) Ad (134x178)_Layout 1 21/04/2016 16:32 Page 1

Experience the

difference… …in toll processing services from product development to full scale up production As experts in size reduction, classification and multi-processing techniques we offer a swift route to market of even difficult to handle products. Customers gain real advantages from our powder processing experience.

• Comprehensive, in-house analytical and test facility support • Separate chemical and food processing suites • High volume or small batch production • We work with you to determine accurate product specifications • Product/process risk assessments completed • Optimum design of production processes to meet product requirements Single stage processing, systematic multi-stage processing or multi-stage processing using a single, specialist machine, our engineers are there to work with you for the optimum solution.

Tel: +44 (0) 1928 755100 • E.mail: info@hmluk.hosokawa.com • www.hosokawa.co.uk Bulk Solids Today

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COMPANY NEWS

BIBBY DISTRIBUTION’S CARBON FOOTPRINT SHRINKS FOR THIRD YEAR RUNNING Bibby Distribution’s CO2 emissions have shrunk for the third year running, thanks to an award-winning array of carbon-cutting initiatives.

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he 3PL’s annual carbon report has found that total CO2 emissions per km have dropped by a further 5.9 per cent on 2015, on top of the continuous improvement seen since 2013. The reduction in emissions is the result of a spectrum of smart initiatives that improve efficiency at every level. Bibby Distribution has also been recognised by the Freight Transport Association (FTA) as a sector leader, with the 3PL winning the FTA’s Leadership in Carbon Reduction Award in May. Andrew Mawson, Head of Safety, Health, Environment and Quality, Bibby Distribution, says: “Carbon emission reduction isn’t an ‘extra’ for Bibby Distribution. It’s at the heart of everything we do. Reducing CO2 means our fleet is working more efficiently. That’s the right thing to do, because it’s good for the environment, but it’s also better for customers, as it’s good business sense. We prioritise innovation, cut costs, and help ensure our customers can do business without costing the Earth.” The ongoing improvement has been delivered by several major projects introduced over the past two years. Dual-fuel vehicles have been introduced on high-mileage contracts, cutting individual emissions by 10 per cent, while the 3PL’s active participation in the

ongoing longer semi-trailer trial has seen Bibby Distribution conduct 8,400 fewer journeys without compromising on volume. Additionally, the introduction of a new type of tanker has cut fuel usage by 53 per cent during the process of collecting milk from farms, and all drivers across Bibby Distribution are now benefiting from individually tailored training, that uses the 3PL’s full fleet telematics to identify and eliminate inefficient driving practices. www.bibbydist.co.uk www.bibbygroup.co.uk

UK FIRST FOR MOVITHERM MIO SERIES

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hermal Vision Research brings award-winning MoviTHERM MIO Series to UK, instantly turning FLIR cameras into complete heat monitoring systems. Specialist stockist of thermal imaging technology, Thermal Vision Research (TVR) has just signed the first UK distributor deal for the award-winning MIO Series modules for FLIR cameras, with California-based thermography business MoviTHERM. TVR saw an opportunity to introduce this new technology to the UK market, potentially saving FLIR camera users thousands of pounds on acquiring and maintaining complex supporting infrastructure. Launched in April 2016 and already the winner of the Innovators Award 2016, the MoviTHERM MIO Series Intelligent I/O module turns FLIR cameras instantly into complete monitoring systems for fire detection. It’s available in two modules, one for FLIR AX8

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Bulk Solids Today

cameras and the other for FLIR A310f cameras both of which are used across a wide range of industry sectors throughout the UK. Matthew Clavey, director of Thermal Vision Research, said: “The MIO Series modules developed by MoviTHERM are a groundbreaking innovation for the thermal imaging industry. For the first time, thermal output can be monitored and warning triggers acted upon through a simple web-based interface – eliminating the need for a vast array of potentially unreliable supporting infrastructure. “The two compatible cameras, the FLIR AX8 and FLIR A310f, are popular recommendations for use where there might be issues with overheating such as plant or server rooms, fire protection installations, warehouse management or even waste disposal sites. And then, the functions of the MIO Series are simply immense – from accessibility via a smart phone, to connectivity across vast multi-camera networks. This really is a new opportunity and a bench mark in thermal imaging monitoring technology.” Each MIO Series module comes with eight digital alarm outputs and eight channels of 4 to 20mA outputs which can be assigned to any of the connected cameras. Up to seven cameras can be monitored through a single unit or the system can be scaled up for connection to over 100 cameras. Set up is straightforward using a built-in webserver and firmware can be upgraded when improvements are made using a simple download process. MoviTHERM is now promoting the product at exhibitions in the US, but on-site demonstrations can be arranged in the UK by calling 0333 200 4667 or visiting www.thermalvisionresearch.co.uk. Full product details and technical specifications can be found at www.movitherm.com.


COMPANY NEWS

80 GHZ RADAR NOW GETS BLUETOOTH WITH EX APPROVAL

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EGA Bluetooth communications have been a standard option across the whole range of plics® transmitters since March this year and it is also backward compatible to all sensors supplied since 2002. It features secure 64 bit encryption and pairing using Apps or PC USB dongle via PACTware. Up until now, it has only been available for safe area devices. Adding yet another new option for the new 80 GHz radar level sensors VEGAPULS 64 (liquids) and 69 (bulk solids), they have added ATEX / IECEx: Ex ia, Ex ia/t (Dust) FM: OL, XP, DIP approvals. This enables the easy set up and sensor management using EX capable tablets and smartphones, run by Android, with Bluetooth 4.0 via the VEGA TOOLS App. They can also be operated via a magnetic pen through a window. This range of product compatibility and dual capability is yet another world first from VEGA. This option means ‘hot work’ permits may not be needed, as no covers are removed or wires connected to sensors or signal cables. Engineers can work from safer locations, possibly even outside clean rooms in electronics, pharma and food industries, saving time and increasing safety. For more details about this exciting innovation, please look under Wireless Adjustment at www.vega.com/radar

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

,ESSFRICTION ,OWTORQUE ,OWMAINTENANCE ,OWERACTUATORCOSTS ,ONGERVALVELIFE -ORERELIABLE Tel: +44 (0) 1908 622366

www.posiflate.com

Bulk Solids Today

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COMPANY NEWS

CHICAGO PNEUMATIC LAUNCHES NEW MID-SIZED FORWARD AND REVERSIBLE PLATE COMPACTOR

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hicago Pneumatic has expanded its range of light compaction equipment with the introduction of a new tough and fast mid-sized forward and reversible plate compactor. The MV 504 is very easy to operate and maintain, and intended for deep and medium deep compaction of granular soils. “With its smooth operation, the MV 504 represents a great alternative to rollers when compacting soil in small areas,” says Andrzej Mrozinski, spokesperson for light compaction equipment at Chicago Pneumatic. “In addition, it provides efficient performance and excellent traction, even on wet soil, helping operators to achieve the right compaction level.” Made to handle tough working conditions, the MV 504 has a bottom plate made of Hardox 400 grade steel that is extremely durable and resistant to wear and tear, making it suitable for intensive usage. The compactor is equipped with a heavy duty frame to protect internal components, with the hydraulic pump mounted on the engine to reduce the risk of impact damage.

For ease of maintenance, the machine is designed to prevent rocks becoming stuck between the plate and the frame. In addition, the machine’s user-friendly design provides operators with easy access to the fuel tank, drive belt and eccentric box, meaning it requires minimal effort to be kept in optimal working conditions. Alongside durability and low maintenance, the MV 504 has great ergonomic qualities that enable operators to perform tasks with less effort and more efficiency. It comes equipped with a vibration reducing handle so that operators are not exposed to high hand/arm (H/A) vibration levels, and is easy to handle even on rough surfaces. The MV 504 forward and reversible plate compactor will be available through Chicago Pneumatic’s worldwide distributor network, which offers sales, aftermarket parts and maintenance services locally. To learn more about the extensive range of Chicago Pneumatic equipment, please visit www.cp.com.

CENTRALISED MOTION CONTROL WITH SINAMICS V90 SERVO DRIVES

NEW FENNER BELT FOR EMERGENCY BREAKDOWN SITUATIONS

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iemens has added PROFINET connection to its popular SINAMICS V90 servo drive system, allowing for centralised motion control when paired with S7-1500 or S7-1200 based PLC system. The addition of a PROFINET connection further enhances the functionality and flexibility of this successful drive system, enabling a wide range of motion control tasks to be implemented cost-effectively and conveniently. Other integration options include PTI, USS and Modbus RTU. The SINAMICS V90 system comprises of the SINAMICS V90 servo converter and SIMOTICS S-1FL6 servomotor. The system features eight converter frame sizes and seven motor shaft heights to cover a performance range from 0.05 kW to 7.0 kW for operation in single-phase and three-phase networks. The SINAMICS V90 PROFINET version is equipped with an integrated PROFINET interface for linking the drive to an automation system via PROFIdrive profile. With integrated real-time auto tuning and automatic suppression of machine resonances, the system automatically optimises itself to achieve high dynamic performance and smooth operation. John Inskip, Product Manager – Sinamics S120/V90 at Siemens UK & Ireland comments: “We are continually investing in our range of servo drives to meet the ever-changing needs of industry. These latest innovations have been designed to deliver reliable, cost-effective performance for a wider range of motion control tasks.” For more information on Siemens visit www.siemens.co.uk.

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Bulk Solids Today

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RIKS, a leading industrial services provider, is pleased to introduce a fast and reliable belt solution for use in emergency breakdown situations on belt drives, avoiding equipment downtime and the associated costs. The Fenner QuickFix belt is incredibly versatile, featuring a dual groove profile so that one belt fits both V and wedge belts profiles. What’s more, the belt is quick and simple to install. Available in four different width profiles; SPZ, SPA, SPB & SPC, the Fenner QuickFix belt comes in five metre rolls enabling the maintenance teams to cut it to the desired length, on site. Thanks to the jointed link belt design, it can save precious time with minimum strip down of the unit during installation. Ideally suited to any site with a large number of belt drives, typical applications for the Fenner QuickFix belt can include hospitals, airports and universities as well as being the perfect addition to facilities management team’s emergency repair kits. With so many different potential applications such as the use in air handling units, businesses can spend huge amounts of money sourcing, purchasing and then storing belts for that just in case scenario. Fenner QuickFix enables businesses to reduce stock inventory considerably, requiring just two five metres boxes of each section size, to cover all eventualities for both new and old systems and for both wedge belt and V belt profiles – saving both time and money. Satish Chandarana, Product Manager – Open Drives at ERIKS, commented: “Downtime is a major concern in any business and so finding a solution that can help keep businesses moving is significant. While the Fenner QuickFix solution is temporary, its concept is simple – providing businesses with a fast and reliable solution that will get them back up and running quickly and a relatively low capital expenditure, whilst original Fenner rubber belt is on order.” www.fptgroup.com


COMPANY NEWS

INDUSTRIAL GEAR UNITS WITH 190 KNM OUTPUT TORQUE Even more comprehensive UNICASE gear unit portfolio

WESTINGHOUSE

couplings, axial fans, motor A new size in the swing bases, torque limiting NORD industrial gear backstops, and cooling and unit range provides the proven advantages: high heating systems are available as well. load capacity, applicationA developer and manufacturer of drive specific configuration, technology for over 50 years, NORD DRIVESYSTEMS and flexible installation employs more than 3,200 people and is one of the world’s leading suppliers of full-scale, comprehensive drive solutions. NORD’s portfolio ranges from standard drives to customized solutions for demanding application requirements, e.g. based on energy-efficient or explosion-protected drives. Gross sales amounted to EUR 540 mn in the 2015 business year. Subsidiaries in 36 countries around the world and an extensive distribution and service network ensure minimal lead times and provide customeroriented services wherever needed on short notice. NORD’s wide variety of gear types covers torques from 10 Nm to 250 kNm and more. The company also supplies motors with outputs from .12 kW to 1,000 kW and manufactures frequency inverters up to 160 kW. NORD’s inverter line-up features conventional models for installation in control cabinets as well as design types for fully integrated drive units in decentralized automation environments. www.nord.com

! n O s i e r u ss e r P e Th

NEW High Pressure Rotary Valve The DMN-WESTINGHOUSE HP valve with specially designed inlet is very suitable for handling granular formed products under a high pressure of maximum 3.5 bar g. The valve has a very important advantage in air leakage: the special configuration of body, rotor and seals does not only protect product against degradation, it also does not allow any axial air leakage.

DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com

Features: • Special inlet for maximum protection against product degradation • High filling efficiency • Lowest air leakage through special seals • Robust construction • Easy assembly and disassembly

360° video

COMPONENTS FOR BULK SOLIDS HANDLING

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ORD DRIVESYSTEMS extends the successful industrial gear unit range by adding a new size with 190 kNm output torque. The series now comprises nine sizes and covers torques from 25 kNm to 250 kNm. The addition of the new size 14 units allows for configurations tailored even more precisely to individual applications. Featuring a single-piece UNICASE housing as is standard for all NORD gear units, they achieve a longer bearing life than gear casings manufactured from jointed parts and ensure efficient power transmission and high tolerance for load peaks and jolts. They can be assembled as two or three-stage helical inline or helical bevel gearboxes with nominal transmission ratios from 7.1:1 to 400:1, or even up to 30,000:1 with an auxiliary primary stage. The input and output direction can be freely selected. NORD industrial gear units can be mounted on any of the six sides. The manufacturer configures industrial geared motors for a diverse range of uses from steel works to process plants. Application-specific features and options include reinforced bearings and shafts, extra-large bearing distance, extended output shafts, and Drywell designs with an additional oil drip disc and a leakage oil display or oil sensor. Disc and drum brakes, dual-gear setups, auxiliary motors, IEC motor adapters, turbo

www.dmnwestinghouse.uk Bulk Solids Today

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BULK MATERIALS HANDLING

DEMAG CRANE SYSTEM FOR PACKAGING BOARD MANUFACTURER • Multi-functional material handling system • Maximum crane availability for increased productivity • Application focused features to meet the manufacturing processes

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erex Material handling has installed a Demag double girder overhead travelling process crane at Iggesund Paperboard (Workington) Ltd’s production facility in Cumbria. Part of the Swedish Holmen Group, Iggesund manufactures high quality folding box board products, which are used for the premium packaging and graphics markets. The crane installation was part of an investment in new and upgraded board production facilities, to increase output by 20,000 tonnes per year. The crane was required due to the increased size and weight of the rolls in the new equipment. The Iggesund production line operates 24 hours a day for 365 days per year, with a reel of board coming off the production line every 30 minutes, meaning that maximum availability and reliability of the material handling system is fundamental to the efficiency of the plant. To meet the specific requirements of Iggesund’s production processes, Demag engineers designed a complex reel handing crane, with a range of application focused features. The solution is a 60 t SWL, 20.4 m span crane equipped with multiple hoists. These consist of two outer 35 t SWL open winch crabs and a central 60 t open winch crab. A 52 t SWL power slew lifting beam is also part of the installation and is suspended from either the central hoist or the two outer hoists. The slewing beam is required to lift reels of paperboard and may be lifted by either the 2 x 35t hoists or the 60t hoist. This gives operational flexibility and back-up lifting capacity in the event of a hoist failure. In addition, each crab is also fitted with an auxiliary Demag wire rope hoist, rated at 5 t SWL, for faster maintenance functions. The Demag crane is capable of travelling along the full 257 m of the paperboard production line, facilitating a wide range of operational and maintenance

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Bulk Solids Today

functions, but its primary role is the unloading of full reels from the board manufacturing line. To accommodate the requirement for smooth movement of loads and precision positioning accuracy, the crane features frequency inverters. It has cross travel speeds of 5 to 15 m/min, long travel speeds of 5 to 40 m/min and hoisting speeds of 0.5 to 5.5 m/min, for loads greater than 30 t, or 0.5 to 8.4 m/min for loads of less than 25 t, providing fast and efficient load handling. The crane system is operated by radio remote control or mobile pendant. Iggesund’s manufacturing programme dictated that Demag technicians needed to complete the installation of the crane without interruption to the production process. This necessitated detailed planning and project coordination, including the removal of sections of the machine hall roof and wall, to allow the crane girders to be lifted into place. Iggesund’s Projects Engineer, Michael Brew, stated: “Demag’s engineers appreciated the specific requirements of our production processes and came up with a multi-functional material handling system, designed to provide maximum operational availability. In the face of stiff competition, they have delivered the best engineered solution for our processes, with a range

of innovative features, which have helped us increase efficiency and productivity.“ ABOUT TEREX MATERIAL HANDLING Terex MHPS GmbH is one of the world’s leading suppliers of crane technology with Demag industrial cranes and crane components. The core competence of the Terex Material Handling business group lies in the development, design and production of technically sophisticated cranes, hoists and components and the provision of sales support and services for these products. Terex Material Handling manufactures at 19 locations on five continents and reaches its customers thanks to its presence in more than 60 countries. Tel: 01295 676100 Email: bnb-help@terex.com www.demagcranes.co.uk


Intelligent Drivesystems, Worldwide Services

RELIABLE

VERSATILE

A complete range of geared motors rated at 0.12...200kW provides the optimum solution for all drive requirements. For convenient control combine with our decentralised inverter range to 22kW.

NORD Gear Limited

11 Barton Lane, Abingdon, OX14 3NB Tel. No.: +44 (0) 1235 534404 Email: GB-Sales@nord.com

Member of the NORD DRIVESYSTEMS Group

GLOBAL


BULK MATERIALS HANDLING

HOISTS AND CRANES – THE CAPTAINS OF INDUSTRY

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he importance of an everexpanding industrial world should not be underestimated. After all, long-term, sustained industrialisation is a key driver for economic development, a fact recognised by the world’s most important leaders. It was no accident, for example, that President Obama made a personal appearance to open the planet’s largest industrial exhibition, Hannover Messe, earlier this year, becoming the first US president ever to do so. Technological innovation, such as that exhibited at Hannover Messe, is paramount in helping industrial companies achieve competitive gain and accrue market share. These technologies must be robust, reliable and require little maintenance. Only this way can the industrial sector maximise its output. For example, take humble hoists and crane systems such as those manufactured by J D Neuhaus (JDN). These lifting mechanisms have become the mainstay of material handling operations the world over as so many industrial tasks require lifting and manoeuvring, which without mechanical assistance would prove unproductive. Even hoists and cranes, however, are constantly evolving. Today’s iterations place great emphasis on long service life, ecological compatibility and recyclability – all of which is achieved without any detriment to safety or performance. And perform they must. The wide ranging demands of industrial applications for these products mean that at crane and hoist manufacturers such as JDN, their products are all engineered for extremes. For instance, imagine the cold, dark, isolated, dangerous conditions in which underwater divers have to operate, or the fast-paced, high temperature, heavy atmosphere that foundry workers must endure. Or how about the howling gales and driving rain environment encountered by oil rig operatives. Even under extreme operating conditions such as these, JDN hoists and cranes, which are available with individual lifting capacities up to 100 tonnes, move loads reliably and with precision, day after day, year after year. They are in use in more than 70 different commercial sectors, including oil and gas, mining, the chemical industry and heavy plant construction. The 100% duty cycling of the equipment, which can either be

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Bulk Solids Today

used directly in applications or as sub-components of other OEM material handling devices, allows workers around the world to work longer and harder with maximum safety and the minimum of stress and physical effort. A further benefit is the streamlined design of the latest cranes and hoists, which ensures that maintenance is non-invasive and both quick and simple to perform, thus minimising non-productive downtime. In practice, benefits such as these have had a resoundingly positive impact at countless industrial companies, where huge increases in productivity have been achieved. To ensure this advantageous position continues moving forwards, the Global Service offered by J D Neuhaus helps industrial users guarantee the continuous operational availability of hoists and cranes, aiding the delivery of product longevity. With JDN Global Service it is possible to diagnose, find a solution and fix the problem, in any remote corner of the world.

Ultimately, for long-term structural change, industry plays a pivotal role. It creates many productive, formal jobs at an early stage of development. It also drives technological development and innovation to sustain productivity and growth in manufacturing and other commercial sectors. In short, the prosperity of the global economy relies on industry, and industry relies on technology. Only by selecting optimised, proven technologies engineered for extremes, can worldwide industries continue to grow. Tel: 01224 722751 Email: info@jdneuhaus.co.uk www.jdngroup.com


BULK MATERIALS HANDLING

BRIGGS FORGES NEW CONTRACT WITH SPECIALIST METAL MANUFACTURER

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riggs Equipment is helping the UK’s largest specialist manufacturer of zinc alloys to improve its environmental performance by switching its materials handling fleet from diesel to electric. The Brock Metal Company has taken delivery of three Hyster J-series counterbalanced electric forklift trucks. Briggs has supplied the machines on a five-year rental contract incorporating full servicing and maintenance support from its national engineering team. Part of the Russian-owned Chelyabinsk Zinc Plant, The Brock Metal Company operates 24 hours / 5 days a week from its base in Norton Canes, which is close to Briggs Equipment’s headquarters in Cannock, Staffordshire. Each year, the manufacturer supplies in excess of 35,000 tonnes of primary zinc alloys for die casting and galvanizing and zinc and copper for electroplating to 25 countries across Europe, Asia and the Middle East. The new materials handling contract came about because The Brock Metal Company was looking to make key savings

on fuel to reduce its operational costs. The move from diesel to electric forklifts enables it to achieve this goal while also reinforcing the company’s commitment to reducing its carbon footprint as part of an exacting environmental policy. Neil Yates, Operations Manager at The Brock Metal Company, said: “Briggs Equipment has provided us with a complete package that suits us perfectly. The upshot is that we have downsized our fleet without compromising on our handling capabilities, and this instils confidence as we focus on helping our customers to optimise product design and minimise costs.” The tough and reliable Hyster J-series of four wheel counterbalanced electric forklift trucks delivers superior manoeuvrability with zero turning radius, while customisable performance settings enable end users to achieve a balance between energy efficiency and performance.

Neil Yates, Operations Manager at The Brock Metal Company (left) is pictured with Briggs Equipment’s Senior Sales Executive Paul Robinson and one of the Hyster J-series counterbalanced electric forklift trucks.

The Brock Metal Company will use its new high capacity machines to unload 3,500 tonnes zinc ingots from the production line and transfer them to lorries for subsequent overland transport to customers located throughout Europe. One of the forklifts will be used as a dedicated warehouse truck. www.briggsequipment.co.uk

Bulk Solids Today

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BULK MATERIALS HANDLING

HOW PREVENTING FAULTS IN AUTOMATED PROCESSES IS HELPING MAJOR OPERATORS Simocode Pro makes costly plant downtimes a thing of the past for bulk materials handling operators like Aggregate Industries.

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here most operators in the minerals and aggregates industry use

standard automation products for components like variable speed drives and soft-starts, there is a motor management control unit available that automatically detects errors before they become faults. Simocode is a flexible and modular motor control system for low-voltage motors. An increasingly essential tool in preventative maintenance at plants, it functions independently of the controller and provides scaleable, flexible solutions for all system configurations. One of Simocode Pro’s functions is to detect stop and start operations; it can therefore identify when a motor may be on when it should not be, and by monitoring current, voltage and power usage, it can in turn help reduce energy use. Simocode is a great example of Siemens technology in practice, bringing a truly integrated solution with seamless communication to the control and automation process. It also reflects the increasing digitisation of condition monitoring and how safety, energy efficiency and environmental considerations are being brought to the front of operations for leading companies like Aggregate Industries. As Dave Brown, Regional Electrical Engineer for Aggregate Industries, explained: “We decided to use Simocode on a screening plant at one of our sites, and found we could install and programme it very quickly. We spent much less time coding, and our lead engineer was delighted with the results. The way the information is presented has been greatly

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Bulk Solids Today

enhanced, improving the reliability of communications and making remote diagnostics management much easier.“ Reducing engineering time and getting more useful, useable data out of the system are key elements to selecting Simocode Pro, which helps improve the productivity, efficiency and reliability of industrial production. Richard Marsh is Aggregate Industries‘ Lead Control System Engineer and he recently carried out a second installation using Simocode: “I have found Simocode‘s advanced diagnostics capability very useful and also its ease of programming for future applications.“ Lee Richardson is Siemens‘ business development manager for low voltage and safety products: “Plant downtime is costly and almost entirely avoidable if you have the right information. By being able to analyse the whole plant and external devices, including activation of emergency stop circuits as well as motors, Simocode can evaluate the whole operating system. Maintenance scheduling reports can be generated which in turn reduce unnecessary labour hours, preventative maintenance alarms can be activated before equipment fails, and full

diagnostics of the plant including energy usage can be monitored at all times.“ As the Simocode device is a standalone system it controls the plant without the need for additional PLC I/O and therefore reduces costs and panel wiring. It can also be retrofitted into an existing system. Simocode is maintenance friendly, and has an external memory module that is interchangeable should the unit fail. Safety I/O can also be added to achieve the highest category SIL3/Ple and can be configured in an easy-to-use software package allowing the user to zone different area processors without the need for additional wiring and complication. Simocode has been successfully used in the water/waste and oil/gas industries for years and has been continuously refined by Siemens so that it helps provide a fully integrated solution, such as at Aggregate Industries‘ Torr Works, where it is monitoring currents and power consumption to help reduce energy use. It is a unique and innovative product for many industry requirements. See more about the range of Siemens solutions for industry at www.siemens.co.uk


BULK MATERIALS HANDLING

HOSOKAWA MICRON ENGINEERS ARE RIDING HIGH ON NEW BUGGY FILL/WEIGH BOOTH

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osokawa Micron Ltd announce the launch of a new ‘twin, buggy filling and weighing, containment booth’, designed to handle safe, easy and accurate FIBC filling. Designed in co-operation with a leading detergent manufacturer, to meet the demands of the high volume product transfer of potentially sensitising powders, the containment system is uniquely configured for automated filling of FIBCs located on a wheeled buggy frame. The booth is connected to the customer’s HVAC system to generate a horizontal laminar airflow which captures airborne particulates generated in the filling operations. The contaminated air is then extracted through the combined booth plenum to a remote filtration system. Double opening doors at the front of each booth allow easy access for the manual loading of the FIBC buggy. As the buggy is pushed into position the FIBC lid is automatically lifted, eliminating the need for an operative to undertake this procedure by standing

Double flap valves

on a step ladder. Guide rails ensure accurate positioning beneath the downward sealing filling head. Once the buggy is in position (defined by a sensor) a mechanic clamp device holds the wheeled buggy in place. Doors are interlocked to prevent unauthorised entry whilst filling operation takes place. On disengagement and removal of the buggy from the filling and weighing system, the FIBC lid is closed. Accurate filling and weighing is controlled from outside the booth and once filled the FIBC buggy can be wheeled away with operatives protected from potentially sensitising or hazardous, residual airborne dusts. The booth incorporates a single rear, personnel door for safety and ease of all round access and maintenance. The booth is equipped with integrated weigh scale, internal lighting and integral dust monitoring system. Tel: +44 (0) 1928 755100 Email: info@hmluk.hosokawa.com www.hosokawa.co.uk

Rotary valves

Slide valves

Atex approved

Ibis Intergrid Ltd. Materials Handling Engineers

Suppliers, manufacturers & distributors of bulk handling equipment worldwide for 25 years

Tel: 01539 731900 Fax: 01539 731910

Email: sales@ibis-int.co.uk Web: www.ibis-int.co.uk

Loading chutes

Screw conveyors

Area Sales Agents Required

Bulk Solids Today

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BULK MATERIALS HANDLING

WIRELESS CRANE OPERATION WITH DEMAG INFRARED CONTROL • System features active range limitation • Eliminates risk of radio system interference • Practical inductive charging station

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erex Material Handling’s new generation of Demag DIR infrared (IR) remote controls provides crane operators with a viable alternative to conventional radio controls. The Demag DIR range incorporates a variety of innovative features for the reliable and efficient control of material handling systems. One of the principal advantages of the Demag DIR system over radio controllers is the considerably shorter range, of some 40 metres between the transmitter and sensor(s), which is of benefit when the operator wants to limit the distance at which the crane can be controlled, for safety reasons. This specifically limited range ensures that operators are always in close proximity to the equipment, providing a clear view of the lifting and moving process. There is no risk that the IR control system will be influenced or impaired by radio systems and the IR offers no potential for interference with other radio controls. The Demag DIR’s rugged hand held transmitter housing is based on the design used for Demag radio controls, meaning that users will be familiar with the controller layout and can use the same keypad concept for both transmission methods. DIR hand held transmitters are offered in two sizes for two stage control, with six buttons (DIR 6) and ten buttons (DIR 10) for the control of two or three motion axes, respectively. Like Demag radio control systems, up to ten crane systems may be controlled simultaneously in an enclosed area. For multiple controller operation, switchover between transmitters is monitored to ensure that the control systems are clearly assigned to specific cranes. The high contrast bi-colour display provides a clear overview of the device and warning information, which affords the highest level of safety. The integrated vibration alarm and stop function conform to Category 3, Performance Level ‘d’ to the relevant standard EN

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Bulk Solids Today

13849-1. Convenient and simple crane control is assured at short distances, of up to 15 metres, as the rays from the high performance infrared LEDs are reflected by the surrounding structure, eliminating the need for the transmitter to be pointed directly at the sensor. High performance rechargeable batteries ensure operating times of up to 30 hours with one charge. The unit can be conveniently charged on an optional inductive charging station. In addition to providing reliable wireless control of industrial cranes, the Demag DIR may also be used to control suspension monorails, transfer carriages and other materials handling equipment. ABOUT TEREX MATERIAL HANDLING Terex Corporation is one of the world’s leading suppliers of crane technology with Demag industrial cranes and crane components. The core competence of the Terex Material Handling business group lies in the development, design and production of technically sophisticated cranes, hoists and components and the provision of services for these products. The business group manufactures in 16 countries on five continents and is present in more than 60 countries, reaching customers in more than 100 countries. ABOUT TEREX CORPORATION Terex Corporation is a diversified global manufacturer engaged in the mechanical

and plant engineering sector. A core activity of Terex Corporation is the provision of reliable, customer-driven solutions for many applications, including the construction, infrastructure, shipping, transport, quarrying, mining, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms, Construction, Cranes, Material Handling & Port Solutions and Materials Processing. Terex Financial Services offers a wide range of products and services to assist in the acquisition of Terex equipment. Please visit our websites at www. demagcranes.com and www.terex.com for further information. Tel: 01295 676100 Email: bnb-help@terex.com


BULK MATERIALS HANDLING

LATEST ELECTRIC X-RANGE LIFT TRUCK FROM NEXEN SETS OFF FOR THREE OCEANS

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owestoft-based Nexen Lift Trucks has supplied a 3-wheel electric X-Range lift truck to Three Oceans, a privately-owned business that, founded by Tim Rose in 1992, recognised a niche in the industry for the supply of high quality white-fish, primarily to the foodservice sector. With application advice and support from Nexen’s Yorkshire-based dealer MH Group, one of the UK’s leading suppliers of forklifts and materials handling systems, Nexen was able to meet the requirements of Three Oceans with its new electric-powered Nexen FBXT 18 counterbalance forklift, which was supplied with additional weatherproofing and IP protection to ensure it could make trips between the customer’s two processing facilities in Hull. The three-wheel FBXT and four-wheel FBX counterbalanced electric forklifts are Nexen’s latest additions to its range and offer lifting capacities from 1,600 to 2,000kg. Both models are available in long- and short-wheel-base formats, providing a productive and energy-efficient solution for numerous indoor/outdoor lifting applications. To cope with the narrow aisle environment of their facilities and ensure zero emissions, a three-wheel electric lift truck was essential for Three Oceans’ food processing environment. So too was weatherproofing and IP protecting of any new vehicle, as the company had been faced with substantial maintenance bills for its previous electric forklifts. Additionally, the lift truck needed good ground clearance to cope with the steep cambers and kerb stones the vehicle would encounter on its many daily trips. Commenting for MH Group, Andy Tuffnell says: “Working with Nexen to meet the customer’s requirements was a breath of fresh air, with the company going above and beyond what was required to ensure that cable connectors, wiring looms, motors and motor controllers were all protected from the weather and operating environments.” He goes on to explain that, where possible, his company tries to source locally and, being a privately-owned British brand with a range of lift trucks that are manufactured in the UK, Nexen Lift Trucks is a supplier of preference for MH Group and its many customers. And when advice or additional services are required – such as the weatherproofing for the Three Oceans FBXT 18 – Andy knows he can pick up the phone and speak directly with Nexen’s directors, or those that have played an essential role in the design and development of its material handling vehicles. “Because Nexen is hands-on with the manufacturing and production, they understand what I want and know how to supply it!” says Andy. Commenting for Nexen Lift Trucks, sales director Pamela Oakes says: “With many manufacturers outsourcing design and build to third parties in China, India and Eastern Europe, Nexen is proud to offer a range of vehicles that can be truly designated as ‘Made in Britain’, with the research, design, development and production of our electric X-Range lift trucks being undertaken at the European headquarters in Lowestoft, rather than those the company owns in Taiwan.” The FBXT is the latest in Nexen’s line-up of counterbalanced forklift trucks and adds to an ever-increasing portfolio of X-Range models that also incorporates diesel- and LPG-powered vehicles, with lifting capacities up to 5,000kg. All models are built to the highest exacting standards using premium quality components which, combined with Nexen’s signature X-Range fully-floating

cabin design, provides exceptional operator comfort and superior ergonomics that dramatically reduces driver fatigue. X-Range electric forklifts also feature regenerative braking to enhance battery life and improve energy efficiency; and an automatic parking brake ensures no adjustments are required, which reduces equipment maintenance requirements. Tel: +44 (0)1502 532211, Email: info@nexenlifttrucks.com www.nexenlifttrucks.com

NUMBER ONE FOR PIPEWORK SYSTEMS Modular pipework systems Stainless Steel, Galvanised or Powder Coated (inside and out) 60 - 800 mm diameter sections as standard 1 - 3 mm thickness Easy to fit Quick Connect nnect nect Jacob (UK) Ltd T: +44 (0) 1694 722841 E: sales@jacob-uk.com W: Jacob-uk.com

Bulk Solids Today

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BULK MATERIALS HANDLING

COULD YOU LIVE WITH A FORKLIFT ACCIDENT? UK’s leading materials handling, workplace transport and safety management training company, Mentor, launches hard-hitting video training module at IMHX.

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ollowing its exclusive premier showing at the National Fork Truck Safety Conference, Mentor Training has announced plans to officially launch its new, hard-hitting video training module at IMHX. Unique in that it targets both fork lift truck drivers and the staff working alongside them, Mentor’s Safely Working with lift Trucks video training module will be publicly aired for the first time on Stand 12W80. Designed to target both the unaware and existing operators at risk of becoming complacent, Mentor managing director Stuart Taylor explains why influencing attitudes and behaviours across the entire workforce is vital. He says: “Those on foot account for 57% of those injured as a result of forklift truck accidents. They’re most at risk so it’s essential that they’re included as part of a holistic approach to training and site safety. “With the number of fork lift related accidents on the rise, it’s abundantly

clear that much more needs to be done to safeguard pedestrians. The FLTA recommend that the relevant training forms part of an induction – while we are aware that some companies achieve this, it’s clear that many more do not…” “They need to understand the risks long before their first interaction with a lift truck. Employers should make certain they understand and recognise the hazards associated with forklift operations, and know how to respond appropriately to potential danger. As well as educating and informing, the new module has been specially developed to engage viewers and challenge the behaviour at the root of unsafe practice. A powerful re-enactment entitled Could you live with that? illustrates – in no uncertain terms – the long lasting impact of a fork lift truck accident… and the importance of taking personal ownership of safety. This development draws on the success

of Mentor’s ground-breaking Safely Working with Lift Trucks course launched earlier this year. Following the release of the concise but high-impact two-hour training session, the video module aims to deliver the same message as the classroom based course but via a more flexible e-learning style experience. Safely Working with Lift Trucks is exclusively available from Mentor Training. However, in support of the FLTA’s Safetember forklift awareness campaign (1st to 30th September), Mentor will give away 1,000 free PIN codes to those who request access – allowing them to experience the new video training module for themselves. To get your PIN today, or to learn more about Mentor’s holistic approach to training, visit mentortraining.co.uk or call 01246 555222… and be sure to visit the team on stand 12W80 at IMHX.

TEREX|FINLAY LAUNCH NEW VARIANT OF C-1540 MOBILE CONE CRUSHER.

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he NEW C-1540 direct drive cone crusher is the latest addition to the Terex|Finlay range of tracked mobile cone crushers. This machine has been developed to satisfy the requirements for any aggregates producer or contract crusher looking for a high output capacity machine that provides large reduction ratios and an excellent cubical shape in the surface ore mining and aggregate industries. This aggressive machine incorporates the proven Terex® 1000 cone crusher

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Bulk Solids Today

that can accept an all in feed and features direct variable speed clutch drive and “on the fly” hydraulic closed side setting (CSS) adjustment. A key feature of the chamber is an overload protection system with automatic reset that permits uncrushable material to pass through and be discharged efficiently from the machine. The feedin box to the chamber is fitted with an ultrasonic level sensor that is calibrated to the feeder to ensure that the chamber is consistently choke-fed for maximizing throughput and minimizing crusher wear. These features all combine to give operators an efficient and aggressive crushing action, high performance and low cost per ton. The standard 5m³ hopper/feeder on the plant has been designed with a low feed-in height so that the machine can be fed directly either by primary crusher, excavator or shovel. A key feature of the hopper is the standard automated metal detection and a purge system that

has been designed to protect the cone chamber and reduce downtime by removing metal contaminants via the purge chute. “We are continually communicating with our customers through several forums and the introduction of this machine is a direct result of this ongoing process. This exciting new model builds upon the success of our current C-1540 prescreen model, C-1545/C-1545P and C-1554 cone crushers. The heart of this new model is the Terex TC-1000 cone crusher which is worldrenowned for its flexibility, versatility and outstanding performance. The functionality and serviceability of the machine where key design criteria of the plant from the outset and we have received only positive feedback on these characteristics. With the introduction of this new model we now have one of the most comprehensive range of tracked cone crushers in the market place.” remarked Alan Witherow, Terex|Finlay Product Development Manager. www.terexfinlay.com


BULK MATERIALS HANDLING

NEW DMNWESTINGHOUSE HIGH PRESSURE VALVE BEATS AIR LEAKAGE

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ecently DMN-WESTINGHOUSE has presented its newly designed HP high pressure rotary valve. This valve has a very important advantage in air leakage: the special configuration of the body and rotor does not only protect product against degradation, it also does not allow any axial air leakage. This means that this valve has an air leakage reduction of one third against other standard high pressure valves. The DMN-WESTINGHOUSE HP rotary valves with specially designed inlet are very suitable for applications in the metering and pneumatic conveying of granular formed products under a high pressure of maximum 3.5 bar g. The configuration of the body, rotor and seals has been specifically developed to minimise degradation of the product which runs through it, whilst retaining the best possible pocket filling efficiency. The HP valves are supplied with a 316 stainless steel body and aluminium end covers, in order to have maximum protection against wear. The standard full end disc rotor is made of 316 stainless steel and has 12 fixed blades. Due to the state of the art manufacturing facility, a high accuracy and tight rotor clearances can easily be attained. The end covers have outboard bearings, lubricated and sealed for life. The special construction of the shaft sealing guarantees the lowest air leakage. All models offer optimum venting through the large vent hole, so a maximum product flow into the vented pockets is guaranteed . DMNWESTINGHOUSE fits SEW drives as their standard. The HP valves are available in 3 consecutive sizes from 200-300, covering a capacity range of the rotor from 8.3-30 litre per revolution at 100% filling. The standard models are suitable for handling products up to a temperature of +80°C and a maximum pressure difference of 3.5 bar. DMN-WESTINGHOUSE have been designing and manufacturing rotary valves and diverter • valves for bulk solids handling for more than 45 years. Offering tailor made solutions to the • global food, dairy, plastics, (petro)chemical, pharmaceutical, mineral, power and biomass • industries, our range comprises a number of universal components suitable for many • applications. Additionally we supply components that are USDA Dairy Accepted, pressure • shock resistant to 10 bar, flame proof, ATEX 94/9/EC compliant, EHEDG Type EL Class I compliant, etc. www.dmnwestinghouse.com

Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features UÊ -iv‡>ˆ}˜ˆ˜} UÊ -iv‡}ÀœÕ˜`ˆ˜} UÊ ˆ}…Ê«ÀiÃÃÕÀiÊÀ>Ìi` UÊ ՏÊÛ>VÕՓÊÀ>Ìi` UÊ -Ì>ˆ˜iÃÃʜÀÊ mild steel UÊ 1Ã>Liʜ˜Ê̅ˆ˜Ê or thick wall pipe or tube UÊ œÜÊVœÃÌ UÊ ,iÕÃ>Li UÊ LÜÀLÃÊۈLÀ>̈œ˜ UÊ ÝÌiÀ˜>Þʏi>Ž«Àœœv

Tuf-Lok (UK) Tel: +44 (0) 1706 822512 “>ˆ\ÊÃ>iÃJÌÕyœŽ°Vœ°ÕŽÊUÊwww.tuflok.com Bulk Solids Today

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BULK MATERIALS HANDLING

TEA TIME IN NO TIME WITH THE COOL PERFORMANCE NEW MICRON GLACIS GC MILL

Hosokawa Micron Ltd announce the development of the high performance cooling type, mechanical mill, the Micron Glacis GC fine grinding mill. Suitable for fine grinding of heat sensitive products, the Micron Glacis GC is ideal for the high volume grinding of green tea which is popular both as a beverage and for use in confectioneries too.

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he fine grinding and low heat generation of the Micron Glacis GC produces a tea with good mouth feel, texture, taste and mellow flavour. The Glacis is able to achieve a high cooling efficiency (7.5 times more than the conventional mechanical mill) by running coolants through the outer liner and grinding rotor. The Glacis can ultra-fine grind low-melting point, heat-sensitive materials that we impossible with conventional units.

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Bulk Solids Today

The Micron Glacis GC offers the particle grinding size accuracy of a jet mill (10-20Âľm) but with a higher volume capacity but with a 50% lower energy consumption. Material is ground by strong impact and shear force generated at the space between the grinding rotor and the liner. Both the grinding rotor and the mill lining are specially designed with an effective cooling structure which alongside the reduced air volume required by the unit for cooling

actively prevents product oxidation and therefore deterioration of the tea quality. The Glacis has a low air volume requirement relative to grinding power which means the additional auxiliary equipment such as the blower and bag filer can be scaled down, allowing for a compact installation. Tel: +44 (0) 1928 755100 Email: info@hmluk.hosokawa.com www.hosokawa.co.uk


BULK MATERIALS HANDLING

YOUR CONNECTION TO A WORLD OF SOLUTIONS

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t IMHX 2016 (NEC, Birmingham, 13-16 September, Stand Nos: 10L61 / 12X95 / AM13) Jungheinrich UK Ltd will be showcasing and demonstrating the significant customer benefits delivered by its broad range of materials handling products and intralogistics solutions. With the theme ‘Jungheinrich Intralogistics. Your Connection to a World of Solutions,’ the company will showcase how leading UK businesses across industries as diverse as manufacturing, warehousing, transportation and logistics, retail and wholesale are boosting operating efficiency and throughput, improving safety, increasing energy savings, reducing total cost of ownership and ramping up productivity thanks to Jungheinrich technology. This year at IMHX, Jungheinrich will have multiple stands representing different, key areas of focus. In addition to the Jungheinrich main stand there will be the Jungheinrich Used Equipment stand – featuring 5-Star re-manufactured trucks and a live auction for used equipment; the Jungheinrich Intralogistics Solutions stand within the Automated Materials Handling Systems Association (AMHSA) pavilion; and the Apprenticeships and Human Resources stand – to support the skilled workforce needs of the company’s rapidly expanding UK operation. The main stand will feature sections dedicated to specific benefits of the company’s range. For example, within the area devoted to Safety, Jungheinrich will be showcasing a number of new technologies and assistance features that improve warehouse safety, help prevent accidents and reduce the cost of damaged goods. Space on the main stand will also be dedicated to Efficiency. Jungheinrich will highlight how the company is leading the way in improving intralogistics efficiencies with solutions that increase throughput, maximise truck fleet utilisation and optimise the effectiveness of personnel. A great example is the new Jungheinrich easyPILOT on the ECE horizontal order picker which significantly improves picking performance while relieving strain on the driver. The truck automatically moves with the operator and stops as soon as he uses the remote control or reaches a pre-defined destination. As a result, both of the operator’s hands

are free to focus on order picking while unnecessary and repetitive actions can be avoided – saving time and fatigue. There is an area dedicated to Jungheinrich’s Integrated Energy Solutions which enable multi-shift operation with no battery change for the lowest energy consumption, a reduced carbon footprint and increased productivity. Jungheinrich has supplied products with 12 Volt fully integrated Lithium-Ion batteries since 2011 and 24 Volt options since 2014. At IHMX 2016 Jungheinrich will introduce the first Lithium-Ion batteries in the 48 Volt range with 360 and 480 ampere hours. This completely maintenance-free technology – which is capable of short interim charges and delivers high value, a small carbon footprint, fast recharging times and a long battery life, can now be applied to reach trucks and counterbalance forklifts. Visitors will be able to view the latest electric pedestrian forklift fitted with lithium-ion technology – the EMD 115i. Thanks to the battery‘s compact dimensions this is the world’s shortest electricpowered pedestrian truck in its class. Jungheinrich will also focus on its Flexibility by highlighting the company’s extensive range of materials handling solutions from entry-level models to the most complex automated solutions, most of which have broad optional capabilities and can be customised for specific needs. Live demonstrations of Jungheinrich’s state-of-the-art Automated Pallet Mover and the new Very Narrow Aisle EKX 5

Series will be another feature of the show. The EKX 5 is the winner of the 2016 International Forklift Truck of the Year (IFOY) award and visitors will be able to get hands-on experience of it at IMHX. Jungheinrich is the only logistics systems and materials handling equipment vendor capable of delivering solutions that meet customer needs across the entire intralogistics spectrum – from a single hand pallet truck through to a fully automated turnkey warehouse solution. “We’re very excited about the significant breadth and depth of intralogistics solutions that we are able to show and demonstrate at IMHX 2016,” explains Jungheinrich UK Ltd’s Managing Director, Jan Lorenz. He adds: “These solutions increase productivity and efficiency, reduce total cost of ownership and improve safety which, in turn, creates significant value for our customers. We will have a team of product and solution experts on hand throughout IMHX to provide advice and guidance on how Jungheinrich’s solutions can be tailored to any company’s unique needs.” Jungheinrich UK Ltd is one of the top three leading Intralogistic providers in the UK, generating a turnover of over £175 million annually. They offer the industry’s widest range of high energy efficiency Pallet Trucks, Stackers, Counterbalance Trucks, Reach Trucks, Order Pickers, Very Narrow Aisle Trucks and Stacker Cranes in more than 600 truck variants. www.jungheinrich.co.uk

Bulk Solids Today

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QUARRYING

NEW DOOSAN EXCAVATOR BOOSTS OUTPUT AT SCOTTISH QUARRY

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ordon Robertson Plant Hire, based at Thurso in Caithness in Scotland, has taken delivery of a new Doosan DX300LC-5 30 tonne crawler excavator for use at the company’s Caithness stone quarry at Barrock near Thurso. Delivered just three weeks after placing the order for the machine with Balgownie Ltd, the local Authorised Doosan and Bobcat dealer, the new DX300LC-5 excavator has already had a tremendous impact by increasing productivity and reducing fuel costs at the quarry. The new DX300LC-5 was purchased based on the excellent performance of Doosan 14 tonne and 6 tonne machines that have been part of the fleet at Gordon Robertson over the last six years. Company owner, Gordon Robertson, said: “Our machines take part in all types of projects, including land drainage work in agriculture and housebuilding and I have been very impressed by the performance and durability of all of the Doosan excavators since I purchased the first 6-tonner in 2010. All of our drivers are delighted with the new DX300LC-5 excavator and have remarked how comfortable the cab is and how smooth the machine is to operate. “The fact that Balgownie and Doosan could deliver me the DX300LC-5 in just 3 weeks from placing the order was also a key feature. We needed the machine quickly to work with a new 3.5 tonne hydraulic breaker we had purchased for breaking out rock at the quarry and we are now producing 50% more aggregate at the quarry since the new Doosan excavator arrived.” GREATER POWER AND TORQUE The new DX300LC-5 is powered by the Scania DC9 5-cylinder diesel engine, with an output of 202 kW of power at 1800 rpm, providing a huge 27% increase in engine power and a massive 30% boost in torque over the previous LC-3 model. The engine meets Stage IV emission regulations without the need of a diesel particulate filter (DPF), through the use of cooled exhaust gas recirculation (EGR) and selective catalyst reduction (SCR) after-treatment technologies. As well as the Scania engine, new innovative and exclusive features have been introduced, leading to huge reductions in fuel consumption compared to the Stage IIIB

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machine. Among these features is the new ‘Trip Meter Setting’ screen which allows operators to check fuel consumption daily (or over a desired period) directly from the control panel; the new Auto Shut-Off which provides an automatic shut down for the engine after a pre-set time when the machine has been idling for a specified time (3 to 60 minutes configurable by the operator); and to save even more fuel, there is a special Doosandeveloped system, SPC (Smart Power Control), to optimise the balance between the pumps’ output and the diesel engine. Gordon Robertson is very impressed, adding: “The new Doosan DX300LC-5 excavator is using 10 litres per hour less fuel than the two bigger 35 tonne machines I run at the quarry. This really begins to add up when you consider it equates to around 500 litres of fuel a week – a massive saving.” As well as the full range of Doosan crawler and wheeled excavator models, Balgownie, based at Inverurie in Aberdeenshire, is responsible for sales and servicing of the Doosan wheel loader and articulated dump truck ranges in Aberdeenshire, Morayshire, Angus and for much of the Highlands. The company is also the Authorised Bobcat dealer for the same areas. Balgownie Ltd started trading as an engineering company in 1907 in sheet metal work and tank manufacturing, supplying to shipyards, farmers and the food industry before diversifying into the manufacture and supply of dairy equipment. Today, Balgownie is one of the leading specialists in Construction, Tractor, Trailer, Agriculture and Groundcare Machinery sales in Scotland. Gordon Robertson commented: “The back-up provided by Balgownie is superb and complements the high performance of the Doosan excavators. A special mention and praise should go to the role played by the service engineers at Balgownie who are excellent.” HIGHER PERFORMANCE AT STAGE IV The DX300LC-5 Stage IV compliant crawler excavator provides greatly improved performance compared to the previous ‘LC-3’ Stage IIIB model. Bucket,

arm and swing forces in the DX300LC-5 remain the same as the Stage IIIB model, but the drawbar pull has been sharply increased by 8%. The operating weight of the DX300LC-5 has increased by 900 kg, resulting in increases in lifting capacities of 1% over the front and 5% over the side. Already excelling in spaciousness and ergonomics, the new cab in the DX300LC-5 has been further refined for outstanding operator comfort and ease of operation. The cab offers super controllability with a new system that enables attachments to be operated from either the joystick or a two-way pedal. Users also have the unique jog shuttle switch which remains a feature exclusive to Doosan excavators worldwide. A side-view camera is available as an option and the control panel allows the views from both the rear and side view cameras to be combined on the same screen, simply by pressing a button on the control panel. For more safety when using the cameras, a menu bar now stays open so that the operator can keep an eye out for warning symbols and the levels of key gauges. The DX300LC-5 features a distinctive new machine styling scheme common to all the Stage IV excavators in the new Doosan ‘LC-5’ range, representing the improvements on the already high standards set by the previous LC-3 range, adding to enhanced comfort and controllability with new features to boost fuel efficiency, uptime and return on investment, with a focus on increased power, robustness and agility. For more information about Doosan construction equipment, visit www.doosanequipment.eu For more information about Bobcat and Bobcat products, visit the website www.bobcat.com


Bespoke Design and Build Solutions

We offer processing solutions for Aggregate, Recycling and Bulk Handling industries in the UK and overseas.

DUO Group Structure and Services Overview

Aggregate Washing

Bulk Handling Systems

Unit Cost Processing

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Ash Recycling Plants

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Crushing and Screening

MRF Manufacture

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Quarrying

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Our position as a leading supplier of Washing, Water and Silt Management,Crushing and Screening,Dry Recycling and Enviromental Waste Processing plant is directly linked to the quality of our partners. Our partners have been carefully selected so that whether its individual pieces of equipment or turn-key installations, we are able to offer industry leading equipment from experienced European and American O.E.M’s.

“Two working as one” DUO Group, 4 Rye Hill Office Park, Birmingham Road, Allesley, Coventry, CV5 9AB, UK.

T +44 (0) 845 22 22 386 E info@duoplc.com W www.duoplc.com


QUARRYING

NEW MODULAR SAND & GRAVEL WASHING PLANT FOR RAYMOND BROWN AT ROKE MANOR QUARRY

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inal commissioning has recently been completed on a new CDE modular sand & gravel washing plant at Roke Manor quarry in Hampshire. The site is operated by Raymond Brown who currently have eleven locations across Hampshire, Dorset, Wiltshire, Oxfordshire and Berkshire. Roke Manor quarry is the latest addition to the group portfolio having been officially opened by Group Chairman, Ron Isaac in November 2014. “The new site was seven years in development and planning permission was granted in 2011” explains Richard Hoare, Project Manager at Raymond Brown. “Our licence will see us extract 750,000 tonnes of sand and gravel at a rate of 125,000 tonnes per year.” The permission is accompanied by a 30 year woodland management plan which involves additional tree planting in line with an approved landscaping plan that formed part of the planning permission. The site is located 11 miles from Southampton on the outskirts of the New Forest and it was the sensitivity and environmental responsibility displayed by Raymond Brown which resulted in the successful planning application. Speaking about the Roke Manor development Steve Clasby, Chief Operating Officer said “This is an exciting new opportunity for Raymond Brown. We pride ourselves on our sustainable and pro-active approach in dealing with our environmental, social and economic impacts.” THE CDE PLANT The new washing plant at Roke Manor will process sand and gravel at a rate of 80 tonnes per hour and includes several items of equipment from the CDE portfolio including the AggMax modular logwasher EvoWash sand washing plant, AquaCycle thickener and decanter centrifuge as well as a feed hopper and transfer and stockpile conveyors. Material is delivered to the plant via the M14 feed hopper with 150mm grid spacings. CDE conducted extensive material testing prior to specifying the plant and the vast majority of material being processed is in the minus 63mm range with 80% typically passing 20mm. “Raymond Brown were looking for performance guarantees that gave them confidence in the capability of the plant

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to tackle high fines and clay content in the feed material and produce a range of washed sand and aggregate products that would meet their customers’ requirements” explains Chris McKeown, Technical Manager at CDE. “Our performance statement covers the production of a range of products from the new plant to agreed specifications: 0-4mm concrete sand, 0-2mm building sand, 4-10mm, 10-20mm and 20-40mm aggregates and a +40mm oversize.” This agreement was reached after extensive material testing at Roke Manor to establish parameters around the likely variations in feed material within the deposit. “It is only through the extensive material testing that we conduct on every project that we are able to deliver washing plants which deliver on our customers’ requirements through the production of consistently graded washed sand and aggregates” explains Matt Bunting, Director of Business Development in the UK for CDE. “This allows us to work with customers on the kind of performance statements included on this project for Raymond Brown.” The feed material is transferred to the first stage of processing via a 23 metre conveyor with an 800mm belt. At the head of this conveyor a washbox fluidises the material before delivery to the AggMax modular logwasher. Before material enters the AggMax a double deck horizontal screen is employed as a pre-screen to remove the +40mm oversize material and the -4mm sand from the feed material. The +40mm oversize is stockpiled in a bay underneath the AggMax via an integrated 4m horizontal conveyor with a 650mm belt. The feed material contains an average of 9 tonnes per hour of this oversize material. While the top deck of the screen removes the oversize material the -4mm material falls through the bottom deck of the screen and is sent to the sand washing phase. This is an important step in protecting the plant explains Matt Bunting. “Logwashers and sand are not a very good combination as if the sand is allowed to get into the logwasher it will result in excess wear on the machine. By removing the sand fraction at this stage we are able to protect the machine, ensuring maximum plant availability and allowing

Raymond Brown to maximise their production volumes and the return on their investment.” Material from the bottom deck of the prescreen is delivered to the AggMax modular logwasher at a rate of 47 tonnes per hour on average where the material is subjected to high levels of attrition before being discharged to a triple deck sizing screen which is integrated onto the AggMax chassis. The AggMax is one of the most popular products that CDE offer and is specified on a range of projects from sand & gravel and crushed rock processing to C&D waste recycling and iron ore processing. “The design of the AggMax has been refined over the last 10 years to ensure it continues to offer our customers the highest level of scrubbing performance while also including a range of design features which ensure it is operational for as close to 100% of the time as possible” explains Product Development Manager at CDE, Glenn Sloan. The most obvious design feature of the AggMax is the arrangement of the paddles in a fan configuration which not only maximises the material on material impact within the machine but reduces shock loads on the bearings to deliver extended equipment life and a reduced power requirement. The AggMax also features enhanced bearing protection with the main bearing housings located on the outside of the machine. “The AggMax bearing arrangement features 13 levels of bearing protection to eliminate the potential for material and water ingress – protecting the machine and ensuring our customers are able to concentrate on meeting their production targets” explains Glenn Sloan. There is also a bearing temperature sensor which has the capability to automatically shut down the plant if the temperature goes beyond a defined level, maximising equipment life and minimising the time required for essential plant maintenance. The scrubbed aggregates are discharged onto an integrated triple deck sizing screen to produce the 4-10mm, 10-20mm and 20-40mm aggregate products. These are then stockpiled via three 15m stockpile conveyors with 650mm belts. Any fines liberated from the aggregates during the attrition phase are combined with the 0-4mm material removed at the prescreening stage and delivered to the EvoWash sand washing plant. The EvoWash produces two sands for Raymond Brown – 0-4 mm


QUARRYING concrete sand and a 0-2mm building sand. “Due to the relatively high level of fines in the feed material it is necessary to produce two sands in order to ensure production of a concrete sand spec” explains Chris McKeown. “There is a lot of material in the 0-2mm range and the first stage of classification involves the removal of some of this material to allow production of the concrete sand.” The material is first delivered to a 500mm cyclone and the cyclone underflow is discharged onto the first side of the split EvoWash dewatering screen. The dewatering screen is set up to allow some of the 0-2mm material to fall through to the sump and this is then pumped to a bank of three 250mm cyclones. This not only achieves the required removal of the minus 63 micron fraction but delivers a slurry containing the 0-2mm material to the second side of the split dewatering screen before this is stockpiled. The waste water containing the minus 63 micron fraction is then delivered to the first stage of water treatment and recycling where the AquaCycle A200 thickener is deployed. The AquaCycle accepts the feed from the cyclone overflow by gravity feed and at the entry point to the thickener it is dosed with flocculent that has been premixed in the integrated FlocStation. The flocculent causes the very fine particles to bind together and sink to the bottom of the AquaCycle tank while the clean water overflows the peripheral weir and is stored in a steel water tank for recirculation to the washing plant. This recycles 90% of process water and reduces the fresh water requirement to top up only. “Fresh water for use on the new CDE plant is limited” explains Richard Hoare of Raymond Brown. “Without the integrated water recycling and sludge management system it simply would not have been possible for us to proceed with this investment in the new washing plant and CDE were able to demonstrate significant experience and capability in this area.” The sludge at the bottom of the thickener tank is conditioned by a set of rakes which rotate around the bottom of the tank. The helps to ensure that the sludge can be easily discharged from the tank but also provides the mechanism by which the automatic sludge discharge function is activated. Once the rakes encounter a specific level of resistance this activates the sludge pump and this is then discharged into a circular steel buffer tank with a capacity of 106m3. As with the AquaCycle thickener, the sludge buffer tank is also fitted with a set of rakes which, as Chris McKeown explains helps to optimise the performance of the decanter centrifuge. “In order to ensure best performance from the decanter centrifuge it is essential that the density of the sludge

is consistent. The rakes in the buffer tank help to maintain this consistency which ensures maximum dewatering of the sludge for maximum water recovery and minimum waste volumes.” After the sludge has been dewatered a screw conveyor discharges the filter cake to a bay below the centrifuge enclosure. On this plant the centrifuge is sized to accept delivery of 8 tonnes per hour of solids. The new CDE plant at Roke Manor quarry is operational for 10 hours per day but the decanter centrifuge will run for an additional 2-3 hours per day after material processing has stopped. This helps to clear the sludge buffer tank in advance of the next day’s production. “The advantage of the centrifuge decanter in this instance is the capability for continuous, unmanned operation” explains Matt Bunting of CDE. “This allows Raymond Brown to not only reduce the level of operator intervention but also gives flexibility in the sizing of the centrifuge.” In addition to the water recovery and recycling benefits offered by the combination of the AquaCycle thickener and decanter centrifuge they also have the effect of significantly reducing the space required on site. This is as a result of eliminating the requirement for settling ponds which are now replaced by the waste bay underneath the centrifuge enclosure where the cake is discharged. “The complete plant footprint for Raymond Brown including product stockpiles is 57m x 48m” explains Matt Bunting. “If no water recycling and sludge management system was in place the washing plant would require a considerably larger area than this and introduce further cost to the project as a result of the requirement to build secure & safe settling ponds.” “Another benefit of eliminating settling ponds that can’t be overstated is the health & safety benefits” explains Richard Hoare. “By removing this risk from our site at Roke Manor we are demonstrating our commitment to best practice. The best way to protect your people is to eliminate the risk

and that is what we have chosen to do at Roke Manor by introducing this closed circuit water recycling and sludge management system.” SUMMARY Given the location of Roke Manor quarry the new washing plant puts Raymond Brown in a good position to take advantage of the aggregate supply opportunities that exist in the Southampton and wider Hampshire area. “We’ve got good access to Southampton at only 11 miles from the city centre” explains Richard Hoare. “We identified the opportunity from an investment at Roke Manor quarry some time ago and are delighted to now have the latest materials washing and classification technology in operation. The will allow us to deliver the highest quality sand and aggregates to the local construction market – something that customers of Raymond Brown have come to expect from us in the last 60 years. For further information on CDE please visit www.cdeglobal.com.

Bulk Solids Today

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QUARRYING

CASE STUDY: HOW AND WHY 80GHZ LEVEL RADAR IS INCREASING PRODUCTIVITY IN THE SCREEN HOUSE AT E&JW GLENDINNING

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t’s well known that following the extraction and crushing operations of aggregates, the screen house is the ‘engine room’ of a quarry where it processes and grades the aggregates. Its principle function is to sort the sizes of aggregates and ensure the right product is there, ready for coating, stockpiling or direct loading out onto transport. The main process challenges encountered in the screen house are the high dust levels, noise and vibration from the screens themselves and the associated machinery, as well as it being a very inhospitable environment for personnel. At E&JW Glendinning Quarry in Devon, they have installed latest generation of VEGAPULS 69 contactless bulk solids radars, replacing ultrasonic level sensors. This followed the previous successful application of the same radar on the secondary crusher feed hopper level over a year ago, which transformed the reliability and control in that key area of the plant. WHAT PROMPTED THE CHANGE? According to the user, ultrasonic level sensors were regularly giving false indications throughout their measurement range, which meant lost time and productivity, both on the lorry loading process and infeed control. To keep them working, the original ultrasonic sensors required regular maintenance, cleaning and adjustment with false signal mapping of the silos. Although this may not be frequent to the individual sensors, maybe a few times per year, when multiplied by tens of sensors, along with the associated outages and delays, this really becomes a significant problem. A typical example of these outages; the plant operator would start to load out to a lorry based on the initial level reading of a particular grade, then being unable to complete the loading process due to the bin running empty and the lorry then having to be topped up by a loading shovel from the quarry stockpiles, losing time, making extra traffic movements and

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Figure 1: The screen house the engine room of the quarry production

Figure 2 Not an unusual view down inside a screen house bin with the typical design of reinforcing bars, creating ridges and product build up, which cause false signals to ultrasonic level sensors

taking resources from other areas of the quarry. Then, once mistrust of level readings takes hold, it can be difficult to regain. THE MATERIALS INVOLVED The materials measured are from 0-4mm with very high dust levels inside the bins, to 60mm size where high levels of filling noise can also be encountered. The sensors are deployed across 9 bins. The plant has a 600TPH load out capacity for road going lorry’s and internal dumpers feed the ready-mix and block production plants. So an accurate ‘picture’

Figure 3 The scada screeen now has reliable representation of the bin levels for efficient operation of the screen house

for the operators is a key component for efficient running of the plant. WHAT ABOUT THE INCREASED COSTS AND INSTALLATION? Radar based level sensors are not as expensive as people think, otherwise they wouldn’t be the fastest growing level technology for bulk solids. The price is equivalent to high power ultrasonic sensors, which often get used anyway in applications with high dust levels. So the difference when coupled with the performance increase becomes very marginal. However,


QUARRYING the payback from using a more reliable solution can be very quick indeed. The installation in the screen house was easy, the sensors were supplied with flanges to match the current sensor locations and they were able to utilise the same cabling. This new 80 GHz radar innovation also has an extremely capable measuring range span, from just a few hundred centimetres up to 120m, offering excellent versatility for solutions in silos, hoppers, crushers, mobile stockpile levels and even fast change response for conveyor positioning. The sister device an 80GHz radar for liquids, is also suitable for Bitumen tank level. WHY IS RADAR TECHNOLOGY BETTER FOR LEVEL IN THIS APPLICATION? It uses microwave signals to measure level, they are unaffected by in flight dust, air movement, pressure, temperature or filling noise, that often affects ultrasonic sensors. The new 80GHz radar has excellent focussing too, a 3.5 degree beam angle is typical, so it can easily avoid the build up on the sides of the bins and focus just on the product level, from top to bottom. The higher frequency is also unaffected by even very large amounts of build up from aggregate dust on the transducer face, which again this can quickly attenuate ultrasonic sensor signals. A question regularly asked: Is microwave based radar safe to use? Latest generation radar devices are safe, they conform to EN LPR (Level Probing Radar) standards, so they can be used both inside or outside the plant with absolutely no risks to personnel. SO WHAT HAS BEEN THE OUTCOME FOR THIS PLANT? Since the installation of the new sensors, Glendinning have seen an increase in plant throughput. The operators are able to control and trim bin levels efficiently. The level increase and decrease is followed in a smoother, more accurate manner, offering a truly ‘analogue or dynamic ‘ representation, rather than a series of jumps and steps they had before. Because there are no false high level alarms, the plant does not unnecessarily place the infeed on hold either, as they are able to trust the levels seen on the SCADA screens. There has been a decrease in the extra traffic movements when directing lorries to the plant or stockpiles, the reduced pressure on stock loader shovels frees them to load the products they are designated for. Of course lower demands on electrical, control and instrument engineers also frees their time for projects and proactive maintenance, as well as reducing risk from working in these areas. They also

purchased another set of sensors for the course screens to complete the efficiency improvements across the screen house. THE FUTURE? This site is now also testing a new VEGA innovation: a Bluetooth sensor set up and maintenance tool. Using Smart phone, tablet or PC with Bluetooth, all VEGA devices can be easily and safely commissioned, and simply monitored. The VEGA Tools IOS or Android App can be downloaded for free, and it is low enough cost for any ‘plics’ transmitter (even all those manufactured since 2002) to have Bluetooth capability to securely communicate via encrypted, protected

Figure 4: Sensors installed in the floor close to the screen infeed, but unaffected by in flight product and build up on the walls

communications. This increases speed of set up and removes the need for personnel to climb silos or work in hostile locations. NO CURE, NO PAY These new 80GHz radar sensors are excellent problem solvers for almost any liquids or solids level application you wish to name. As a mark of confidence in performance, they are available for test and trail on your application, if they don’t prove to be successful solution, you don’t pay. Tel: +44 1444 870055 www.vega.com/uk Email: info.uk@vega.com

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CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS

SANITARY BULK BAG WEIGH BATCH UNLOADER A new BULK-OUT® Bulk Bag Weigh Batch Unloading System with Manual Dumping Station and Flexible Screw Conveyor automatically conveys weighed batches of contamination-sensitive materials to downstream processes and allows rapid sanitising..

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he BFC model discharger frame is equipped with a cantilevered I-beam with electric hoist and trolley for positioning of bulk bags without the use of a forklift. A SPOUT-LOCK™ clamp ring atop a TELETUBE™ telescoping tube securely connects the clean side of the bag spout to the clean side of the equipment intake, and maintains constant downward tension on the bag as it empties and elongates, promoting complete discharge from the bag. At timed intervals, FLOW-FLEXER™ bag activators increasingly raise opposite bottom edges of the bag as it lightens, ultimately forming a steep V-shape that promotes complete discharge of free- and non-freeflowing materials from the bag. A bag dump station with folding bag shelf allows manual dumping of minor additions into the hopper from hand-held packaging and containers. The hopper is vented to a BAG-VAC™ dust collection system that draws airborne dust from manual dumping activities away from the operator when the hopper lid is open. When the hopper lid is closed during bulk bag discharging, the dust collection system additionally prevents displaced air and dust from entering the plant atmosphere, and collapses empty bags prior to tie-off, preventing dust generated when empty bags are flattened manually. A FLEXI-FORCE® lump breaker integral to the hopper reduces agglomerates and promotes the continuous flow of material into the charging adapter of the flexible screw conveyor. Load cells supporting the entire system are linked to a PLC that stops the

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flexible screw conveyor once the system has lost a pre-set amount of weight. The flexible screw is the only moving part contacting material, and is driven above the point at which material exits the conveyor, preventing material contact with seals and allowing rapid sanitising in place. The screw can also be removed through the bottom of the tube for sanitising and inspection. Positioned above the clamp ring is a POWER-CINCHER™ pneumaticallyactuated flow control valve that cinches the spout concentrically, allowing re-cinching of partially empty bags for leak-free tie-offs.

The entire system is constructed of stainless steel finished to sanitary standards, and is rated for wash down. Flexicon also manufactures tubular cable conveyors, pneumatic conveying systems, bulk bag conditioners, bulk bag fillers, bag dump stations, drum/ box/container tippers, weigh batching and blending systems, and automated plant-wide systems for handling of bulk food, dairy, pharmaceutical, chemical and mineral products. For information contact Flexicon Europe Ltd, Tel: +44 (0)1227 374710, Email: sales@flexicon.co.uk, www.flexicon.co.uk


CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS

FB CHAIN TO SHOWCASE UPTIME-ENHANCING CONVEYOR COMPONENTS AT RWM 2016

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ritish industrial chain manufacturer and supplier FB Chain will use its RWM 2016 stand (5S79) to showcase cleverly-designed scrapers, wear strips and sprockets that are helping recycling and waste management customers all around Europe to maximize their conveyor uptime and profitability. Throughout its 30-year history FB Chain has acted not only as a supplier to the recycling and waste management sectors – of conveyor and roller chains, sprockets, pins, bushes, rollers and attachments – but also as a design consultant, helping customers to achieve the very best performance from their conveyor operations. FB Chain’s Inno scraper attachments made from multilaminated beech, for example, were originally designed to combat the costly consequences of overloading experienced by recycling customers in Germany. When customers’ traditional steel scrapers (from another supplier) had buckled under pressure, causing irreparable damage to chains, sprockets and even chipping units and furnaces, FB Chain came to the rescue with a range of wooden flights that simply snap when overloaded. While just as durable, FB Inno scrapers cause no damage to surrounding components, are simpler, quicker and cheaper to replace and at one tenth of the weight of traditional steel scrapers, they dramatically reduce stress on conveyor drives, not to mention energy running costs. FB Chain’s two-colour polyethylene wear strips, meanwhile, were first developed for a biomass customer in the UK to help better manage replacement schedules. In FB Chain’s unique design two contrasting coloured plastics are layered over each other and as soon as the base colour becomes visible through the top layer, technicians know that it is time to replace the chain guide. This visual cue acts as a convenient built-in wear indicator. Technicians do not need to stop the conveyor to check the degree of wear and it ensures they are replaced at the optimum time – not too early, generating unnecessary expenditure, and not too late when damage could be caused to the conveyor chain.

Just as these key innovations help to keep customers’ conveyors up and running, so too do FB Chain’s popular self-cleaning sprockets with induction-hardened teeth made from corrosion-resistant steel. The grooves around the edge of each sprocket prevent loose material from becoming trapped between the teeth, reducing maintenance requirements and increasing the life of the sprocket. FB Chain will be showcasing each of these industry-leading products, alongside its portfolio of conveyor and roller chains, at Hall 5, Stand S79 at the forthcoming RWM exhibition, taking place at the NEC in Birmingham 13th–15th September. FB Chain’s representatives will be on hand to discuss materials, coatings and attachments, as well as other design challenges specific to the recycling and waste management industries. “At FB Chain we don’t just supply conveyor components, rather we work together with customers to develop innovative solutions that overcome their individual challenges and boost the performance of their entire conveyor – including efficiency, ease of maintenance, service life and total cost of ownership,” says Darran Green, sales manager at FB Chain. “We are very much looking forward to meeting with new customers at RWM in September and having some stimulating discussions about how to solve their conveyor problems.” For further information, please visit: www.fbchain.com

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CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS

GREAT ORME BREWERY

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reat Orme Brewery is a 12.5 barrel micro-brewery and was established in November 2005 by Jonathan Hughes. Back then the brewery was situated on a hillside in the Conwy valley between Llandudno and Betws-y-Coed, with impressive views of the Conwy Estuary and the Great Orme, from which the brewery takes its name. Jonathan was a consultant for 10 years and the company he worked for was moving into an area away from his core skills. Jonathan therefore took the opportunity to leave and move back to North Wales. At the time he had limited knowledge of brewing but he knew people were very interested in understanding the origins of where their food and drink came from and the idea came from there. The business over time has expanded and they recently moved from the family farm to the building they are in now due to the growth of the business. Jonathan approached UniTrak Powderflight as the brewery was increasing its capacity by around two and a half times. With his expansion of the business the Great Orme Brewery was having to move to new premises which meant the equipment they had was not fit for purpose and needed a new solution. The challenge was to raise Malted Barley (grist) from one level to another in its simplest form without damaging the Barley, but long enough to reach from the dry raw materials room into the brewing room. Jonathan stated that “It is very important that the dry raw materials are kept away from the dampness of the brewing room itself and so we have to keep them in separate rooms, otherwise this spoils the dry materials”. He then added “The volume of materials being used at the old plant was around one third of a ton and now it’s a lot closer to two thirds of a ton. This can’t be mixed by hand so needs a mechanical way of doing it so it can be more efficient”. After a very open discussion about the challenges and the solution that the brewery needed, UniTrak Powderflight’s Phil Booth guided Jonathan through the process of what could be done as Jonathan admitted that he didn’t really know what kind of machinery was needed. He was new to this kind of technology with him not implementing anything like this before himself, but he had seen photographs of the same kind of machinery to UniTrak’s equipment at other brewers. Phil recommended that the F75 UniFlex Conveyor would be best as it is ideal to handle Malted Barley. UniTrak Powderflight do have free onsite testing facilities, but this 38

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product had been tested a number of times before so a test was not needed. Phil was very confident that the material would convey very well with little damage to the product. The F75 UniFlex Conveyor is simple but sturdy in design. The receiving hopper which can be fabricated from mild or stainless steel, is attached to a food-grade polyethylene tube. Situated within it is the only moving part of the conveyor, the stainless steel spiral which draws the grist to the discharge chute. The F75 UniFlex also has other features which includes: • Cleaning out cap - attached at the bottom of the tubing for quick removal for fast cleaning. • Safety grille – helps keep foreign materials out of product system. • Low-level probe – this allows for automatic shut down when the hopper is nearing empty. • Heavy duty clamp and seal – provides dust control. • Flexible discharge chute – the length can be customised to suite your requirements. • Minimal maintenance - when required, is easily accomplished with minimal tools. • Simple to install, operate and clean. Jonathan goes on to comment that the brewery’s general engineer had no issues installing the F75 UniFlex Conveyor as he found it very simple and straight forward. Great Orme Brewery had the equipment delivered in January 2015 and have been using since with no mechanical issues and maintenance is rarely required, but if any spare parts are needed they can be sourced directly from UniTrak Powderflight. The F75 UniFlex Conveyor has made a difference to the production and the company as Jonathan goes on to explain “It’s eased the use of lifting the upper grist case. This has involved reducing the dangers of manual handling significantly, so has speeded up that end of the process as well.” Jonathan added “The other benefit is because we are able to raise from a small level to a high level through the new UniFlex conveyer it allows us to get a better quality mash. The other alternative was to just throw the bag of dry materials in, but that would more than likely get a fairly insufficient mash which would then reduce the overall production volumes,

by this process we can obtain better efficiency of the grain we are using”. Great Orme Brewery had approached three other companies, but found that UniTrak Powderflight was better with a quick all-rounded package, with competitiveness, no hard sell and the quality of the advice given. Jonathan said “UniTrak would be our first port of call for a similar sort of solution”. For more information contact UniTrak Powderflight on: +44 (0)1457 865038 or visit the website at www.unitrakpowderflight.com


CONVEYORS, ELEVATORS, TRANSMISSIONS & COMPONENTS

A BRAND YOU CAN TRUST

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he marketing of Roller chain products in the UK from Donghua Limited is about to change with the creation of two new brands for its popular roller chain range: Donghua Standard Donghua Standard Plus The move follows an in-depth review which helped firmly establish the positioning of Donghua’s products within the UK market-place and is aimed at helping Distributors and OEMs differentiate more easily between Donghua’s roller chain products and communicate their benefits to customers. Bob Wellsbury, managing director, of Donghua Limited explains: “Our standard roller chain products are extremely popular and we have developed a strong customer base of Distributors and OEMs in the UK over the last seven years. To help our customers market these products more effectively, we have decided to group them within ‘Standard’ and ‘Standard Plus’ brands.”

“All of our roller chain products, whether Standard or Standard Plus, are made to the highest standards irrespective of which of the new brands customers choose. There are, however, some application advantages versus pricing benefits associated with each which we felt could be made clearer.” He added: “We have also introduced new pricing structures for the new brands which are both highly competitive and extremely attractive to our customers. We guarantee that no other supplier in the UK can beat us on price for standard roller chain.”

Donghua Limited’s Standard Roller chain products incorporate a split bush and solid roller, whereas Donghua’s Standard Plus Roller chain uses a solid bush and solid roller which improves wear life and reduces elongation. Other variants are also available such as Chromised pin chains. Both Standard and Standard Plus chains are available in ANSI and BS. Further additions to the Roller chain range is planned for 2017. www.donghua.co.uk/roller-chain, Email: sales@donghua.co.uk Tel: 01902 866 200

NEW SOLUTION PARTNERS FOR SIEMENS LARGE DRIVES

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iemens has appointed two new Large Drives Solution Partners as it increases focus on growing its Large Drives business in the UK. Drives and Automation, based in Worksop, and NCE, based in Glasgow, are companies with significant pedigrees in the areas of designing and supporting motor drives and control systems. They join existing Large Drives Solution Partners Iconsys and IAC in being able to provide engineering expertise and project management to Siemens customers in many industry sectors across the UK. NCE specialises in power systems for marine and offshore and the oil and gas industry, and has a 30-year pedigree, with its own production facilities in Glasgow. Drives and Automation is based in Worksop and specialises in drive system integration and process line applications, particularly with food packaging, textile and paper industries. Both are already supplying Siemens technology solutions for industry, including Sinamics AC/DC drive modules, and both have extensive in-house design, installation and commissioning services. Siemens Solution Partners are part of a growing global network of over 1400 companies, certified by Siemens with quality and control standards that

are uniform worldwide. Each partner provides outstanding expertise in its field, combining that with system expertise from the Siemens portfolio to optimally fulfil every project with professionalism and efficiency. As well as providing Siemens drive and automation systems, they also cover power distribution. Geoff Hirst is Siemens general manager (Large Drives) and he commented: “We value long-term cooperation and companies who share our commitment to providing the best performance and support. Expertise and professionalism are just some of the factors, right through from initial consultation to bespoke technology solutions and service. By welcoming these two experienced companies into our Solution Partner network, we are significantly strengthening our support to Large Drives customers.“ Siemens Solution Partners help customers in many industries improve the quality of their technology solutions through outstanding industry and technical knowledge, by optimising availability, performance and energy efficiency, increasing throughput and profitability and improving safety and security. Significant savings in long-

term production costs and futureoriented automation solutions can be achieved through the tailored support of Siemens Solution Partners. See more about the range of Siemens solutions for industry at www.siemens.co.uk

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SIEVES, SIFTERS, SEPARATORS & SCREENING

BUNTING SECURES RECORD EXPORT ORDER FOR MAGNETIC SEPARATORS

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unting Magnetics Europe Ltd has secured their largest single export order from a German processing plant designer and builder. The record order is to manufacture and supply 63, high-strength, Rare Earth Plate Magnets, which will be installed in a tobacco manufacturing operation in Indonesia. Bunting Magnetics is one of the world’s leading suppliers of Magnetic Separators and Metal Detectors and the European manufacturing headquarters are based in Berkhamsted in Hertfordshire, UK. The Plate Magnets are used to remove metal from the shredded tobacco. Metal enters the tobacco process at various points, including at source, with the raw material infeed, and during the slicing and cutting of the leaves. The Plate Magnets attract and hold the magnetically susceptible particles, including abraded stainless steel. This prevents damage to delicate processing equipment such as the cutting blades as well as maintaining the quality of the end product.

5 of the 63 Bunting Plate Magnets being packed in specially made boxes for export

The recent order in June 2016 was for 63 Rare Earth Plate Magnets and followed an earlier order for 26 placed in February 2016. Two different models of Plate Magnet are being supplied, with 34 having a magnetic face width of 609mm and a 125mm deep magnetic field and 29 with a face width of 508mm projecting a 90mm deep magnetic field. A Plate Magnet comprises of a stainless steel box or housing into which high strength Rare Earth blocks are positioned. The type of Rare Earth block and configuration of the blocks within the housing dictate the shape, strength, and depth of the magnetic field. A deep magnetic field was important in this application. Head of Sales, Dave Hills, explained the importance of the order: “Developing export business is vital for our continued growth in the UK. This is our single largest order for Magnetic Separators on record

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Bunting Plate Magnets under construction

and is the result of a prolonged focus on developing business overseas. On this project we worked closely with the German client and had several meetings in Germany to understand their requirements before we proposed the best metal separation solution. This is a very exciting development for Bunting Magnetics in Europe.” The Plate Magnets will be manufactured and supplied in batches

in specially designed transportation boxes and are due to be despatched between June and August 2016. For further information on separating and removing metal with Magnetic Separators or Metal Detectors, please contact the Bunting technical sales team on sales@buntingeurope.com or visit the website www.buntingeurope.com.


SIEVES, SIFTERS, SEPARATORS & SCREENING

MAGNETIC SEPARATOR FOR DAIRY AND BABY FOOD

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he Hydrohansu-type rotating cleanflow magnet recently introduced by Goudsmit Magnetics Group BV of Waalre (NL) was developed in collaboration with producers of top-tier food products. The driving force was a pressing need for removal of very fine iron (Fe), AISI 304 and 316L particles in the dairy industry, for products such as baby food, yet it is also suitable for use in the sugar and lactose industry. Rotating magnets prevent the accumulation of fatty powders on the magnetic bars and guarantee a high level of separation. The new magnet system is hygienically designed in accordance with the EHEDG guidelines and can be cleaned semi-automatically. The magnetic separator shown at PPMA in Birmingham, stand D92. HYGIENIC DESIGN The single-piece, hydroformed housing is made entirely of grade 316 stainless steel and therefore has no dead ends, sharp corners or welded seams, which prevents bacterial growth. The complete system has a high quality surface finish (Ra ≤ 0.6 µm). The magnet rotor has pneumatically operated magnet bars, is mounted in the door and rotates on a bearing. To prevent product from entering the space between the rotor and the housing, it is fitted with a removable labyrinth air lock. A continuous, clean stream of air (+0.2 bar) feeds that air lock and blows from the inside towards the product chute. The use of rotating pneumatic magnet bars ensures that the powerful magnetic value (11,500 gauss) is in direct contact with the product. Tests have shown that in addition to separating Fe (99%) a high percentage of the AISI 304 and 316L particles are also separated.

in Romeoville, IL (USA), which makes complete production lines for the food industry. They wanted to use a KUKA robot for a packaging line that employs a magnetic gripper to palletize filled jars. The Goudsmit R&D department developed a lightweight palletization magnet of this type to meet the established requirements. The system can also be optionally fitted with quickchange connectors for robots. www.goudsmitmagnets.com

CLEANING The semi-automatic cleaning process can be performed during a production stop. After the rotor is released and pulled out manually, compressed air internally shifts the magnet packs to the cleaning position. This provides a quick, easy and safe cleaning method in which the metal particles are carried away. Moreover, the Hydrohansu – in comparison to previous versions of rotating magnets – no longer has any delicate loose parts. This results in a high level of efficiency and user-friendliness. Sensors ensure that all these steps can only be performed in the correct order. LIGHTWEIGHT PALLETIZATION MAGNET FOR ROBOT APPLICATIONS Another product that will be presented at PPMA is a palletization magnet for palletizing filled glass jars, tins and aerosol cans and is suitable for robot applications. The use of powerful Neoflux® magnets in an aluminium enclosure results in weight reduction and makes the palletizer also suitable for smaller robot arms. This results in considerable cost savings. A further benefit of the client specific design of the connection to the robot arm is a savings of several kilograms of weight. The palletization magnet has vacuum suction cups for removing the paper separator sheets as well as an extra gripper for moving the empty pallet. Even at an acceleration of 2m/sec2 the magnetic plate continues to hold the load securely. The palletizing magnets are made to order. FLEETWOODGOLCOWYARD The lightweight palletization magnet has been developed for clients such as special machine builder FleetwoodGoldcoWyard

Bulk Solids Today

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RECYCLING & WASTE MANAGEMENT

VELDE PUKK OPEN NEW 300TPH WASHING PLANT FOR CONSTRUCTION & DEMOLITION WASTE RECYCLING

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he new 300tph washing plant for construction and demolition waste was purchased by Velde Pukk in late 2014 and is the first of its kind in Norway. “We opened discussions with CDE a number of years ago as we see the huge opportunity presented by the recycling of C&D waste to high quality, high value recycled sand and aggregates with a wide range of applications” says Managing Director of Velde Pukk, Mr Egil Velde. “We visited a number of existing CDE installations and have watched very closely the technological innovations from CDE in recent years which combine to maximise material quality and minimise waste from the process.” As well as processing C&D waste received at the Sandnes quarry the new CDE plant is also processing overburden from the company’s hard rock quarry operations at the same site. The CDE project was initially led by Eoin Heron, CDE Regional Director for Europe and Russia and he says that the flexibility offered by the CDE equipment was an important factor in winning the project. “We looked at the overburden for Velde and determined that we could design a plant that would allow them to not only recycle the C&D waste but also to recover material from the overburden which could subsequently be used in their integrated operations.” As well as operating the quarry in Sandnes, Velde also specialise in the production of ready mix concrete, asphalt production and laying and have their own transport fleet which you can’t fail to notice on any trip around the Sandnes and Stavanger areas. The North Sea oil industry is a big driver for the economy in this part of Norway and the short trip from Stavanger airport to the quarry in Sandnes reveals a huge amount of infrastructure development on the ground, matched only by the number of helicopters you see transporting people and parts back and forward from the oil rigs off the coast. “We are a well established and respected name in this area and are providing material to a large number of local projects on a daily basis” explains Egil Velde. “Our investment in the first wet processing plant for C&D waste in Norway

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is a symbol of our success – people expect innovation from our company because of our history and we hope that our investment in the CDE plant is taken as a symbol of the potential that exists for this highly valuable resource to be turned into high quality, high value recycled sand and aggregates.” The story of Velde as been one of continuous investment and diversification since the company was originally formed in Sandnes in 1984 by the father of the current Managing Director. “When my father started the business we were producing aggregates for road and pipe construction from the quarry in Sandnes” explains Egil Velde. “Now my father has retired and I run the business in partnership with my two brothers, Harald and Reidar.” The company has expanded significantly in the last decade, beginning with the introduction of an asphalt plant at Sandnes quarry in 2006. By 2007 they had built what they say is the largest, most modern and environmentally friendly production facilities for crushed rock processing and asphalt production in the world. This was followed in 2008 by the establishment of a contracting business for road construction and in 2009 a ready mix concrete plant was introduced to the site. “Our business has always been about doing things the right way” says Egil Velde. “Our ambition to grow and build on the strong foundations that our father built always run in tandem with a desire to ensure that the business we build is sustainable and has minimal environmental impact. In CDE we found a company that shared this ethos and also shared our desire for this project to be much more than a cold business transaction. We want to build long term relationships with our partners built on trust and respect that will allow us to achieve our growth ambitions while maintaining a focus in our people, our customers and the world around us.” PROJECT DELIVERY This partnership approach between Velde and CDE allowed for significant efficiencies to be enjoyed during the project delivery phase. The CDE project manager on this job was Colum Bryson

and he believes the level of engagement with the Velde brothers and the wider operations team in Sandnes was critical to the success of the project. “This is one of the largest mechanical installations that CDE has ever completed and as with all projects there were some very specific challenges to overcome during the design and delivery phase” explains Colum. “Sandnes quarry is a very busy working site so the installation and commissioning phase had to be managed with respect for the essential daily operations of the crushed rock processing plant, the ready mix concrete plant and the asphalt production plant. Thanks to the engagement and commitment of the full team at Velde we were able to not only manage these issues but actually reduced project delivery time by 40%.” There were 55 lorries involved during the transportation phase to deliver the new washing plant to Sandnes quarry and due to limitations on space it was essential that staged deliveries were organised. It was also essential that this was done in such a way as to minimise crane hire requirements on site. “Due to space restrictions on site this project posed a number of challenges if we were to ensure that there were no additional project costs incurred” explains Colum Bryson. “We were able to achieve this as a result of the commitment that Velde demonstrated to the project from the outset. The value of getting the new plant up and running in the shortest possible time is often underestimated but not in this instance.” The Velde commitment to doing everything the right way is immediately apparent whenever you visit Sandnes quarry and see the work that has gone into the civils on which the plant is located. A concrete pad was constructed as well as a variety of concrete product bays built to facilitate the introduction of the many radial product conveyors on the plant. “The concrete pad at Sandnes quarry is an example of how all projects such as this should be accommodated” says Colum Bryson. “The long term benefits of this are huge - easier and more efficient movement of site vehicles around the site and quick, easy and safe access for essential plant inspection and maintenance.”


RECYCLING & WASTE MANAGEMENT The specification of several radial stockpile conveyors for the washed recycled sand and aggregates is another example of the Velde commitment to minimising the environmental impact of their operations. “This has the effect of significantly reducing transport movements on site bringing significant cost savings” explains Harald Velde, Operations Director at Velde. “This also eliminates unnecessary double handling of our products. In addition to the cost benefits the reduction in transport movements also reduces health and safety risks on site – safer, happier people are more productive people and this was a big factor for both us and CDE in the design of our new plant.” THE PROCESS Feed material is first delivered two R2500 primary screening units located side by side and with integrated apron feeders which split the feed across two separate 150tph processing lines. From the feed hopper material is sent to the R2500 primary screening unit and the +90mm material is removed via a double deck 5m x 1.5m grizzly screen. The remaining material is discharged to two horizontal feed conveyors. The 0-90mm material then arrives at two AggMax 151 modular logwashers where a pre-screen removes all the 0-4mm material which is delivered directly to the EvoWash 201 sand washing plant. “The prescreen is essential at this stage to ensure the efficient operation of the AggMax” explains Eoin Heron. “Not only does it ensure that the aggregate fraction is satisfactorily scrubbed but it minimises wear in the AggMax and maximises sand production.” After aggressive scrubbing in the two AggMax units the 4mm-90mm recycled aggregate to sent to a ProGrade P2-108 sizing screen. The two AggMax machines also include a trash screen at the rear which removes any lightweight and organic contamination from the recycled aggregate product. Any sand liberated during the attrition phase is also sent to the EvoWash sand washing plant and ensures maximum product yield from the C&D waste feed. The ProGrade P2-108 sizing screen is from the new Infinity screening range from CDE which includes a patented side wall construction which removes unnecessary weight and reduces the power required to run the screen. The screen is set up to produce a 4mm-11mm, 11mm-16mm. 16mm-22mm and 22mm-90mm product all of which are stockpiled using static and radial stockpile conveyors. The EvoWash sand washing plant produces two grades of sand – a 0-2mm and a 2-4mm. The 0-2mm product is used in the asphalt production

plant at Sandnes quarry while the 2-4mm product is used in the concrete plant. Given the space restrictions on site it was essential that full water recycling and sludge management was included on the new plant for Velde Pukk. There is no option to include settling ponds at Sandnes quarry but the Velde commitment to minimising environmental impact meant that this was an essential requirement of the new plant anyway. “Not only does the plant require much less space with the full water and sludge management system but the fresh water requirement is 95% less than if we simply included settling ponds. It also results in a cleaner, safer and more productive site” explains Harald Velde. The wastewater from the plant is first delivered to an AquaCycle A1500 thickener where it is dosed with flocculant. This forces the very fine particles of silt and clay to bind together and sink to the bottom of the tank. Meanwhile, the recycled water overflows the peripheral weir and is stored in a concrete buffer tank before being recirculated to the washing plant. The sludge at the bottom of the AquaCycle thickener is discharged automatically at certain pressure and is sent to another concrete buffer tank which is fitted with a set of agitators to ensure the a consistent sludge is delivered to the overhead beam filter press. The filter press model specified is one of the largest available and has 169 plates each measuring 2mx2m. These plates press the sludge to remove more water before the filter cake is discharged to a bay below. “We are currently using the filter cake – which has a dry solids content in excess of 80% – for the construction of embankments which means that we have eliminated waste from this stage of the process” explains Harald Velde. “Of the

300 tonnes per hour feed to the plant the only waste from the process is made up of the lightweight and organic contamination removed during the attrition phase.” THE FUTURE The new CDE plant at Sandnes quarry will divert approximately 600,000 tonnes of C&D waste from landfill every year. Velde Pukk aim to develop the market for recycled material in Norway in the months and years ahead through extensive testing and use of material in their own operations. The business case for the CDE plant was made on the basis of the cost savings that would be realised by Velde Pukk as a result of the diversion from landfill – but that is not enough for the Velde brothers who see this new plant as an opportunity to build the brand value of recycled material and increase its use not only in Norway but across Europe and the rest of the world. “We are committed to finding more sustainable ways to meet growing demand for our mineral reserves” says Egil Velde. “Construction, demolition and excavation waste is a hugely valuable resource that can help us to extend the life of our natural reserves for future generations.” This is a view that is shared by all three of the Velde brothers. “We wouldn’t accept a wasteful approach to the processing of virgin materials so it’s time that the same approach was taken with C&D waste” says Harald Velde. The approach taken by Velde is a refreshing one and signals not only a change in attitude to C&D waste and the potential it offers but also that the industry is in good hands as it seeks to stay relevant, viable and secure the future innovation that will keep the sector thriving and strong. www.cdeglobal.com

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SPECIAL FEATURE

HANDS UP IF YOU KNOW ONE ROBOT ARM FROM ANOTHER What determines the choice of palletising robot to handle product X at point Y on the line? With a choice of 20+ FANUC robots arms all capable of performing palletising tasks, Roger Harris Regional Sales Manager at FANUC UK picks out some of the main criteria that factories should consider in order to specify the best robot arm for the job.

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o the untrained eye, one robot may look very similar to another. In reality, there are a host of variables, not just in the overall type of robot, but in the precise specification which can be tailored to the particular needs of a given application. A robot may last 20 years in a single installation. If you look after the robot, it will look after you. And ‘looking after’ the robot starts with ensuring that you have the correct specification to begin with. Any reputable automation specialist will talk potential customers through their detailed needs and how they can best be met. But many of those with robot-shaped gaps at the end of their production lines could benefit from a brief overview of the main considerations:CYCLE TIME VERSUS SPEED Most manufacturers know that in relation to any type of equipment, ‘speed’ is often less useful as a concept than it might appear. This is as true of robots as it is of other machines. Most robots can be programmed to move extremely quickly – up to around 4000mm/second, but they will need to ramp up to this top speed, and then slow down from it. When the distance of travel is short, the arm will never reach maximum speed. Sometimes, we slow the arm down in order to reduce the cycle time.

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By using FANUC Roboguide robot simulation package the system integrator can check to see if the cycle-time is achievable and in turn this can aid robot selection. FANUC Roboguide will aid the programmer in developing a robot path program which can reduce unnecessary overheating and wear and tear on the robot whilst achieving required cycle-time. PAYLOAD A key element in productivity calculations will be the payload of the chosen robot arm, and how closely the integrator feels it is wise to approach the rated weight. For example, in a palletising pick-and-place application, a magnetic end effector may be able to lift, say, 20 cans at a time. But choosing a smaller number may make more sense. This will avoid excessive stress on the servo drives, gearboxes and mechanical unit: therefore prolonging the life of the robot. Remember to take into account the weight of the end effector. That is part of the payload, too. In fact, it can form a substantial proportion of that payload. A 4-axis palletising robot may be able to lift 180kg, but the gripper on a palletising robot may contribute around 50kg of that load. In selecting a payload range, the customer will also be estimating future needs and how much of a margin to leave in order to accommodate any likely change in the robot’s role.

Roger Harris, Regional Sales Manager at FANUC UK

COST AND RETURN-ON INVESTMENT When a robot supplier or integrator visits a prospective customer, the first task is to determine whether the proposed process is viable at all. The next step is to determine what measurables the customer will use to calculate their ROI, whether it be resource, health and safety, production volumes or quality etc. Once ROI viability is established, the precise mechanics, detailed specification, layout, installation cost and ROI can be determined. It is because the working life of the robot is at the core of any ROI calculation that decisions about cycle time, payload and overall utilisation are of such importance. In Germany, for example, it is quite common to buy an additional robot cell rather than running a single cell at maximum utilisation, it also provides a level of redundancy to protect production. REACH If you are fortunate enough to be designing a new packaging line, then there should be few challenges in maximising efficiency and performance in the palletising robot. But if the line already exists, you are going to have to conform to it. You may have to perform some ‘surgery’ on the line, but you would normally try to minimise this. It is not only cost which is typically kept to a minimum, but also disruption to the line and production.


SPECIAL FEATURE

One important element in the calculations around a palletising installation will be the reach of the robot. Making changes to the line to reduce the robot envelope may improve productivity and therefore make sense in terms of total cost. It may also mean that a lower-specification robot is needed. There is a general assumption that the bigger the robot, the longer the reach will be, and the heavier the payload. This ‘rule’ normally holds, even though there are exceptions. NUMBER OF AXES Along with issues such as hygiene ratings (which are not normally significant at end-of-line – unless of course it’s a cleanroom manufacturing environment), the number of axes of movement may be more important in pick-and-place applications. But there are reasons why

the choice between a 4-axis and 6-axis robot may come up more often in palletising. For simple palletising, a 4-axis robot will normally be sufficient. But customers may need a 6-axis model, if they want the robot to handle pallet bases and layer sheets, too. There are other reasons why an additional axis (or two) of movement may be helpful – or even necessary. In FANUC’s experience, a 6-axis robot may be needed in applications which would otherwise suit four axes because of unavoidable obstacles in the factory which the arm has to clear or negotiate. Finally, customers should push their robot suppliers to ensure that what is on

offer is the best solution for that particular application. In this situation, even if you do not know all the answers, knowing which questions to ask your supplier can be very helpful. www.fanuc.eu

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PACKAGING

LIGHTWEIGHT CONTAINERS TO OPEN NEW KEYKEG PRODUCTION LINE IN GERMANY Lightweight Containers is opening a new production plant in Grossbreitenbach, Germany.

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he fully automated production line has a capacity of 400 KeyKeg® Slimlines per hour and will be operational in the third quarter of this year. The line can produce all the members of the KeyKeg® Slimline family of kegs. PET-Verpackungen Deutschland is the production partner and will manage the day-to-day production. The new production capacity will ensure that Lightweight Containers can meet the region’s sharply rising demand for the next few years. Anita Veenendaal, Chief Commercial Officer of Lightweight Containers, says, “We see service as a crucial element for our success. We aim to offer the best possible service, so we want to produce as close to our customers as we can. This new location and the extra capacity will reduce both delivery times and transport distances even more. In the last six years, our sales have grown more than 40% each year, and we’re seeing accelerated growth in the demand for our kegs almost everywhere in the world we serve. With this new production line, we can continue to serve our customers in this region at the level they’re used to.” CONCENTRATION ON SOLUTIONS FOR THE TOTAL SUPPLY CHAIN The new plant is being set up in close collaboration with production partner PET-Verpackungen Deutschland. Jan Veenendaal, CEO of Lightweight Containers adds, “Our one-way kegs have a lot of added value throughout the supply chain. They also fit in perfectly with trends like specialty beer exports and wine on draft, which partly explains why we’re growing so fast. We intend to keep concentrating on solutions for the beverage industry, and on crucial trends. We can do this by collaborating with a professional and flexible production partner like PET-Verpackungen, who completely shares our view of quality.”

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TWO PARTNER COMPANIES According to Oliver Wiegand of PET-Verpackungen GmbH, “Lightweight Containers has an international focus that fits in well with our international ambitions. Construction of the production line is going very smoothly. Lightweight Containers’ knowledge of and experience with production processes makes them a valuable partner. Both companies are also family-owned, which turns out to be a good foundation for an efficient and pleasant working relationship. We have all confidence that this line is just the beginning of a long and successful collaboration between two partner companies.” KeyKegs are currently produced in three locations: Schwerin (Germany), Den Helder (the Netherlands), and Joliet (USA). The line in Grossbreitenbach (Germany) will be operational in the third quarter of 2016. LIGHTWEIGHT CONTAINERS BV Lightweight Containers is well known for the one-way 20- and 30-liter KeyKeg®. The family-owned company, market leader in high-quality one-way kegs, develops, produces, and sells the KeyKeg® and guarantees the continuity and quality of the KeyKeg® concept. This revolutionary and successful oneway keg develops and leads the market for one-way kegs and is available in 10, 20- and 30-litre versions. Breweries,

wineries and other beverage companies prefer and use KeyKegs all over the world, as they are especially suited for carbonated and still beverages. KeyKegs are currently sold to clients in more than 52 countries. KeyKegs are produced in Germany, the Netherlands and the US. Further expansion of production plants is planned. PET-VERPACKUNGEN GMBH PET-Verpackungen GmbH Deutschland, part of the Wiegand Glas Group, takes full advantage of more than 400 years of proficiency and tradition in the production and distribution of food and beverage packaging. The managing directors, Nikolaus Wiegand and Oliver Wiegand, run a successful family-owned company which offers a variety of packaging solutions. They adhere to glass as the traditional material, while the same time also creating new possibilities and the latest trends in PET packaging with PETVerpackungen GmbH Deutschland. PET-Verpackungen GmbH, located in Grossbreitenbach (Thuringia), has become one of the most advanced and well-known preform and PET bottle manufacturers in Europe today by continuously upgrading and improving molds and production systems with the latest technology. www.unikeg.com


PACKAGING

LINX TO HIGHLIGHT WIDE-RANGING CAPABILITIES

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n stand E36 at this year’s PPMA Total Show, Linx will showcase some of the latest models across its printing technologies, underlining the company’s versatility in offering coding and marking solutions tailored to customers’ precise requirements and applications. Alongside just-launched additions to the company’s pioneering Linx 8900 series CIJ (Continuous Ink Jet) printer, Linx will also demonstrate its innovative entry-level Linx SL1 laser coder and the Linx IJ375 high definition large character outer case coder. The new Linx 8920 and 8940 incorporate a number of further enhancements to the successful Linx 8900 that deliver even faster line speeds and easier set-up, together with a further extension of service intervals from 13,000 hours or 18 months to 18,000 hours or 24 months. A unique feature is the first-in-class Advanced System Monitoring which provides a continual check of the printer’s operation in terms of ink system running parameters and environmental conditions. This enables it to identify simple actions that users can

take to prevent unscheduled stoppages. Both models have a top speed of 6.25m/s for a single line code, and the capability to print up to five lines. The Linx 8940 also offers an IP65 rating that prevents dust ingress as well as providing wash down protection, ideal for operating in more challenging environments. The Linx SL1 laser coder is an entry level solution that enables more companies to adopt laser technology. One of the most compact and lightweight one-box laser solutions on the market, it fits easily into tight production spaces, as well as coding in any orientation. The Linx SL1 delivers class-leading speeds and offers 20 per cent more power than other products in its class, but at the same time uses much less laser energy in the coding process. It is also capable of greater coding versatility than comparable models, with the ability to produce multiple lines of texts and logos in one message, as well as machine readable codes such as QR and Data Matrix. The Linx IJ375 has been designed to cut production costs while maximising line uptime and print quality for the coding

of secondary packaging. Its innovative ReFRESH® ink system, robust design and printhead protection technology mean significantly reduced downtime and savings on consumables. The patented ReFRESH® system maintains premium print quality and avoids wasted ink during printhead cleaning. Ink and dust that collect on the nozzles are removed with an ink purge and air knife, then ink from this procedure is collected, passed through a high performance filter to remove impurities, and delivered back ready for printing. In addition, the tough stainless steel nozzle guard protects the printhead from potential damage from impact with boxes on the line, while allowing the printhead close enough to the pack to ensure superior print quality is maintained. For more information on Linx’s products and services, visit www.linxglobal.com

BUBL BAG – THE ANSWER TO PACKAGING WASTE

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ave you ever received something in the post and it is in a box which is much too big and has masses of paper or bubble wrap inside to stop the goods rattling around? You are not alone. A major packaging company recently ordered 119 items on-line and then assessed the packaging. Key findings included: • 10% arrived damaged • 41% contained too much packaging resulting in disposal issues • 47% of packaging was not recyclable • 30% were sent in packaging that was too large Enter the BUBL Bag – it is a unique innovation in protective packaging The plastic bag has an inflatable inner core which envelopes the goods to be protected and holds them securely and safely in place. The user simply inflates the bag using the tube supplied (or using compressed air for more regular use) and a one-way valve traps the air. To deflate the bag the user simply inserts the tube again to break the seal.

BUBL Bags are designed to replace cardboard boxes, padded envelopes and bubble wrap by providing better protection at a lower cost. The bags are also easy to store as they take up very little space and can be reused a number of times. Ross Woodburn, director of BUBL Bags, said: “Bubl Bags offer an environmentally friendly alternative to traditionally forms of packaging as they are only a fraction of the weight, are 100% recyclable and they can be reused multiple times.” He added: “If you need to send anything that is fragile or easily damaged BUBL Bags offer the ultimate solution in protective packaging. The unique inflatable core means that the goods are held firmly in place during transit. It also means that a number of small items can be placed in the small bag and they will not touch each other. “The bags will accommodate any shape of object from a shoe to a piece of jewellery as the inflatable core forms around the

item. The number of sectors which could use the BUBL Bag are almost limitless from ecommerce and manufacturing to mobile phones and antiques. BUBL Bags are available to order online and come in a variety of sizes from 10cm x 20cm up to 50cm x 50cm. www.bublbag.co.uk Email: enquiries@bublbag.co.uk

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PACKAGING

ENDOLINE SEALS THE DEAL IN BRAZIL

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ollowing a request from Latin America’s leading textile and retail clothing company; Endoline Machinery has not only secured its first order fulfilment in Brazil but designed a brand new, high speed, random ‘0204 case sealer’. The sealing solution has the ability to handle cases with overlapping inner flaps for greater product protection – while sealing random sizes cases without bar codes. In most packing applications products are packed within cases where the flaps are folded to meet in the middle. However the Brazilian clothing giant required a high speed case sealer with the ability to handle random sized 0204 case types, which have overlapping inner flaps for extra product security. “Not many companies use type 0204 cases because they are very difficult to automate.” explains Andrew Yates, Endoline’s Sales Director. “While the double layer offers added protection and overcomes any plastic covering ‘seeping’ out of the gaps, sealing these cases at high speed can cause

challenges due to the fact that two flaps need to be folded on top of each other.” Traditionally the folding head of a case sealer incorporates a hook which ensures that all case flaps are in position before sealing. However the 0204 cases are designed so that the inner flaps overlap which presents a much bigger technical challenge. To resolve this issue Endoline re-engineered the design and speed of the hook to effectively push down one flap before re-positioning itself quickly to allow the second flap to be pushed down on top of the first by a side former. To allow the machine to handle a variety of different sized cases in a random order, Endoline’s high speed random sealing systems have integrated bar code readers to detect the case size and automatically adjust itself at high speed. As the 0204 cases did not feature a bar code Endoline overcame this by integrating a custom case size detection system, which incorporated multiple sensors uniquely placed to identify multiple

box sizes passing through the sealer. With over 850 stores throughout Latin America the clothing company exports its range of clothing brands globally. “E-commerce is growing and with this comes the need for greater protection of goods to protect product integrity.” Andrew concludes. “The new 0204 case sealer is testament to the fact that we, as experts in end of line machinery, are able to offer the technical solution to meet our customer’s need, without compromising on speed and efficiency.” www.endoline-automation.com

ENTRY LEVEL SYSTEMS WITH FAST ROI – PPMA TOTAL SHOW, STAND E46

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ndoline Machinery will showcase its range of entry level systems at this year’s PPMA TOTAL Show in a bid to cater to the growing demand for automation with fast ROI – targeting food and FMCG manufacturers hit by the minimum wage hike.

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Over the last 12 months Endoline has witnessed a 40% surge in enquiries for standard end of line systems from SME’s automating for the first time and multinational food producers looking to automate slow running production lines. As a direct result the award winning machinery manufacturer now offers a range of entry level case erectors and sealers offering fast ROI. “In the face of changes to the national minimum wage and squeezing from retailers looking to lower their costs, being able to demonstrate how quickly manufacturers should see a return on their investment is vital.” Andrew Yates, Endoline Machinery’s Sales Director explains, “While still built to the high quality Endoline machines are synonymous with, our entry level system range provides customers with an automated solution at a lower cost.” Endoline’s entry level range incorporates semi-automatic AND fully automatic case erecting and sealing solutions. With an average case run of 18 cases per minute, each system delivers a flawless finish and is capable of operating 24/7.

An award winning company for its innovative engineering prowess Endoline have many bespoke, high speed solutions capable of dealing with random sized cases. “The entry level system range comes as standard, without the technical bells and whistles which sets the high speed, random range apart.” Andrew explains. With an entry level Endoline system a company should expect to see a return on their investment within 12 months. This was the case with SME Ramona Hazan who invested in an Endoline entry level case erector and case sealer: “It was initially scary to make the investment but at the same time important to make that plunge as I realised the efficiencies which could be gained. I am now in a position where I have doubled my capacity and am anticipating a return on my investment within 12 months. Basically it comes down to simple arithmetic and for me it was a no brainer!” Visitors to the PPMA TOTAL Show will have the opportunity to view machines from Endoline’s entry level range and experts will be on hand to help calculate how quickly ROI could be achieved. www.endoline-automation.com


PACKAGING

PACEPACKER PROVES ITS PEDIGREE FOR PET FOOD WITH CASE LOADING CELL A bespoke pick and place cell, designed by Pacepacker Services for loading trays into autoclave baskets, has enabled a leading UK pet food manufacturer to capitalise on growing demand for wet food in trays and pots.

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he company, a leading UK based manufacturer of dried and wet pet food, supplies both domestic and international markets. Whilst canned pet food is still a major chunk of the market, in recent years, alternative formats, such as pouches and sealed trays, have grown in popularity due to re-sealable lids that are easier to open and the avoidance of cuts from metal edges. In line with this trend, the company took the decision to move some of its canned production into plastic trays. However, the system it was using to load cans into autoclave baskets was not compatible with the new tray format. “We needed a machine that could place the individual trays in layers into baskets, transport the baskets into the trolley system that takes them into the autoclaves, and unload the baskets of cooked product afterwards. We needed to do all of this at speeds of 220 trays per minute,” explains a director from the pet food company. Pacepacker Services, the award-winning designer of turnkey automatic packing systems, conceived a bespoke robotic pick and place cell for this complex application. Upturned trays of uncooked pet food are counted into the system via a photo electric sensor mounted on a modular belt conveyor. When a complete row has been counted, the trays are indexed across onto another conveyor. Once the required layer configuration has been reached, for example, ten rows of ten, and the trays are assembled neatly on the conveyor, a robotic arm equipped with suction cups picks up the trays and places then onto a layer pad, within the autoclave basket. “You can’t just pile the trays on top of one another as they will stick together during cooking, which is why each layer of trays is separated by a layer pad,” explains Richard Gladwin, Pacepacker’s technical director. Pacepacker custom designed the layer pads, which comprise of a stainless steel mesh supported on spigots in the corners. “We had to come up with a design that was rigid enough to support the trays but without wasting too much space in the basket,” explains Gladwin. This process is repeated until the basket

is full, and the next empty basket is presented to the pick and place system. Pacepacker’s brief also included designing a system for transporting the empty autoclave baskets into the cell in groups of six, and transporting the full baskets into the trolley car system that services the ovens. “Moving the baskets on and off the machine in groups of six was a challenging job in its own right. We did this by using sensors and building different sections of drive into the conveyor to bring the baskets close together,” says Gladwin. Once the empty basket is in place in the machine, a hydraulic scissor lift raises the loose stainless steel base plate to the top of the basket ready to accept the first layer of trays. The robot transfers the first layer onto the plate and the lift lowers it down into the base of the basket, ready for subsequent layers. Besides feeding the trays into the autoclave baskets, the system also handles product post cooking, effectively performing the same pick and place process in reverse. The same vacuum gripper picks the cooked product from the basket and loads it onto a conveyor for transfer to a packing area. “The beauty of the system is that it can simultaneously be unloading one basket whilst loading another,” Gladwin comments. One of the challenges with the design of the outfeed system is that trays exiting the autoclave are very wet. To stop water from collecting in the bases of the upturned trays, Pacepacker incorporated an industrial air knife into the system. Every time a layer of trays is removed by the robot arm, this sweeps across the next layer to remove excess water. The robot specified by Pacepacker was the M-410iB 300, FANUC’s latest generation four-axis, servo-driven industrial robot. Pacepacker has been a strategic automation integrator for FANUC for nearly 20 years, and chose this particular arm for its large working envelope and fast cycle times, but above all, its best in class 300kg payload. “We knew that the robot would have

to be fitted with pretty heavy tooling due to the technology that went into the vacuum head,” says Gladwin. Explaining the vacuum head technology, he says: “The robot needed the capability to pick up not just complete layers but also half layers of product. In order to do this, the head had to be designed so that only the suction cups in contact with a tray apply a vacuum. This was achieved by locating a tiny valve beneath each suction cup and calibrating the valves to stay open if the suction cup is blocked.” The ability to pick up part layers means that whatever the length of the production run, the precise number of trays will be placed into the basket. This design also enables the system to deal with variations in tray sizes and shapes. “There might be 42 rectangular trays on a layer one run and 100 round pots the next. This head can cope with any configuration that is thrown at it,” says Gladwin. The wet environment in which the system would be operating added to the complexity of the project. “This made component sourcing challenging, as everything had to be food grade stainless steel for full washdown, and all the electrics had to be sealed to IP67,” says Gladwin. “It also influenced the type of vacuum system used; we couldn’t have specified an electric pump, as it would have broken down as a result of water getting sucked into it. Instead, the vacuum is generated by compressed air.” The entire cell is controlled by two HMIs with colour touchscreens, making it very userfriendly – operators simply have to select the ‘recipe’ or layer configuration they require. In the event of new pot sizes or shapes being introduced, new recipes can easily be created. www.pacepacker.com

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BUYERS GUIDE Aero Mechanical Conveyors

Conveyors & Elevators

Mixers & Blenders

“Often copied NEVER matched�

Suppliers of the Original EnteconŽ Aero Mechanical Conveyors Other Products: • Sack Openers • FIBC Fill / Discharge Tip or Automatic • Pneumatic Conveyors

Sales office for UK & ROI: SGH Equipment - EnteconÂŽ Agent

Tel / Fax: 01270 651611

E: sales@sghequipment.co.uk • www.sghequipment.co.uk

Bulk Storage & Handling

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Bulk handling with complete confidence Designers and UK manufacturers of:

Dynamic Air Ltd. Milton Keynes, England

+44 (0) 1908 622344 www.dynamicair.com

• Bucket elevators • Chain & flight conveyors • Screw conveyors & bin dischargers • Belt conveyors

www.perryengineering.com Tel: 01404 891400 Fax: 01404 891402

Redbrook, Barnsley S75 1HR Tel: 01226 730037 Fax: 01226 730066 Email: info@eb-equipment.com Web: www.eb-equipment.com

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Feeders Powder Handling Specialists

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Tray, Tubular, Screening & Cooling Hygienic - no moving parts Efficient electrical or pneumatic Feed Rate varied/controlled easily Easy cleaning quick release or hinged lids

Tel: 01608 662878 Web: www.processlink.co.uk

Screening for removal of product lumps

Remote Silo Monitoring

FIBC Big Bag Filling Powder Handling Specialists

FIBC/Big Bag Filling

Dust Tight

*Controlled Feed System *Filling by Weight *Auto loop release *Dust Tight Inflatable Seal *Compaction for improved fill *Adjustable frame for various bag sizes

Web: www.processlink.co.uk Tel: 01608 662878

50

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Rotech Systems

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Posi-flate Milton Keynes England +44 (0) 1908 622366

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www.posiflate.com

Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions

www.InterBulkGroup.com

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Bulk Solids Today

51


BULKEX 2

0

1

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THE UK’S MATERIALS HANDLING EXHIBITION AND CONFERENCE

HARROGATE INTERNATIONAL CENTRE 5-6 OCTOBER 2016

COME AND EXHIBIT Showcase your products and services to key decision makers across the bulk materials handling industry. New for 2016 is Speaker’s Corner, bringing the programme of high profile speakers and presentations into the heart of the exhibition hall. Those wishing to make an extra impact can take advantage of a range of sponsorship opportunities to suit all budgets.

REGISTER NOW Tickets for BULKEX16 are free. Register to attend at: www.mhea.co.uk/bulkex-2016/attend-bulkex-2016/

To exhibit at the event, find out more about sponsorship or to register for your free ticket, contact the BULKEX events team. 01787 226995 www.mhea.co.uk/bulkex-16/

BST August 2016