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Issue 123



12  BULK MATERIALS HANDLING BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: 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 SUBSCRIPTIONS Subscriptions are available via www.bulksolidstoday.co.uk/subscribe No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements.




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



www.bulksolidstoday.co.uk Bulk Solids Today





ortex Global Limited, a solids and bulk handling components company, has been recognised with the Materials Handling Engineers’ Association (MHEA) Excellence Award for Supplier of the Year. The MHEA Excellence Award for Supplier of the Year is intended to recognise companies who have made significant impact on customer successes through outstanding customer service, robust product offerings, excellent product quality, or has exceeded expectations in the bulk materials handling industry. Vortex was nominated by LeBlansch Bulkhandling Equipment B.V. for their excellent collaboration during a recent project for PPG Industries Chemicals. In reflection on the project, Jan Le Blansch, owner of LeBlansch Bulk Handling Equipment BV, said: “Vortex has always strived to offer the correct equipment for even the most challenging applications put forward – while at the same time, continuing to provide quality components of a high standard. We have been working on projects with Vortex

Global Limited for many, many years, and it is always a pleasure to stay in contact with the Vortex team.” The award was presented on Wednesday, October 18, at MHEA’s secondannual Excellence Awards Ceremony & Dinner, hosted in Nottingham, UK, at Eastwood Hall. Other recipients of MHEA Excellence Awards include: Apprentice of the Year: Adam Christie, Rotary Power Ltd. Innovation Award: ConveyorTek Ltd. Project of the Year: Telestack Ltd. The MHEA Excellence Awards Ceremony & Dinner concluded BULKEX 2017, a two-day conference & exhibition organised by MHEA to provide networking opportunities and present technical knowledge to professionals and organisations from across bulk material handling industries. “Vortex is proud to receive this

award because it recognises our increased presence and success in international bulk handling markets,” said Laurence Millington, managing director at Vortex Global Limited. “It is always a pleasure to work with our international sales groups, such as LeBlansch, on challenging engineered projects. In doing so, we expand our knowledge on the different types of conveying applications, and what equipment is necessary to approach them. “MHEA is a staunch supporter of UK and overseas companies such as ours, and we enjoy working with likeminded people to advance the knowledge base for bulk handling industries.” www.vortexglobal.com



oozi Body Care – manufacturer of a range of cocktail-inspired hand and body creams and washes – has outsourced its B2B and B2C supply chain processes to Berkshire-based Walker Logistics. Walker will provide picking, packing, kitting and fulfillment services for Boozi Body Care’s online sales and supply replenishment orders to the company’s growing list of UK-based retail partners. The contract will run from Walker Logistics’ 250,000 sq ft multi-client warehouse facility on the outskirts of Reading. William Walker, sales director of Walker Logistics, commented: “Boozi Body Care needed a logistics specialist with a successful B2B and B2C track record and we are delighted that they chose us.” “We offer a very personalised 4

Bulk Solids Today

service and provide a quality interface between our clients and their B2B and B2C customers.” Established in 1999, Walker Logistics

offers a comprehensive range of bespoke logistics services to a broad range of clients operating in diverse industry sectors. www.walkerlogistics.com




nward Holdings Ltd, renowned for supplying high quality sites for warehouse and logistics operations, has attracted a unique mix of businesses to the company’s Unit 4 at Langthwaite Business Park in South Kirkby, near Wakefield in West Yorkshire. Now nearly fully occupied, ‘the new kids on the block’ are a growing logistics company expanding its operations, a school for musical roadshow professionals, a leading fabrication company and a centre for training LGV drivers and haulage contractors. These thriving UK businesses have all snapped up warehouse space at the Yorkshire site, citing the need for improved facilities, increased storage space and the close proximity to the major motorway networks as major reasons for choosing South Kirkby. Moving its distribution facilities into larger Langthwaite Business Sizepremises Reductionat(2017) Ad (130x180)_Layout 1

Park site is helping DBL Transport & Storage Ltd to meet demand for the packaging materials it supplies. DBL decided on a five-year lease on Unit 4 at Langthwaite, a 22,000sqft warehouse which was adapted to perfectly meet its requirements. Cato Academy, the only school in the world that trains the next generation of touring and production managers, backline technicians and live sound engineers under one roof, is part of Production Park at the South Kirkby site, where it provides a real live events environment for students whilst they complete their studies. Training 4 Logistics has a learning facility in Langthwaite Business Park for Fork Lift Truck training and logistics operators for Driver CPC, First Aid, ADR and Transport Manager CPC. From logistics and music to the welding and plasma services 13/09/2017 15:07 Pageprofiling 1

provided by Allen Fabrication at the company’s fully equipped 13,500sqft workshop on the site, Langthwaite accommodates a variety of sectors. Onward Holdings’ director, Neil Storey, said: “We have made a considerable investment in modernising the facilities and are delighted to report that Unit 4 at Langthwaite Business Park site is almost fully occupied. However, we still have space at some of our other sites and would urge any business looking for an operations hub in the north of England to get in touch.” Onward Holdings also owns purpose-built sites in Featherstone, Castleford, Normanton and Scunthorpe offering a range of logistics options to suit most budgets, together with additional value-added warehouse services. https://www. yorkshirewarehousing.com/

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Bulk Solids Today





leading mobile vehicle lift company in the West Midlands is putting health and safety firmly on the agenda with the launch of its new online training solution. Bosses at TotalKare HDWS Ltd, of Chancel Way, Halesowen, are hoping the firm’s brand new online training solution will help ensure those using its mobile vehicle lifts do so in a competent and ultimately safe manner. The online training solution follows the successful launch of TotalKare’s CPD-approved training course in mobile vehicle lift competency, and allows customers to fully manage and report on the training of staff in this area of competence via an online platform. Through this platform, customers can easily identify that staff have been trained in accordance with health and safety legislation and safe working practices. It also provides full reportability on all employees’ progress at each stage of the training process. The mobile vehicle lift competency courses cover such key subjects as the safe operation of equipment, pre-use checks, and the very latest updates on

such legislation as the Provision and Use of Work Equipment Regulations 1998 (PUWER) and the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). While the course content is relevant to any mobile column lifts, the functionality section relates specifically to TotalKare’s lifting equipment and thus can be tailored specifically to the model(s) of lift the customer has on site. The introduction of the online training course provides a solution for companies where engineers’ time on the shop floor is at a premium while training remains an important requirement. Online training of mobile vehicle lift competency can be delivered at a convenient time, minimising disruption to the workplace while engineers attend. “As most will be aware, the Health and Safety at Work Act 1974 requires employers to provide whatever information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety at work of employees,” said Tim Jackson, Managing Director of TotalKare, “We take safety very seriously

at TotalKare and build a number of failsafe measures into our mobile vehicle lifts as standard in order to safeguard the operator. However, we’ve seen recent examples in the industry of improper practice leading to injury and hefty fines from the HSE. “As the UK’s foremost provider of heavy duty workshop solutions, TotalKare is leading the way in this area through the creation of these training courses, ultimately designed to help people work smarter, more effectively and return home safely each day.” For further information, please contact TotalKare on 0121 585 2724 or visit the website www.totalkare.co.uk



ulk materials handling equipment specialist ProSpare has opened a new, custom-built two-storey office block and warehousing unit at the site of its existing head offices to accommodate ambitious growth plans. The Nottinghamshire-based firm will use the new unit, in Pinxton, to house its growing team of engineers, site fitters and expanded stockholding of components. ProSpare specialises in helping to solve abrasion, impact, noise, material flow and dust containment problems in heavy industries, along with supplying hygienic powder handling equipment to the food, pharmaceutical and animal feed industries. It is a sister company of ConSpare Ltd, which specialises in providing concrete production solutions. Managing Director, James Bullock, said: “We have more than 40 years’ 6

Bulk Solids Today

experience in the concrete production industry and a lot of the expertise we’ve built up over that time lends itself perfectly to the bulk handling sector. “The products we supply and the engineering know-how we have built up means we can help businesses which handle bulk materials to take cost out of their manufacturing processes, maximise the efficiency and effectiveness of production equipment

and bring about productivity, quality, safety and environmental performance improvements. “We believe that ProSpare has tremendous growth potential. The new building signifies our commitment to the expansion of ProSpare and will provide enough dedicated space for its expanding team and product range to flourish.” www.prospare.co.uk




n November 2017, Vortex was certified to the ISO 9001:2015 standard. Previously, Vortex was certified under the ISO 9001:2008 standard, and has been ISOcertified for more than 10 years. ISO 9001 is an international standard that specifies requirements for a management system. By gaining ISO 9001:2015 certification, ISO 9001 acknowledges that Vortex has demonstrated the ability to consistently provide products and services that meet customer and regulatory requirements. In essence, the ISO 9001 standard acknowledges Vortex’s credibility as a reliable and consistent supplier of material handling equipment and technical services to the dry bulk solids industry. Among the major changes of ISO 9001:2015 versus ISO 9001:2008 was a transition of emphasis from “preventative actions” and “required

documentation” to “top-down leadership and communication” and “business opportunity/risk assessment.” This communication emphasis includes more open communication with customers and suppliers, and greater information transparency within the organization and its shareholders. Over time, Vortex will gather data on the effectiveness of these communication channels and refine their approaches to best communicate with internal and external audiences. To improve internal transparency, Vortex top management created a document to assess both short-term and long-term opportunities and risks for the company’s operations, and developed strategies for how those opportunities and risks will be approached to improve the business. Vortex top management also developed a long-term business plan to provide employees and stakeholders with a clear understanding of the company’s goals and strategic

objectives for the future. “By making these revisions in our management processes, we hope to continue building customer trust and piece-of-mind around our improving operations,” said Mark Sander, standards manager at Vortex. “By keeping current on ISO standards, we are able to use their guidelines as a road map for how to most efficiently operate our business, while also being focused on continuous improvement opportunities. The end goal for each of these changes made by top management is to improve satisfaction among Vortex employees, its customers and its suppliers.” Email: vorterx@vortexglobal.com Web: www.vortexglobal.com

Bulk Solids Today



PARTNERSHIP CREATES VISION AND INSPECTION PRINT TECHNOLOGY POWERHOUSE Baldwin expands global platform with the acquisition of QuadTech, Inc.


aldwin Technology Company Inc.—a world leader in providing process automation solutions, consumables and services for the print, packaging, textile and corrugated industries—has acquired QuadTech, Inc., from its parent company, Quad/ Graphics. With this acquisition, Baldwin adds all of QuadTech’s highly regarded technology and strategic locations across the Americas, Europe, China, Japan and India. QuadTech is a global leader in the design and manufacture of control systems that help commercial, newspaper, packaging and publication gravure printers improve their performance and productivity. Headquartered in Sussex, Wisconsin (USA), QuadTech maintains a worldwide network of sales and service operations, and sells automated systems in more than 100 countries. Baldwin will strategically unite QuadTech with two of its existing divisions—Web Printing Controls and PC Industries—creating a global platform that will operate as Baldwin Vision Systems. The resulting combination of businesses and technology will represent the industry’s most comprehensive

portfolio available for print process automation, inspection and related services. Karl Fritchen, current QuadTech President, will lead the new Baldwin segment, which brings together the best and brightest global talent and capabilities in the industry. Product technologies will span closedloop automation for registration, inking, color management, web handling and 100 percent inspection for the commercial, newspaper, labels, packaging, converting and publication gravure industries. “The combination of products and expertise held within both companies will enable us to reach areas of the market we were unable to reach individually,” commented Fritchen. “From an international operations and market perspective, each party’s strengths are highly complementary. This is definitely a situation where we can accomplish much more together than we could have as independent companies.” “QuadTech will serve as a catalyst for the formation of our new Baldwin Vision Systems segment, which will greatly enhance Baldwin’s ability to provide an even more comprehensive automation portfolio for our customers around the world,” said Brent Becker, President and CEO of Baldwin. “Together, we provide our customers an unmatched portfolio in commercial and newspaper automation, and I am very excited about the additional capabilities we will gain in L to R: John Woolley, Business Leader, PC Industries; Herman Gneuchtel, the packaging Business Leader, Web Printing Controls; Brent Becker, President & markets. CEO, Baldwin; and Karl Fritchen, President, QuadTech. 8

Bulk Solids Today

The work QuadTech has done recently on color within the packaging market clearly places us as the industry leader, and we have aggressive plans to build upon that position. I fully expect that our combined global presence, coupled with a new tiered product offering, will position the company to further satisfy our customers’ needs in an even larger geographical area.” QuadTech is Baldwin’s fifth acquisition since joining the BW Forsyth Partners family of companies in 2012, and the fourth completed in 2017. “We are thrilled to partner with the QuadTech team, as this investment underscores our continued commitment to a strategy that blends organic and acquisition growth to enhance our global footprint, advance the technology and service we can deliver to our customers, and cultivate our unique culture of care and collaboration,” said Kyle Chapman, Founder and Managing Director of BW Forsyth Partners. “We will continue to support Baldwin’s strategy execution, as the team seeks opportunities to expand the company’s reach into new industries and new geographic markets, increasing solutions for customers.” ABOUT BALDWIN TECHNOLOGY COMPANY, INC. Baldwin Technology Company Inc. is a leading global manufacturer and supplier of process-automation equipment and related consumables for the printing, packaging and other industrial segments, including technical textiles, chip and fiberboard, and film extrusion. Through our global footprint, Baldwin offers our customers a broad range of market-leading technologies, products and systems that enhance the quality of industrial-produced products, with a focus on improving the economic and environmental efficiency of the production process. As a total solutions provider, Baldwin not only offers new equipment to our customers, but also dedicates extensive resources to maintaining and servicing existing equipment. Baldwin is privately owned by BW Forsyth Partners, a Barry-Wehmiller company. For more, please visit baldwintech.com.




ITA’s forklift truck Market Index shows that sales of trucks rose by 8.2% year-on-year, reaching 33,407 by the end of the third quarter of 2017, continuing the improvement on 2016 levels. This is the third successive quarter of growth, painting a picture of a sector that can withstand short-term economic fluctuations. Sales into manufacturing sectors were again high, with a 5.9% improvement on the previous year’s figure, reflecting the growth in UK manufacturing output this quarter. BITA Secretary-General James Clark commented: “Despite the uncertain economic environment, forklift sales have continued their recovery from the downturn seen during H2 of 2016, particularly in the retail distribution and manufacturing sectors.”  However, the positive picture for construction sales at the beginning of the year, which had shown a 26% increase in annualised sales compared with 2016, has subsided – with the latest figures pointing to a 3.4% reduction on the previous year’s deliveries. This mirrors the contraction in the construction sector over the last two consecutive quarters. Retail distribution remains a major growth area, and the dip registered in 2016 has since been replaced by a strong recovery, sales up 40% on last year. However, manufacturing remains the largest single sector user of industrial trucks, making up over a third (32%) of sales. www.bita.org.uk

LIFTING THE UK ECONOMY: QUARTERLY SNAPSHOT OF THE FORKLIFT INDUSTRY Forklift trucks are supporting growth in the UK economy. They operate in every major area of business from agriculture to waste management and in both the public and private sectors. Following a strong start to 2017, annualised forklift truck sales are up 8.2% compared with 2016 but economic fluctuations play a role in quarterly changes.


Demand from the retail distribution sector remains 40% higher than last year, and pedestrian warehouse trucks have continued their dominance as the most in-demand truck having a market share of 39% over the 12 months to September.





















lugston Distribution, part of the privately owned Clugston Group, which also has interests in construction, facilities management and property development, is pleased to announce the appointment of Mr Tim Doggett as distribution director. Mr Doggett joins Clugston Distribution from Rhenus Logistics, where he held the position of general manager and was responsible for the organisation’s sales and operations across the North West region. He brings a wealth of commercial, general and senior management experience, having also worked as the regional director for Europa Worldwide Logistics Group, overseeing locations in Northern England and Scotland. With over 25 years in the logistics industry across road, air, sea and warehousing distribution channels, Mr Doggett’s other previous positions include senior roles at UPS, RH Stevens and H&S Handel und Transport. Mr Doggett added: “I’m proud to have a joined a company with such a strong history within the industry, and particularly in its 80th anniversary year. I am looking forward to working with the team to further develop opportunities for the division and the Group.” www.clugston.co.uk.

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



WILLIAMS RACING DRIVER SHARES THE SECRET OF HIS SUCCESS Williams Martini Racing Formula One driver Lance Stroll shared some of the secrets of his sporting success during a visit to JCB and the JCB Academy.


troll was just 18-yearsold when, in November last year Williams Martini Racing announced he would drive for them. Then in June this year he finished third in the Azerbaijan Grand Prix – making him the second youngest man in history ever to stand on a Formula One podium. Today he shared those experiences with JCB employees – including apprentices and graduates – during a question and answer session in the company’s theatre at its World HQ in Rocester, Staffordshire. Stroll then headed to the nearby JCB Academy where he met and took questions from dozens of students before posing with the Williams Martini Racing’s Formula one car. JCB Chairman Lord Bamford said: “Lance Stroll is the epitome of what 10

Bulk Solids Today

can be achieved at a very young age through hard work and determination and Lance has only just got started. As JCB nurtures and develops its next generation of engineers, hearing about his success first hand was an inspiration to our young people.” Canadian-born Stroll said: “It’s every boy’s dream to be a racing driver and I have had some amazing experiences in such a short period of time. If telling my story to JCB’s young engineers and JCB Academy students encourages them to aim even higher, I will be delighted.” JCB has just completed its first year as a partner of Williams Martini Racing – offering the company huge opportunities to promote its brand around the world. As part of the partnership agreement, JCB branding appeared on the Williams Mercedes FW40 chassis and rear wing end plate. JCB also

featured on drivers Felipe Massa and Lance Stroll’s race suits and helmets. The partnership has helped JCB generate additional machine sales with new and existing customers from 32 different countries, with many of them attending races with JCB and events linked to Formula One. www.jcb.com




n inflatable seated butterfly valve designed for dry bulk solids or liquid slurry applications is available from Posi-flate. The valve is ideally suited for abrasive materials such as sand, feldspar, fly ash and most other dry, granular materials, which reduce valve life. The inflatable seat design provides a better seal by utilizing air pressure to expand the seat against the disc, providing more sealing area and an even pressure distribution against the disc every time. The seat automatically compensates for wear when it inflates

against the disc, extending valve life considerably. Because the Posi-flate disc only makes casual contact with the seat during opening and closing, torque requirements are substantially lower. This ease of movement also allows the disc to come to a perfect 90-degree position every time. Additionally, the smooth profile of the disc helps material flow easier and reduces build-up. For unique fail-safe monitoring, a pressure switch can be utilized to verify a perfect seal. Two Series are available, a one-piece housing with separate shaft and disc and a split housing design with integral disc and shaft. Standard sizes range from 2” (50mm) to 30” (750mm). The valves are available in a wide variety of construction materials. Tel: +44 (0)1908 622366 Email: sales@posiflate.co.uk www.posiflate.com



ollowing a review of the latest heavy lifting equipment facilitated by Cooper Specialised Handling, a wellestablished container services company has added a new SANY empty container handler to its fleet. With 25 years of experience in the shipping container industry, Northern Containers specialises in the sale of new and used containers. Part of the Ace Group, it operates a UK-wide container hire service, provides depot and self-storage facilities and carries out conversions and fabrications. The company was due to replace one of its machines and a SANY SDCY100K7G-T double lift empty container handler is now in service at its Leeds base. The acquisition of new equipment represents a major investment for Northern Containers, so managing director Sean Birdsall and Ace Group CEO John Hanson set up a fact-finding mission, travelling throughout Europe, including Denmark and Sweden, to assess which manufacturer could best meet their requirements. Cooper Specialised Handling is SANY’s exclusive distributor in the UK and hosted a visit to the manufacturer’s European headquarters near Dusseldorf, Germany. Northern Containers was able to review machine capabilities at close quarters, as SANY empty container handlers were put through their paces in simulations of typical applications. Sean Birdsall said: “Our operation demands quality equipment that we can rely on day in, day out and we were impressed both with SANY’s manufacturing facilities, the build quality of the trucks, overall machine stability and the high standard specification. “For us, it’s also important to work with an experienced partner who understands our business and Cooper Specialised Handling has given us untold support, creating a cost-effective handling solution that is already boosting productivity.” 12

Bulk Solids Today

Built on a nominal 30-tonne chassis, the SANY SDCY100K7G-T was specified with 14.00 x 24 solid tyres. Not only does this larger-than-standard diameter tyre offer a smoother ride, but also, in a ground-breaking twist, the solid tyres do not interfere with the structural warranty and the machine was supplied with a full and extended warranty. SANY is believed to be the only manufacturer of empty container handlers to fabricate its own structural assemblies in-house. To ensure the SANY empty container handler would meet the customer’s needs, Cooper incorporated a series of options to the specification at no extra cost. Supplied as part of its Valu+ initiative, they include a double box with hook and side clamp and Autolube attachments and spreader. A Grammer XL seat with air suspension, heating and lumber support; additional cabin lighting and a rear window sun curtain enhance operator comfort, while a reversing camera and rear sensors offer greater visibility during manoeuvring and so promote safety. Cooper Specialised Handling’s sales director Chris Barnes said: “We’re delighted to have secured this important new contract with Northern Containers. Seeing the equipment at work in a realistic environment enabled the directors to gain a better understanding of the technology and appreciate how they can use it to benefit their expanding business operation.” www.cooperhandling.com




he world record for the heaviest object pulled over 100 feet belongs to a US reverend who pulled a 68-tonne lorry. This is an impressive achievement, but one that manufacturing plant engineers must regularly equal using specialist equipment — with various degrees of success. Here, Hugh Freer, a director of electric tug specialist MasterMover, looks at why these traditional methods are ineffective. In 2016, Reverend Kevin Fast, otherwise known as the Powerlifting Pastor, achieved the world record for the heaviest object pulled over 100 feet by pulling a 68-tonne lorry over the course. While a load of that weight would be unusual in many factories, manufacturers everywhere face a daily challenge moving heavy tools and parts through their production halls. Unfortunately, few people in the average manufacturing facility share Reverend Fast’s strength, so they keep large parts in one place or rely on methods such as cranes or forklifts to move large loads around the facility. In many industries, the movement of work in progress, sub-assemblies and tooling provide a challenge. The default answer for many companies is to use overhead cranes to move large parts through the factory. Not only are these expensive to install, but the process of lifting heavy loads using overhead cranes can be a cause of downtime. For example, production blockages can occur at one end of the plant while the overhead crane is tied up at the other end undertaking complex lifting operations. Motorised electric tugs like MasterMover’s MasterTug allow for more flexibility when handling objects than an overhead crane, while still moving objects up to 30,000kg. While an overhead crane can move parts from side to side on the lift bar and up and down on the girders on the factory roof, the part cannot be moved in all directions or to an adjoining building. However, electric tugs, handled by a single pedestrian operator, can move in all directions and can be used to move objects in between production facilities. In one such case, a company was using a lorry to move large metal plates from one assembly building to the next. Although the buildings were adjacent, the layout of the factory meant that work in progress was loaded onto a lorry and then driven on a mile long circuit of the plant before being unloaded in the production hall next door. By using an electric tug, the company virtually eliminated this lost time. A single pedestrian operator could move the load between the two buildings in minutes, using the tug to move a transfer trolley. Large parts are often objects in the later stages of the assembly process, meaning they are often high value. It is therefore important that plant staff have complete control over the object when it is being moved, but dangling the object from a height over the production line presents obvious risks. By using an electric tug, which easily connects to the object, the operator can move the part across the plant with complete control. This is without the risk of the object falling from a height, swinging or hitting any other objects while dangling. By reducing downtime, increasing flexibility and making

large objects faster and easier to move across the plant, it is clear to see than an electric tug is a good alternative to the traditional use of cranes. Unlike Reverend Fast, most plant staff are unable to push large, heavy parts across the plant. It’s therefore vital that plant managers choose a method of moving large items that is safe, efficient and effective. www.mastermover.com

Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. • • • • • •

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


Bulk Solids Today





move to a new storage unit and the introduction of some of the latest intralogistics technologies, allowed bathroom products specialist Roper Rhodes to make considerable immediate supply chain cost savings Roper Rhodes Ltd is a leading independent supplier of bathroom furniture and products. Founded in 1979 and based – appropriately – in Bath, the company’s range is sold via a network of merchants and other bathroom equipment specialists across the UK. Due to the success of the business, the company recently looked to overhaul its storage and intralogistics processes. Roper Rhodes had, for a number of years, operated several ‘satellite’ storage sites within a few miles’ radius of its main Bath headquarters facility, so, when a much larger building became available in the Avonmouth area, the company took the opportunity to consolidate all of its warehousing and logistics activities under one roof. But, while it offered the storage space Roper Rhodes sought, the new facility had to undergo some significant modifications to enable it to function efficiently and Flexi Warehouse Systems – the intralogistics project division of space saving materials handling specialist, Narrow Aisle Ltd – was chosen to develop a collaborative turnkey solution and then project manage the upgrade. The former print works is, in fact, five separate but linked buildings and these annexed spaces have been designed to handle different aspects of Roper Rhodes’ inventory management operation. The first of the units works as a goods-in and goodsout area where incoming product lines are block-stacked before put away and outgoing orders are collated and assembled before being loaded on to delivery vehicles. The remaining four units are a mix of half- and fullyracked stores featuring two deep racking designed by Flexi Warehouse Systems and served by a combination of Flexi SToRMAX and Flexi AC 1200 articulated lift trucks, as well as a fleet of low-level order pickers (LLOPs) with long forks to handle the ISO type pallets which are used as a base for assembling customer orders. The project was completed in phases to meet Roper Rhodes’ business needs and the efficiency and financial gains have been almost immediate, as Flexi Warehouse Systems’, John Maguire, explains: “Because Roper Rhodes had outgrown the space that its various original units offered, the company had been using third party warehousing to store many slow moving 14

Bulk Solids Today

lines. This not only incurred significant storage costs but also led to additional transport costs, and double handling within Roper Rhodes’ internal supply chain as well as an unacceptably high incidence of avoidable and costly product damage.” The Flexi solution involved housing all slow moving items within high density two deep racking accessed by Flexi SToRMAX trucks and, because it enabled Roper Rhodes to dispense with its third party storage site – and the overheads that came with it – straight away, this was the first phase of the new store to be completed. In simple terms, the Flexi SToRMAX technology and two-deep system installed across the Roper Rhodes site, allows two pallets from the same side of each very narrow aisle to be handled which effectively doubles the capacity of each run of racking within the store. Adopting this configuration allowed Roper Rhodes to achieve 4900 pallet locations just within the slow-moving storage system. This figure is a staggering 50 per cent more pallets than would have been possible within the available footprint using a conventional reach-truck-based solution. In total, the entire facility offers 14,200 pallet locations, which provides an additional 6,700 pallet locations in single and two-deep pallet racks. The Flexi clear narrow aisles allow all ground level locations to be utilised as dedicated product picking locations to service Roper Rhodes trade customer orders as well as their online customer order fulfilment. To ensure that the battery-powered materials handling fleet – including the Low Level Order Pickers – operates at optimum efficiency, Flexi Warehouse Systems installed an integrated battery charging system. The low energy usage Hoppecke system features the latest call-forward alert technology to identify the most appropriate fullycharged battery for the truck operator to select when it is time to change. This means that batteries often last for up to 12 hours between charges, extending battery life and dramatically reducing energy consumption. John Maguire added: “Flexi Warehouse Systems’ ability to offer a complete service from design through to supply and installation of all storage and material handling equipment allows companies to make real operational cost savings and by utilizing some of the latest intralogistics technologies and handling techniques at its new facility Roper Rhodes has been able to create a highly cost-effective and efficient operation with a very attractive pay-back period.” www.flexi.co.uk




yster Company has adapted a 30 tonne lift capacity Hyster® forklift to simplify transportation of hot metal coils, while reducing truck wear and tear. Uniquely, the lift truck mast has no chain. “The customer operates a steel mill and needed a durable solution for transporting coils that can have a temperature up to 450 degrees,” says Chris van de Werdt, Commercial Manager for Hyster Big Trucks. “The challenge was that due to the high temperatures of the metal being handled, the chain grease and hoses on a regular forklift mast would rapidly wear out. An added challenge was that the truck needed to be able to move in and out of buildings where the driving height is limited.” The Hyster Special Engineering Department developed a solution where the Hyster® H30XM-12 was delivered with a direct lift mono mast and an integrated coil ram attachment. “This direct lift mast uses only lift cylinders, removing the issue of maintenance of the mast chains,” Chris says. “The tough coil ram attachment allows hot coils to be moved easily and even stacked two-high. Also, the restricted driving height of the truck has not been affected as the special mast design enables a full free lift with no parts extending above the mast at any time.” The rugged Hyster® H30XM-12 forklift is ideal for



ynamic Air BulkBuster bulk bag unloaders provide the solution for effectively emptying large bulk bags and getting the material where you want it in your process. Safety is always a primary concern when handling and maneuvering extremely heavy and cumbersome bulk bags. The Series 422 Model 1900 BulkBuster bulk bag unloader offers a continuous cleaning method of discharging bulk bags because it includes internal dust collection for containing all fugitive dust. Features include easily removable bayonet mounted cartridge filters for recycling the fugitive dust by discharging it back into the process hopper below. Also included is a bag closing device, sight glass and work gloves to allow the bulk bags to be untied and emptied without contacting any of the process material being discharged. One unique but standard feature is a set of air operated bulk bag jostlers for massaging the bulk bags for faster discharging of difficult to handle materials. An optional bag closing mechanism is also available to allow partial bulk bag unloading. www.dynamicair.com/products/bagunloader/html Tel: + 44 1908 622344 Email: sales@dynamicair.co.uk

heavy duty applications and is particularly suited for operations handling metals and blocks. Featuring a 1200mm load centre, it has a range of carriage, fork and front-end attachments. With quick disconnect forks for fast attachment exchange, it offers the user maximum flexibility for handling varied heavy loads with just one truck. “Even though Hyster® forklifts offer the reliability and strength to suit a heavy application, sometimes unique challenges need a custom solution. We work with our customers and partners to provide special engineering that not only helps get the job done, but, in cases like this, is essential for maintaining productivity and keeping maintenance costs low,” says Chris. The Hyster Special Engineering Department is located at the Nijmegen plant in the Netherlands, the global centre for Hyster® Big Trucks design, development and testing. For more information visit www.hyster.eu

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oyle Plant & Construction’s latest MercedesBenz Arocs is not just any contender – driver Dave Coombes reckons that with striking Rocky Balboa artwork adorning the cab, his new eight-wheeler is a knockout! Dave chose the Sylvester Stallone blockbuster as the theme for the muscular tipper’s graphics, and employer Charlie Doyle was happy to roll with his idea. “We like our vehicles to look smart and have a high profile, so they double as mobile advertisements for the business,” said Mr Doyle. “As he’s been with us for more than 10 years, we invited Dave to suggest a design for his next truck. “I wasn’t surprised by his choice, because he’s a big Rocky fan. But I agreed the movie would be an excellent subject and we’re both delighted with the result. The livery has already drawn a huge number of positive comments from other


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drivers, and from members of the public who have phoned the office to tell us they’ve seen the truck out on the road.” Windsor-based Doyle Plant & Construction provides bulk excavation and groundworks services for customers across the South-East, as well as supplying a wide range of materials, including sand, aggregates and ballast. The 8x4 Arocs 3240 is one of two supplied to the company by the Heathrow branch of Mercedes-Benz Dealer Group Rygor Commercials. It was painted and lacquered by Tor Trucks, of Somerton, Somerset, with renowned truck artist Matt Paint applying the striking airbrushed images. Powered by 10.7-litre straight-six engines generating 290 kW (394 hp), which drive through smooth and efficient PowerShift 3 automated transmissions, both trucks are fitted with steel Thompsons tipping bodies and Palfinger cranes. The second is in Doyle’s standard colours.


Gavin Duffy added: “The rugged Arocs is purposedesigned for the construction sector, and certainly packs a big punch. I’m delighted that thanks to our customerfocused approach and commitment to Setting Standards, we’ve been able to supply Charlie and his team with another two exceptional trucks that can be relied upon to go the distance.” www.cdoyleplant.co.uk

The company runs three tractor units and eight 32-tonne rigids, a combination of tippers and tipper-grabs, which it maintains in-house. It has operated vehicles by various manufacturers but an Arocs eight-wheeler supplied by Rygor Commercials in 2014 made a real impact. “It can be difficult in our line of work to compare fuel figures between trucks, because of the big variations in the jobs they’re doing from one day to the next,” said Mr Doyle. “You certainly get a feel for it, though, and that truck was noticeably better than anything else on the fleet, in terms of both diesel and AdBlue consumption. In fact, you might say the others couldn’t lay a glove on it!” He continued: “The driver loved the Arocs and it proved superbly reliable. Nothing went wrong in three years of operation, while the warranty and parts back-up from Rygor was every bit as good as we’d hoped. So we had no hesitation in returning to the same Dealer for our latest trucks.” Rygor took back the original Arocs and a Swedishbuilt eight-wheeler in part-exchange against the two new vehicles. “Sales executive Gavin Duffy handled our order and was very attentive, always available seven days a week,” added Mr Doyle.

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HYSTER® TRUCKS OVERCOME TOUGH TESTS AT SAND-LIME BRICK FACTORY From large quantities of dust, to extreme temperature variations, Hyster® forklift trucks help overcome the tough conditions at Radmacher Kalksandsteine, a sandlime brick production plant in Wendeburg, Germany.


he family business has been producing sand-lime bricks using only sand, quicklime and water since 1963. The blocks are hardened in 15bar pressure autoclaves where more than 60 employees ensure continuous production in a threeshift, around the clock operation. Due to the demands of the application, including a climate that varies from -15°C in Winter to more than 30°C in Summer, the business tested various forklifts thoroughly before selecting new trucks.

“NO STONE IS MOVED WITHOUT A HYSTER® FORKLIFT” The sand-lime bricks are manufactured in standard sizes as well as in varying dimensions dependent on customer requirements and specific building plans. Hyster® trucks ensure a continuous, reliable process, from production to storage of the blocks. “No stone is moved without a Hyster® forklift,” says Christian Baars, Production Manager at the plant, who is especially pleased with two new Hyster® H13XM-6 heavyduty forklift trucks. These trucks, with a lifting capacity of 13-tonnes and a load centre of 600mm, were acquired after testing several different trucks from well-known manufacturers.

HYSTER® TRUCKS HANDLE SLOPES EASILY While all trucks tested performed well when unloading trolleys and equipping saws, one competitor was unable to deliver the required performance working on the ramp. The heavy forklifts, fully loaded with sand-lime bricks, have to manage a short ramp with a grade of approximately 12 percent. Although some competitor trucks with strong engines managed the ramp, they consumed significantly more fuel than the Hyster® H13XM-6, which is equipped with a powerful six-cylinder Cummins QSB 6.7 litre engine. “The engine power was not the only deciding factor though,” says Hyster Dealer Torsten Franke, Managing Director 18

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of GS-Gabelstapler Service, in Wolfenbüttel, Germany. “The truck has to be a good overall fit, from the 3-speed ZF hydrodynamic transmission to the transmission ratio.”

HIGH PERFORMANCE WITH LOWER FUEL CONSUMPTION “For us, the high-power reserves and low fuel consumption of the Hyster® H13XM-6 were key,” says Christian Baars. “After all the testing, we put the first forklift into use in our sand-lime brick factory in Uslar, and then ordered another 13-tonne truck, with an S + H stone clamp, to use at the Wendeburg plant.” The state-of-the-art heavy-duty trucks, which comply with Stage IV / Tier 4 final requirements, consume around 20 percent less fuel compared to their predecessors. Good all-round visibility is delivered by the ergonomic Hyster® cab, and further enhanced by the VISTA® mast with external chains and three, instead of four, hydraulic lines. The noise level has also been reduced, enabling the driver to concentrate during the shift. Additionally, the wide chassis and wide drive axle ensure maximum lateral stability when using attachments.

PERSUADED BY THE COOL TRUCK AT HYSTER® HUB The business connection between GS Gabelstapler Service and Radmacher Kalksandsteine has developed over 30 years, with the Hyster® dealer offering advice, fast service and relevant solutions. For example, at the Hyster® HUB in Weeze, Germany, Baars was able to learn first-hand about the latest technologies, such as the Hyster® “Cool Truck”. Based on the H4.0-5.5FT product range, Hyster has developed the Cool Truck especially for use in the dusty

BULK MATERIALS HANDLING conditions found in the paper and recycling industry. The Cool Truck has numerous functions and adaptations to prevent the common problem of the motor overheating due to dust deposits. Hyster® heavy-duty forklift trucks, such as the 13-tonne truck at the stone works, are also designed for use in the toughest operating conditions.

PROTECTION AGAINST DUST AND VARIABLE TEMPERATURES To avoid the problems caused by dust, there is an option to extend the air inlet of the pre-filter. This reduces the amount of polluted air that is sucked in when the standard pre-filter is no longer sufficient. An automatic lubrication function can also be installed to keep dirt out. Drivers also benefit from the Hyster® VISTA Cabin which features an easy-to-clean air filter. Temperature fluctuations pose no problem for Hyster® forklift trucks as they leave the factory in Nijmegen, the Netherlands, ready to withstand operation at temperatures from -18°C to 50°C.

HYSTER® FORKLIFTS PROVIDE UP TO 3,500 OPERATING HOURS PER YEAR Four Hyster® H3.0FT Fortens ICE forklift trucks are used

by Radmacher Kalksandsteine to their maximum performance, reaching up to 3,500 operating hours per year. The trucks are primarily used to transport the sand-lime blocks around the site. Equipped with Superelastic tyres and the maintenancefree Hyster® Stability Mechanism (HSM), which improves side stability, the rugged Hyster® Fortens forklifts support the heavy demands of the operation. Set to the ECO-eLO fuel efficiency mode, these are among the most fuel-efficient forklift trucks available, another deciding factor for Christian Baars. Visit www.hyster.eu for more information.



eading third party logistics specialist, Great Bear, has introduced a new fleet of Narrow Aisle Ltd’s Flexi HiMAX articulated forklift trucks at its major multi-user hub at Brackmills in Northampton. A total of six Flexi HiMAX models will operate aroundthe-clock at the facility while a seventh ‘sub-core’ truck has also been supplied on a Service Level Agreement low-hours contract to be used as a ‘stand-by’ truck to cover seasonal peaks in demand and to ensure Great Bear has the ability to operate at 100 per cent fleet availability all-year round. The Flexi HiMAX can operate in aisleways as narrow as 2000mm and its design allows pallet loads to be stacked up to 12 metres high at Great Bear’s Brackmills site. Pallet throughput cycles of 30 per hour are being achieved within the facility’s 70 metre long aisles - which compares very favourably with either guided man-up or traditional reach type trucks. In addition, Narrow Aisle Ltd has supplied its newly launched Easi-Change battery changing and management system at the Brackmills hub.  Great Bear’s battery charging bay was completely reconfigured by Narrow Aisle and now just 14 batteries are required to deliver optimal Flexi fleet efficiency 24/7. This means that not only have battery numbers been reduced by 20 per cent but, significantly,

overall electricity consumption within the charge room has been cut by 50 per cent. The Easi-Change system combines the latest battery charging technology with established materials handling techniques. The six-hour high frequency, low energy and low maintenance chargers are all linked to provide fully charged batteries on demand, thereby ensuring that the electricpowered Flexi articulated truck fleet requires the fewest number of battery units to operate at maximum efficiency. Furthermore, because the battery changing process is carried out by just one worker in less than five minutes, truck downtime is minimised Great Bear has acquired the trucks on a five-year inclusive contract rental package that includes all planned maintenance, safety inspections and repairs in one fixed monthly rental charge. www.flexi.co.uk Bulk Solids Today




Mรกquina Solo is the ALLU distributor for its Transformer and Processor ranges of equipment throughout Brazil. The company, founded in 1998, has particularly found a ready market for the ALLU M-Series, with the enormous processing power of the equipment being put to good use in various surface mining applications.


ounded in 1998, Mรกquina Solo is a Brazilian company which specializes in supplying foundation, geotechnical, mining and environmental equipment throughout the country. Considered to be one of the leading specialist equipment distributors in Brazil, the company, which began operations supplying hydraulic hammers, now acts as the representative for fourteen leading manufacturers, supplying over twenty four different product lines. Driving the business forward into its 19th year is the commitment of all at Maquina Solo involved in the business to deliver solutions that meet the needs of its customers. This is achieved by being involved in all aspects of the supply process, and covers such as aspects as application analysis, equipment selection, sales through to service, and aftermarket support. One such company that has forged excellent relations with Mรกquina Solo is Finnish manufacturer ALLU, whose Transformer and Processor attachments have been particularly well received in Brazil. The reasons for this are manifold, but the power, flexibility and transportability of the equipment has contributed to ALLU equipment being highly prized in Brazil, with the service and support 20

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provided by Mรกquina Solo complimenting the equipment.

SURFACE MINING An area that has particularly seen the benefits of the ALLU Transformer range has been in surface mining operations. As the Transformer is essentially designed to fit an excavator or loading shovel, this has made the equipment ideal for large scale surface mining operations, where transportability and productivity are essential requirements of material handling equipment. With many units now working throughout Brazil, one such application has seen the ALLU Transformer M-Series being used at a nickel mine, screening chalcedony directly in the mine, in order to upgrade the nickel concentration on the processed material. This particular model was chosen due to its high mobility and functionality in screening the material in-situ, instead of loading onto trucks, then transporting the material to stationary screening plant, and then retransporting the material back to where it originally came from. This has meant the company has been able to replace its stationary screening equipment, freeing up resources as well as enjoying greater flexibility in its operations.



M ALLU M - TRANSFORMING THE WAY YOU WORK There is no surprise that Brazilian surface mining operations have adopted ALLU technology as the ALLU M-Series effectively transforms the carrier it is mounted on (loader or excavator) into a high capacity mobile material processor. The ALLU Transformer M-Series attachment is able to crush soft and brittle material, separate hard unwanted impurities in the rock mass, while loading a dump truck or conveyor system. This makes it ideal for processing of soft rock and other minerals in often hard to get to areas, with the M-Series delivering simultaneous mobile crushing, separating, enrichment and loading. What ensures that the ALLU Transformer M-series really stands out from the rest is the way its use helps to actually transform the entire surface mining operation. The profitability of a business is transformed as materials can be processed at the face, rather than be transported for further processing. This also reduces outside waste deposits and brings environmental benefits, as waste rock is separated before transportation. Business efficiency is further transformed as the loading and processing of materials is now accomplished in one stage resulting in faster, more efficient processing. Essentially the loader or excavator now becomes a multi-machine that can load and process whilst simultaneously replacing ‘overlapping’ machines at the jobsite. This eliminates material double handling needs and helps with cost reduction. Both highly sort after benefits for efficiency driven mining operations.

THE IDEAL SOLUTION The ALLU Transformer M-Series has proved to be ideal for soft rock surface mining applications in Brazil (and elsewhere) as it can easily handle in ‘one-step’ any materials within its range. It can screen any type of material, and by applying the correct amount of crushing force together with the correct drum type, the attachment also efficiently separates hard unwanted waste materials in the rock mass, while crushing the soft material. By adapting to the processing needs and rock mass it encounters, the attachment boosts productivity, through delivering operational efficiency. Different drum configurations of 50mm (2”) and 75mm (3”) mean differing fragment sizes may be processed with high productivity in ‘one step’. The entire process is fully mobile, and can replace conventional crushing and screening plants in many cases such has been found in Brazil. The ALLU Transformer M-Series has been developed specifically for those companies who deal with large amounts of material on a regular basis, specifically quarries, aggregate producers, surface miners, power plants and process industries. It has been designed to fit excavators and wheel loaders of up to 160t (154.4 US t). www.allu.net

entor is delighted to announce that the level 2 mobile and static plant apprenticeship programmes are now underway after the first apprentice was signed up in October this year. Working closely with industry specific employers and specialist training companies, Mentor have been able to strategically tailor and offer a range of engaging and flexible programmes that meet the new Level 2 Mineral Processing Mobile and Static Plant Operator standard to those operating within the extractives industry. Lead training provider Mentor, have worked with the team at Hills Quarry Products Ltd to sign up the first level 2 apprentice, Aidan Jeffreys, based at Hills’ Shorncote Quarry near Cirencester. Aidan will complete a valuable range of external training courses delivered primarily by Mentor, along with industry specialist training providers with whom they have partnered including Rob Shore of Safety Coaching, MRS training, Ifast Fire and Safety Training and Serac UK, which will ensure that Aidan receives a quality learner experience. During his time as an apprentice, Aidan will spend the majority of his time onsite supported by his mentors, receiving specific, practical training. He will follow a structured apprenticeship programme and training plan that Mentor have constructed in line with the apprenticeship standard whilst meeting the needs of Hills’ operation and expectations. Aidan will receive a range of mandatory training including both theoretical and practical units required to achieve the standards with additional training options available. On completion of his apprenticeship, Aidan will hold an NVQ relevant to the pathway that he undertakes in addition to the level 2 qualification itself. Mentor are keen to continue working with employers and their learners and believe that Aidan will prove to be a positive role model to those who are looking to start an apprenticeship. To find out more about the mineral processing operator apprenticeship programmes available from Mentor Training Solutions, please contact Tracy Colton, Head of Apprenticeships on 01246 263443/ tracy.colton@mentortraining.co.uk Aidan Jeffreys (left) with Peter Steffens, operations manager at Hills Quarry Products

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oosan is launching the new DL420CVT-5 Stage IV compliant wheel loader, the first model in the Doosan® wheel loader range to be equipped with a Continuously Variable Transmission (CVT). A CVT transmission is composed of a hydraulic motor combined with a hydraulic pump which provides a smooth and continuous speed variation. The CVT design combines the benefits of a mechanical transmission and a hydrostatic transmission in the same machine. It allows the DL420CVT-5 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 new CVT technology ensures high loads can be carried at low engine speeds with high dynamics for an optimum wheel loader operating cycle. The DL420CVT-5 therefore provides an increase in machine performance for operators working in digging, loading and lifting applications. With a maximum bucket capacity of 4.2 m3, the new Doosan DL420CVT-5 wheel loader is intended to meet a wide range of material-handling needs from loading and transporting granular material (such as sand and gravel) to industrial, construction, demolition, mining and quarrying applications. For most tasks, operators will utilise the hydrostatic part of the transmission, which offers greater fuel efficiency in lowspeed 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 22

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off softly and hydraulically. Furthermore, with the CVT, a fuel saving of up to 15% can be achieved. The ability to split hydrostatic and mechanical power has allowed Doosan to move to the Scania DC09 engine in the DL420CVT-5, as the CVT system maintains the machine’s efficiency even at low engine rpm. With an output of 232 kW (311 HP) of power at 1800 rpm, the Scania DC09 engine provides generous torque at low rpm and meets Stage IV emission regulations without the need of a diesel particulate filter (DPF), through the use of cooled exhaust gas recirculation (EGR) and selective catalyst reduction (SCR) after-treatment technologies. On the DL420CVT-5 and all other Doosan wheel loaders, the engine Auto Idle system when activated saves on fuel costs by lowering the idle level from 950 to 750 rpm – when the operator does not give any input to the steering wheel, arm and bucket for more than 10 seconds (ideal for applications where there is a lot of waiting time such as truck loading). In all DL-5 loaders, the Engine Auto Shut Off shuts down the machine after it has been idling for a specified amount of time (3-60 minutes, configurable by the operator via the control panel). This feature saves on fuel and reduces operating costs. The engine compartment door size has been increased to provide easier maintenance of engine area. The exhaust and after-treatment system for the engine is installed on the left-hand side of the machine, whilst the components for maintenance are grouped on the right-hand side. All the daily checking of gauges can take place from ground level to ensure it is a quick and safe process. The impressive breakout force and high traction allow the DL420CVT-5 to tackle the hardest materials, with a powerful hydraulic system that ensures that work is quick and efficient. Combined with the power provided by the Scania DC09 engine, these features

QUARRYING & MINING gives the DL420CVT-5 excellent penetration power, ensuring an optimum bucket load in each cycle. As with all Doosan Stage IV wheel loaders, operators can select between several driving modes that adjust the maximum engine rpm based on the operator’s preference and the application. • Normal: Balances fuel consumption for everyday digging, grading and lifting tasks • Economy: Reduces fuel consumption for low-demand applications

TWO NEW MODES HAVE BEEN INTRODUCED: Digging mode - this mode is available below 3 km/h and by pressing a button, the machine exerts the maximum torque to the transmission to ensure the best performance. Drive mode - when the machine travels forward at over 14 km/h (or backwards at over 5.4 km/h), with the front pressure stabilized, the loader recognises that the task is driving only and thus shifts automatically into the Drive mode to ensure the best traction and decrease the fuel consumption. A Creep setting is also available with the CVT transmission. The Creep ‘function’ enables the operator to drive the machine at low speed with no need to press on the accelerator pedal when shifting into forward or reverse. Four Creep settings are available: 0 km/h, 1 Km/h, 2 km/h or 3.1 km/h. This function also avoids the transmission autobrake.

LOAD-SENSING HYDRAULIC PUMPS All new generation Doosan wheel loaders have a load sensing hydraulic pumping system, whereby the variable axial piston pump generates the flow upon demand in the amount necessary to perform the work. This also gives better traction for penetrating into the stockpile, as less force is necessary to operate the bucket in many situations. Load sensing hydraulics also minimise loss in the hydraulic circuit during a carrying operation in which the loader is usually running, which is an essential technology for wheel loaders. In response to customer feedback, the load-sensing system has been designed so that the bucket has higher priority when the boom and the bucket operate at the same time and there is limited force available. Joystick control on the new DL420CVT-5 wheel loader is designed to easily combine several movements at the same time. As an option, 3-lever fingertip lever control can be provided for smooth and near-effortless control. Both of these controls use electrohydraulic piloting. The machine has a Boom Kick-out function as standard, which is useful when working in confined spaces or when repeating similar operations in specific work ranges (for example, when a certain dump height must be reached every day). The same system is used to set the bucket automatically to the Return-to-Dig position. The LIS (Load Isolation System), often called ‘Ride Control’, provides the operator with a smoother ride over rough terrain and enables a more comfortable ride at higher speeds. The benefits are reduced cycle times, higher productivity and better fuel efficiency while performing load and carry applications. LIS also contributes to longer frame and machine life. The new loader also offers a ‘third function’ to power a hydraulic system on a work tool, allowing greater machine versatility in a number of applications. The third function valve’s

capacity has been increased significantly to at least 250 l/min. Doosan has also installed an automatic greasing system as standard to reduce working time and increase operating comfort. To facilitate access and mobility on the machine, multiple hand-rails ensure that the operator always has a firm support to hold on to. The cooling compartment is separated from the engine compartment to prevent warm and dusty air from entering and to allow better control of the air intake. An automatically reversing fan is a standard feature - the radiator fan is hydraulically driven and controlled by an ECU. Changing the fan direction for cleaning the radiator can be done manually from the cab, without having to switch off the engine. Fan reverse intervals (30 minutes to 2 hours) can be set via the menu.

HIGH COMFORT CAB The cab on the DL420CVT-5 demonstrates how Doosan has placed operator comfort at the very centre of its design priorities. Offering generous headroom and an ultra-comfortable, fully adjustable, heated Grammer air suspension seat, the cab features a new steering column design giving more clearance for the operator’s legs and knees. The steering wheel can also be tilted and moved telescopically to match the operator’s preferred position or if they prefer, they can use the convenient and ergonomic electric joystick steering control fixed on the seat armrest which provides a smooth and comfortable drive. The increased space, better visibility and plentiful storage space in the cab allows operators to work for hours without fatigue or discomfort. Meeting ROPS/ FOPS regulations, the cab also offers a wide emergency exit (located on the right hand side) to provide fast and easy evacuation in critical situations. The 5.7 inch full colour LCD panel is suitable for day and night work. The user-friendly monitor has two customisable screen displays to suit the operator’s preference, giving a full readout of machine settings and maintenance data. The rear-view camera greatly enhances visibility and safety. The screen in the cab shows the operator what the camera sees and includes several lines to help judge distances; it also has other functions, including light intensity control, viewing angle control, language setting and power on/off setting. www.doosan.com Bulk Solids Today





surumi Pumps’ products are featured on the eighth season of Gold Rush, the popular Discovery Channel reality series that follows the exploits of 316 Mining. The Oregon, U.S.-based mining company chose Tsurumi as its exclusive provider of pumping equipment, which includes numerous pumps, variable frequency drives and custom-built pontoons. Key personnel from Tsurumi’s U.S. division also offered extensive engineering consultation on the job site in Fairplay, Colorado, U.S., before shooting began. A handful of crew members at 316 Mining — known by fans as “The Hoffman Crew” — had previous experience using Tsurumi pumps in their operations, which made the choice to use the company’s products during the latest season an easy one. Prior to filming Gold Rush’s eighth season, 316 Mining had been using engine-driven pumps from another manufacturer in its gold processing plants, where high amounts of water are pumped to help separate dirt and rock from gold in a mining process called “sluicing.” But Fairplay’s elevation of 3,034 m (9,953 ft) above sea level made it impossible to


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run the pumps’ diesel engines at a constant RPM, and the resulting surges in power were not conducive to maintaining a steady flow of water. In an industry where lost time equates to lost gold, 316 Mining quickly turned to a more dependable solution: electric submersible pumps from Tsurumi. Series star Todd Hoffman, leader of the Hoffman Crew, said that once he determined the need for electric submersible pumps, his crew quickly pointed him in the direction of Tsurumi, a company with a proven track record of resilience in the field of mining. “I asked our foreman, Trey Poulson, what the best company was for electric submersible pumps,” he said. “Tsurumi’s pumps were at the top of the list because of their durability and reliability.” The Hoffman Crew visited Tsurumi’s booth at MINEXPO 2016 in Las Vegas, Nevada, U.S., to learn about the company’s pumps and to gauge interest in working together. For Tsurumi, it was a natural fit. “Any time you put your product on a popular television

QUARRYING & MINING show to be featured, you’re taking a risk,” said Glenn Wieczorek, managing director of Tsurumi America, which is based in Glendale Heights, Illinois, U.S. “But our pumps have a long, proven track record in the field of mining. We had confidence going in, and there was no question that our pumps would address the Hoffman Crew’s needs in this particular application.” That confidence paid off, and the MINEXPO meeting resulted in a partnership that has already led to measurable success for 316 Mining. “If our operations are down for even a day, it can mean up to US$30,000 in gold loss,” Hoffman explained. “We explained our issues to the folks at Tsurumi during MINEXPO, and after working with the company’s engineers and leasing three pumps, we’ve mined quite a bit of gold and haven’t had any pump-related downtime on the job site. It’s been a great relationship.” Key personnel from Tsurumi America visited Fairplay in April of 2017 to get a better feel for the Hoffman Crew’s pumping needs. Tsurumi’s engineers consulted with the miners to determine that the washing plant might need to move as much as 9.5 m3 of water per minute (2,500 gpm) at 30.5 m (100 ft) of head for optimal sluicing. The ideal pump for the job turned out to be Tsurumi’s 100 hp GSZ-75-4L electric submersible pump, equipped with a variable frequency drive (VFD). Today, the Hoffman Crew’s GSZ-75-4L is set up on a custom-built pontoon, also provided by Tsurumi. The pump is floating in a manmade reservoir and is currently moving 9.5 m3 of water per minute (2,500 gpm) at only 12.2 m (40 ft) of head, a lower level of performance than was first determined. Luckily for the Hoffman Crew, the pump’s duty point and VFD enable them to easily adjust flow and head to meet changing demands on the job site. According to Freddy Dodge, gold recovery and wash plant expert for 316 Mining, the combined flexibility of the GSZ75-4L and the VFD has led to a successful yield at the mine. “Even though things changed, it didn’t matter,” he said. “Not only are we seeing a return on our investment, but we’re experiencing less downtime, fewer headaches, less maintenance, and we’re recovering more gold because the pump is so constant. It’s such a steady flow of water compared to the engine-driven pumps we were using.” Chuck Rickman, vice president of sales at Tsurumi America, who spent several days onsite during filming, explained why the GSZ-75-4L helped the Hoffman Crew to achieve success.

“Our GSZ series pumps are made especially for the mining industry,” he said. “They can handle larger solids, and they give miners the ideal duty point for this kind of work. The GSZ-75-4L in particular is a versatile pump with a very wide performance curve, which gives added flexibility in case parameters change. And with the VFD, performance can be dialed in to meet the most exacting specifications.” Gold Rush is broadcasted in 130 different countries and reaches nearly 300 million global viewers. In 2016, the show was the top program on cable TV in the Netherlands, Sweden, Denmark, Belgium, Finland, Poland, South Africa and Australia. The program focuses on the mining of gold placer deposits found in various locales around the globe. “We take pride in the way our pumps perform in the field of mining, so we’re glad that the Hoffman Crew has put their trust in Tsurumi,” Wieczorek concluded. “Getting Tsurumi pumps on Gold Rush is a great opportunity to show the world what our products are capable of, and the success they’ve had with their operations so far speaks for itself.” www.tsurumipump.com Bulk Solids Today



SENSOR TECHNOLOGY KEEPS HYDRAULIC PROJECTS ON COURSE Innovative TorqSense wireless sensors from Sensor Technology are playing an important role in new product development for Hydraulic Projects Limited (Hy-Pro), one of the UK’s leading developers and suppliers of hydraulic drive units for marine steering and autopilot systems.


he sensors, which accurately measure shaft torque in rotary drive systems, are providing the essential data that Hy-Pro needs to refine the design of the electrically powered pump assemblies used in the high-performance hydraulic steering systems that the company supplies for use in yachts and other small pleasure craft. Developing suitable pump assemblies for these marine applications in small vessels is challenging. The motors must operate economically as electrical power is usually derived from 12 V or 24 V storage batteries with limited capacity, yet the pump systems must be able to supply high power when called upon to do so, to ensure that the steering systems continue to operate reliably in heavy seas and bad weather. To ensure that its products offer the best possible performance in relation to these seemingly conflicting requirements, HyPro is constantly evaluating potential improvements to its pump drive systems. A crucial part of the evaluation process is accurately measuring the torque delivered by the electric drive motor to the pump, under varying load conditions and over a wide range of speeds, in a purpose-built test rig. “We considered various ways of measuring the torque in the motor shaft on the test rig,” said Barry Wynn, Senior Design Engineer at Hy-Pro, “but all were either inconvenient or were incapable of delivering the accuracy and fast response that we needed. Then we looked at TorqSense sensors from Sensor Technology, and realised that they offered a reliable, easy-to-use and cost-effective solution that would meet all of our requirements.” TorqSense sensors, which are covered by patents, depend for their operation on surface acoustic wave (SAW) transducers. These transducers comprise two thin metal electrodes, in the form of interlocking “fingers”, on a piezoelectric substrate such as quartz. When an RF signal of the correct frequency is applied to the transducer, surface acoustic waves are set up, and the transducer behaves as a resonant circuit. The key feature, however, is that if the substrate is deformed, the resonant frequency changes. When the transducer is attached to a drive shaft, the deformation of the substrate and hence the change in resonant frequency will be related to the torque applied to the shaft. In other words, the transducer, in effect, becomes a frequency-dependent strain gauge. Since the transducers operate at radio frequencies, it is easy to couple signals to them wirelessly. Hence, the TorqSense sensors 26

Bulk Solids Today

incorporating the SAW transducer technology can be used on rotating shafts, and can provide data continuously without the need for the inherently unreliable brushes and slip rings that are often found in traditional torque measurement systems. In the Hy-Pro application, a TorqSense sensor is used to measure the torque applied to the pump over the critical speed range of 500 to 4,000 rpm. The results are displayed in real time, so that the progress of tests can be readily monitored, and are also captured and stored for more detailed analysis later with Labview software. “The TorqSense sensor has proved to be completely dependable and very accurate,” said Barry Wynn. “The data it has provided us with has played an important role in helping us to refine our systems by ensuring an optimum match between the characteristics of the pump and motor over the full operating range.” “In fact, the insights we’ve gained during our tests have enabled us to further enhance the performance and reliability of our steering and autopilot systems, which, of course, means big benefits for our customers and a very useful boost to our own competitive position.” www.sensors.co.uk


CURTISS-WRIGHT EXTENDS ROTARY SENSOR FAMILY New NRH305DR rotary position sensor offers dual-redundant outputs


urtiss-Wright’s Industrial division has announced the launch of the NRH305DR, a new ‘nocontact’ rotary position sensor that extends the company’s portfolio of position sensors and offers an optimal combination of performance, safety and cost for OEMs designing vehicles and control systems. Sharing many of the same features and benefits as the NRH300DP model launched in 2016, the new NRH305DR rotary position sensor – from the Penny & Giles brand family – enhances system performance by incorporating two completely independent power supplies and output channels for full electrical redundancy, operating from a 5Vdc regulated supply. With an 8mm low-profile sensor body and small footprint, this fully-encapsulated, IP68/IP69K-rated sensor offers exceptional levels of performance against water, dust, shock, vibration and temperature. The separate magnet assembly that activates the sensor can have a permissible air gap between 1.5mm and 8mm (depending on magnet style) and can accommodate up to ±2mm radial offset to ease setup and installation. Versatile, factory-programmable electronics can be easily set to one of two analog voltage output ranges or one of three PWM frequencies. Additionally, the polarities of each of the analog outputs can be independently set, with on-board

diagnostic functions ensuring the outputs are put into safe, pre-defined states should an internal sensor error be detected. Features and benefits of the NRH305DR include: • No-contact design and sensing technology provides wear-free operation • Can be factory set to correspond to rotations of 20° to 360° in 1° increments • Industry-standard 38mm mounting centers – for easy replacement or upgrades • Analog output from 0.5-4.5V or 0.2-4.8V • Transmissive measurements can be made through non-magnetic materials The new NRH305DR – which replaces the company’s legacy NRH285DR rotary position sensor – uses proven, wear-free Hall-effect sensing technology. The design features a number of magnet arrangement options, and includes an over-molded magnet carrier that simplifies the interfacing of the magnet and sensor during installation. Optional bolt, plug or loose carrier variations are also available. .For more information on Curtiss-Wright Industrial products, visit www.cw-industrialgroup.com Email: cwig.uk@curtisswright.com or call +44.1202.034000. Bulk Solids Today



CHEMICAL ENGINEERS TALK SENSE ABOUT MIXER EFFICIENCIES Manchester University’s School of Chemical Engineering and Analytical Sciences is leading world class developments in energy efficiency in the process industries. Researchers have incorporated TorqSense transducers into a test rig that is analysing losses in in-line mixers.


fficient production is fundamentally important to success in the process industries, many of which serve global markets. While there are multiple elements of cost in the production processes, optimising energy consumption is seen as essential because improvements will repay dividends over many years. The energy consumption involved in in-tank mixing processes is well researched and understood. But with in-line rotor-stator mixers the flow is often controlled independently of the rotor speed and collecting sufficient data to accurately model the process has to date required a large number of experiments. Now researchers Dr Mike Cooke and T. L. Rogers at Manchester University have developed two simplified methods for obtaining the necessary information for particular statorrotor mixers: one uses torque measurements, the other heat balance. Dr Cooke explains that high shear rotor-stator mixers are widely used in process industries, including the manufacture of many food, cosmetic, healthcare products, fine chemicals and pharmaceuticals. Rotor-stator devices provide a focussed delivery of energy, power and shear to accelerate physical processes such as mixing, dissolution, emulsification and deagglomeration. “To reliably scale-up these devices from laboratory size to industrial scale we need to understand the relationship between rotor speed, flow rate and the energy dissipated,” he says. “The first step is to link the energy dissipation rate to desired process results.” The scientists created two mixing experiments and set about measuring the torque profile and heat balance. In the first experiment torque was measured by a Sensor Technology’s TorqSense in-line torque meter fitted to the drive shaft. There are two main sources of potential error when measuring the torque on the rotor shaft: time-based zero-drift and bending moments on the shaft, both of which are easily counteracted with the TorqSense. Other corrections also have to be made for bearing losses, temperature fluctuations etc. 28

Bulk Solids Today

TorqSense proved a good choice for this work because its non-contact operation meant extra drag forces were not added to the system and also allowed rapid assembly and disassembly during the experiments. It uses two piezo-electric combs which are simply glued to the drive shaft at right angles to one another. As the shaft turns it naturally twists along its length very slightly and in proportion to the torque, which deforms the combs changing their piezo-signature. This change is measured wirelessly by a radio frequency pick up and used to monitor the torque. Its data is output to a very user-friendly computer screen which uses graphics to aid instant interpretations and also automatically logs all data for later analysis. In fact the School of Chemical Engineering and Analytical Sciences at Manchester University is a major user of TorqSense, having many installed on permanent teaching aids and various research rigs. “The students like the readout displays, which look no more complicated that a car’s dashboard,” says Dr Cooke. “For us researchers, the ease with which they can be mounted and removed is a God-send in experiments where you are constantly reconfiguring the rig. Also their lack of slip rings means one less set of calculations to account for – and one less fiddly fixing task.” The conclusion from Dr Cooke’s experiments is that the performance characteristics of in-line mixers can be easily modelled. This lets industrial users calculate their optimum energy consumption and tune their mixer drives accordingly. Power and cost savings will accrue during the whole production period, and make a valuable contribution to the company’s bottom line and green credentials. www.sensors.co.uk

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