Bulk Solids Today February 2021 Issue

BULK MATERIALS BULK HANDLING MATERIALS • POWDER HANDLING HANDLING • FEEDERS • QUARRYING & CONVEYING • RECYCLING • COMPANY & WASTE NEWSMANAGEMENT

FEBRUARY FEBRUARY 2021 2017

BOBCAT ROLLS OUT NEW LIGHT COMPACTION PRODUCT RANGE

see pages 16-17

HIGHLIGHTS:

5

Gericke adds Ploughshare Mixers and Reactors to its range

14

RenCom starts the production of its durable biomaterial with ZSK technology

22

Apple producer picks Brillopak to automate packing facility

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 146

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.

4

NEWS

12

SPECIAL FEATURE

14

BULK MATERIALS HANDLING

16

ON THE COVER

18

FEEDERS & CONVEYING

22

SPECIAL FEATURE

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

www.bulksolidstoday.co.uk Bulk Solids Today

3

COMPANY NEWS

HAYWARD UTILITY SERVICES CELEBRATE QEHS AWARD AFTER CONTINUING TO DELIVER FOR THEIR CUSTOMERS THROUGHOUT COVID One of South Wales’ key providers of civil engineering services to the utility industries has successfully navigated various pandemic-related issues to successfully increase business at the same time as getting its quality, environmental and health & safety management systems recertified.

Hayward Utility Services, based in Bridgend, provides services around enabling works and civil engineering for projects in power generation and renewables across the UK. Even though their work was classed as essential, the family owned and run business found it difficult in the early stages of the pandemic to manage suppliers, materials, deliveries and site operations while the country got to grips with the new way of working.

But they quickly overcame these issues and, through careful management, saw a steady increase in turnover as major companies came to rely on their professionalism and competencies.

Chris Lawless, Managing Director, said: “We’re thrilled that, despite often extremely trying circumstances, we’ve shown how we’ve still been able to give our clients a high level of service and this has been recognised in the achievement of our ISO 9001, ISO 14001 and ISO 45001 recertification.

“There were a number of complex issues which we had to tackle when lockdown first took hold, but we worked around these successfully.

“We spent significantly on sanitiser, face masks, gloves, etc and put sanitisers on every site to make sure workers had enough for their personal use as well as providing disinfectant cleaning products for cleaning touch points such as machinery controls and door handles after use. We closely followed government guidelines and amended our working 4

Bulk Solids Today

procedures to take into account the risks associated with the spread of the virus which was then also reflected in our work instructions.

“Fortunately a lot of our work meant it was not necessary for workers to get too close to each other and we created a policy for our vans to contain only one member of staff, meetings were to be socially distanced and out in the open, where they could not be held remotely.

“We also introduced a raft of other measures such as regular cleaning, the stopping of visitors coming to site, and office-based meetings being held via videoconference. On-site signage was made up to warn staff, customers and members of the public of the requirement to maintain social distancing and PPE had social distancing messages printed on it.

“We now enter 2021 full of confidence and have purchased new tools, vehicles and machinery.

“The health and wellbeing of our own people and that of our customers was our key priority and, still today, we continually monitor Government guidelines on social distancing to implement, as appropriate, their recommendations.

“I’d just like to thank our whole staff, who have delivered a magnificent response to keep our level of service as high as it has been in extremely testing circumstances. I’d also like to extend our gratitude to The Ideas Distillery who were brilliant in getting us ready for our ISO recertification,” he said.

Hayward Utility Services often carry out work on brownfield sites and are used to dealing with complex problems related to previous site uses, working through them to find solutions that will ensure successful project delivery

and conformance with safety, quality and commercial targets.

They were quick to set up a COVID strategy which revolved around: - Setting up a dedicated Management Team who met daily.

- Issuing new guidelines to all field operations staff including providing them with the appropriate PPE. - Ensuring a constant supply of hand sanitiser and disinfectant cleaners within the business.

- Introducing agile working for many support functions including working from home, where possible, and removing any non-essential travel.

Russell Lawson, Managing Director from The Ideas Distillery, said: “We would like to extend our most heart-felt congratulations to Hayward Utility Services who really stepped up to the plate for their customers in very turbulent times.

“Their great commitment to their quality, environmental and health & safety management system is readily evident and it was no surprise when they were recertified to ISO 9001, ISO 14001 and ISO 45001 despite all of the issues they have had to overcome over the past months.

“We’ve no doubt that they’ll continue to deliver for their customers in the coming months, no matter what else is thrown at them,” he said.

COMPANY NEWS

GERICKE ADDS PLOUGHSHARE MIXERS AND REACTORS TO ITS RANGE To further strengthen its position as a leading global system and component provider in the powder processing industry, Gericke announces the extension of its single shaft batch mixing line with the GBM M Mixers.

In addition to the established and broad range of batch and continuous mixing systems, Gericke now also covers all needs in the single shaft batch mixing and reacting applications. This program extension includes larger batch mixer models (up to 10’000 l), extractable mixing tools, and mixers suitable for solid-solid, solid-liquid, and solid-gas reactions. To effectively drive reaction processes of any kind the Gericke single shaft batch mixers are available with double shells (for heating, cooling, or drying) and designed for high pressure and vacuum operation.

When producing food, chemical, and pharmaceutical products there are additional demands on the highest possible degree of safety as well as for hygiene and reliable operation.

These mixers and reactors have been developed as an answer to the demanding network of group companies requirements of operational and local partners. The Gericke safety and hygiene in those test centres are available to industries. The mixers are ATEX select and verify the right certified and individually mixing solution and the configured according to the complete system setup. requirements.

Like all other Gericke equipment, these solutions YOUR SIEVING & SCREENING PROCESS are globally supported by the Gericke

REDEFINED WITH SIEVMASTER BY FARLEYGREENE.

If you are interested in advertising or contributing to BST, please get in touch using the details below: bst@abbeypublishing.co.uk 01933 316931 www.bulksolidstoday.co.uk Sieves, screens, sifters. +44 (0) 1256 474 547 www.farleygreene.com enquiries@farleygreene.com

Bulk Solids Today

5

COMPANY NEWS

ROAD DEATHS TO BE CUT AS TFL’S PIONEERING DIRECT VISION STANDARD COMES INTO FORCE In a world first, TfL’s lorry safety scheme is now enforced on all roads in London with free safety permits required for all freight operators More than 90,000 permits have been issued to date Several freight operators and major projects such as Tideway have invested significantly to ensure 5-star lorries operate in London More than 30,000 dangerous heavy goods vehicles have been fitted with safety measures to protect people walking and cycling This is the first step in dramatically improving lorry safety in London, with standards set to tighten further in 2024 Transport for London (TfL), working with the London boroughs, has delivered a radical improvement to road safety in the capital that will save lives and serious injuries, with the introduction of the pioneering Direct Vision Standard (DVS).

The vital lorry safety scheme is now operating 24 hours a day, seven days a week and is enforced on all roads in London, with standards set to tighten further in 2024.

More than 30,000* Heavy Goods Vehicles (HGVs) have been made safer thanks to TfL’s Direct Vision Standard scheme, which reduces lethal blind spots by introducing a free permit system that assigns vehicles a star rating based on how much the driver can see directly through their cab window.

All owners of HGVs over 12 tonnes now need a valid permit to operate in London. Those without a permit face a new penalty charge notice (PCN) of up to £550**. To date, more than 90,000 permits have been issued, including more than 3,000 to 5-star vehicles which provide the highest levels of 6

Bulk Solids Today

direct vision. TfL data shows that around 150,000 HGVs enter London every year.

Introduced with the support of London Councils, the Direct Vision Standard forms part of the Mayor of London’s Vision Zero plan to eliminate all death and serious injuries from London’s streets by 2041. HGVs continue to be disproportionately deadly.

While big lorries accounted for just three per cent of the overall miles driven in London 2018-20, they were involved in nearly half (41 per cent) of fatal collisions involving people cycling and 19 per cent involving people walking. This means that HGVs are five times more likely to be involved in a collision resulting in a fatality, relative to their share of traffic. Provisional data*** shows that in the first two months of 2021 alone, three people walking and cycling in London have already been killed by HGVs. Developed through extensive engagement with lorry manufacturers and the freight industry, TfL’s Direct Vision Standard measures the driver’s direct field of vision from their cab and rates it from 0 to 5 stars, depending on how much they can see.

HGVs rated 1 to 5 stars received their free safety permit automatically. The operators of lorries rated 0 star – around half of HGVs operating in London – are required to fit safe systems including: • cameras covering blind spots linked to a video display in the cab • an audible warning when turning left • motion sensors covering the sides of the lorry at low speeds • a prominent warning on the back of their vehicle As a result, more than 30,000

dangerous zero-rated HGVs have now had safe systems fitted, improving protection for vulnerable road users and saving lives. More than 60,000 HGVs rated 1 to 5 stars received their safety permit automatically and this includes more than 3,000 5-star vehicles. Several freight operators including SUEZ Recycling and Recovery and FM Conway and major projects such as Tideway have led the way in introducing 5-star vehicles to London, which provide high levels of direct vision and are the most effective at reducing tragic road deaths and serious injuries.

The DVS and Safety Permit scheme is progressive and the standards will tighten in October 2024 when the minimum DVS star rating will be three stars and above. All HGVs below three stars will need to feature a progressive safe system which takes into account any additional technology or safety equipment not currently available.

Meanwhile, a tighter Low Emission Zone (LEZ)**** standard has also come into force today to coincide with the DVS. Heavy vehicles including lorries, buses, coaches and specialist vehicles now need to meet Euro VI (NOx and PM) emissions standards or pay a daily charge to drive within the Greater London area.

Compliance with the Ultra Low Emission Zone (ULEZ) and Low Emission Zone (LEZ) standards has continued to grow throughout 2020 despite the pandemic, showing that schemes such as ULEZ and LEZ are effective in achieving significant air quality reductions.

Will Norman, London’s Walking and Cycling Commissioner, said: “I’m really proud that London is leading the way and our world-first Direct Vision Standard is now

COMPANY NEWS in operation 24 hours a day, seven days a week across all the roads in our city. This will save lives and improve road safety from day one by reducing lethal HGV blindspots, with more than 30,000 lorries fitted with vehicle safety measures ahead of enforcement beginning.

“More Londoners are walking and cycling than ever before and by taking this bold action we are doing all we can to protect them. It is a major step forward in the Mayor’s Vision Zero plan to eradicate all deaths and injuries from our roads, and is also set to transform road safety across Europe in the coming years.”

Christina Calderato, Head of Transport Planning for TfL, said: “We know that the Direct Vision Standard will protect all Londoners who walk and cycle by ensuring that the most dangerous vehicles on our streets have effective safety measures.

This will prevent needless death and injury on our roads - there will be people alive by the end of this year who wouldn’t have been if we hadn’t taken this bold and necessary action.

“We are immensely proud that our Direct Vision Standard – a world-first for lorry safety – will not only save lives in London, but in the UK and all over Europe as operators upgrade their entire fleets, sometimes upgrading hundreds of vehicles.

This vital step is core to our Vision Zero plan to eliminate deaths and serious injuries on London’s roads.”

Victoria Lebrec, Head of Policy, Campaigns and Communications at RoadPeace, said: “In 2014 a driver behind the wheel of a lorry failed to see me whilst I was cycling, and crushed me. I lost my leg as a result of the crash, and have been left permanently disabled.

The Direct Vision Standard will prevent crashes like mine.

Transport for London should be commended for introducing the scheme, which will save lives and prevent serious injury.

the General Safety Regulation “I urge operators to go which includes the need for beyond the minimum star rating improved direct vision for lorries. standard required now, and All vehicles will have to meet a ensure their vehicles have as minimum direct vision standard much direct vision as possible.” by 2028 – saving an estimated Joshua Harris, Director of 550 lives a year across Europe.

Campaigns for Brake, said: “The Gordon Sutherland, Road Direct Vision Standard is a clear Logistics Manager at Tideway, forward step for road safety in said: “Tideway adopted a the capital and one which we number of vehicle safety hope is replicated across the measures at the outset of the country, and globally. Protecting project in 2014.

Since then, we the safety of those who walk have ensured our supply chain and cycle, through measures operates vehicles that meet the like the Direct Vision Standard, conditions of the Safety Permit is fundamental to a Vision Zero Scheme, incorporating the Direct approach and, hopefully, as Vision Standard. Rolling it out the danger from motor traffic across London is a welcome step decreases, more people will and will help to save lives. choose to travel in active ways, “We have committed to meaning less motor vehicles moving materials by river and safer cleaner roads for wherever possible, which is everyone.” safer, cleaner and better for It’s vital that TfL acts now pedestrians and cyclists. But to prevent more dangerous where we need to use HGVs, collisions involving HGVs. Each our supply chain’s compliant year, around 4,000 people are and 5-star fleet will ensure this is killed or seriously injured on done as safely as possible.

London’s streets. Each fatality “As we continue our vital has caused heartbreak and trauma for everyone involved, and each is an unacceptable tragedy. TfL is committed to creating a safer future for Tuf-Lok ring grip pipe and tube couplings are everyone in the rugged, heavy duty, self-aligning and self-grounded capital. couplings with a high end pull. They can be used Longer term, for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning the DVS will save couplings install quickly and easily with little effort. even more lives by helping to Features strengthen the • Self-aligning freight industry’s • Self-grounding safety culture.

• High pressure rated Over the next • Full vacuum rated decade, it will • Stainless or mild steel help to transform • Usable on thin lorry design: in or thick wall February 2019, pipe or tube with support • Low cost from the Mayor • Reusable of London, • Absorbs vibration the European • Externally leakproof Parliament Tuf-Lok (UK) accepted an Tel: +44 (0) 1706 822512 amendment to Email: sales@tuflok.co.uk • www.tuflok.com Bulk Solids Today

7

COMPANY NEWS

HOW THE BELLA FLUIDIZED ZONE MIXER WORKS The Bella fluidized zone twin shaft paddle mixer by Dynamic Air achieves fast, high-capacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action with typical mixing times of 15 to 30 seconds.

A weightless zone created by low-speed counter rotating paddles generates very low friction without shear. This makes it ideal for abrasive products and fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact The Bella mixer consists of twin drums which have two counter-rotating agitators with specifically angled paddles.

They overlap at the center and completely sweep the entire bottom of both mixer drums and allow it to be started under full load (Figure 1). The material in the mixer moves in a horizontal counter-clockwise direction at the perimeter while simultaneously moving both left and right in the center (Figure 2). The material in Zone B (Figure 1) is in its normal gravimetric state as it is being moved and disbursed. In Zone A, a weightless zone is created which effectively lifts the ingredients to an almost weightless state allowing them to move freely and randomly, regardless of particle size and density. Thus the two zones’ interaction becomes highly efficient as every particle moves rapidly to a highly homogeneous mix, the key to the Bella Mixer mixing technology for fast, precise mixing.

The Bella mixer is available in stainless steel for food applications. Custom sizes, 8

Bulk Solids Today

Figure 1 finishes and materials of construction are available upon request. http://www.dynamicair. com/products/mixer.html

Figure 2 Dynamic Air Ltd. Milton Keynes, United Kingdom +44-1908-622344 E-mail: sales@dynamicair. co.uk www.dynamicair.com

COMPANY NEWS

NEW ORGANISATIONAL ANNOUNCEMENT AT PORTABLE POWER EMEA Jan Moravec appointed as General Manager for EMEA region The Portable Power business of Doosan Bobcat has announced a new global leadership structure to provide the company with increased efficiencies in terms of global operational footprint, global product platforms and other key initiatives. This change is aimed at streamlining the performance of Portable Power products within Doosan Bobcat.

Jan Moravec has been appointed as General Manager, Portable Power for Europe, the Middle East and Africa (EMEA).

Jan has been with Portable Power for over 18 years and is based at the Doosan Bobcat EMEA campus in Dobris in the Czech Republic.

Jan Moravec commented: “I’m delighted to be taking on the new role of General Manager for Portable Power EMEA. Our business has more than 100 years of experience in providing superior products and services for our customers, with a great team of people offering the drive, focus and passion to continue this success. Our key goals for this year include the completion of our Stage V compressor range with the introduction of a new family of small compressors, enhancing our product offering

for MEA markets and to continue to strengthen our dealership network and to fulfill all of our customer’s needs in the EMEA region.”

In his new role, Moravec will retain responsibility for product and program management as well as taking on responsibility for sales, service, along with supply chain sales, inventory and operations planning and responsibility for the company owned stores in EMEA. Jan will report to Lance Mathern, Vice President, Global Portable Power.

As well as portable compressors for the construction, rental, quarrying and many other industries, the Portable Power range from Doosan Bobcat includes generators and lighting products aimed at the same markets.

For more information about Portable Power products from Doosan Bobcat, visit the website: www.doosanportablepower. eu

Bulk Solids Today

9

COMPANY NEWS

NARROW AISLE ANNOUNCE SIGNIFICANT US INVESTMENT Narrow Aisle Ltd – the UKbased manufacturer of space-saving intralogistics solutions – has announced a significant investment in the USA and Canada as it seeks to further develop the global distribution of its Flexi range of articulated warehouse trucks.

From its current hub in Dallas, Texas, Narrow Aisle has been developing US sales and after-sales support for the Flexi range for over 20 years. During this time Flexi has become established as a leading articulated forklift brand across the USA. John Maguire, managing director of Narrow Aisle Ltd, commented: “North America has long been one of the most important markets for Narrow Aisle’s range of articulated lift trucks and, with US-based third party and fulfillment logistics operators increasingly challenged to make maximum use of the storage area they have available and reduce labour costs we see huge potential to grow sales of the Flexi design even further in the future.”

Narrow Aisle Ltd pioneered the concept of articulated warehouse trucks in the 1990s, since which time Flexi has become a world-renowned brand with an extensive range of products and over 10,000 machines supplied to users in more than 65 different countries.

The Flexi’s iconic articulated design delivers safe and highly space and throughput efficient operation within narrow aisle storage units. Furthermore, because Flexis are used to load and unload delivery vehicles and transport palletised loads directly to/from their pallet location, ‘double handling’ is eliminated and fewer types of forklift are required. As a result, materials handling costs can be reduced by up to 50%.

Models in the Flexi range have been adapted for the US market with the introduction of three- or four-stage

quad masts which, when lowered, allow the trucks to be driven into the back of a waiting semi-trailer to retrieve or deposit pallets.

The latest Flexi range has been developed to be easy to drive with digital power steering, aisle sensing and many ‘cobotic’ aids to improve efficient safe handling.

IF YOU ARE INTERESTED IN ADVERTISING WITHIN BULK SOLIDS TODAY MAGAZINE, PLEASE DO GET IN TOUCH BY VISITING WWW.BULKSOLIDSTODAY.CO.UK OR EMAILING US AT BST@ABBEYPUBLISHING.CO.UK 10

Bulk Solids Today

COMPANY NEWS

URBASER COMMERCIAL DIVISION EXPANDS WITH NEW WASTE AND RECYCLING CONTRACTS Urbaser Ltd Commercial Services (ULCS) is expanding its portfolio with the addition of new local authority trade waste collection services, which include Eden District, and the management of Household Waste and Recycling Centres (HWRCs) located across Northamptonshire and Central Bedfordshire.

The new commercial contracts are part of Urbaser Ltd’s recent acquisition of waste management contracts from Amey, involving the provision of waste and recycling collections, street cleansing and grounds maintenance, or HWRC management, for a number of councils across the UK. The commercial services in Eden and the HWRCs in Northamptonshire and Central Bedfordshire commenced on 01 March.

Gary McKinnon, Commercial Business Manager, ULCS: “We welcome our new customers and look forward to providing a high standard of service to local businesses, as well as visitors to the Household Waste and Recycling Centres we will manage. We have a wealth of experience in sustainable waste management and can help our commercial customers improve their environmental credentials.”

The Eden District Council commercial waste collection service currently has over 500 customers, and ULCS has already invested in a newer waste collection fleet with in-cab technology, 360° safety cameras and onboard weighing to improve service delivery and customer

experience.

Cllr. Mike Tonkin, Services Portfolio Holder for Eden District Council: “I welcome the news that Urbaser Ltd Commercial Services is taking over Eden District Council’s commercial waste collection service and investing in new vehicle technology. We look forward to working with them.”

ULCS is also in the process of implementing a new, more efficient on-site weigh and pay software system at those HWRCs that to improve the service for business users.

Gary continued: “We will be using the latest waste management software combined with handheld tablets to provide a quick turnaround for small businesses, so they can bring their waste on site, dispose of it, and pay by card immediately.”

ULCS was launched in 2020 to provide the full range of trade waste and recycling collection services with a focus on providing closed-loop solutions and waste reduction strategies for its customers. The company is able to provide an entirely paperless service and uses the latest vehicle technology, equipped with bin weighing equipment and 360-degree camera systems, combined with specialist software to deliver an efficient service and provide customers with accurate data.

For more information about ULCS tel: 01242 248880 email: commercial@urbaser.co.uk or visit: https:// commercial.urbaser.co.uk/

Bulk Solids Today

11

SPECIAL FEATURE

ROAD DEATHS TO BE CUT AS TFL’S PIONEERING DIRECT VISION STANDARD COMES INTO FORCE • In a world first, TfL’s lorry safety scheme is now enforced on all roads in London with free safety permits required for all freight operators • More than 90,000 permits have been issued to date • Several freight operators and major projects such as Tideway have invested significantly to ensure 5-star lorries operate in London • More than 30,000 dangerous heavy goods vehicles have been fitted with safety measures to protect people walking and cycling • This is the first step in dramatically improving lorry safety in London, with standards set to tighten further in 2024 Transport for London (TfL), working with the London boroughs, has delivered a radical improvement to road safety in the capital that will save lives and serious injuries, with the introduction of the pioneering Direct Vision Standard (DVS). The vital lorry safety scheme is now operating 24 hours a day, seven days a week and is enforced on all roads in London, with standards set to tighten further in 2024.

More than 30,000* Heavy Goods Vehicles (HGVs) have been made safer thanks to TfL’s Direct Vision Standard scheme, which reduces lethal blind spots by introducing a free permit system that assigns vehicles a star rating based on how much the driver can see directly through their cab window.

All owners of HGVs over 12 tonnes now need a valid permit to operate in London. Those without a permit face a new penalty charge notice (PCN) of up to £550**. To date, more than 90,000 permits have been issued, including more than 3,000 to 5-star vehicles which provide the highest levels of direct vision. TfL data shows that around 150,000 HGVs enter London every year.

Introduced with the support of London Councils, the Direct Vision Standard forms part of the Mayor of London’s Vision Zero plan to eliminate all death and serious injuries from London’s streets by 2041. HGVs continue to be disproportionately deadly. While big lorries accounted for just three per cent of the overall miles driven in London 2018-20, they were involved in nearly half (41 per cent) of fatal collisions involving people cycling and 19 per cent involving people walking. This means that HGVs are five times more likely to be involved in a collision resulting in a fatality, relative to their share of traffic. Provisional data*** 12

Bulk Solids Today

shows that in the first two months of 2021 alone, three people walking and cycling in London have already been killed by HGVs. Developed through extensive engagement with lorry manufacturers and the freight industry, TfL’s Direct Vision Standard measures the driver’s direct field of vision from their cab and rates it from 0 to 5 stars, depending on how much they can see.

HGVs rated 1 to 5 stars received their free safety permit automatically. The operators of lorries rated 0 star – around half of HGVs operating in London – are required to fit safe systems including: • cameras covering blind spots linked to a video display in the cab • an audible warning when turning left • motion sensors covering the sides of the lorry at low speeds • a prominent warning on the back of their vehicle As a result, more than 30,000 dangerous zerorated HGVs have now had safe systems fitted, improving protection for vulnerable road users and saving lives. More than 60,000 HGVs rated 1 to 5 stars received their safety permit automatically and this includes more than 3,000 5-star vehicles. Several freight operators including SUEZ Recycling and Recovery and FM Conway and major projects such as Tideway have led the way in introducing 5-star vehicles to London, which provide high levels of direct vision and are the most effective at reducing tragic road deaths and serious injuries.

The DVS and Safety Permit scheme is progressive and the standards will tighten in October 2024 when the minimum DVS star rating will be three stars and above. All HGVs below three stars will need to feature a progressive safe system which takes into account any additional technology or safety equipment not currently available.

Meanwhile, a tighter Low Emission Zone (LEZ)**** standard has also come into force today to coincide with the DVS. Heavy vehicles including lorries, buses, coaches and specialist vehicles now need to meet Euro VI (NOx and PM) emissions standards or pay a daily charge to drive within the Greater London area. Compliance with the Ultra Low Emission Zone (ULEZ) and Low Emission Zone (LEZ) standards has continued to grow throughout 2020 despite the pandemic, showing that schemes such as ULEZ and LEZ are effective in achieving significant air quality reductions.

Will Norman, London’s Walking and Cycling Commissioner, said: “I’m really proud that London is leading the way and our world-first Direct Vision Standard is now in operation 24 hours a day, seven days a week across all the roads in our city. This will

SPECIAL FEATURE save lives and improve road safety from day one by reducing lethal HGV blindspots, with more than 30,000 lorries fitted with vehicle safety measures ahead of enforcement beginning.

“More Londoners are walking and cycling than ever before and by taking this bold action we are doing all we can to protect them. It is a major step forward in the Mayor’s Vision Zero plan to eradicate all deaths and injuries from our roads, and is also set to transform road safety across Europe in the coming years.”

Christina Calderato, Head of Transport Planning for TfL, said: “We know that the Direct Vision Standard will protect all Londoners who walk and cycle by ensuring that the most dangerous vehicles on our streets have effective safety measures. This will prevent needless death and injury on our roads - there will be people alive by the end of this year who wouldn’t have been if we hadn’t taken this bold and necessary action.

“We are immensely proud that our Direct Vision Standard – a world-first for lorry safety – will not only save lives in London, but in the UK and all over Europe as operators upgrade their entire fleets, sometimes upgrading hundreds of vehicles. This vital step is core to our Vision Zero plan to eliminate deaths and serious injuries on London’s roads.”

Victoria Lebrec, Head of Policy, Campaigns and Communications at RoadPeace, said: “In 2014 a driver behind the wheel of a lorry failed to see me whilst I was cycling, and crushed me. I lost my leg as a result of the crash, and have been left permanently disabled. The Direct Vision Standard will prevent crashes like mine. Transport for London should be commended for introducing the scheme, which will save lives and prevent serious injury.

“I urge operators to go beyond the minimum star rating standard required now, and ensure their vehicles have as much direct vision as possible.”

Joshua Harris, Director of Campaigns for Brake, said: “The Direct Vision Standard is a clear forward step for road safety in the capital and one which we hope is replicated across the country, and globally.

Protecting the safety of those who walk and cycle, through measures like the Direct Vision Standard, is fundamental to a Vision Zero approach and, hopefully, as the danger from motor traffic decreases, more people will choose to travel in active ways, meaning less motor vehicles and safer cleaner roads for everyone.”

It’s vital that TfL acts now to prevent more dangerous collisions involving HGVs. Each year, around 4,000 people are killed or seriously injured on London’s streets. Each fatality has caused heartbreak and trauma for everyone involved, and each is an unacceptable tragedy. TfL is committed to creating a safer future for everyone in the capital.

Longer term, the DVS will save even more lives by helping to strengthen the freight industry’s safety culture. Over the next decade, it will help to transform lorry design: in February 2019, with support from the Mayor of London, the European Parliament

accepted an amendment to the General Safety Regulation which includes the need for improved direct vision for lorries. All vehicles will have to meet a minimum direct vision standard by 2028 – saving an estimated 550 lives a year across Europe.

Gordon Sutherland, Road Logistics Manager at Tideway, said: “Tideway adopted a number of vehicle safety measures at the outset of the project in 2014. Since then, we have ensured our supply chain operates vehicles that meet the conditions of the Safety Permit Scheme, incorporating the Direct Vision Standard. Rolling it out across London is a welcome step and will help to save lives.

“We have committed to moving materials by river wherever possible, which is safer, cleaner and better for pedestrians and cyclists. But where we need to use HGVs, our supply chain’s compliant and 5-star fleet will ensure this is done as safely as possible.

“As we continue our vital work to clean up the River Thames, we’re proud to be playing our part in improving the lives of Londoners by creating a safer, cleaner environment.”

James Griffin, Technical Manager at SUEZ Recycling and Recovery UK, said: “Whilst safety is a critical element within the culture of SUEZ Recycling and Recovery UK, and we already invest heavily to make our vehicles as safe as possible, the TfL Direct Vision Standard represents a major step-change in our being able to protect other vulnerable road users who may be affected by our HGV operations in Greater London. This TfL initiative is definitely a worldleading benchmark for vulnerable road user safety on heavily congested road systems in cities such as London.”

Peter Parle, Senior Transport Manager, FM Conway, said: “FM Conway is proud to support the Mayor of London’s new HGV Safety Permit system and the Direct Vision Standard for heavy HGVs, much like the ones that we use in London. Safety is at the heart of our business and the DVS five-star rated Mercedes and Dennis tipper grabs that we use give us high performance at the same time as the safest cab view for our drivers and for the cyclists and pedestrians they share the streets with.”

Bulk Solids Today

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BULK MATERIALS HANDLING

RENCOM STARTS THE PRODUCTION OF ITS DURABLE BIOMATERIAL WITH ZSK TECHNOLOGY Swedish innovation company RenCom AB announced the start of production of RENOL®, an innovative thermoplastic biomaterial that can be used to replace fossil-based plastics. Following comprehensive studies in Coperion’s extrusion test lab in Stuttgart, Germany, RenCom and Coperion have developed the innovative extrusion process of RENOL®, a lignin-based material. Using Coperion’s ZSK twin screw extruder technology lignin can be transformed into durable, reusable biomaterial.

Coperion has delivered a ZSK twin screw extruder, gravimetric feeders, a strand pelletizing system, a lignin bag dump station and a big bag station to RenCom. The system has now been successfully commissioned and production has already started, according to schedule. RenCom will be able to produce more than 1,000 tons of RENOL® per year.

EXTRUSION TECHNOLOGY FOR FUTUREORIENTED BIOMATERIAL RenCom’s patented technology is based on lignin, a by-product from the forest industry, transforming it into a high-performance renewable material that is able to replace plastics. Renol® can be used in ratios up to 50 % in applications such as films (shopping bags, mulch films or retail bags), injection molding (furniture and

automotive parts) and as an infill material for artificial football pitches replacing toxic and non-degradable rubber. It can be used directly in existing production infrastructure without any modifications to machines or methods. With a very low carbon footprint and water consumption, and with high mechanical and physical properties, RENOL® is a powerful solution for replacing and reducing the use of fossil-based plastics.

Coperion has in cooperation with RenCom designed a complete extrusion system comprising a ZSK Mv PLUS -co-rotating twin screw extruder as well as auxiliary equipment. The ZSK Mv PLUS series unites an optimally balanced large free screw volume with high screw speeds and a high specific torque. Thanks to the deeply cut screw flights thermal stress on the raw material is very low and product processing is very gently.

PARTNERSHIP OF TWO INNOVATIVE COMPANIES The comprehensive studies in Coperion’s test lab and the realization of the extrusion system for the production of RENOL® has been the beginning of a successful partnership between RenCom and Coperion.

“We are very happy to be able to support this innovative company on their exciting journey. We see big potential for their lignin-based product decreasing the carbon footprint by substituting fossil-based plastics.

We are proud to support the production of their sustainable products”, comments Peter von Hoffmann, General Manager Business Unit Engineering Plastics & Special Applications at Coperion.

“We, at RenCom, are very proud that the ZSK extruder has started. We are now in a position to produce RENOL® in large quantities and thus make a major contribution to the challenges with fossil-based plastics. We are excited to start our production and supply our customers with hundreds of tons of material”, says Johan Verendel, RenCom’s Chief Technical Officer.

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Bulk Solids Today

BULK MATERIALS HANDLING

MIDLAND PALLET TRUCKS URGES WAREHOUSING INDUSTRY NOT TO OVERLOOK HUMAN ELEMENT DURING ROBOTIC REVOLUTION As the robotic revolution continues to gain momentum in the UK’s warehousing and logistic sectors, Midland Pallet Trucks, a provider of high-quality lifting equipment including pallet trucks, manual stacker trucks and lift tables, is urging managers not to forget their human workers when investing in new robotic technologies.

With Covid-19 being something of a turning point for the UK warehousing sector due to the added demand placed on the industry, many warehouse owners have been looking into ways to automate certain tasks to improve efficiency and streamline processes to maximise productivity.

With the demand for good quality warehousing space hitting an all-time high due to the global pandemic and Brexit, the ability to move goods quickly through warehouses and distribution hubs is essential for businesses working within the sector to be as profitable as possible.

Seen as the future of logistics and warehousing, robotic technology is set to allow later ordering cut off times and next day delivery subscription services. It’s likely that certain roles usually undertaken by humans will be carried out by robot control systems that are capable of working at the same rate of productivity 24/7 without the need for breaks or the risk of workplace injury.

According to a recent report, it has been estimated that automated robotics goods-to-person order-picking can increase efficiency by an incredible 84% which will, in turn, save over 58% on labour costs as well as increasing picking performance from 100 picks per hour to over 600.

However, as many members of the warehousing industry keep their focus firmly on robotics and efficiency improvements, Phil Chesworth, Managing Director of Midland Pallet Trucks is urging those working within the sector to consider the bigger picture and not forget about the needs of the people that will still be a necessary part of warehouses of the future. ″There’s no denying that automation and robotics have a significant part to play in the future of the warehousing sector, but we mustn’t lose sight of those people that will still be working in the industry alongside this brand-new technology.

“Just as robots need repairs and maintenance, humans need certain pieces of equipment to protect them against the risk of injury. When planning new warehouse layouts and labour needs, it is important that lift equipment for human workers isn’t forgotten

as they will still be an integral part of the fabric of any warehouse.″ To find out more about the wide range of materials handling products available from Midland Pallet Trucks, visit https://www.midlandpallettrucks.com/

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15

ON THE COVER

BOBCAT ROLLS OUT NEW LIGHT COMPACTION PRODUCT RANGE Compaction applications are a required part of numerous industries, and no construction site is complete without a soil and asphalt compactor. To meet this demand, Bobcat has launched the company‘s new Light Compaction Product Line, in collaboration with the Ammann Group, a brand known for its comfort and productivity.

This latest expansion of the Bobcat product range under the company’s Next is Now banner is designed to meet work requirements on almost any compaction job site. Machine specifications include state of the art technologies that allow maximum performance, while not compromising on comfort, safety and simplicity of use. Altogether, the Bobcat light compaction range comprises seven different product families and will ultimately offer 37 models, from vibratory rammers weighing 29 kg up to 2.6 tonne tandem rollers.

Mike Vought, Senior Director for Product Management at Doosan Bobcat EMEA, said: “The launch of the complete compaction lineup is part of the exciting diversification strategy under our innovative Next is Now umbrella. Along with product innovations this is another driver on the way to achieving our vision – becoming the world leader in the compact equipment market. To accomplish our goals, even in the extremely difficult year of 2020, we introduced an unprecedented number of new products and technologies and we will continue this in 2021.

“Compaction is one of the completely new product categories together with wheel loaders, that Bobcat introduced in 2020. This expansion was complemented by significant developments in the market-leading mini-excavator, rotary and rigid frame telehandler, skid-steer and compact track loader and backhoe loader ranges from Bobcat.”

The Bobcat Light Compaction Range includes: • • • • • • • 16

Vibratory rammers Vibratory forward plates Reversible vibratory plates Hydrostatic plates Walk behind rollers Trench rollers Tandem rollers

Bulk Solids Today

Light compaction machines can be used in a wide range of applications, such as: Construction – Light compactors increase soil strength, improve stability and load bearing capacity by removing voids and interlocking soil particles.

Roadwork – Compacting asphalt and base materials improves their capacity to withstand heavy traffic and improves their general durability.

Landscaping – Rammers and forward plates are used for gardening and other landscaping applications, as their compact size and low weight ensures they are easy to move between job sites.

VIBRATORY RAMMERS

The Bobcat line-up of vibratory rammers consists of six models - the R30, R60, R68, R60P, R68P and R70D from 29 to 89 kg and is intended for small compaction works for trenches, drainage and pipelines. Due to their ease of transport they are often used for road maintenance as well. They are suitable for compacting mixed soils, sand, gravel materials, loam and clay.

ON THE COVER All Bobcat vibratory rammers come with a reduced vibration handle and a state-ofthe-art CAD calculated weight distribution, ensuring maximum safety and operator comfort. The R60 and the models above also include an integrated height adjustment system.

VIBRATORY FORWARD PLATES

There are also six different vibratory forward plates, which are suitable for compacting sand, gravel, lean concrete, bitumen coated gravel and paving stones.

Again, their compact size makes them easy to transport between job sites, and ideal for compaction in tight spaces (trenches, pipelines and sidewalks) and even landscaping.

The FP10.33, FP12.40, FP15.40, FP15.50, FP20.50 and FP20.50D models are the smallest products in the Bobcat vibratory plate offering, ranging from 54 to 115 kg. The smart engineering design of the handles protects the operator from unwanted vibration, while the machine frame enables a secure grip and easy machine control.

REVERSIBLE VIBRATORY PLATES

Bobcat reversible vibratory plates are suitable for jobs mainly in civil engineering and road construction. They can easily compact all ground materials, such as sand, gravel, crushed stone, concrete and sett paving. With machine weights from 109 to 490 kg, there are 12 models in the range - the RP22.40, RP22.40D, RP25.40D, RP25.50D, RP30.50, RP30.50D, RP30.60, RP30.60D, RP40.60, RP40.60D, RP49.20D and RP59.20D. All Bobcat reversible plates operate with a twin-shaft system, enabling change of direction during compaction. The twin-shaft technology also results in dual weight and a better compaction force. Hydrostatic steering controls guarantee ease of operation and a quick change in compaction direction.

HYDROSTATIC PLATES

Complementing the rest of the compaction plate range, there are four hydrostatic plates - the HP50.75, HP55.75, HP60.85 and HP65.85 models - weighing between 450 and 582 kg. Hydrostatic plates are designed for heavier compaction work in civil engineering and road construction.

They can compact all ground materials - such as sand, gravel, crushed stone, asphalt and sett paving - with ease. The Bobcat hydrostatic plate line-up relies on a fully hydraulic system that does not require a V-belt. They operate with a dual (HP50.75 and HP60.85) or unique triple shaft (HP55.75 and HP65.85) excitation system for maximum compaction output and unbeatable climbing ability.

WALK BEHIND ROLLERS

Walk behind rollers are versatile machines, suitable for compacting bituminous material but also for light earthwork and other compaction tasks.

Bobcat offers the WR65 model in two versions offering a choice between Hatz or Yanmar engines, both equipped with dual drums for maximum compaction.

They are fully hydraulic machines, with an integrated water sprinkler system as standard. The Bobcat walk behind rollers are also equipped with dual amplitude settings, enabling a change between soil/gravel and asphalt/bituminous compaction in just seconds.

TRENCH ROLLERS

Trench rollers are mainly designed for trench compaction as their name suggests. Bobcat is offering the 1340 kg TR75 (articulated) and 1305 kg TR85S (skid-steered) models. They also cover a wide range of other applications such as pipeline construction, electric and other cable installations, whilst commercial or industrial developments and even dumpsite and landfill jobsites can take great advantage of these machines.

They can be used for soil, sand or gravel compaction and can even tackle hard to compact materials such as clay.

TANDEM ROLLERS

Tandem rollers are used for larger surfaces of sub-base, asphalt or other ground materials. They are mostly present in small to medium commercial development sites and road construction sites.

Bobcat is looking to offer a range of five articulated ride-on tandem rollers and the first two models will be available in March 2021 - the ATR23 and ATR26 weighing 2.3 and 2.6 tonne, respectively. The other three models starting at 1.2 tonne will be rolled out in the summer of 2021.

To view a video on the new Bobcat Light Compaction Product range, please click on the link: https://youtu.be/XjZD9giaV-8

Bulk Solids Today

17

FEEDERS & CONVEYING

ALL-STEEL FLEXIBLE SCREW CONVEYOR RESISTS ABRASION Flexicon have introduced a wearresistant flexible screw conveyor with carbon steel conveyor tube, heavyduty flexible screw, and heavygauge floor hopper and discharge housing, capable of moving crushed glass, garnet, aluminium oxide, silica sand, aggregate, cement and other abrasive materials.

The screw is available in lengths up to 12 m in round, square, flat or beveled profiles to optimise conveying efficiency for each application. The 115 mm diameter conveyor tube is available curved to vertical, to horizontal or any angle.

The screw is the only moving part contacting material. Its lower end has no bearing, while its upper end is driven beyond the material discharge point, preventing material contact with the upper seal or bearing. This configuration facilitates simple maintenance in harsh environments since the single moving component can be quickly replaced if necessary.

As it rotates, the screw selfcentres, providing ample space between itself and the tube wall to minimise or eliminate grinding. The gentle rolling action imparted by the screw prevents the separation of blends, while the enclosed conveyor tube prevents product and plant contamination.

Supplied as standard with a durable industrial coating, the unit is available with an optional start-stop control panel and a range of flowpromotion devices.

The company also manufacture other flexible screw conveyors, as well as pneumatic conveying systems, tubular cable conveyors, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, manual dumping stations, drum/box/container tippers, weigh batching systems, and automated plant-wide systems integrated with new or existing process equipment.

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Bulk Solids Today

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

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Bulk Solids Today

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FEEDERS & CONVEYING

SPIROFLOW’S MOBILE SACK TIP AND AMC COMBO PROVIDES FLEXIBLE VERSATILE SOLUTION FOR MANUAL SACK EMPTYING OPERATIONS Spiroflow’s mobile sack tip unit and Aero Mechanical Conveyor (AMC) combination is a fully independent and versatile solution designed specifically to make manufacturers and processors jobs easier.

The system comprises of a sack tip hopper, mounted on a mobile frame with heavy duty castors, into which bags of raw materials can be ‘ripped and tipped’. Providing a safe and convenient way to store and transfer product into the main process, the hopper has a control panel affixed, together with a hood for dust containment. Connected to the hopper is an AMC, which elevates raw materials directly into the mixer, thereby providing operator safety by reducing the requirement for manual handling.

Being able to handle a vast range of different powders and capable of feeding multiple mixing vessels at different locations to reduce batch delivery time, the mobile unit provides a highly efficient method of conveying materials.

Ideal for a variety of applications in a multitude of industries, AMCs are a tubular design, consisting of a wire rope assembly with evenly spaced polyurethane discs that move at high speed. This action creates an air stream running at the same velocity and as the material is fed into the air stream, it is fluidised and conveyed to the outlet where it is ejected.

AMCs offer a dust-free sealed system for ultra fine powders, can convey a wide variety of materials, is ideal for powdered or granular food products or chemicals, has low power consumption, easy cleaning and multi-outlet distribution.

In a mobile configuration, the AMC also has optional height adjustment when it has to pass under low doorways or when it is needed to discharge at differing heights.

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Bulk Solids Today

“We’re working with a number of customers currently who require maximum versatility on-site, for which the mobile sack tip unit and AMC is ideal. A true ‘plug in and operate’ system, the unit increases workflow, whilst ensuring operator safety,” said Rhodri Jones, a regional sales manager at Spiroflow.

To find out more about Spiroflow’s mobile sack tip unit and AMC combination, visit spiroflow.com, email sales@spiroflow.com or call +44 (0) 1200 422525 in the UK or (1) 704 246 0900 in the US.

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SPECIAL FEATURE

APPLE PRODUCER PICKS BRILLOPAK TO AUTOMATE PACKING FACILITY A complete end-of-line automation project with Brillopak has seen Adrian Scripps, Tesco’s top apple supplier, triple productivity per head.

The project saw Brillopak install two PAKStations, four UniPAKer robotic crate packing systems, four Crate DESTAKers, two bale arm closers, four vertical accumulation units and three robotic palletisers.

Thanks to this investment, Adrian Scripps has tripled productivity from 2.5-5 packs to 15 packs per person per min. This has enabled the packing hall to align its capacity with increased production that has come about as a result of replanting orchards, introducing new varieties and adopting new farming methods.

“Any equipment investments in our packing house have to stack up against investments in our orchards,” says James Simpson, Managing Director of Adrian Scripps.

Adrian Scripps’ commitment to automation has earned this family business pioneering status in a sector that is heavily reliant on manual labour for picking, processing and packing.

“In our sector it has been difficult to automate; you might assume that apples flow easily because they are round, but they don’t…and pears are even more awkward, so there are considerable handling challenges to overcome.

But we have invested significantly in automation so that we can pack apples more efficiently and it is paying dividends; our productivity per person has been accelerated by robotics,” says James.

From starting life in 1960 as a traditional Weald of Kent fruit, hops and livestock farm, Adrian Scripps has grown into one of the UK’s premier growers and packers of English fruit.

Several varieties of apple – Braeburn, Kanzi, Jazz, Opal, Gala, Red Prince and Bramley – along with Conference pears and blackcurrants, are grown on five farms totalling 750 hectares.

As well as being the UK’s largest exporter of apples, the family owned farming business is one of Tesco’s key apple suppliers – a relationship that stretches back more than 30 years and has seen much change in the way that fruit is handled at the company’s centralised packing facility on Moat Farm.

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Bulk Solids Today

TOP OF THE TREE

In a sector that has historically shied away from automation, Adrian Scripps has become something of a trailblazer whilst remaining true to its roots as a family farming business.

Whilst every single apple is still handpicked, the company’s sorting operation has been automated for over 30 years. Here, fruit is transported through a pre-sizing machine in water channels; letting the apples float like this protects them from bumps, bruising and damage that may result from over-handling.

Imaging technology checks the colour, sugar content, internal quality, size and shape of each individual apple, identifying any blemishes and imperfections. Apples are then graded by weight, quality etc. Same category fruit are packed into 300kg plastic crates and transferred to the packaging operation.

“This means that the packaging operation is presented with a uniform product that has already been sorted and graded,” says James.

It is the packaging process that has been the company’s focus for automation in the last eight years, initially with the aim of reducing handling through a linear automated process.

Historically, apples were sold either loose in moulded fibre trays or in plastic bags with a neck tie. Both packing operations were entirely manual, and packing staff worked at a rate of 2.5-5 packs per minute (ppm) on average.

Then, in 2013, Adrian Scripps took the

SPECIAL FEATURE decision to invest in automated flow wrapping equipment, accelerating the speed of the packaging operation.

“That left us with lots of packs coming off the flow wrapper at speed, creating a very repetitive task – that was when we engaged Brillopak, who we knew had experience in automation in FMCGs for the grocery trade,” explains James.

On visiting Adrian Scripps, Brillopak quickly got the measure of the situation.

“Up to three people were trying to manually pack flow wrapped apples into retail crates at a rate of up to 60 per minute per line. The packing operatives couldn’t consistently keep up with the pace, which meant upstream efficiency improvements from their grading and flow-wrap investments were impacted,” recalls David Jahn, director at Brillopak.

“Brillopak immediately understood what we were looking for and very quickly got to grips with the challenges,” says James.

“Our orchard productivity has increased through advancement of the trellis system and the replanting of old orchards, introducing new varieties such as Red Prince, Gala and Braeburn.

As a result we have doubled our per hectare productivity in the last 15 years, from 35 tonnes per hectare to 70-80 tonnes per hectare,” says James.

He continues: “We knew we had a lot more fruit coming into production between 2018 and 2022, so we needed our packing facility to be able to accommodate this. In 2013 our facility processed approximately 30,000 boxes of apples and pears every week, each containing 10-12kg of fruit. Now typical weekly production is 80-100,000 boxes a week.”

FLEXIBLE UNIPAKER FITS THE BRIEF

The company considered other packing systems, but it was the inherent flexibility of the

ERGONOMIC PAKSTATION REPLACES ROTATING TABLE

Brillopak’s engineers designed a semi-automated version of the traditional ‘Lazy Susan’ style packing station, which, later branded the PAKStation, was to go on to become one of its best-selling packaging solutions. The ergonomic system, which helps manual staff load packs of fresh produce into retail crates, has significantly enhanced productivity at more than 12 UK fresh produce packhouses to date.

“The PAKStation has made the entire process easier for the person packing. Historically, packs were presented to packing staff on a Lazy Susan rotary table, which allows a large area for crates to accumulate.

We wanted a solution whereby crates were presented to the operator without accumulation, so that the pace of packing is dictated by the machine rather than people,” says Simpson.

The PAKStation gave Adrian Scripps a flexible semi-automated solution on two of its four lines.

However, with the vast majority of the company’s production in one single format, and volumes increasing year on year, it wasn’t long before Adrian Scripps was ready for the next automation chapter – upgrading its other two lines to a fully automated workflow and installing two completely new packing and palletising lines.

Bulk Solids Today

23

SPECIAL FEATURE award-winning UniPAKer robotic crate packing solution that once again convinced Adrian Scripps to partner Brillopak on this project.

“We looked at mechanical systems where the pack is turned to orientate it, but the flexibility of the UniPAKer won us over – it is infinitely programmable and allows you to make very small adjustments to get the pack to the exact target location,” explains James.

Each of the four UniPAKer crate loading cells at Adrian Scripps houses two delta type robots, each performing a single pick. The benefit of a single pick is that it eliminates the need for accumulation. To maximise packing speed, the crate is dynamically loaded as it is moving; working alongside each other, the robots take it in turn to partially fill the crate, picking individual packs off the infeed conveyor and positioning them deftly and precisely in the crate at the programmed orientation. The robots perform this task with a degree of dexterity and rotation that would not be feasible with a layer-based automated handling system.

Many robotics suppliers shy away from applications involving delicate fruit such as apples, as they bruise very easily. The speeds required to achieve target paybacks cannot be met without unacceptable levels of product damage, rendering some automation projects unfeasible.

Brillopak overcomes these challenges through innovative end-effector design, combined with in-depth knowledge of motion control and

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Bulk Solids Today

robotics.

“Apples are not an easy fruit to handle because they bruise very easily. This, combined with the need to execute a range of crate patterns, made this project a challenge that couldn’t be met by a mechanical system.

Brillopak rose to the challenge,” says James.

CASE FOR DESTAKER STACKS UP

Each UniPAKer is fed by a Brillopak Crate DESTAKer, an automated crate destacking solution that works on a unique operating principle; rather than picking up the entire stack and relying on gravity to despatch the bottom crate, the Crate DESTAKer clamps the bottom crate down, lifts the rest of the stack up and then despatches the bottom crate. This prevents two crates from being despatched simultaneously in error if they get stuck together.

BALE ARM CHECKS

When reducing the amount of labour on a line, additional controls are often needed at certain locations. At Adrian Scripps, after the packed crates leave the UniPAKer, they converge onto a single conveyor and pass through a bale arm closer.

“If the bale arm is broken or out of position, the crate won’t stack properly on a pallet. In an automated workflow, you can’t afford to compromise efficiency or stack stability with crates that aren’t intact,” says David.

On the bale arm closer, fingers push the

SPECIAL FEATURE plastic bale arm into closed position; four cylinders then come down and apply pressure. If there is no resistant force, this means the arm is broken or out of position.

VERTICAL ACCUMULATION PREVENTS PALLETISER BOTTLENECK

Each line also incorporates a vertical accumulation unit just before the entrance to the palletiser. When there is a pallet changeover, instead of crates passing straight from the UniPAKer to the palletiser, the accumulation system lifts them vertically upwards. When the palletising robot is ready to accept its next load, it lowers the crates back down onto the track.

“When a finished pallet is removed from the line, there is a lag of 26 seconds before the robot is ready to start working on a new pallet load. The principle of this vertical accumulation system is simple but it eliminates the need to stop the line whilst the palletiser catches up with the rest of the workflow,” says David.

The final element of the project was the palletising operation. Brillopak supplied three compact robotic cell palletisers capable of operating at a rate of up to 30 crates per minute.

Besides its smaller-than-average footprint, the beauty of Brillopak’s palletising system is that the whole operation can be managed with a handtruck rather than a forklift. Empty pallets are delivered via handtruck to the inbuilt pallet dispenser, which automatically feeds them to the machine for presentation to the Nachi articulated robot.

The system then automatically places the loaded pallet stack onto the floor to be taken away by a handtruck. For maximum efficiency, Brillopak’s compact palletiser accommodates two pallet stacks side-by-side. When one stack is full the cell door slides open and the full pallet is removed.

To maximise efficiency, all the machines in the workflow communicate with one another via sensors and a common control platform. For example, the Crate DESTAKer will only release another crate when it receives a signal from the UniPAKer. Adrian Scripps now has a fully automated crate packing operation with six packing lines each capable of running at up to 75 ppm, giving the company the capacity uplift it needed.

Unlike many automation projects in the produce industry, this isn’t about reducing manual labour – it is about reducing cost per head.

PRODUCTIVITY PER PERSON INCREASED “THREEFOLD”

“Reduction of labour is a consideration, but it is productivity per person that we are really interested in,” says James. “Thanks to our investment in

automation, this is considerably higher than it was.

In 2013, we were working at 2.5-5 packs per person per minute. Now we are working at 15 packs per person per minute. That is a threefold increase.”

The packing facility employs 55-60 staff – and even though throughput has tripled this figure hasn’t changed in many years, which clearly demonstrates the effectiveness of this approach.

Other metrics underline the success of the project too: whilst labour is 35% more than it was five years ago, Simpson says that cost per pack has come down. Whilst he concedes that other factors, such as reduced pack rates, have contributed to this, improved economics are a direct result of the company’s investment in automation.

James says that taken individually, all the different elements of the project will have different payback periods.

“The palletisers, for example, are one of the most expensive pieces of kit, and because they don’t entirely remove an operator, they are slow to pay back. Other parts of the line, such as the UniPAKer, pay back more quickly, as each UniPAKer cell is an immediate replacement for two operators.”

He continues: “But just because a system doesn’t pay back quickly doesn’t mean it is not worth the investment. If we hadn’t purchased the palletisers, we wouldn’t be seeing the benefits that we are from the rest of the automation.”

James concluded “You can honestly trust Brillopak. A British company, on our doorstep at the forefront of their field. They’re innovative, proactive and delivered everything we asked. We couldn’t have worked with a better partner on this project.”

Bulk Solids Today

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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

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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

E: enquiries@atsackfillers.co.uk www.atsackfillers.co.uk manufactured in the UK

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

www.kasoneurope.co.uk

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Screw Feeders, Mixers & IBC Systems

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Screw Feeders, Mixers & IBC Systems

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Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706

Russell Finex

www.ajax.co.uk email: solids@ajax.co.uk

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WITH SIEVMASTER BY FARLEYGREENE.

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InterBulk GROUP

Bulk Solids Today

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