Bulk Solids Today August Issue

BULK MATERIALS HANDLING • POWDERHANDLING HANDLING••CONVEYING QUARRYING •• PPMA RECYCLING & WASTE MANAGEMENT BULK MATERIALS PREVIEW

FEBRUARY AUGUST 2021 2017

see page 10 HIGHLIGHTS:

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Workforce Technology

Packaging Hub Live

Keeps Lift Truck Drivers

Drives Business Growth

UK Launch At PPMA

On Track For Heavy

For Brewster Bros

2021

Metal Handling

BigChange Mobile

IMA Flexible

Hyster Telematics

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

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 150

BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley

CONTENTS

BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk

advertising@bulksolidstoday.co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk 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.

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NEWS

10

ON THE COVER

12

PPMA SHOW PREVIEW

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BULK MATERIALS HANDLING

24 CONVEYING

ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2017

www.bulksolidstoday.co.uk Bulk Solids Today

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COMPANY NEWS

CLEGG FOOD PROJECTS DELIVERS ‘COOLEST’ PROJECT YET FOR GREGGS A brandnew automated cold store has been built by food and drink construction expert Clegg Food Projects for the UK’s leading bakery food on the go chain Greggs.

Located between two existing manufacturing units at Greggs’ Balliol Business Park in Newcastle Upon Tyne, the new automated high bay frozen cold store is 32m high and will be used for the bulk storage of frozen products ready for distribution to Greggs stores across the UK, supporting the firm’s growth plans.

Clegg Food Projects was appointed as the principal contactor for project, marking the 20th large scale CAPEX scheme completed for Greggs, with a cumulative value of almost £100 million.

John Moxon, business development director at Clegg Food Projects, said: “We have a great relationship with Greggs and really enjoy working with the team, so we’re delighted to have delivered another successful project.

“Following coordination meetings with the Greggs team and their specialist mechanical systems suppliers and logistics consultants, works started on site in October 2019. The construction sequence was continually updated and modified as details were confirmed, with extensive groundworks and 4

Bulk Solids Today

piling installations carried out to cope with the high structure as well as the volume and weight of the products being stored in the building.

“Access routes alongside installation and commissioning plans were also jointly agreed and equipment was installed during the main construction works to meet the overall project timescales and ensure the project ran smoothly.”

The new cold store is a fully ‘lights out process’ facility and will free up space on site as well as enabling efficient and faster delivery of finished goods to be baked in store.

The facility also includes six new loading docks, nine levels of automation, and reduced oxygen fire suppression.

Senior project manager at Greggs, Peter Boughton, said: “We are very pleased with the cold store as it enables us to free up space in the existing facility and improve the distribution efficiency to our stores. Designed

with sustainability in mind, this project highlights our commitment to Net Zero Greggs with carbon efficiency considered at every stage of the construction process.

“A first for Greggs, the automated warehouse demonstrates our commitment to innovation and investment in our sites and the business. The Clegg team brings a wealth of knowledge as well as an understanding of our business and our priorities when it comes to the delivery of projects.”

Clegg Food Projects is a national designer and constructor of food manufacturing and distribution facilities with more than 40 years’ experience in the sector. Part of Clegg Group, the firm has worked for a number of household brands, both in the UK and abroad, across a wide range of sectors including bakery, beverages, dairy, fresh and frozen produce and many more.

For further information visit www.cleggfoodprojects.co.uk or follow @CleggFoodP on Twitter.

COMPANY NEWS

PEEL PORTS NOMINATED AS PORT OPERATOR OF THE YEAR Peel Ports has made the shortlist for Port Operator of the Year at the prestigious 2021 Multimodal Awards for the logistics industry.

As the country’s second largest port group, Peel Ports manages several key regional trading hubs for the UK economy, including major facilities in Liverpool, London Medway and Glasgow.

The nomination for the award comes on the back of a decade of strong financial performance and investment, which has seen EBITDA double over the last 10 years, by £131m (FY11) to £275m (FY21), and £750m+ invested on infrastructure over the past five years, contributing to significant employment, regeneration, and regional growth.

Mark Whitworth, CEO at Peel Ports said: “Our company has transformed since 2011 and we believe the long-term approach we have taken with the business is a significant factor in being recognised as one of the UK’s top operators. The investment we have made into our ports and our wider logistics business continues to improve services for customers, create jobs and support the wider economy.

“Despite the challenges of Brexit and the pandemic, our team has risen to every challenge and continued to provide first class services to the supply chain. That gives us a lot of confidence that we are on the right track and I’m certain that even more successful times are ahead of us.”

The 2021 Multimodal Awards recognises excellence in air, road, rail, maritime, and freight forwarding services, with categories voted for by readers of the Multimodal newsletter and exhibitors & visitors to Multimodal.

The awards ceremony will be held at the NEC in Birmingham on Tuesday 19th October 2021, with more than 650 guests from across the sector expected to attend.

Peel Ports Group is the UK’s second largest port group, owning and operating six of the UK’s

most important ports (Liverpool, Headquartered in Liverpool, it Heysham, Manchester Ship Canal, employs around 1,600 staff, Medway (Sheerness / Chatham), and had revenue of £760m and Clydeport and Great Yarmouth). It EBITDA of £275m for the year also operates a container terminal ended 31 March 2021. in Dublin and owns BG Freight Line, which provides short sea YOUR SIEVING & SCREENING PROCESS container services between the UK, Ireland and mainland Europe and feeder WITH SIEVMASTER BY FARLEYGREENE. services between the UK and Ireland. Peel Ports Group also owns Peel Ports Logistics (formerly Quality Freight UK), which provides chartering and port services from a 40 acre multi modal facility at Ellesmere Port in Cheshire.

REDEFINED

Peel Ports handles 70 million tonnes of cargo every year. 14% of the total UK major ports traffic flows through ports operated by the Group.

Sieves, screens, sifters. +44 (0) 1256 474 547 www.farleygreene.com enquiries@farleygreene.com

Bulk Solids Today

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COMPANY NEWS

NORILSK NICKEL BUYS FIVE NEW BOBCAT ROTARY TELEHANDLERS The new TR50.210 rotary telehandlers are the first in Russia MMC Norilsk Nickel, one of the leaders in the Russian mining industry, has purchased five new Bobcat TR50.210 rotary telehandlers and related attachments from the Bobcat Authorised Dealer in Russia, NAK Machinery. These are first of the new range of Bobcat rotary telehandlers to be purchased in Russia and the biggest order since their launch in December last year.

A NEW SOLUTION BORN OUT OF A STRONG ONGOING RELATIONSHIP In 2021, MMC Norilsk Nickel finished the reconstruction of its warehouse complex in Norilsk, a city in Krasnoyarsk Krai, located above the Arctic Circle. This project was part of a long-term modernization of the Unified Warehouse Facility (UWF) run by the company. This facility supplies material and technical resources to all the production departments of the Polar Division, subsidiaries and third-party organizations of the Norilsk Industrial District.

One of the main elements of the modernization was the renovation of the equipment fleet, including the telehandlers. New machines were needed to improve the speed and quality of cargo handling. Given the extreme climatic conditions in the region beyond the Arctic Circle, the company needed reliable special equipment capable of working in any situation, even when the average winter temperature is around −30 °C. Specialists at MMC Norilsk Nickel have been working with Bobcat products for a long time and have first-hand experience with the durability of these machines.

This fact together with the long-term relationship with Krasnogorskbased NAK Machinery, the largest Authorised Bobcat Dealer in Russia, predetermined the choice of the Bobcat new TR50.210 model. These rotary telehandlers, launched in December 2020, are unique in 6

Bulk Solids Today

the Russian market. MMC Norilsk Nickel also purchased a range of attachments for the new machines, including light material buckets, pallet forks and a crane jib.

“The delivery of the new Bobcat TR50.210 machines is a first for our company in rotary telehandlers, but we are confident that the customer will appreciate this new line, and we will receive new orders for such equipment in the future,” said Andrey Gerasimov, Bobcat Brand Manager at NAK Machinery.

GROWING MARKET FOR ROTARY TELEHANDLERS Evgeny Supletsov, Country Manager for Russia & CIS for Bobcat said: “In the EMEA region, the concept of rotary telehandlers is gaining popularity and in the last five years showed strong growth from 1035 units in 2015 to 1809 units in 2020. In fact, about 85% of all global sales of these machines came from EMEA, and that is why Bobcat has brought new models of this class to the market.

COMPANY NEWS “We are delighted that our long-time partner MMC Norilsk Nickel became one of the first customers for these new machines.

This demonstrates a high level of confidence in Bobcat’s special equipment, and we are sure that the quality of our machines will meet the harsh conditions in which they will have to work.”

CHALLENGING LOGISTICS THROUGH NORTHERN SEA ROUTE Thanks to the close cooperation between Norilsk Nickel and NAK Machinery, the companies were able to successfully coordinate the complicated process of delivering the new equipment. Norilsk is not connected to the mainland by roads, so the machines could only be delivered by the Northern Sea Route.

In the first part of the journey, the telehandlers were transported by trailers to the seaport of Murmansk, and then went by sea to the port of Dudinka, from where they finally reached their destination on trailers again. In spite of such a difficult and long route, the delivery went according to plan and without any delays.

A NEW MULTIFUNCTIONAL RECRUIT Bobcat rotary telehandlers have a number of features that make them versatile and suitable for a variety of industries and applications. The possibility to rotate the platform through 360° allows the operator to move a load anywhere within the reach of the boom without having to change the machine’s position. This is ideal in densely built-up cities or in warehouses, where manoeuvring space is limited. Versatility is also offered by the wide range of Bobcat attachments for the rotary telehandlers, which allow the customer to optimize machines for different tasks.

The Bobcat TR50.210 is the middle model in the new range of rotary telehandlers, designed specifically for the Russian and CIS markets, but also for use in Europe, the Middle East and Africa. The lift capacity of the TR50.210 is 5 tonne and it can lift loads up to a height of 21 m.

FEATURES OF THE MACHINE Like all the new rotary telehandlers, the Bobcat TR50.210 is highly automated, which simplifies the work of the operator, as well as enhancing the reliability of the machine and increasing safety on site. For example, the 134 HP engine can automatically adjust its speed depending on the load, and the rear axle is equipped with automatic hydraulic locking.

The cab is also fitted with a wide range of features designed to increase comfort and therefore productivity.

For example, its patented design includes an overpressure and fulldiagram helps the operator to keep flow air filtration system, as well as track of the load’s centre of gravity. air conditioning, which allows the For more information about operator to work in difficult weather Bobcat and its products, visit www. and environmental conditions. The bobcat.com. machine’s fully glazed cab is offset to the side, giving the operator superior visibility.

At the same time, a large touchscreen display, intuitive controls, certified ROPS/FOPS Unlike other valves that seal protection systems, with friction, Posi-flate’s unique an adjustable butterfly valve uses an steering inflatable seat column and a to seal with air comfortable, fully pressure. Thus it adjustable seat requires less torque make operating and a smaller actuator, the machine easy resulting in lower cost. and safe.

Plus, the seat automatically Thanks to compensates for wear, providing RFID technology, longer life. Some users have the loader reported over six million automatically cycles and the valves are recognizes still going strong. attachments while loading and displaying a • Less friction chart of the load • Low torque characteristics.

• Low maintenance This allows • Lower actuator costs the machine • Longer valve life to be ready to • More reliable work almost immediately, and Tel: +44 (0) 1908 622366 the displayed www.posiflate.com

Other Valves Fight Friction, We Designed it Out

Bulk Solids Today

7

COMPANY NEWS

BIGCHANGE MOBILE WORKFORCE TECHNOLOGY DRIVES BUSINESS GROWTH FOR BREWSTER BROS Recycled aggregates and waste management specialist Brewster Bros. has doubled its business with the help of the latest mobile workforce management technology from BigChange. The cloudbased system has completely automated the sales process, from initial enquiries through to order fulfilment and invoicing, as part of a move to paperless working. Providing an endto-end solution, BigChange is also reducing the back-office administration required to manage the mobile operation and is improving customer service with an online booking and tracking portal.

“We initially introduced BigChange’s JourneyWatch product when we took over the company a few years back to monitor driver behaviour and track our vehicles,” commented Scott Brewster, Managing Director of Livingston-based Brewster Bros. “We just needed to know who was doing what, where and when! However, after six months we realised the full jobbing system has so much more to offer. BigChange is now fundamental to our business and has helped us grow the operation by around 100 per cent from 2018 to 2020.”

A resource management company for the construction industry, Brewster Bros operates across the central belt of Scotland. Offering environmentally compliant waste disposal as well as supplying quality recycled aggregate products, Brewster Bros. can transport up to 500,000 tonnes of waste and product per year in its fleet of HGV tippers.

“Heavy bulk haulage is quite different from other types of haulage as it is local, high frequency work and our drivers have to return to base and/ or visit the same customer site multiple times per day,” continued Brewster. “Prior to BigChange we were heavily reliant on large volumes of paperwork which could be incorrect, incomplete or even go 8

Bulk Solids Today

missing, and therefore consumed a significant amount of back-office resource to support.

“Using BigChange, we have complete visibility of the whole transport function of the business.

We know where our vehicles are, how they are being driven and even when they tip! We capture this data, including complete proof of delivery and waste transfer note evidence, to improve our customer service offering, ensure regulatory compliance and expediate our accounting, which is improving cashflow and in turn fuelling continued business growth.”

Providing a single platform CRM, Job Scheduling, Vehicle Tracking and Mobile Workforce App, the BigChange solution is further supporting Brewster Bros as the business continues to expand. It is hoped the recently introduced BigChange powered portal will help customers to self-serve, booking and tracking collections and deliveries online, and automating waste transfer and delivery notes and invoices. www.bigchange.com

Global sieving & filtration specialists

COMPANY NEWS

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Customized solutions - Applying innovation to meet your requirements Comprehensive customer service - Technical support & global stocking Specialized testing facilities - Trial your products for total peace of mind Call us on: +44 (0) 20 8818 2000

Email: sales@russellfinex.com Bulk Solids Today

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BULK MATERIALS HANDLING

DYNAMIC AIR OFFERS 16 DIFFERENT PNEUMATIC CONVEYING CONCEPTS • Four different vacuum conveying systems • Twelve different pressure conveying systems.

Each system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is extremely critical to match the system operating characteristics to the material to be conveyed in order to achieve the most desired conveying performance and to provide the best value to you, the customer.

Dynamic Air’s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. Dynamic Air can convey many materials with conveying velocities as low as 50 feet per minute (0.25 m/sec) using the HDP 6000 dense phase pneumatic conveying system and, using the LDP 2000 dilute phase pneumatic conveying system, Dynamic Air can convey at velocities well over 7000 feet per minute (35 m/sec).

Plus Dynamic Air’s conveying capacities range from just a few hundred pounds (100 kg) of material per hour up to 400 tons per hour and conveying distances exceeding 5000 feet (1500 m) in length.

In addition, Dynamic Air’s pneumatic conveying systems become highly efficient when they employ the unique patented DC5™ Air Saver technology and are unmatched for performance and reliability. These systems can handle even the most difficult of materials, plus they significantly reduce the energy requirements and convey material at much lower conveying line velocity with higher conveying line densities and reduced dynamic loading.

When Dynamic Air’s DC-5 Air Saver technology is employed on lower pressure systems using less than 15 PSIG (1 barg), in many applications the conveying line velocity can be lowered well below the normal saltation velocity. Depending on the material being conveyed, energy requirements can be reduced and system performance and reliability drastically improved.

The Result: Gentle handling of heavy abrasive and nonabrasive materials that cannot tolerate degradation. For many fragile crystalline and granular materials there is no finer material handling process. Dynamic Air’s 16 different pneumatic conveying concepts can offer a 10

Bulk Solids Today

more gentle treatment of system components as well.

Because of lower velocities, system wear and related breakdowns are minimized.

Dynamic Air Pneumatic Conveying Systems Are: • Energy and labor efficient • More reliable, because of our DC-5 Air Saver technology • Flexible to design in tight plant environments • Easy to install with minimum disruption to existing plant production • Clean - because the system totally contains the material conveyed • Friendly to the environment • Equipped with fewer moving parts • Lower in initial investment costs • Lower in maintenance https://www.dynamicair.com/systems.html www.dynamicair.com

RADAR IS THE BETTER

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£405 VEGAPULS C 11

All advantages of the radar technology:

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PPMA SHOW PREVIEW

IMA FLEXIBLE PACKAGING HUB LIVE UK LAUNCH AT PPMA ’21 The all-inclusive end-to-end packaging line and eco-materials test lab enterprise UK food, pharma, wet wipes and pet markets manufacturers seeking end-to-end fully optimised packaging lines designed to run the latest array of eco-materials are invited to join IMA Ilapak for the UK live launch of the IMA FLEXIBLE PACKAGING HUB, taking place on IMA stand D10 at PPMA ’21.

Also known as IMA FLX HUB, the new all-inclusive packaging enterprise is where the finest global materials specialists, customer manufacturing processes and technology designers converge to develop sustainable end-to-end systems to meet today’s manufacturing needs. To create this millionpound hub with worldwide reach, IMA strategically acquired six specialist international horizontal, vertical and end of line packaging OEMs with international manufacturing sites: IMA Ilapak (Switzerland, Italy, Germany, China), IMA Delta Systems (USA), IMA Record (Italy), IMA Tecmar (Argentina), IMA Eurosicma (Italy) and IMA Ciemme (Italy).

Central to project success is IMA’s state-of-the-art, proof of concept materials facility and manufacturing process intelligence centre, OpenLab. Here, IMA FLX HUB projects will benefit from an all-inclusive packaging chain approach, with expert material scientists and equipment technologists working with the latest eco-films to deliver optimised line solutions.

IMA FLX Managing Director Klaus Peters comments on the enterprise: “Everything needed to process all types of flexible packaging for the food, pharma, wet wipes and pet markets is now available. Accommodating emerging materials, including 12

Bulk Solids Today

those with unique sustainable properties, is central to how we design and engineer packaging lines. But without a closely managed co-ordinated approach, lines combining multiple suppliers can become disjointed, leading to vast inefficiencies and waste.

We have united some of the most brilliant engineering and film scientist mindsets to give our customers a broad scope of resilient packaging equipment solutions.”

Collectively, the six businesses hold 250 years’ engineering expertise in both food and non-food sectors and offer the full array of packaging systems, including: weighing, counting, feeding, dosing, loading, bagging, flow wrapping, cartoning and end of line systems. Converging production of all technologies under one roof and driven by IMA’s quest for excellence, sustainability and innovation in engineering and films, the IMA FLEXIBLE PACKAGING HUB offers UK manufacturers a single source flexible packaging equipment chain.

Completing the all-inclusive packaging chain is IMA’s OpenLab – a scientific film and engineering development facility capable of testing and analysing 1,000+ films every year. Tony McDonald, IMA Ilapak UK Sales & Marketing Director, comments: “Running new films and designing cutting-edge equipment is a chicken and egg scenario – which comes first for

the best outcome? The answer is to combine machinery, material manufacturer and customer knowledge from the outset to perfect application performance throughout the line – this is what OpenLab will deliver, no matter how customer and retailer requests for biodegradable, performance-enhanced or ultrathin films evolve. IMA Ilapak customers can expect streamlined processes, the most resilient packaging lines and sustainable payback as a result of being supported by FLX HUB.” IMA FLX HUB is ideal for specifying vertical or horizontal systems and full lines, including those for modified atmosphere applications (MAP) and vacuum, as well as machines for fourside seal, multi-lane and sticks, fold pack, sandwiching and fully automated Doy pouch production. With best practice shared and IMA’s sustainable business methodology applied, customers can expect singlesource advantages and continual digital tech investments backed

by IMA, along with the personal touch from the six businesses.

Show visitors with packaging projects, those seeking assistance with materials or application trouble shooting will find FLX HUB experts on IMA stand D10 at the PPMA 2021 show, 28-30th September, NEC.

PPMA SHOW PREVIEW

NEW UNIPAKER ACTIONS ENERGY & READY MEAL WASTE Stand K80 At PPMA 2021, Brillopak will showcase its newest award-winning and affordable UniPAKer robotic crate packing platform, launching its most compact and energyefficient system to-date.

By lowering compressed air consumption in the generation of vacuum by up to 45%, the overall carbon footprint of the system is significantly reduced. The single dual head crate packing cell simultaneously reduces supply chain waste by minimising damage to protective ready meal films.

Taking the lead to reduce automation carbon emissions and meet the UK’s new 2050 Net Zero targets, Brillopak has re-engineered the UniPAKer’s compressed air pressure system and endeffector vacuum generators.

Creating sustainable value across the entire packing cycle, by adopting this ‘whole system air flow approach’ and improved control and distribution of air, Brillopak reports a 10% reduction in power usage compared to previous models in the series.

Central to this upgrade, which features on all new UniPAKer systems and can be retrofitted onto existing UniPAKer cells, is the introduction of vacuum generators into the end-effector head. Rather than sitting external to the end-effector, air is drawn into the centre of the head and fed to each of the five generators, all of which are contained within a special internal casing.

Delivering more consistent, targeted and faster airflow.

The small footprint single robot system is highly efficient at picking up and moving up to 70 chilled and ready meal products

per minute. For example two selection dips or two family-sized convenience meals. With the new dual-head patent pending end-effector design guaranteeing consistent lifting capacity when suctioning up and gently placing meals of various weight, size and packaging type into retail crates.

“This gentle handling is especially imperative when handling thin films, pillow bags, resealable packs and newer more sustainable packaging substrates,” emphasises David Jahn, Director at Brillopak.

Taking action against the nine million tonnes of food wasted annually in the UK – which alone accounts for 25 million tonnes of carbon emissions (the equivalent of ten million cars) – the next-generation UniPAKer also helps to address one of the biggest avoidable waste hotspots in ready meal production and distribution. Split top seal packaging and torn film lids.

“Spillages are one of the key

causes of ready meal waste. On high speed side or drop loading automated production lines, one broken seal on a ready meal has the potential to tip and cross contaminate an entire tray,” notes David.

With a ten percent smaller footprint than earlier UniPAKer generations, one cell can handle multiple product types and place into crates in multiple patterns.

Striking the optimum balance of fast acceleration and gentle pick and placement, the new UniPAKer is especially beneficial for crate loading perishable products which are more prone to leaks and damage, including meat, fish, ready meals and fresh produce. At PPMA 2021, Brillopak will showcase the single dual-arm delta robot picking up and placing ready meals into retail crates. Depending on applications, a single UniPAKer cell can be configured to incorporate up to three robot configurations working in unison.

Bulk Solids Today

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PPMA SHOW PREVIEW

HOLMACH LTD TO LAUNCH NEW MACHINERY AT THE FORTHCOMING PPMA SHOW Process solutions provider, Holmach Ltd are looking forward to debuting Lyco’s market leading machinery on stand C30 at the forthcoming PPMA show in September 2021.

Lyco Manufacturing’s simulator for cooking and cooling of pasta, beans, rice, noodles and vegetables will be making its debut at the event and will be demonstrated alongside the PerfithermTM quick batch preparation system from Perfinox; Atlantic Engineering’s patented Inofill; Roboqbo’s low volume/NPD cooker and Mengibar’s 16 head rotary mass flowmeter filler.

Shown for the first time in Europe, Lyco Manufacturing’s simulator is able to replicate the processes on Lyco’s continuous production systems which are already a big hit for cookquench-chill operations in the UK. The simulator will be demonstrating the handling of hot filled pouches for rapid cooling, showcasing why the Lyco unit is the most efficient and quickest pouch cooler on the market.

The Holmach stand will be a hub of activity and demonstrations with process machinery from four other globally recognised manufacturers.

- Perfitherm™, is the new quick-batch preparation system from Perfinox of Porto, for the production of fresh Mayonnaise, sauces and soups as well as pharmaceutical and cosmetic creams and emulsions.

Perfinox founded in 1998, specialises in the production of continuous and batch cooking and cooling systems. The Perfitherm™ scraped surface heat exchanger focusses on delicate handling with good mixing without shear, unless required. Soft particulates up to 25mm can also be handled as well as abrasive materials containing sugar, grit or other compounds. With low back pressure and a large surface area for heating and cooling, one machine can replace multiple units, minimising maintenance down time and cost for seal changes.

Capacities from 30 – 12,000 kgs/hr.

- Atlantic Engineering’s innovative inline filling concept demonstrates fast changeovers.

The patented Innofill large pouch filling system for foodservice pouches, eliminates the need for manual handling.

- The low volume/NPD cooker with vacuum cooking and cooling option, from Roboqbo of Bologna has been designed for the production of confectionery and dessert products as well as hummus, tapenades and pesto sauces.

- Completing the line-up is a 16 head rotary mass flowmeter filler from Antonio Mengibar of 14

Bulk Solids Today

Barcelona. Suitable for household, chemical and personal care products, the flowmeter filler operates at speeds up to 250 containers per minute.

Mengibar’s patented predictive filling software will demonstrate how manufacturers can save product and reduce wastage during the filling process. The artificial intelligence is able to adjust the dose on every fill to achieve very tight filling accuracies, greater than 0.2%. The patented low Reynolds nozzles eliminate the need and complexity for bottom-up filling even on the most foaming of products - without bottle lifting cams and weigh scales the machine is easy to maintain.

For more detailed information on any of these innovations, please contact Holmach on 01780 749097.

For more information on this press release, please call Annalie Hempstead on 07825 429478 or email annalie@holmach.co.uk

PPMA SHOW PREVIEW

OMRON HALVES COST TO COBOT PALLETISE SOLVING CURRENT WORKFORCE CHALLENGES Stand B34, PPMA Show 2021, 2830 September, NEC, Birmingham Responding to manufacturers’ end-of-line labour challenges including staff shortages, social distancing measures and self-isolation, OMRON UK will debut its game changing cobot palletiser, the RB1200, at PPMA Show 2021. Thanks to OMRON’s renowned iAutomation proprietary technology, the cobot system boasts a 50% cost saving, rapid delivery within weeks and plug-and-play system architecture to help businesses of all budgets and sizes immediately de-risk their line against today’s unprecedented labour challenges.

The introduction of the RB1200 could not be timelier. Companies are navigating social distancing guidelines amid high vacancy rates compounded

by Brexit and the long-term skills shortage, putting pressure on existing staff and affecting productivity – October 2020-April 2021 saw the lowest level of employment in the manufacturing sector since 1996. Adding to manufacturers’ anxiety is the risk of production being halted entirely due to an on-site Covid outbreak or high numbers of staff self-isolating; events which are outside of their control.

The RB1200 was developed in partnership with OMRON’s automation partner Reeco. Together, the two companies have designed a cobot palletiser that makes manufacturers resilient to the detrimental effects of both labour shortages and the possibility of immediate workforce interruptions. Using OMRON’s 3i concept of intelligent, integrated and interactive engineering methods has dramatically shortened system design and delivery time resulting in a 50% cost reduction compared to same spec cobot palletisers.

A modular, plug-and-play solution, the RB1200 has a maximum payload of 10kg and a cycle time of 12 picks per minute. It requires no system integration and boasts a 60% smaller footprint than conventional robot palletisers. Tts inherent flexibility also means it can easily switch between lines and handle rapid changes in demand, maximising users’ investment.

In addition to its automated palletising solution, OMRON will also showcase the Quattro; the world’s fastest and most flexible Delta pick-and-place robot.

With a pick rate of 300 per minute and the only Delta robot to be USDA-certified, the Quattro’s fourth arm allows it to reach up to 30% further than traditional designs, facilitating a larger operational area. The powerful combination of speed, manipulation, reach and a 15kg payload make it ideal for any general packaging application.

For a full demonstration of the RB1200 cobot palletiser or the Quattro pick-and-place robot, visit stand B34 at PPMA Show 2021.

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

The result is a more consistent material.

Dynamic Air Ltd. • +44 (0)1908 622344

www.dynamicair.com Bulk Solids Today

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PPMA SHOW PREVIEW

FULL PANDEMIC-RECOVERY INSPECTION SERIES LAUNCHES AT PPMA 2021 Stand B01 Made in the UK and designed for every food application and factory configuration to offset inflation, food price hikes and reduce waste and giveaway, Fortress Technology debuts its new zero-contaminant pandemicrecovery Raptor series at PPMA 2021.

Including an X-Ray first.

Comprising all THREE food inspection disciplines – metal detectors, checkweighers and x-ray - plus any combination category, the Raptor series uniquely features EVERY British retailer COP digitally pre-programmed into every inspection machine before installation.

Custom built in the company’s state-of-the-art manufacturing centre in Banbury, the affordable end-to-end Raptor series is Fortress Technology’s most high-spec economic inspection range for washdown environments.

Responding to the wide-range of pandemic-recovery challenges, the Raptor series has been engineered to counteract wasteful and costly product giveaway. Particularly staples such as grains, sugar, soybeans, corn, farmgate produce and spices.

Having topped a six year price high, these ingredient commodities, along with others, are impacting pricing strategies and profits for bakers, confectioners, producers of chilled meals, condiments, healthy eating and wellbeing products.

One OEM … endless food safety possibilities Few companies manufacture and service all three inspection equipment technologies. Let alone deploy a single software package on integrated lines and make every system sustainably compatible.

Being a single OEM for every inspection need, Fortress is paving the way to greater production integration and data-driven capabilities. European managing director Phil Brown explains: “Providing truly integrated software, a single HMI, data capture, and automatic testing addresses rising demand from customers seeking heightened food safety solutions and zero tolerance for all food contaminants.”

To help preserve capital, offset food price hikes and emerge stronger from Brexit and the pandemic, Fortress Technology’s Raptor Checkweigher and Raptor Combination systems deliver 100% reliable weight control.

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Bulk Solids Today

Phil explains: “While giveaway is a long accepted practice to guarantee compliance with weight regulations, even nominal overfilling escalates rapidly to lost profits.”

The standard Raptor Checkweigher can weigh lightweight product packs, up to a maximum of 8 kilograms. An XL version is available for bulk applications. Operating as a standalone product feed and packing weighing unit, the Raptor Checkweigher’s modular electronics suite allows for full integration with a Fortress metal detector or x-ray machine to create a high-precision combination system when investment budgets allow. “The food safety innovation possibilities are now limitless,” exclaims Phil.

The Raptor’s debut at PPMA (Stand B01) features four different conveyor configurations, including a compact Combination Metal Detector and Checkweigher and the Fortress X-Ray first. Making this PPMA showcase a must see exhibit for food factories resetting productivity and profit margin targets.

PPMA SHOW PREVIEW

AVE TO SHOWCASE UNMISSABLE MOZZARELLA LINE AND ONE-STEP BEER FILTRATION SYSTEM

Stand B40, PPMA Show 2021, 2830 September, NEC, Birmingham AVE UK will showcase TWO innovative solutions for the food & beverage sector at PPMA Show 2021 with the launch of their OMNIA B cross flow filtration system for brewers PLUS an unmissable mozzarella ball processing line for processing and dairy visitors.

Designed to recreate the high-spec taste, presentation and texture of traditional Italian mozzarella within a modern UK setting, the mozzarella line comprises six individual systems including an automatic coagulation vat, drainage trolley, whey recovery system, cradle coagulation vat, ricotta trolleys and salting cheese vats. This will be the ONLY opportunity to see the line in its entirety before it is delivered to London-based Italian mozzarella manufacturers, Fratelli Amodio, straight after the show.

“Innovation doesn’t have to mean creating a new technique – for this project, it was essential that our solution respects and reproduces the traditional methods of mozzarella making to replicate the true flavours of Italy right here in the UK, while also incorporating the safety, efficiency and reliability requested by today’s market. It’s about cutting cost and waste, not taste and quality,” says Steve Bradley, AVE UK’s Sales Director.

Also on display will be AVE’s revolutionary OMNIA B cross flow filtration system which delivers beer clarification, product recovery and microbiological stability in one single solution. Incorporating ceramic membrane technology with a five-year guarantee, this compact automated filter enables beer producers of all sizes to increase their yield by maximising product recovery from lees, as well as significantly limiting the Biological Oxygen Demand (BOD) of brewery effluent.

Steve adds: “As part of the Della Toffola Group, AVE combines 60 years’ experience in the dairy & brewing sectors with the latest smart technology to deliver ultra-hygienic, cutting-edge processing solutions to food & beverage businesses of all sizes.

We look forward to showcasing our unique solutions to visitors to our stand.”

Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost.

Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong.

• • • • • •

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

www.posiflate.com

Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort.

Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof

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

Bulk Solids Today

17

BULK MATERIALS HANDLING

HYSTER® TELEMATICS KEEPS LIFT TRUCK DRIVERS ON TRACK FOR HEAVY METAL HANDLING Hyster has provided a new fleet of forklift trucks and ReachStackers featuring the Hyster Tracker wireless asset management system to support tough metal handling operations at the Port of Oxelösund in Sweden.

The Port of Oxelösund specialises in receiving big vessels and has a dedicated steel port. Here, metals, mostly coils, arrive at the port by trains, which are unloaded with a crane. Then, forklifts carry the goods to the port cranes, which load coils onto the ships.

When the port was recently looking to update its fleet, local Hyster® distribution partner in Sweden, Nordisk Truck-Trans and Hyster worked with the customer to create a total application-specific solution, including the Hyster Tracker telematics system.

“The beauty of Hyster Tracker is that it has a wide range of functions for effective fleet management,” says Dmitry Dubrovsky, Big Truck Manager for Hyster Europe. “This enables applications to utilise the features that are relevant to their specific operation, so they can see the

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Bulk Solids Today

bigger picture, gain insights, and reduce costs.”

For instance, at the Port of Oxelösund Hyster Tracker is fitted to Hyster® H32XM-12 and H20XM-9 lift trucks, with 32 and 20-tonne capacities, as well as Hyster® RS46-36CH ReachStackers to limit drivers, so only those who are correctly authorised can drive a truck during working hours. Drivers present a card to a reader by the steering wheel and the system then

BULK MATERIALS HANDLING

confirms whether the driver has the right license to operate the particular truck. This gives the busy metal handling application increased security.

“With Hyster Tracker, operators at the Port of Oxelösund also have a daily pre-use check to complete that appears via an in-cab display,” says Erik Progrebnjak, sales representative for the local Hyster® distribution partner, Nordisk Truck-Trans AB. “This check-up must be done before the truck is used and then at intervals after the vehicle has started.”

The Port can also see how the vehicles move on a map. This allows the operation to analyse potentially difficult traffic situations and see how the trucks are being driven.

“Increased productivity starts by knowing what your trucks are doing,” says Dmitry Dubrovksy. “With truck utilisation analysis, Hyster Tracker helps enhance fleet management and workforce productivity. It provides data-driven insights to help applications fine-tune the fleet size and composition to keep operations running efficiently.”

Hyster Tracker, which can be accessed on a Desktop portal or via a free app, also provides diagnostics and tracking which can help address problems before they arise by monitoring equipment performance.

“Even though most drivers think they are efficient, Hyster Tracker can show the facts,” explains Erik Progrebnjak. “There are sensors that detect if an

impact occurs. It also warns if the speed limit is violated.”

Hyster Tracker telematics also helps applications to streamline maintenance scheduling, conserve energy and reduce unnecessary equipment wear. Battery and tyre pressure monitoring add-ons are available to further help manage maintenance and costs and optimise equipment performance.

For more information on fleet management solutions for metal handling applications, or to locate a local Hyster® dealer, visit www.hyster.com

IF YOU ARE INTERESTED IN SUBSCRIBING TO BST MAGAZINE, PLEASE DO GET IN TOUCH BY VISITING WWW.BULKSOLIDSTODAY.CO.UK OR EMAILING US AT BST@ABBEYPUBLISHING.CO.UK Bulk Solids Today

19

BULK MATERIALS HANDLING

DOOSAN LAUNCHES NEW DL420CVT-7 WHEEL LOADER New Model in Award-winning DL-7 Series Features Fuel-Saving CVT System As part of the company’s award-winning DL-7 series, Doosan has launched the new DL420CVT-7 Stage V compliant wheel loader equipped with a Continuously Variable Transmission (CVT). With a maximum bucket capacity of 4.5 m3, the Doosan DL420CVT-7 wheel loader is intended to meet a wide range of material-handling needs from loading and transporting granular material (such as sand or gravel) to quarrying, mining, construction, demolition, industrial, waste and recycling applications.

A CVT transmission is the result of a permanent combination of a hydraulic technology and a mechanical technology which provides a smooth and continuous speed variation. The CVT design combines the benefits of a hydraulic mechanical transmission and a hydrostatic transmission in the same machine. It allows the DL420CVT-7 to automatically transition from hydrostatic power at low speed to the mechanical system to operate at higher speeds.

By combining the two types of transmission, the CVT technology ensures high loads can be carried at low engine speeds with high dynamics for an optimum wheel loader operating cycle. The DL420CVT-7 therefore provides an increase in machine performance for operators working in digging, loading and lifting applications. For most tasks, operators will utilise the hydrostatic part of the transmission, which offers greater fuel efficiency in low-speed applications. The combination of the two transmissions is automatic and fully transparent for the operator.

UP TO 15% ADDITIONAL FUEL SAVINGS The complete driving range, forwards and in reverse, is controlled by the CVT system. Low engine speeds ensure a high efficiency and the highest driving comfort irrespective of the traction speed. The power splitting continuously variable technology facilitates moving off softly and hydraulically. Furthermore, with the CVT, a fuel saving of up to 15% can be achieved.

With an output of 240 kW (326 HP) of power at 1800 RPM, the Scania DC09 engine in the DL420CVT-7 provides generous torque at low RPM and meets Stage V emission regulations without the need for exhaust gas recirculation (EGR), through the use of selective catalyst reduction, diesel oxidation catalyst and diesel particulate filter (DPF) aftertreatment technologies. The soot cleaning cycle on the DPF has been improved to over 6000 h and the operator is fully informed about the status of the DPF via a soot level indicator on the new touchscreen display in the cab.

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Bulk Solids Today

NEW AWARD-WINNING DESIGN The new DL420CVT-7 features the same awardwinning external design common to all models in the DL-7 series, creating a three-dimensional effect with an innovative cover shape and a vibrant, dynamic image for the range. It has already received great acclaim globally, winning Germany’s 2020 iF Design Award, one of the world’s top three design awards and the ‘Best of the Best’ category in the Korean PIN UP Design Awards.

INCREASED PRODUCTIVITY AND VERSATILITY The Z-kinematic lift arm on the DL420CVT-7 delivers high breakout forces and lifting capacities, especially for heavy materials, and a large dump angle for efficiently unloading sticky materials. An optional high lift arm is available where higher dump heights and increased versatility are required. Doosan is also offering a wider choice of options to provide more work tools for a better match with applications, further increasing output.

Like all DL-7 wheel loaders, the DL420CVT-7 loader has smooth and responsive hydraulics and auxiliary hydraulic connections. It is equipped as standard with a 3rd spool valve with settable flow and detent function, providing a constant flow for hydraulically driven attachments. Operators can easily and comfortably control hydraulic attachments via the proportional switch on the joystick. Various bias and radial tyre options are also available from leading global manufacturers, to cover the widest possible range of conditions and applications.

In addition, the new wheel loader can be ordered with a heavier optional counterweight, depending on the application.

EXCELLENT OPERATOR VISIBILITY The new cab on the DL420CVT-7 offers a greatly improved field of vision for the operator, with blind spots around the cab minimized and a 14% larger glass window area compared to the previous DL-5 model. The DL420CVT-7 wheel loader also offers the option of electrically adjustable rear view mirrors for added safety. Full LED working lights are installed on the cab (four on both the front and rear as standard, with the option of six each at the front and rear). For higher pedestrian safety, the LED lights on the rear bonnet have an automatic strobe function to indicate when the wheel loader is reversing.

An air compressor with air blower is available as an option - fitted in the cab for easy access, this is a powerful tool that can be used to clean the cab whenever necessary.

BULK MATERIALS HANDLING NEW SPACIOUS ERGONOMIC CAB DESIGN Inside the cab, the DL420CVT-7 provides significantly enhanced operating comfort, an enhanced steering system and advanced electronic controls. Using the new Doosan Smart Key system on the control panel in the cab, the operator can start the machine using a keyless device, helping to prevent machine theft. The Smart Key system provides remote door control, door lock and unlock, door release, searching and other functions. The control panel also includes two USB sockets.

The new cab has a Grammer Actimo XXL seat with fully adjustable horizontal and vertical suspension settings, a pneumatic lumbar function and seat heating as standard. There is a 3-point safety belt with alarm icons on the new Doosan Smart Touch 8 inch touchscreen monitor and on the gauge panel, which features a new layout and anti-reflective glass.

The new EMCV (Electric Main Control Valve) joystick fully integrated in the armrest is another standard feature in the cab, providing the operator with smoother and precise controllability of the lift arm and attachments on the wheel loader. Features available via the EMCV system include Automatic Return-to-Dig, Bucket Tilt Kick-out and the Bucket crowd stop position and shock prevention for higher operator comfort.

Designed to give the operator more precise control with a shorter lever stroke, resulting in less fatigue, the sensitivity of the ergonomic joystick control can be set and altered according to operator preferences using the new Doosan Smart Touch touchscreen monitor.

User-friendly and easy to read in all conditions, the new touchscreen provides all the important settings and information the operator needs in one place.

Included in the information at the operator’s fingertips on the touchscreen is the feed from the rearview camera, the weighing system, the HVAC controls (heating, ventilation and air conditioning), Radio & Bluetooth devices (music streaming, hands-free) and the operator help function.

Overall, the redesigned interior offers a much larger, quieter and more comfortable operator environment, which improves safety and productivity and helps the operator work with high concentration.

The operator also has increased leg room, an enlarged storage area and cool-box position and an improved air conditioning system (with optimized air circulation).

HIGHER PERFORMANCE The LIS (Load Isolation System) provides a smoother ride and higher comfort for the operator, as well as higher productivity due to improved stability when the wheel loader is moving. The lift arm is cushioned by a hydro-pneumatic accumulator linked to the lift hydraulic system, acting as a shock absorber. The benefits include reduced cycle times, higher performance and better fuel efficiency while carrying out load and carry applications.

With heavy duty HDL axles as standard and

enhanced traction with Differential Hydraulic Lock (DHL), the DL420CV-7 wheel loader operates exceptionally, especially in high-load environments.

The differential hydraulic 100% lock can be engaged at full torque automatically without any action from the operator.

Optional independent oil cooler circuits for the front and rear axle ensure low oil temperatures, provide oil filtration and extend the lifetime of axle components, especially for demanding applications, such as long distance load and carry in high ambient temperature conditions.

Improvements have been made throughout the powertrain, to provide operators with best-in-class driveability and faster driving, reaching the 38 km/h maximum speed quickly and safely.

FULL 3-YEAR/5000 H WARRANTY AS STANDARD The upgraded hydraulic system and major parts ensure greatly improved durability and maintainability. Providing increased peace of mind for the customer, the high reliability and quality of the new DL420CVT-7 wheel loader is backed up by a standard full 3 year/5000 hour warranty.

DOOSANCONNECT FLEET MANAGEMENT SYSTEM AS STANDARD The DL420CVT-7 wheel loader is factoryinstalled with the latest DoosanCONNECT TMS2.0 state-of-art wireless fleet monitoring system. The DoosanCONNECT system is a tool designed specifically for the Doosan range, providing comprehensive information about machine performance in a dual mode (satellite, Mobile network).

The DoosanCONNECT system offers a web-based fleet and asset management solution which is very useful for managing the performance and security of machines and promoting preventative maintenance.

For more on Doosan construction equipment, please visit the website: www.eu.doosanequipment. com Bulk Solids Today

21

BULK MATERIALS HANDLING

MOBILE BULK BAG DISCHARGER WITH MOBILE FLEXIBLE SCREW CONVEYOR, HOPPER A new Flexicon Mobile Bulk Bag Discharger with Mobile Flexible Screw Conveyor allows dust-free discharging of bulk solid materials and conveying to downstream process equipment or storage vessels throughout the plant.

Mounted on locking castors, the BULK-OUT® BFF Series discharger has four adjustable extension posts to accommodate bulk bags 915 to 2135 mm tall.

The removable bag-lifting frame with Z-CLIP™ strap holders allows bulk bags to be attached at ground level, then forklifted into receiving cups on the discharger frame.

A SPOUT-LOCK™ clamp ring atop a pneumatically-actuated TELE-TUBE™ telescoping tube secures the clean side of bag spout to the clean side of the equipment, and exerts continuous downward tension on the bag as it empties and elongates, promoting flow and evacuation.

A vent port with filter sock contains dust.

Additional flow is afforded by FLOW-FLEXER™ bag activators that raise and lower opposite bottom sides of the bag at timed intervals into a steep “V” shape, and top-mounted POP-TOP™ extension devices that elongate the entire bag, promoting total discharge with no manual intervention.

The discharge housing of the mobile flexible screw conveyor is supported by a mast affixed to the mobile discharger frame, allowing the transfer of free- and non-free-flowing bulk materials to multiple destinations.

The flexible screw is the only moving part contacting material and is driven by an electric motor beyond the point at which material is discharged, preventing material contact with seals.

The entire unit can be rolled to a cleaning station.

A lower clean-out cap on the conveyor tube can be removed to flush the smooth interior surfaces with steam, water or cleaning solutions, or to fully remove the flexible screw for cleaning and inspection.

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Bulk Solids Today

The system is available in carbon steel with durable industrial coating and stainless steel material contact surfaces (shown), or in all-stainless steel finished to industrial, food, dairy or pharmaceutical standards.

Flexicon also manufacture other configurations of bulk bag dischargers and flexible screw conveyors, as well as tubular cable conveyors, pneumatic conveying systems, bulk bag conditioners, bulk bag fillers, bag dump stations, drum/box/container dumpers, drum fillers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls.

For information contact Flexicon Europe Ltd, +44 (0)1227 374710, sales@flexicon.co.uk, www.flexicon.co.uk

BULK MATERIALS HANDLING

AJAX AGITATED SCREW FEEDER FOR LIANHETECH EUROPE Solids handling specialist, Ajax Equipment, has supplied leading fine chemical manufacturer, Lianhetech Europe, with an Alloy 22, extremely corrosion resistant high nickel alloy, agitated screw feeder for Lianhetech Europe’s Seal Sands production site near Middlesbrough, UK. The feeder receives batches of product from a centrifuge into its horizontal cylindrical hopper section fitted with a multi-bladed agitator that sweeps the body internal diameter and along the full length to disturb time consolidation and sweep product into an integral LynFlow™ ribbon screw feeder that extracts along the full length to regulate feed into the site’s dryer. The agitated feeder is ATEX compliant for Zone 1/21, category 2 equipment (inside and out) with N2 purge and was water fill tested as part of successful Factory Acceptance Tests (FAT) at Ajax’s Bolton, UK works. The agitated screw feeder also features multiple sight glasses enabling monitoring at several points.

“Following initial meetings and the specification of Lianhetech’s requirements, Ajax provided a bespoke design for the screw feeder and supplied the unit within the challenging timelines of the project. Ajax takes the time to understand the requirements of each specific process rather than supply a generic design and this is one of the key reasons that ensures

the units can do the job from the start,” said Imran Khaliq, engineering manager, Lianhetech Europe.

“Ajax designs its agitated screw feeders to each customer’s process needs including the flowability of the material, required discharge rate and holding capacity,” commented Eddie McGee, managing director, Ajax Equipment. “Due to the process materials involved the construction required Alloy 22 which is noted for its excellent resistance in a wide range of chemical environments. It is significantly harder than stainless steel so working to shape and of course polishing for smooth flow conditions was quite the task which Ajax duly met.”

For more information on Ajax Equipment agitated screw feeders call +44(0)1204 386723, email: sales@ajax.co.uk and visit www.ajax.co.uk.

If you are interested in advertising within BST magazine, please feel free to get in touch using the details bleow: Bulk Solids Today Magazine bst@abbeypublishing.co.uk www.bulksolidstoday.co.uk Office - 01933 316931 Bulk Solids Today

23

FEEDERS & CONVEYING

ADVANCED DESIGN EXPERTISE ENSURES SUCCESS OF ULTRALONG OVERLAND CONVEYOR FOR MAJOR ALUMINA PRODUCER TAKRAF India outlines the design features and challenges overcome in designing an overland conveyor, the “life line” for Utkal’s alumina plant, supplying bauxite ore from mine to plant.

The successful completion of the approximately 19 km overland conveyor system for the green fields Utkal Alumina project in Tikri, Raigada, in the Orissa state of India, marked yet another TAKRAF milestone development for the global conveyor industry. The contract from Utkal Alumina International Limited (UAIL) called for an overland conveyor system to transport bauxite from the mines to a new 4.5 mtpa alumina plant. This also included the longest singleflight conveyor system to be installed to date within Indian territory.

With the best quality bauxite as its input, and tightly integrated logistics between the mines and the refinery, Utkal Alumina’s operating cost per ton of alumina is among the lowest in the world. The bauxite for Utkal Alumina is sourced entirely from the Baphlimali mines, some 16 km (aerial distance) from the plant site in the Doragurha village. Prior to being conveyed overland to the processing plant, the bauxite is crushed to a size of -150 mm, with the fixed crushing package having been provided in 2012/13 by a sister company, the then Bateman India (acquired by Tenova in 2012).

CONVEYING ORE FROM MINE TO PLANT

The scope of the overland conveyor project covered design, basic and detailed engineering, procurement and fabrication, right through to erection, which included civil and structural work, commissioning, performance guarantee test runs and handover of the 2,850 t/h conveyor system. An intermediate transfer point and unloading station, including silos and buildings, were also supplied with complete electrical and instrumentation systems.

The system design brief called for the primary crushed bauxite ore of size -150 mm to be fed from the mine end junction house, through a chute to an overland conveyor of 14.5 km. This overland conveyor, ending at an intermediate junction house, in turn feeds an overland conveyor of 13.6 km.

The latter, shorter conveyor ends at a plant end junction house, feeding a 500 t material surge hopper via a two-way chute. The overland system comprises 2,000 and 4,000 tensile strength steel cord conveyor belting, with a minimum belt safety 24

Bulk Solids Today

factor at a steady state of >5.5, supported on a series of underslung-type idlers. These, in turn, are supported on a structural system made up of ground modules and gantries, with the overland conveyors routed partly along the ground and partly along an elevated portion. From the surge hopper, material is fed either directly to plant conveyors or to a stockpile through stockyard conveyors supplied by others.

ADVANCED DESIGN AND ENGINEERING

The execution of the project represented a group-wide effort, drawing on the global overland conveying expertise of TAKRAF Group, with the length of the required conveyor system and the challenging topography along the conveyor path calling for state-of-the-art design and engineering.

Industry-leading software was used to maximize routing and equipment utilization and specifications.

The conveyor design was supported by horizontal curve analysis and dynamic analysis to optimize the long-distance conveyor power and belt tensions.

Global procurement was also followed in order to optimize costs but at the same time source the most advanced and reliable components.

Initially, two technologies were considered, overland trough belt conveying and cable belt, with the client selecting the former due to its many advantages in such inhospitable and remote terrain.

In addition, a major advantage of using trough belt conveying was that almost all the components and spares for trough belts are available in India, with a very small percentage of imported components.

DESIGNING FOR A COMPLEX TERRAIN

In its final configuration, the system’s two conveyors traverse a highly undulating and complex terrain. Dropping in total by 250 m over its course from material loading to discharge, the conveyor system passes through 11 nalas (branch rivers), the Ratachuan River, one forest stretch of nearly 470 m in length, a high voltage line crossing, 37 road crossings, a paddy field adjacent to the plant boundary with a stretch of approximately 2.5 km, eight hills and several villages. The elevated structures were provided with cage ladders spaced

FEEDERS & CONVEYING at approximately 150 m, and pile foundations were provided for the river crossing and one of the downhill crossings.

As a result of the topography and due to the conveyor length, the conveyors were designed with head and tail drives, and multiple, very tight compound horizontal and vertical curves.

In total, the conveyor system features 10 right hand curves, 4 left hand curves and horizontal curve radii of 2,500 m across all locations but one: a critical zone on the shorter conveyor where the horizontal curve is 1,800 m. This portion of the conveyor passes over a hill and through the plant boundary. The longer conveyor has a ground module and a graded portion. The ground module comprises 17 straight sections, 1 left hand curve and 1 right hand curve section, while the graded portion consists of 12 straight sections, 2 left hand curves and 4 right hand curves. The overland gallery on both conveyors together features 403 straight sections, 154 right hand curves and 61 left hand curves, with a maximum gallery length / support interval of 49.5 m and standard gantry length of 27 m.

The idler spacing for the straight and inclined portions of the galleries on both conveyors is 4.5 m for the carry idlers and 9.0 m for the return idlers, except for one section on the longer conveyor where the carry idlers are spaced at 3.5 m and the return idlers at 7.0 m. On both conveyors, the carry idler spacing for the horizontal curved galleries is 2.25 m; and the return idlers are spaced at 4.5 m.

With an installed power of 6x850 kW and 2x850 kW, the conveyor system features 6 drives at the tail end and 4 at the head end on the longer conveyor, while the shorter conveyor has 2 drives at the head end only. There are 2 belt turn-overs on each conveyor, 1 at the tail end and 1 at the head end.

Each conveyor features a fail-safe hydraulic disc brake at the tail end. A take-up winch with capstan brake arrangement has been provided at the head end of both conveyors.

The intermediate transfer point between the 2 conveyors is located in hilly terrain and, since the 4 head end drives of the longer conveyor are also located there, the conveyor drive and takeup areas are mounted on a portal steel structure.

These lightweight but high strength structures provide the design flexibility to accommodate the terrain. Advanced material flowability testing and modelling was used in the design of the transfer chutes at the intermediate transfer point and the plant end junction house to minimize risks such as

environmental pollution and spillage, accelerated belt wear and blockages. To facilitate maintenance, approach roads and a mine road were made available all along the conveyor length, with the cage ladders provided on the elevated structures enabling ease of access.

CONVEYOR ERECTION FOCUSES ON ZERO HARM

Erection of the conveyor system was complicated by the requirement to accommodate and minimize disturbance of the population of the various villages through which the conveyor system passes, as well as the need to blast and excavate a suitable route through the hilly region of the conveyor path.

Approach roads for erection of elevated structures on the hilly terrains also had to be provided.

With major equipment such as heavy cranes and excavators used for erection of the elevated structures, particularly in the challenging hilly terrain, TAKRAF India placed particular focus on safety, strictly conforming both to TAKRAF’s global promise of Zero Harm and to the client’s safety protocols.

Performance guarantee testing was carried out over nearly one week, with the system consistently achieving its present capacity of 1,500 t/h. As a result, the conveyor system could be handed over to the client in December 2016 at a special event where celebratory Pooja rituals were carried out in the presence of top management of both companies. The successful completion of this project is testament to TAKRAF’s ability to employ their long-standing experience in designing conveyors to meet new challenges.

For further information, visit: www.takraf.com Bulk Solids Today

25

BUYERS GUIDE Aero Mechanical Conveyors

Conveyors & Elevators

Mixers & Blenders

“Often copied NEVER matched”

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

Sales office for UK & ROI: SGH Equipment - Entecon® Agent

Tel / Fax: 01270 651611

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

Bulk Storage & Handling

MANUFACTURERS OF SILOS, TANKS AND CONVEYING SYSTEMS Redbrook, Barnsley S75 1HR Tel: 01226 730037 Fax: 01226 730066 Email: info@eb-equipment.com Web: www.eb-equipment.com

Bulk handling with complete confidence Designers and UK manufacturers of: • Bucket elevators • Chain & flight conveyors • Screw conveyors & bin dischargers • Belt conveyors

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

Powder Handling Systems

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FIBC / Big Bag Filling

FIBC Dischargers

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Bulk Solids Today

Remote Silo Monitoring

BUYERS GUIDE Sieves & Sifters Cont’d

Sack Filling

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Manufacturers of semi/fully automatic weighing and filling machines into valve/open mouth sacks.

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T: +44 (0)1487 711114

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www.kasoneurope.co.uk

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Tel: +44 (0)1782 597540 Fax: +44 (0)1782 597549 sales@kasoneurope.co.uk

Screw Feeders, Mixers & IBC Systems

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Vacuum Cleaning

AJAX

Screw Feeders, Mixers & IBC Systems Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706 www.ajax.co.uk email: solids@ajax.co.uk

Valves

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YOUR SIEVING & SCREENING PROCESS

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WITH SIEVMASTER BY FARLEYGREENE.

www.farleygreene.com

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

www.InterBulkGroup.com

InterBulk GROUP

Bulk Solids Today

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