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New Developments in Doosan ADT Range



Vortex’s pivoting chute diverter


Efficiency supplied by DUO


Bardyke Chemicals chooses Ajax

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
























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


Dense Phase Transporter, J-Series

BulkBusterTM Bulk Bag Unloader

Issue 122



12  VALVES 16  MIXERS BLENDERS & DRYERS 18  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





uf-Lok ring grip couplings are low cost, heavy-duty self-aligning couplings for either high pressure, to 150 psig, or full vacuum rated applications. Utilized in all industries where pipe ends need to be connected, they are ideal for pneumatic conveying systems as well as gas and liquid applications. These couplings install quickly and easily, reducing installation costs. They are available in 2-inch (50mm) through 10-inch (250mm) pipe sizes and are made for use on plain end

pipe or tube, regardless of pipe or tube wall thickness.. Other features include self-grounding, vibration resistant, leakproof, with an extremely high end pull for difficult applications. No machining or grooving is required to maintain pipe integrity. Every coupling becomes a union, providing easy, low-cost maintenance when piping components need replacement. Standard gasket materials are available to meet special design conditions, such as food grade, higher temperatures or special chemical

resistant applications. http://www.tuflok.com/primary/ products.html Phone: +44 (0) 1706.822512 Email: sales@tuflok.co.uk www.tuflok.com



CB is celebrating a major milestone in its long record of innovative machine design – the 40th anniversary of the Loadall telescopic handler. First launched on October 20th 1977 the machine mechanised lifting and loading tasks on building sites more usually carried out by a small team of men. The potential for the Loadall in agriculture was also quickly harnessed and it went on to revolutionise materials handling tasks on farms, stacking bales, loading muck and shovelling grain, replacing rudimentary tractor mounted hydraulic loaders. JCB has sold more than 220,000 Loadalls to date, generating more than £7 billion in sales – £4.5 billion of which has been from exports. Today daily output of JCB telehandlers at the World HQ in Staffordshire is currently at its highest level since the launch, with the number of machines built expected to increase by 25% by the end of the year compared to 2016. Such is the success of the product


Bulk Solids Today

that one Loadall rolls off JCB’s Rocester production line every six minutes. The business making the machines today employs more than 1,200 people. JCB Chairman Lord Bamford said: “When we launched the Loadall in 1977, we sold just 64 machines that year but we were very confident that the telescopic handler would grow in popularity simply because it made jobs so much easier on construction sites and on farms. “The concept soon took off and the faith we put in the telescopic handler four decades ago has been repaid. It’s wonderful to celebrate 40 years of success of the Loadall with production hitting historic levels. “I’d like to congratulate everyone around the world who has contributed to this success over the past 40 years. We must now look forward to the next 40 years and build on what has been achieved so far.” Eddie Finney, 59, of Rocester, is a Team Leader in Loadall. He said: “I started my JCB career in 1976 in the machine shop but the following year I transferred and started working on the Loadall assembly line. At the time there were only four Loadalls coming off the line every day. I can’t believe the volume we

have now achieved 40 years later.” Kevin Holley, 60, of Uttoxeter, works in the Loadall Fabrication Shop on a laser machine. He said: “I joined JCB in 1978, working on a gas cutter for several types of machine. I then became a gas profile cutter for the Loadall division. At that time, with only four a day coming off the line, Loadall was thought to be the poor relation because it wasn’t as busy as backhoe. But I could see the potential straight away. It did amazing things and nobody else had anything like it.” Keith Weston, 61, of Marston Montgomery, near Rocester, has worked in Maintenance at JCB since 1973. He said: “I have been on general manufacturing maintenance for most of my career but I was responsible for shot blasting and painting on the Loadall assembly line in the 1980s. In the early days I never realised Loadall would reach the volume of sales that it has. I have been proud to work on it.” It took almost 30 years for JCB to sell the first 100,000 Loadalls but it took less than 10 years for the next 100,000 to be sold – testament to the growing importance of the product and JCB’s strength in this sector. JCB is World Number One for telescopic handlers with more than one in every three sold being a JCB. The public launch of the JCB Loadall on October 20th 1977 was promoted under the banner of ‘Obsolescence Day is Coming’ as an indication that the new machine, with its ability to reach forwards and upwards, would render the masted forklift obsolete. www.jcb.com




unson Machinery Company’s new 200-page website, www.munsonmachinery. com, details the company’s mixing/ blending, size reduction and liquid/ solid separation equipment utilised across all industries in which bulk solid materials, pastes and solidsladen slurries are processed. A mixing and blending section details Rotary Batch Mixers, Ribbon/Paddle/ Plow Blenders, Fluidised Bed Mixers, Vee-Cone Blenders, Rotary Continuous Mixers and Variable Intensity Blenders. Size reduction machinery covered includes Screen Classifying Cutters, Rotary Knife Cutters, Pin Mills, Attrition Mills, Lump Breakers, Hammer Mills and Shredders. A separate liquid/solid separation section describes Rotary Drum Screeners. Each of 16 equipment sections includes separate overview, features, options and specifications pages. Selection chart downloads compare Sizetypes Reduction Ad (130x180)_Layout 1 seven of the(2017) company’s mixing/

blending equipment, and six types of size reduction equipment offered according to 14 material characteristics and 10 equipment requirements. A technical library of 58 case study 13/09/2017 15:07 Page 1 articles published in 400 trade journals

is cross referenced by 11 industries and 180 bulk materials handled. For information contact Munson Machinery Company, Inc., +1-315-7970090, info@munsonmachinery.com, www.munsonmachinery.com

Experience the

difference… …in innovative size reduction We have one of the largest ranges of size reduction equipment on the market and provide a single source supply of comminution equipment and expertise: from <1g to multi-tonne.

• From lump crushing and coarse grinding to micronizing, fine grinding and nano-milling

• Wet and dry milling equipment and systems • Unique equipment for small batch milling <1g • Accurate, repeatable particle size reduction Milling systems contained within an isolator/glovebox can operate to meet OEB 6. Hosokawa Micron size reduction equipment can be designed specifically for installation within an isolator for a more bespoke solution.

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

Bulk Solids Today





clipse Magnetics is delighted to welcome Tom Bibby to its Sales Team as Technical Sales Engineer for foreign body removal. Tom will be responsible for growing Eclipse Magnetics’ well established range of foreign body removal (FBR) equipment, namely magnetic separation, metal detection and sieving equipment into the Food, Pharmaceutical and Chemical industries. Martyn Cotterill, General Sales Manager for Magnetic Technologies at Eclipse, said: “With previous experience working as a UK Sales Manager in a similar industry, Tom’s knowledge and skills will be very

valuable to this role, and to the Eclipse Magnetics Sales Team as a whole. We are really pleased to have Tom commence employment with us and wish him every success in his new role.” Eclipse’s magnetic separation systems are used in almost every processing industry to remove ferrous and paramagnetic contamination from process lines, preventing product contamination and damage to machinery. Leading the way for product quality, performance and service, Eclipse manufactures the full range of options for every stage of production, from simple manually cleaned magnetic separation units to fully automated PLC controlled

systems. Eclipse’s highquality, high-power magnetic separators, metal detectors and vibratory sieves are suitable for most applications, including bulk, grain, dry powders, damp powders, liquids and syrups. www.eclipsemagnetics.com



LLU is proud to announce Igarreta Maquinas is its new distributor in Argentina. The company will not only be supplying the comprehensive range of ALLU Transformer and Soil Stabilization equipment, but will also be providing full aftermarket care, spare parts and dedicated customer service. ALLU’s world leading Transformer series needs no introduction; but now customers throughout Argentina will be able to benefit from even greater levels of support through its new distributor, Igarreta Maquinas. The appointment of such a professional and experienced distributor reinforces


Bulk Solids Today

ALLU’s commitment in providing even greater levels of customer focus, and further enhances its locally focused customer support, whilst at the same time enabling customers to benefit from dealing with a truly global company. Buenos Ares based Igarreta Maquinas is an established name through Argentina, and is also Komatsu’s only official distributor in the country. The company has placed an emphasis on developing long term partnership relationships with its customers, with continual training and development of its employees being key to its success. Thus with offices,

workshops and service engineers located throughout, the company has since its foundation in 1999 successfully serviced the requirements of the Argentinean construction, mining and forestry industries. In addition to the local support which will be provided to customers by Igarreta Maquinas, when the need arises the company will be able to call on round the clock support from ALLU’s head office in Finland. This will further enable customers to benefit from the specialized advice and assistance that has made ALLU the world leading supplier of material processing attachments – the Transformer series. Of the appointment of Igarreta Maquinas Marjut Lindroos, Group Marketing Manager ALLU Group states: “We are sure that the combination of ALLU equipment and global aftermarket support, together with the local knowledge and industry expertise of Igarreta Maquinas will enable ALLU customers throughout Argentina to benefit from a winning combination.” Igarreta Maquinas was appointed the ALLU Distributor for Argentina on the 29th September of this year and all at ALLU offer congratulations on them becoming part of the Global ALLU family. www.allu.net




ith the addition of new agents in South Korea and Pakistan and a new location for its Thailand operation, the Swiss Gericke group underlines its commitment to these dynamic markets. Since the establishment of Gericke Pte Ltd in Singapore in 1993 the company has successfully expanded its presence in the Asian-Pacific market. The philosophy to combine the European based manufacturing of key components such as mixers and feeders with local engineering know-how and sourcing has proven to be the right fit to support multinational as well as local customers with the proven Gericke quality. Today the Singapore office acts as regional engineering and service competence center, and covers the area with a network of subsidiaries and agents. Continuing this approach, JW Microtec in South Korea and Imtec

in Lahore (Pakistan) will represent Gericke in their respective home markets. They both bring many years of experience in various industries to ensure professional local support. Additionally a new location of Gericke in Thailand reflects the increased significance of this market for Gericke. Beside Thailand this office also covers Myanmar. The market activities in Asia are supported by a state-of-the-art test center in Singapore. The test center is equipped with original machines and allows for customer tests under nearproduction conditions. Experienced specialists design the test layout and perform the tests for various types of powder handling and processing applications. The Swiss Gericke Group has been designing and manufacturing

Preparations for a customer trial at the Gericke Test Centre in Singapore

equipment and systems for modern bulk material processes, as well as providing design and consultation services for more than 120 years. Gericke bulk materials processing technology can be found throughout the world in many sectors including the food, chemical, pharmaceutical, plastics and construction material industries. Gerickeâ&#x20AC;&#x2122;s wholly owned group companies employee more than 300 experienced professionals and are located in Switzerland, Germany, Great Britain, The Netherlands, France, USA, Brazil, Singapore, Indonesia, Malaysia, Thailand and China.

Bulk Solids Today





ower management company Eaton has expanded its range of hydraulic hoses with the launch of the Dynamax EC881 hose series. Qualified to 1 million impulse cycles, this new two wire-braided hose has been designed to last and withstand tough applications. Intended for deployment in mobile applications such as compact construction equipment, agricultural vehicles, aerial lift platforms and forestry machines, this hose is also suitable for industrial applications such as hydraulic presses. In today’s productivity driven environment, owners and operators simply cannot afford machinery downtime. It is therefore imperative that OEM designers and engineers design for reliability. Impulse cycle capabilities are a key measurement in terms of life expectancy. Standard EN857 Type 2SC hoses are qualified up to 200,000 impulse cycles. The new EC881 series from Eaton exceeds this standard by five times. This durability helps decrease maintenance costs, improves safety and minimizes downtime. “To maintain operational effectiveness and productivity it’s essential that hydraulic systems operate effectively,” said Dimitar Atanasov, product manager, Fluid Conveyance products EMEA. “Operators simply cannot afford downtime in the field. When developing the new EC881 Eaton focused on the main customer pain points and designed a hose that will help combat the common failure causes such as abrasion. Here at Eaton, we are seeing a growing demand on the market for more compact machines and for hoses with a better bend radius, which allows for easier tube routing in tight spaces. What’s more, the EC881 is ideally suited to high pressure systems and has been qualified for 1 million impulse cycles, thus increasing in field reliability.” There is a growing demand for OEMs to develop compact machines that have the same operating capabilities as their larger counterparts. This is creating a need for hydraulic systems that can cope with high pressure and high impulse. Thanks to a new generation of inner tube and hybrid plies, EC881 delivers a 35 percent higher pressure capability when compared to standard hoses of standard EN857 2SC. Where expensive four spiral hoses have had been used to cope with system pressures, the new EC881 two wire braided hose can be an alternative hose which helps deliver a direct cost saving for OEMs. As the need for compact machines grows, OEMs face challenges concerning the routing of hydraulic hoses through tighter spaces. Utilising hoses with standard bend radii ultimately costs more as they take more time to install and greater quantities of hoses could be needed. It is important to note that the increased quantity of hose increases the weight of the machine, thus reducing fuel efficiency. To solve this problem the new EC881 hose has been engineered to feature a 50 percent better bend radius when compared to standard two wire braided hoses. Standard EN857 Type 8

Bulk Solids Today

2SC size 8 hoses are only qualified to 130mm radius, whilst EC881 offers a bend radius of 60mm. This makes the new hose the ideal choice for installation in tight spaces as it delivers increased design flexibility and offers the potential to reduce hose quantity therefore decreasing build / operating costs. Abrasion is a leading cause of hose field failure and is a problem that needs to be addressed. Featuring Dura – Tuff covers, the EC881 is eight times more resistant to abrasion than conventional synthetic covered hoses, ultimately leading to less failures and improved machine up time. In extreme operating environments high velocity leads to high temperatures, conventionally rated hoses simply cannot deliver the protection needed and service life times are impacted. EC881 has been designed to offer temperature capabilities up to 126°C, thus mitigating against the risk and ultimately controlling maintenance costs. What’s more, inside out failure can be correlated to hose material aging and is a common cause of operational breakdown. Eaton engineers have focused on developing a next generation inner tube that has three times the life span capabilities when compared to standard hose of standard EN857 2SC. EC881’s high fatigue resistance and low compression set provides better sealing and leak free performance. To learn more about Eaton visit www.eaton.com/hydraulics. Eaton’s hydraulics business is a worldwide leader in supporting companies that want to increase efficiency, reliability and safety within industries including – construction and mining, agriculture and forestry, traditional and renewable energy, manufacturing and processing, oil and gas, transportation and material handling. The global Hydraulics team designs, manufactures and markets a comprehensive line of reliable, high-efficient hydraulic and industrial systems including electro-hydraulics, fan drive, hybrid and steering solutions to leading edge components including adapters, couplings, cylinders, fittings and assemblies, hose and tubing, motors, pumps and valves. Eaton is a power management company with 2016 sales of $19.7 billion. We provide energy-efficient solutions that help our customers effectively manage electrical, hydraulic and mechanical power more efficiently, safely and sustainably. Eaton is dedicated to improving the quality of life and the environment through the use of power management technologies and services. Eaton has approximately 95,000 employees and sells products to customers in more than 175 countries. For more information, visit www.eaton.com.


PELI BIOTHERMAL EXPANDS EUROPEAN MANUFACTURING CENTRE EXTENDED FACILITIES IN FRANCE TO PRODUCE BULK THERMAL SHIPPER COOLPALL™ VERTOS TO MEET GROWING GLOBAL DEMAND Peli BioThermal, the global name in temperature controlled packaging, announces the expansion of its European manufacturing capabilities in France.


his extension is in response to meet the rising requirements of the worldwide transportation of pharmaceuticals throughout Europe and globally. David Williams, President of Peli BioThermal, said: “I’m pleased to announce the extension of our production capability in France, to manufacture our single use bulk thermal shipper CoolPall™ Vertos. It is an exciting development and customers will benefit from the consistent quality and processes implemented worldwide. “These significant changes and investments represent the ongoing efforts that Peli BioThermal is making and are a clear indication of our commitment to our customers, the industry and our global expansion of manufacturing and services.” This implementation of the additional European manufacturing capabilities complements the company’s expanding existing facilities, providing solutions for

customers globally, which included the recent introduction of new service centres in Belgium and Puerto Rico. The latest European expansion demonstrates the company’s commitment to significant investment to serve customers globally and follows the qualification of production of the company’s reusable Crēdo Cube™ line of thermal shippers at its facility in the United Kingdom and the expanded manufacturing capability for the single-use Chronos™ Advance, Chronos™ Express and CoolPall™ Vertos product lines to its facility in the United States. Visit www.pelibiothermal.com to learn more about the wide range of Peli BioThermal products. Peli BioThermal is a division of Peli Products, S.L.U., which is the European arm of Pelican Products, Inc., which is a portfolio company of Behrman Capital, a private equity investment firm based in New York and San Francisco.



obson Handling Technology, specialists in providing endto-end handling solutions are delighted to announce the appointment of South Yorkshire entrepreneur Julie Kenny CBE as Chairman. Julie brings with her a wealth of experience from an impressive working background. In her early years Julie forged a successful career as a litigation lawyer before changing direction and founding £30m turnover South Yorkshire manufacturer Pyronix Limited, which she sold in 2016. Along her journey, in recognition of her contribution to business in the region Julie received a CBE and Honorary Doctorate from Sheffield Hallam University. Julie takes the reins from outgoing Chairman Bill Speirs, who made a significant contribution to shaping the future of the business. Keen to build on this, Julie said “Robson is grateful for the contribution made by Bill and thanks him. The outstanding customer focus, reputation for innovative solutions and unique group expertise with Robson Site Service and RJD Engineering provide an exciting and excellent opportunity.” www.robson.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





t is pleasing to report that on site works have now accelerated at the Barruecopardo Tungsten project in Salamanca, Spain. The Barruecopardo Project is a low cost, simple mining and simple metallurgy tungsten project, located in the safe and stable location of Western Spain. The project, after commissioning towards the end of next year, will produce ~260,000 metric tome units of WO3, representing some 12% of current non-Chinese world tungsten concentrate supply. Fairport Engineering, Saloro’s Engineer, has been prominent in supporting these activities having previously undertaken the Basic Engineering studies for the project and

is now advancing the ordering and manufacturing of proprietary equipment as well as defining the civil works associated with the processing plant and infrastructure. These civil works have recently been awarded and will commence in October 2017. Notwithstanding these on-site activities, Fairport continues to develop other aspects of the project including the mechanical and structural packages together with the

electrical and control system areas. For further information please contact Fairport Engineering’s Communications Manager, Mrs Linda White lwhite@fairport.co.uk.



onecranes has simplified the overhead crane specification process with the introduction of its innovative online tool, Crane Advisor. The menu driven application may be accessed via desktop computer, iPad, tablet and smart phone, allowing convenient use of the tool from any location. Crane Advisor has been introduced successfully in North America and has now been launched in the UK, Europe and selected regions worldwide. Crane Advisor is a user friendly, icon driven platform designed to help customers narrow down potential lifting equipment options, according to their specific material handling application. Users are prompted to input parameters, including industry type, crane capacity, girder span and lifting cycle duty. Based on the information supplied, the Crane Advisor software generates an immediate response, providing a personalised crane specification, tailored to the user’s specific requirements. On receipt of the recommendation, customers can familiarise themselves with the product offering before continuing discussions with a Konecranes’ sales representative. The system saves the customer valuable time in the initial decision making process and provides sufficient information for a preliminary 10

Bulk Solids Today

project analysis, before committing further time and resources to the details of the specific material handling solution. Jari Myyryläinen, Vice President, Konecranes Industrial Applications, stated: “As a leader in the overhead crane industry, Konecranes invests in R&D to bring new technologies and innovation to the market. Crane Advisor is a service that will revolutionise the way of purchasing overhead cranes. The tool offers the customer valuable information on the most suitable material handling equipment, according to their lifting needs.”

Konecranes is a world-leading group of Lifting Businesses™, serving a broad range of customers, including manufacturing and process industries, shipyards, ports and terminals. Konecranes provides productivity enhancing lifting solutions as well as services for lifting equipment of all makes. In 2016, Group (comparable combined company) sales totaled EUR 3,278 million. Tel: +44 (0)844 3246599· Email: paul.bartlett@konecranes.com www.konecranes.co.uk




owder characterisation specialists, Freeman Technology, have expanded their global operations with the establishment of an office in Germany. “We have been working with businesses in Germany since the company was founded. “It has long been a region with a significant number of powder processing companies across a range of industries” said Tim Freeman, Managing Director. “The region’s economic status is supported by competence in engineering and manufacturing. Following our recent expansions into other countries and the diversification of our product line, Germany was the obvious next step for Freeman Technology.” Headquartered in the UK, the company has specialised in the characterisation of powders since the late 1990s with the introduction of its flagship product, the FT4 Powder Rheometer®. Tim Freeman, Managing Director, said “I am confident that the increased

local support provided by our new operation, will further enable customers to benefit from the technologies and experience that Freeman Technology have developed over the last 17 years’”. Daniel Weber joins the team as Product Manager and will be based in the region to provide sales and customer support. Freeman Technology’s solutions include the FT4 Powder Rheometer, a unique and comprehensive powder tester, which uses patented dynamic methodology, automated shear cells (in accordance with ASTM D7891) and a series of bulk property tests to quantify powder behaviour in terms of flow and processability. This is complemented by the Uniaxial Powder Tester, which provides an accurate and repeatable measure of the uniaxial unconfined yield strength (uUYS) of a powder to assess and rank flowability. The company also offers in-line, real-time flow measurement

capabilities via an exclusive partnership with Lenterra Inc, manufacturers of optical flow sensor technology. With nearly two decades of experience in powder flow and powder characterisation, expert teams assist users around the world to address their individual powder challenges, focusing on delivering the most relevant information for their processes. The result is world-leading solutions for understanding powder behaviour in development, formulation, scale-up, processing, quality control, or any area where powders are utilised. For more information about the range of products offered by Freeman Technology please visit www. freemantech.co.uk. Tel: +44 (0)1684 851 551 Email: pr@freemantech.co.uk Freeman Technology and Powder Rheometer are registered trademarks of Freeman Technology Ltd.



utch company WEC Lines is beginning a new service connecting the Port of Liverpool with Huelva, Vigo, Leixoes and Dublin. The service will begin from the end of September with weekly 300TEU vessels, but this is expected to grow significantly once trade develops.

Jouke Schaap, Container Port Director at Peel Ports, said: “We’re very pleased to be welcoming a second WEC Lines service to Liverpool. This further underlines what we’ve been saying about how the dynamics of the UK logistics sector is changing. Shipping directly into the North-west of the UK provides cargo owners with the chance to reduce costs, congestion and carbon emissions by getting closer to their end market. It’s a further endorsement of the compelling case behind our Cargo200 initiative, which is now backed by 225 supporters representing more than 1.5m TEU a year. That is clear evidence of the demand for direct deepsea calls at Liverpool.” Nico Valkenier, Managing

Director WEC Lines, added: “We are delighted to announce a new maritime link connecting both Huelva in the south of Spain and Vigo in the north of Spain with Liverpool and Dublin. In addition, this new service will improve connection times from Leixoes to Liverpool and Dublin.” In 2016, WEC Lines began weekly calls at the Port of Liverpool connecting with Lisbon, Setubal, Leixoes and Sines, with other links to Ireland, Scotland, Morocco, Spain and the Canary Islands. The Cargo200 campaign calls for importers and exporters whose goods begin or end their journey in the north of the UK to switch current delivery of ocean freight from southeast ports to the centrally-located Port of Liverpool. The initiative aims to cut freight mileage by 200 million miles by 2020. http://www.peelports.com Bulk Solids Today





ortex established its Titan Series product line in 2011 to address several abrasion concerns expressed across bulk material handling industries. Such applications include handling materials that pose excessive abrasion or wear issues, situations that call for extremely large valves or diverters, conditions that require a valve to be successful in especially harsh environments, or other more specialized heavy-duty applications. Among those Titan Series products is a diverter that has recently garnered much attention across industries: the Pivoting Chute Diverter. Per the demands of companies handling especially abrasive materials – such as alumina, bauxite, cement, clinker, coal, fly ash, gravel and rock, glass, industrial sand, lime, limestone, metals and ores, potash, sands, wood, and others – Vortex designed the Pivoting Chute Diverter to improve processing speeds and provide a valve with longevity when operating in particularly wearing environments. Since its release, the Pivoting Chute Diverter has improved operations for cement, grain, mining, power generation, and many other industries worldwide. In recognition, the Pivoting Chute Diverter was awarded the 2016 Breakthrough Product of the Year from Processing Magazine.

INNOVATIVE FEATURES OF THE PIVOTING CHUTE DIVERTER INCLUDE: • A body constructed from carbon steel. • An independent, internal pivoting chute. • Diverter’s wetted parts (eg: material contact areas) are lined with choice of abrasion-resistant metal. • Optional abrasion-resistant liners, installed internally on the diverter’s inlet and outlet legs. The purpose of abrasionresistant liners is to provide additional durability for the diverter’s internal. As a standard, abrasion-resistant liners are constructed from abrasion resistant steel. In extreme applications, liners may instead be constructed from chromium carbide. • Dust-tight to atmosphere. • The Pivoting Chute Diverter may be shifted “on the fly” while materials continue to flow, allowing a non-interrupted material flow. This is an improvement upon traditional flapper-style diverters, which recommend material flow be shut off prior to shifting the blade. • Inspection, maintenance or repairs may be quickly and easily performed while the diverter remains in-line, from an 12

Bulk Solids Today

access panel on the front of the diverter. • Removable chute, in case it must be inspected, repaired or replaced. • Material flow may be directed partially toward two different destinations at once. However, because material flow will be shared through one chute toward two destinations, flow rates toward each leg will be diminished, in comparison to typical one-to-one flow rates. • Available in either a two-way or three-way configuration.

WHEN CONSIDERING THE PIVOTING CHUTE DIVERTER FOR USE IN YOUR APPLICATION, PLEASE ALSO BE MINDFUL OF: • Stack-up height: In order to install a Pivoting Chute Diverter, the space needed between flanges is slightly more than that of a traditional flapper-style diverter. • Material dusting to the opposite leg is possible. However, in most applications, these considerations are not of major concern. For more information on how the Pivoting Chute Diverter can improve your system operations, visit www.vortexglobal.com/pivoting-chute-diverter/.

ABOUT VORTEX: For 40 years, Vortex has provided quality slide gates, diverters, iris valves and loading spouts designed specifically for handling dry bulk solids in gravity, vacuum, dilute, or dense phase applications. Vortex valves and spouts are engineered for dependability, durability, easy maintenance, and offer proven solutions to material handling and process efficiency problems. With an in-house team of engineers, Vortex products can be completely customised for individual applications or special installations. Tel: +1 785 825 7177 Email: vortex@vortexglobal.com Web: www.vortexglobal.com




osi-flate 585/586 butterfly valves feature seats and discs for application pressures up to 10 bar. The design improves on existing 485/486 seats to provide the same incredible valve life at even higher pressures. The 585/586 valves are designed to fit PN 10 flanges, and come in sizes 80mm to 600 mm.” The Posi-flate Series 585/586 butterfly valves are designed for the most the most severe of applications. They are ideally suited for very abrasive materials which can 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. The Posi-flate 585/586 butterfly valves are available in a wide variety of construction materials including stainless steel and lightweight aluminium. Tel: + 44 1908 622366 Email: sales@posiflate.co.uk www.posiflate.com



n production and processing operations, version 5.0 of the Coperion RotorCheck contact monitoring system for rotary valves registers, evaluates and reports unwanted contact between the rotor and housing in order to be able to prevent metallic abrasion and thus potential contamination of the product being conveyed. Industrial sectors with high quality requirements, frequently changing products and recipes or a high number of cleaning cycles stand to benefit from this in particular. The newly introduced physical separation of measured value logging and evaluation electronics has advantages in terms of operation and maintenance, while the redeveloped control system provides advanced options for event diagnosis and connection to host systems. Furthermore, the use of extremely high-quality components contributes to longer uninterrupted running times. The monitoring principle of the RotorCheck remains unchanged: An electrically conductive connection is created as soon as the housing and rotor come into contact. This is then registered by the control system. In the process, the software filters out coincidental measurement signal fluctuations – such as those caused by the product – and reports potentially dangerous faults to the customer’s control center. While the signal detection itself takes place in the valve, for the first time Version 5.0 allows for the snap-in installation of the control system housing in the control cabinet. The physical separation reduces the amount of space required on the valve while simultaneously simplifying the operation and maintenance of valves with an extraction device. This is particularly advantageous in production environments where dirt, dust, heat, vibrations, moisture or 14

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electromagnetic waves may occur. What’s more, the control system is now also accessible even when it is impossible to enter the production area itself for safety reasons, e.g. while CIP cleaning is underway. RotorCheck 5.0 is suitable for deployment in Ex zones in combination with optional Zener barriers. Extremely high-quality components are used in the latest generation of RotorCheck products for maximum reliability and ease of maintenance. Hybrid bearings with ceramic roller elements optimize electrical insulation between the rotor and the housing, to name just one example. At the same time, these are considerably more robust than conventional solutions with regard to installation and maintenance. The slip-ring rotor is designed for a service life of around five years and thus only requires around one tenth of the maintenance effort of comparable conventional products with a biannual replacement interval. Thanks to the new lower number of individual parts, Version 5.0 is easier to install and calibrate, which reduces the effort required for quick cleaning in particular. The electronic functions of the RotorCheck 5.0 are also considerably more comprehensive than in the previous version. Consequently, an optional field bus interface that significantly reduces installation effort is now available to the user alongside analog and digital inputs/outputs. Moreover, the new control system facilitates flexible adaptation of the device’s parameters to changing production conditions and cleaning cycles. The measurement signal is now available in graphic format via web interface, which makes diagnosis more convenient. And due to the fact that the operating data is cached in the control system, faults can be reproduced and analyzed at a later time. In addition, LEDs on the RotorCheck housing now visually indicate the presence of anomalies with improved clarity. New and existing rotary valves alike can be equipped with the extended features of the optimized RotorCheck 5.0, making them ideally prepared for the increasing complexity and degree of automation in modern industrial plants. For more information visit www.coperion.com or email info@coperion.com.




PX FLOW invests a great deal into ensuring customers have all the support and aftermarket care they need to keep their operations running smoothly. As part of this commitment, it has released a series of maintenance videos covering products including valves, pumps, homogenizers and heat exchangers. The latest of these popular guides covers maintenance steps for the APV Constant Pressure Valve (CPV). Correct and timely maintenance is an essential part of keeping a plant running smoothly and preserving process integrity. The new CPV maintenance video gives an easy to follow, step by step visual guide to assist technicians in efficiently carrying out correct valve disassembly, replacement of O-rings and bushings, and reassembly. The CPV is a diaphragm valve that keeps process pressures constant. It is typically used in the food and beverage, dairy, pharmaceutical and personal care industries in applications including separation, pasteurization, UHT and filling. It has bidirectional flow capability and uses a double layer membrane which offers long life and durability. It provides stable, accurate and responsive modulating pressure control in a hygienically designed configuration with excellent cleanability. Maintenance of the CPV constant pressure valve is straightforward. The clear instructions provided in the video will help technicians ensure steps are carried out correctly

and efficiently. Alongside walking the viewer through every point of the procedure, the video tutorial also covers the tools required, safety points and warnings of where particular care needs to be taken to ensure the valve is not damaged during maintenance. This latest online maintenance video is one of a continuing series that is designed to help customers correctly maintain equipment to maximize operating life and ensure hygienic and operational integrity is preserved. The videos are part of the many services and materials SPX FLOW offers its customers to help ensure they get the most from their investments. The new CPV maintenance video can be found on YouTube: www.youtube.com/watch?v=v5EgHESZtYI For more information about the CPV constant pressure valve or other SPX FLOW offerings, please visit www.spxflow.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



ABRASION-RESISTANT ROTARY BATCH MIXER ACHIEVES UNIFORMITY IN 1 TO 3 MINUTES A new model 700-THX-50-ARI Rotary Batch Mixer from Munson Machinery blends abrasive materials such as concrete, premix, mortar mix, glass/cullet, fibreglass, refractories, tungsten powder and ceramics, in one to three minutes with minimised abrasive wear or product degradation.


he mixer features abrasion-resistant steel material contact surfaces, internal mixing flights with easy-toreplace wear plates and radial seals for dust-tight operation. It has a useable batch capacity of 1.4 cu m or 1815 kg, and achieves uniformity with equal efficiency from 100% to 15% of rated capacity, regardless of disparities in the bulk densities, particle sizes or flow characteristics of batch ingredients, according to the manufacturer. Its horizontal rotating vessel contains proprietary mixing flights that tumble, turn, cut and fold material gently, preventing degradation and imparting minimal energy to the batch. A stationary inlet and outlet at opposite ends of the vessel allow hard piping to upstream and downstream conveyors, process/ packaging equipment or storage vessels. Unlike mixers with stationary vessels that force agitators through the batch, the drum requires only a 7.5 kW motor for rotation in most applications. Optional 15 kW motors are available for mixing of materials with bulk densities in the range of 3.2 gm/cc. The rotating vessel and internal flights lift and direct the entire batch into the discharge spout for evacuation with no residual â&#x20AC;&#x153;heelâ&#x20AC;? of material requiring manual removal, 16

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eliminating waste and allowing rapid cleaning. The mixing vessel rotates on exterior trunnion rings, eliminating the need for internal shaft seals prone to failure when mixing abrasives. It is equipped with an optional cage-style intensifier that is independently powered. Mounted at the inlet end of the vessel, the intensifier promotes uniform dispersion of non-free-flowing and other difficult-to-blend materials, imparting shear to reduce agglomerates into discreet particles. Also optional are internal spray nozzles for uniform distribution of liquids over the bed of moving material. The company also offers Rotary Batch Mixers designed for sanitary or other applications in carbon steel or stainless steel in capacities from 0.25 to 17 cu m, as well as Continuous Rotary Blenders, Variable Intensity Blenders, Vee Cone Blenders, and Ribbon-Paddle-Plow Blenders. Size reduction equipment produced by the company includes Screen Classifying Cutters, Centrifugal Impact Mills, Lump Breakers, Attrition Mills, Hammer Mills and Shredders. For information contact Munson Machinery Company, Inc., +1 315 797 0090, info@munsonmachinery.com, www.munsonmachinery.com




he Bella Series 543 mixer/dryer/cooler by Dynamic Air Inc. offers an improved method for drying or cooling powders, granulates and filter cakes. The Bella dryer can be used for drying, mixing, spraying, agglomerating and cooling in the same unit without additional equipment or costs. Operation is extremely efficient because air



he Coperion MIX-A-LOT unit ensures particularly efficient, high-speed and gentle homogenization of the fed material. The readily accessible and easy to clean MIX-A-LOT is available in three sizes for throughput rates up to 5 t/h, there is also an ATEX version. The surface of the mixing chamber can be electro polished. The combination of an outstanding mixing effect and extremely short mixing time is due to the optimized design of the mixing rotor. Its low circumferential velocities and the optimum design of the gap to the housing, permit gentle handling without particle destruction or heating of the product. The large inspection door on the front of the MIXA-LOT provides easy access to the entire process chamber. An additional opening at the discharge flap also facilitates inspection and cleaning of this section. www.coperion.com

flows around material while it is suspended in the weightless zone of the mixer. This maximizes the total surface which is exposed to the air, increasing the desired effect. The drying process will go through an adiabatic evaporation with thermal efficiency at about 80 percent. Only small air volumes are required compared with other fluidizing dryers. Benefits include better air distribution which increases drying/cooling efficiency; homogeneous mixing during drying/cooling process; low air volume reduces filter requirements, rotating paddles prevent material lumping and air channels; increased air contact creates better thermal efficiency; random material/air movement reduces drying/ cooling time; gentle paddle motion creates low shear and low energy usage due to high thermal efficiency. http://www.dynamicair.com/products/dryer.html Corporate Headquarters Dynamic Air Inc. St. Paul, MN USA +1 651 484-2900 e-mail: info@dynamicair.com www.dynamicair.com UK Office: Dynamic Air Ltd. Milton Keynes, United Kingdom +44-1908-622344 e-mail: sales@dynamicair.co.uk

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

Dynamic Air Ltd. â&#x20AC;˘ +44 (0)1908 622344

www.dynamicair.com Bulk Solids Today



GITI LAUNCHES KEY TRAILER TYRE SIZE FOR GROWING VOLUME TRANSPORT SEGMENT Giti Tire has added size 445/45R19.5 alongside the 435/50R19.5 in the Giti GTL925 pattern, as the company completes its wide base range in the growing volume transport segment.


he new size offers a lower diameter which gives high cube trailer fleets the opportunity to maximise the inside loading volume of up to three meters height, while still respecting the total vehicle height of four meters allowed across Europe. Both tyres carry a load index of 160 and speed index J. The 445/45R19.5 can use the same rim and be fitted to same axles as the 435/50R19.5. The GTL925 pattern features an extra wide shoulder for enhanced resistance to tearing, a seven rib tread pattern for regular wear across the tread and high mileage potential and optimised rolling resistance which achieves a B label rating citing good fuel economy. 18

Bulk Solids Today

Both sizes are M&S marked to indicate superior all-season traction and braking properties. Tony McHugh, TBR Sales and Marketing Director UK at Giti Tire, said: “Since it was introduced several years ago under the GT Radial name, the GTL925 has proven to be a very reliable and cost-effective tyre in this heavily demanding usage segment. “The new size further increases the operational options for high cube trailer fleets as the operators look to maximise loads while simultaneously ensuring highly competitive penceper-kilometre running costs, already we are seeing significant interest and orders throughout the UK and Europe.” Further information can be found at www.giti.com


COST-EFFECTIVE PART FEEDING SYSTEM SUSTAINS FREQUENT PART CHANGES In response to growing demand for a simple, competitively priced and flexible, automatic bulk parts feeding system, RARUK Automation has introduced, FlexiBowl®. It allows entire families of parts to be fed reliably into the assembly process and is ideal for manufacturers whose production involves frequent product changeovers and reduced volumes.


lexiBowl is highly versatile and suitable for feeding a wide variety of parts regardless of their shape, fragility, material composition, weight and surface characteristics. They can be smooth, sticky, tangled or burred, yet FlexiBowl will feed the parts uniformly, effectively and, if required, continuously. The working principle is very simple. FlexiBowl includes a rotating disk and an impulse generator; the disk itself is actuated by a servomotor that allows clockwise or anticlockwise movement. When parts are released by the hopper, they fall onto the moving disc and are separated by the rotation and vibration. Acceleration, deceleration and impulse frequency are all selectable according to the part geometry to achieve the optimal result. In a typical application, the parts are then located by a vision system mounted above the FlexiBowl which guides a robot to pick and place individual parts to an ongoing process. FlexiBowl is equipped with a variety of communication ports – Ethernet, Ethercat and digital i/o signals – for easy integration with the vision/robot systems. The FlexiBowl is available in four different sizes with an inner diameter from 350mm to 800mm. Its rotating disk is made from standard conveyor belt material and is therefore easily replaceable; a choice of colours and materials are available to suit the application. An optional internal backlight is available in red, white or infrared LED. A range of hoppers with standard 5, 10 and 20 litre capacity complete the FlexiBowl system; larger hoppers up to 80 litres or elevating trays may also be supplied. To see FlexiBowl in action go to: https://www.youtube.com/ watch?v=WVz0EiK1x-I

BESPOKE SIEVING SOLUTIONS We offer innovative sieving equipment technologies for all industry sectors


Did you know we also offer a remesh service?

farleygreene.com Bulk Solids Today



FIRST DOOSAN DX210W-5 WHEELED EXCAVATOR IN SCOTLAND Banffshire-based Currie Contractors Cullen Limited has purchased the first Doosan DX210W-5 21 tonne wheeled excavator in Scotland from Balgownie Ltd, the local Authorised Doosan and Bobcat dealer with headquarters in Inverurie in Aberdeenshire.


he new Doosan wheeled excavator has already worked on projects spanning the length of the UK. Its first project was on a new solar power installation outside Andover in Hampshire in Southern England, where it worked alongside another Doosan DX225LC-3 excavator owned by Currie Contractors. Ian Currie, a Director of Currie Contractors, said: “We provide a wide range of services and have always run a 20 tonne plus wheeled excavator for the advantages it offers in trenching for ducts and for general deep sewer work. This type of machine is also well suited to road works and hardcore levelling of the type that it was carrying out in Andover. The new Doosan DX210W-5 wheeled excavator provides exceptional performance for these applications.” Ian’s son, James, also a Company Director, commented: “We favour the Doosan brand in our fleet and have been buying Doosan excavators from Balgownie since 2008, when we purchased our first machine – a DX255LC model. We still have that excavator – it’s a great machine and its performance over the years has convinced us to stay with the Doosan range for our fleet. The excellent service provided by Balgownie was very important in opting for Doosan again for the new wheeled excavator. We think it is a distinct advantage to have all your machines from one manufacturer, all with the same set-up and our preferred Geith quick hitches, so buckets and attachments can be interchangeable.” On the solar park project, the DX210W-5 wheeled excavator was operated by Gordon Durno, who has been with Currie Contractors for over 30 years. James Currie added: “Our operator, Gordon, is very well respected in the industry and everybody knows what a good job he does. Quite often he is the very last machine on site and loads up all the containers, reinstates the compound area and finishes any batter works.” Gordon commented: “The DX210W-5 is a nice piece of kit, with plenty of speed and power. I’m finding the two20

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piece boom to be very useful too. The cab comfort level is incredible so it’s a good place to spend your working days.” Located between Aberdeen and Inverness, Currie Contractors is a specialist in road construction and road recycling, but offers a wide range of other services, including mulching; forestry; snow ploughing and renewable energy. As well as Doosan excavators, the company owns a wide range of other plant and attachments for use on projects and for hire to external customers. As well as the full range of Doosan wheeled excavator models, Balgownie is responsible for sales and servicing of the Doosan crawler excavator, wheel loader and articulated dump truck ranges in Aberdeenshire, Morayshire, Angus and for much of the Highlands and parts of Perthshire and Kinross-shire. The company is also the Authorised Bobcat dealer for the same area. Balgownie Ltd started trading as an engineering company in 1907 in sheet metal work and tank manufacturing, supplying to shipyards, farmers and the food industry before diversifying into the manufacture and supply of dairy equipment. Today, Balgownie is one of the leading specialists in construction, tractor, trailer, agriculture and groundcare machinery sales in Scotland. As well as meeting the latest Stage IV emission regulations, the DX210W-5 goes much further and sets a new benchmark for wheeled excavator design worldwide. This achievement is marked by a distinctive machine styling scheme that is common to all Stage IV machines from Doosan. The DX210W-5 offers enhanced comfort and controllability together with a number of features to boost fuel efficiency, uptime and return on investment, with a focus on increased power, robustness and agility. For more information about Doosan construction equipment, visit www.doosanequipment.eu For more information about Bobcat and Bobcat products, visit the website www.bobcat.com


HANDLING WITH EASE: DEMAG MANULIFT FOR LOADS OF UP TO 500 KG Demag Cranes & Components has added a new model to its DCM-Pro Manulift range to accommodate increased load capacities. The new DC 5 Manulift allows users of Demag chain hoists to handle loads weighing up to 500 kg simply and safely.


he DC Manulift, used in conjunction with a Demag DC chain hoist, may be used for simple and safe horizontal and vertical movement of loads with minimum operator effort. Loads may be manoeuvred with the operator using just one hand, leaving the other hand free to operate the crane control system. This provides ergonomic advantages over the use of conventional chain hoists, where the operator often needs to use both hands to lift and position loads. The DC Manulift’s control unit is rigidly connected to the load handling attachment, allowing the operator to guide the load with a central handle and, at the same time, lift and lower the load via integrated rocker switches, without having to change the hand position. This arrangement enables loads to be handled quickly, precisely and safely with fluid motions. The DC Manulift has been enhanced by the introduction of material handling innovations, such as the latest D-Grip manual force control unit. It does not need switches or buttons for travel commands, with the load simply following the operator’s hand movements via the control system handle. The DCM-Pro Manulift is well established as an efficient

handling device in many production and assembly lines and is employed in numerous sectors of industry worldwide. An extension to the load capacity range is a logical step in its further development, allowing it to be specified for a broader range of heavier duty applications. The DCM-Pro 5 incorporates all of the safety and operational features associated with the established Manulift range. These include a slipping clutch, with a speed monitoring function, which protects against overloads, as well as the clutch located in front of the brake, preventing loads from dropping abruptly. Tel: 01295 676100 Email: bnb-help@demagcranes.com www.demagcranes.co.uk



eliable sensing, measuring stability and accuracy, along with the speed and change of direction of rotation in heavy duty machinery presents tough challenges and it’s where the BAUMER MAGRES range of magnetic absolute encoders excel. Heavy duty industrial applications like utility vehicles, cranes, wind energy plants, steel and metal processing require accurate, efficient and reliable components and Magres absolute encoders are ideal for these situations. The MAGRES EAM580 and EAM360 are the latest addition to the extensive range of absolute encoders available from Baumer Ltd. They combine outstanding reliability with precision, even in the harshest conditions and comply with EN13849 requirements. Their maximum angular accuracy of ±0.15º ensures absolute reliability and precise positioning for optimum process control for applications which previously required optical encoders. Thanks to their compact size Magres encoders fit into the tightest spots while the modular design means that the ultracompact 36mm option utilises the same large ball bearings as the 58mm version which helps to ensure a consistent and robust performance. Another feature is the bearing less encoder kit where the magnet motor is installed separately as an individual component which means without bearings, the encoder

operation is virtually wear-free. Installation is also simplified as the multi-turn variants feature a 2mm wide air gap. The robust steel housing provides optimum resistance to shocks of up to 500g, vibration up to 30g and also high immunity against external magnetic fields. Furthermore, the large, widely spaced ball bearings are able to withstand radial and axial shaft loads up to 80N and 40N respectively while corrosion resistance to C5-M and IP67 protection is standard across all models. The EAM580 with PROFINET supports the latest communication standards to OPC UA ensuring reliable and non-reactive data exchange for different systems. This open, platform independent design allows for easier adaptation to future requirements. http://www.baumer.com/uken/products/rotary-encoders-angle-measurement/ absolute-encoders/robust-magnetic-scanning/ Bulk Solids Today



COVERS TIMBER AND BUILDERS MERCHANTS LOOKS TO THE FUTURE WITH DOOSAN ELECTRIC TRUCKS Covers is a family owned timber and builders merchants operating a network of thirteen branch locations across the South of England. With a history that stretches back over 170 years the business has a long-established reputation for service, reliably supplying its customers with essential building materials, such as timber, paint, bricks and blocks, from an extensive range of over 25,000 product lines.


aintaining a focus on customer service is of prime importance to Covers. That is why the company has always invested well in its fleet of over one hundred diesel forklift trucks – ensuring that yard duties, like the loading and unloading of lorries, are performed reliably and with the greatest efficiency. Such a harsh and dusty environment as a builder’s yard has always has been thought of as the domain of the diesel powered counterbalance truck. However, this traditional builders merchants business is turning that thinking on its head by taking a revolutionary approach to powering its materials handling fleet. A Doosan B30X-7 3-tonne electric counterbalance truck was order in 2015 and after a successful trial period a second B30S-7 was ordered. Both machines have now been in operation at Covers’ main branch in Chichester for some time and the startling results point to a strategic shift in the type of trucks that they expect to specify for their future needs. Along with the strong environmental reasons for considering electric trucks, Covers’ energy cost comparison of diesel vs. electricity show huge savings – a cost per hour of £0.29 for electric as opposed to £2.30 for diesel. The case was compelling. “We are a very environmentally conscious company, so we wanted to explore the possibility of using electric counterbalance trucks in the yard,” says Adam Conrad, Group Transport Manager at Covers. “But what was impressive was that when we compared the expected total lifetime costs, it showed in favour of the electric truck – which was great. However, we needed to prove the concept by putting an electric truck through its paces on site. The trial truck proved the case, so we ordered a second.” 22

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Covers is looking to get at least seven years from their Doosan electric trucks, which is less than the 10 year lifespan of a diesel forklift, but going by Covers’ calculations the financial savings on energy and the lower servicing costs of the electric trucks make owning and running an electric forklift fleet the best option. The idea of moving to electric trucks was proposed by David Scammell, Managing Director of 4K Systems – Doosan’s local dealer – who presented the idea based on the potential for cost savings. After taking Adam Conrad on a visit to a customer of 4K Systems that was using electric trucks for yard duties, and after doing a few sums, the possibility of switching to electric vehicles looked promising. In addition, 4K Systems offered to provide a guaranteed buy-back after seven years. All looked good, especially as Covers had a long-standing relationship with 4K Systems and the Doosan diesel trucks in their mixed fleet were favoured for their rugged and reliable performance. The question was – could the electric truck perform as well as the diesel in such a harsh environment? “The first electric truck has been in place for over a year now and the second for several months, and they are really standing up to it, with no problems to date – no issues at all,” says Mr Conrad. A big concern for Mr Conrad was whether the battery would last all day before it needed recharging. In practice, Covers found that the heavy-duty 80-volt batteries only needed to be charged every third day. “Generally, we charge the trucks overnight and top up the electrolyte once a week, which is easily manageable, especially when you look at all the positives of going electric,” he says. “We are now looking at ways to use the electricity generated by our solar panels in our charging regime.” Listing some of the benefits of an electric fleet Mr Conrad says: “They are cleaner, no emissions, they cost a fraction


in terms of energy, have fewer moving parts so servicing is cheaper, they can move in and out of our warehouses without any problems because there are no exhaust gasses, and you can easily customise how the trucks drive by setting parameters such as speed of lift and travel.” Both Doosan electric counterbalance trucks supplied are standard with Doosan’s well renowned oil-cooled disc brakes, and have been upgraded with weather-proof cab, 5.5m triplex mast, hydraulic side-shift fork positioner and full LED road lights. Mr Conrad seems convinced electric is the way to go: “We will probably put another electric Doosan in next year in another area and we will look to roll them out to other branches too.” “Our experience working with 4K Systems and Doosan has been excellent,” says Mr Conrad. “David put a lot of work in with facts and figures and we have been through numerous calculations to try and predict how the electric trucks are going to perform over time. We’re over a year in now and it’s all going well, every sign looks good, so we believe we’re going to get in excess of seven years life out of the trucks. After seven years, it’s a bonus. And if it all works out, our fleet will be younger at lower cost.” A very significant factor in the equation was Doosan’s willingness to back the idea through its warranty scheme, as Adam Conrad explains: “No other manufacturer would put any warranties on an electric truck working in a builders yard, but Doosan were fully prepared to give us a five year warranty for the trucks. That was hugely important to us as it demonstrated that Doosan believe their electric trucks will work reliably in that environment, whereas other big brands didn’t want to commit. In fact, in the last two years now, Doosan has been our main supplier of counterbalance

trucks for that reason – it’s their commitment that counts.” Doosan Industrial Vehicle is one of the world’s leading manufacturers of forklift trucks. A complete product range of more than 200 models from the smallest hand pallet truck to the giant 25-tonne diesel trucks all offering maximum durability, reliability and ease of use. Doosan’s UK head office is based in Northampton and is supported by a nationwide network of approved dealers. It offers the lowest total ownership cost (TCO) of any lift truck brand (www.doosanforklifts.co.uk). Doosan Industrial Vehicle is part of the $21-billion global Doosan Group (www.doosan.com), a South Korean conglomerate established in 1896, over 120 years ago, with products and services ranging from consumer goods to power plants, engines and construction equipment, including the global-leading brand Bobcat. Bulk Solids Today



NORTH LINCS AGGREGATES LTD INVEST IN MORE EFFICIENCY SUPPLIED BY DUO Located at Sandtoft, Doncaster, North Lincs Aggregates Ltd (NLAL) is a family run independent business that owns and operates three quarries in the area. The Finningley operation has been established for 12 months and operates a Terex Washing Systems (TWS) M1700 Wash Plant. Operating at 160tph the plant produces a 0-4 grit sand, a 20mm and 10mm aggregate and oversize which is sold to the local concrete plants and satisfies the demand in the local market. 24

Bulk Solids Today


he Terex® M 1700 wash plant is a mid-sized mobile washing plant complete with on board hydraulically folding side conveyors for up to 5-way splitting of material in applications such as coal, crushed stone, recycled materials, iron ore, sand and gravel. The M 1700 wash plant at Finningley works independently and is part of the range of innovative washing solutions from the TWS portfolio, and was supplied by DUO (Europe) Plc who are the English and Welsh dealer for TWS. Originally moved in from their quarry at Cove the processing operation has produced an increasing amount of oversize and a decision was made to invest in a Powerscreen® 1000 Maxtrak Cone Crusher, a Powerscreen® Warrior 1400 and a tracked DUO Conveyor which has also been supplied by DUO (Europe) Plc. Richard Mills – MD of NLAL takes up the story, “We have had a longstanding relationship with DUO who supplied the M1700 and other equipment for our other operations


and it made sense to buy a 1000 Maxtrak cone to crush the oversize and a Warrior to dry screen the sand” The quarry which has reserves of approximately 3 1/2 – 4 million tonnes of Quartz gravel and sand is the last of the old Trent Valley seam and was originally an old former quarry which had laid dormant until purchased by NLAL 12 months ago. Richard, commented, “We are a self-funding company and purchasing Powerscreen® equipment off a trusted supplier like DUO makes sense. We purchased the equipment outright as the brand retains a good residual value for when we need to upgrade again.” The company currently operates 20-25 vehicles and has just acquired their third operation which is a clay quarry. Completing their current portfolio is a silica sand quarry at Cove which has very large reserves of 4 million tonnes. At this location, a DUO supplied Screener is at work processing top soil. The processing operation at Finningley is relatively simple. Sand and gravel dug from the quarry floor is sent to the M1700 wash plant with the oversize stockpiled. This is then delivered by wheeled loader to the Maxtrak 1000 cone crusher. Operating at 100tph the material is crushed down to 20mm and an associated dust which is then stockpiled and then refed back through the wash plant with the raw material to bulk the feed material up. Richard, further commented, “We have had both machines delivered in the last 3 months along with the tracked conveyor and it is great kit. The Warrior duties are to dry screen sand

and gravel through a 4mm piano wire mesh and provide us with a dry building sand. Overall we are very happy with the equipment supplied by DUO and have every confidence in the reliability of the equipment and the service back-up.” Nico Stroh – Development Manager at DUO, commented, “Powerscreen® has a rich heritage of design and manufacturing excellence, and has grown to become a leading force in the original equipment manufacturing (OEM) sector. Powerscreen® machines cover the full range of material processing requirements in terms of mining equipment, quarrying equipment and crushing and screening machines for the mining, quarrying, demolition and recycling industries. The machines supplied to NLAL are perfect for their operation and offer reliability and efficient processing. We are very confident in our supply of the full range of Powerscreen® equipment which blends perfectly with the TWS range of world beating washing equipment.” Tel: 0845 22 22 386 Email: info@duoplc.com www.duoplc.com Bulk Solids Today




Gallagher Group Ltd is a multi-faceted organization with interests ranging from quarrying, civil engineering and farming to property development and recycling.


eadquartered in Maidstone, Kent, the business was started 40 years ago by current chairman Mr Pat Gallagher and has grown in that time to become one of Kentâ&#x20AC;&#x2122;s largest employers. Gallagher Aggregates operate from two quarries in Kent, Hermitage and Blaise Farm from which Kentish Ragstone is extracted. This is an indigenous limestone deposit formed during the cretaceous period some 15 million years ago. Famous buildings that use Kentish Ragstone include Leeds Castle, the Tower of London and the Guildhall. In keeping with the company ethos of continuous development by investing in the latest technology and equipment to maintain their rigorous standards, the Gallagher Group have recently taken delivery of a Gipo RR 130/20 Tracked Mobile Roller Screen. This Swiss built machine was identified by Mr Gallagher at the Hillhead Show as having the potential to streamline the operation and improve efficiency. Supplied by Tamworth based Aggregate Processing & Recycling Ltd, this track mounted screen features a heavy-duty steel plate feeder discharging onto a two-step roller grizzly. The Gipo RR 130/20 is particularly sturdy machine capable


Bulk Solids Today

of working in the most challenging of conditions making it ideal for pre-screening blasted rock even with a high percentage of moisture and dirty material present. The grooved roller shafts, one in front of the other, create a virtually square opening, forming a type of grizzly thus permitting the passage of dirty material. Following successful trials, a decision was taken to purchase a new machine. The Gipo RR130/20 is configured to produce 3 different products; hassock fines retained at point of extraction for site remediation, a mid-size product for market and the now clean oversize material being further processed into high quality aggregates for the on-site concrete plant. T: +44 (0)1827 260290 W: www.agg-pro.com


NEW DEVELOPMENTS IN DOOSAN ADT RANGE Doosan Bobcat EMEA has announced a wide array of new standard and optional features for the company’s articulated dump truck (ADT) range.


he first of the new standard features is an angle limitation system to prevent the truck body from tipping over when it is being loaded with materials. This new function is incorporated as standard on all ADTs manufactured after 1st January 2017 and is also available if requested by customers as a software update for all ‘-5’ machines produced before that date. In the new angle limitation function, a tip limit point can be set to meet the requirements of the machine owner. This allows the body to tip in accordance with the slope of the ground as set by the system. Based on a study of the customer’s application, Doosan can provide recommended limits for the company’s trucks, but it is up to the owner to decide which limits they want to use. If the slope is over the limit, the angle limitation system ensures the body does not move. The function therefore offers increased safety and efficiency as the operator always knows the machine will be in a stable position. Another new standard feature of the ADT range is the engine auto shut down function. ADTs can spend between 30% and 60% of their time standing with the engine idling while they are waiting to be loaded and in some conditions, the waiting time can exceed 60%, with consequent losses in terms of fuel, warranty and service costs. In order to reduce these costs, Doosan has introduced the auto shut down function which can be switched on and off by the operator on the display. Using the system, the operator can set a time after which the engine will automatically shut down if the computer does not detect any activity in the machine. This function is incorporated in all new Doosan ADTs and is available upon customers’ requests as a software update for machines produced before 1st January 2017. To meet strict safety rules demanded on some sites, Doosan customers can now order new Sears high performance heated seats. The new seats can be supplied with a choice of three different kinds of seat belt with a 2, 3 or 4 point design. The rear position and direction lights on Doosan ADTs are now LED lights as standard, whilst the work lights, main lights and even the roof light bar are also available in optional LED versions. As well as improving visibility, the LED systems have longer lifetimes. Safety can also be increased by the additional hand rails for service and maintenance work that can now be installed on both the DA30-5 and DA40-5 ADTs. A new protection system for the rear lights avoids damaging the lights when reversing and is particularly useful in very tough

applications. There is also the option of a blue or orange flashing rear light which is activated when in reverse gear and works simultaneously with the reverse lights. This is designed to be an excellent additional warning device, especially when working in the dark or on very noisy work sites where normal reverse signals may be not heard. This feature is a mandatory requirement on some sites and is a very popular feature in the UK. The design of the Doosan DA30-5 and DA40-5 ADTs goes far beyond just meeting the latest emission standards and incorporates many additional features and product improvements to establish a unique benchmark in load carrying performance, fuel efficiency, enhanced controllability and high operator comfort, together with improved reliability, durability and reduced maintenance and servicing costs. The ‘best-in-class’ fuel consumption of the DA30-5 and DA40-5 ADTs is down to a combination of features including Scania Selective Catalytic Reduction (SCR) and Exhaust Gas Recirculation (ECR) diesel engines and a ZF EP transmission, improving the transfer of power from the engine to the wheels for outstanding traction. When this is coupled with the enhanced rear differential system which reduces engine rpm and further increases machine durability, customers are ensured of an improved cost per tonne carried with the Doosan ADT range. www.doosanequipment.eu Bulk Solids Today



MAKING A CASE FOR URETHANE PARTS: 5 KEY FACTORS TO CONSIDER Urethane’s unique properties and versatility is helping to solve some of the industry’s most challenging component design issues By Del Williams, technical writer based in Torrance, California.


or engineers, meeting part design challenges can be exceedingly difficult when traditional materials like plastic, steel, and rubber do not possess the required specialized characteristics, lack the versatility to be adapted, cannot be economically produced, or do not readily bond with other materials or system components. As a solution to some of today’s complex design challenges, engineers are turning to high-performance polyurethane elastomers. These tough, elastic materials retain their original shape for a long service life, while offering a number of unique properties and capabilities. Here are five key points that make a strong case for why urethane is providing engineers with the design flexibility they need to produce cost-effective parts that meet ever more demanding design specifications. 1. Urethane provides specialized load bearing properties. Urethane offers superior load bearing characteristics that can help to optimize the part. Its ability to sustain higher stresses, as well as withstand both tension and compression, is one of its outstanding characteristics. While it can change shape under heavy load, it will return to its original shape once the load is removed. “Urethane offers elastomeric characteristics that provide a different type of load bearing, not as rigid as plastic or metal, and capable of managing energy in a more versatile way,” says Fred Boyle, senior process engineer at Argonics, one of the U.S.’s largest producers of wear-resistant and customizable urethane products. In terms of load bearing, urethane covers a class of materials that can absorb and release energy under varying loads or impacts in places where metals are not suitable, adds Boyle. Urethane excels, for instance, in impact loading applications such as for bumpers, shock absorbers, die pads, machinery mounts, vehicle suspension mounting bushings, or anything to do with shock or vibration. “Where rigid mounts in oscillating machinery would be subject to fracture or fatigue failure, urethane can absorb that load and decelerate it without shock loading either the component or the stop,” says Boyle. “It can take the load of impact and spread it over a relatively short duration. In cases of varying load, urethane can either dissipate it or return it to the source of the load for reliable, extended, cyclical loading.” 2. Urethane enables maximum abrasion resistance. The outstanding abrasion resistance of urethane elastomers 28

Bulk Solids Today

has led to many important applications where severe wear is a problem. In mining applications, for instance, it withstands abrasive ore, sand, and gravel moving through a conveyor, which can cut and abrade both the steel materials inside, as well as typical rubber skirtings outside that are designed to prevent dust and spillage at transfer points. “Rubber is not as abrasion resistant as urethane, and fancy steel liners do not provide sufficient resistance either,” says Charles Pratt, Operations Manager at Kinder Australia, an independent supplier and manufacturer of conveyor and bulk material handling equipment. Pratt turned to a proprietary urethane formulation by Argonics called Kryptane, an extremely wear-resistant material for applications where abrasion, sliding, or impact occurs regularly. Examples of its use include chute, bin and hopper liners; pipe, fitting and valve liners; impact-and abrasion-resistant plates; blasting curtains and screens; vibration pads; seals and gaskets; as well as truck bed liners, wheel chocks and crossover pads. “In testing for some mining applications, we found that the urethane skirtings on the outside of a conveyor can last 10-15 times longer than rubber,” says Pratt. “Compared to a steel liner on the inside of a conveyor, a urethane liner can get 5-8 times the life.” According to Argonics engineer Boyle, urethane provides a better life and more cost effective solution for abrasion resistance in most applications.

SPECIAL FEATURE “Urethane can be formulated to resist low angle abrasion with high resilience that allows the material to slide, bounce, and tumble along a surface without transferring too much energy into the abrasion-resistant liner,” says Boyle. “For impact abrasion from high angles, it can be formulated to dissipate the impact energy.” 3. Urethane offers a variety of adaptable properties. Because urethane’s properties are tailorable over wide ranges of hardness, resilience, spring rate and dynamic properties, its versatility offers custom solutions to difficult design challenges. “Urethane, even in relatively small quantity production, can be adapted and tailored to prioritize the physical properties that design engineers need,” says Boyle. According to Boyle, for instance, urethane is often used to provide a high degree of resilience, and can return incoming energy to its source, such as for spring applications. This can be done over a long, slow extension or a very quick impact, or the material can be formulated to dissipate the maximum amount of energy when it is more appropriate to cushion an object rather than bounce it. Hardness is also readily adaptable. While most rubbers have a hardness that is typically found between 30 and 80 on the Shore A scale, and structural plastics begin at 55 on the D scale, some urethanes bridge the rubber-plastic hardness range. One proprietary urethane, for instance, offers a wide range of formulations from a 52 shore A to a 70 Shore D to suit a variety of applications. As such, Kinder Australia’s Pratt looked to a proprietary urethane when a unique combination of attributes was required for mining applications to optimize conveyor skirting so it would not prematurely wear the conveyor belt if rubbed against it. “Argonics was able to formulate a conveyor skirting material that was not only abrasion resistant, but also soft and slippery to minimize any potential conveyor belt wear,” says Pratt. “The urethane is very customizable. For applications such as coal mining, you can also make it resistant to fire and temperature as well as anti-static.” 4. Urethane parts can be produced with a low cost, low pressure mold. Urethanes can be poured as a liquid mixture into less expensive, low pressure moulds so complex mold cavities can be filled without highpressure moulds and presses. This provides a multitude of advantages, not the least of which are lower tooling and production costs than both rubber and plastic moulding, and lower material cost than metals and ceramics. Because of short lead times and more economical tooling costs, urethane is often the choice for one-off parts and prototypes, or high volume, repeat production runs. “To produce a good part in the rubber part-making process, you have to apply significant pressure to force the material into all the nooks, crannies and corners,” says Boyle. “This requires rather costly hydraulic presses.”

“Urethane, however, is castable at atmospheric pressure so you can use relatively inexpensive moulds to create prototypes, design iterations, and even production runs more quickly and inexpensively,” adds Boyle. 5. Urethane can bond with an array of substrates. Urethane is versatile in how it bonds with a wide range of substrates such as steel, aluminium, fibreglass and plastic. “Since urethane is cast as a liquid, it can be bonded to a wide variety of shapes and moulded into a wide variety of shapes,” says Boyle. “Urethane can even be bonded to substrates so the bond will be stronger than the urethane. This is an advantage when bonding dissimilar materials, when strength and adhesion are required.” Other conventional materials lack this range of bonding capability. For instance, steel can bond to steel but cannot be reasonably bonded to aluminium; and aluminium can be welded to aluminium, but not attached to plastic in this way. When engineers require unique high-performance properties in the construction of component parts, they can often improve their design by utilizing urethane, and by partnering with an expert provider who can tailor the parts to their exact design requirements. For more information contact Argonics, Inc., 520 9th St., Gwinn, MI 49841; visit www.argonics.com; call 800-991-2746; Email information@argonics.com. Bulk Solids Today





new Flexicon Bag Dump Station with explosionproof electrical system contains dust emitted from manual dumping activities, compacts empty bags and conveys the material to an elevated destination. Bags are staged on the bag tray and transferred through a plastic strip curtain into a hooded glove box and onto a grate, which supports the bag and prevents unintended operator contact with moving parts. The hood is equipped with a polycarbonate skylight that illuminates the interior of the enclosure for improved bag slitting, dumping and disposal. A bag infeed chute through the sidewall of the glove box permits the operator to pass empty bags directly into an integral bag compactor, causing dust generated from compaction as well as dumping activities to be drawn onto the system’s two filter cartridges. The automatic reverse-pulse filter cleaning system employs timer-activated solenoid valves to release short blasts of compressed plant air inside the cartridges, causing dust build-up on the outer filter surfaces to fall into the hopper, conserving useable product. Filters are readily accessed by removing the interior baffle, and replaced rapidly using quick-disconnect fittings.

The compactor employs a pneumatic air cylinder that compresses bags into a removable polybag-lined bin that accommodates 50 to 80 bags. The main waste access door and a flapper door within the bag infeed chute are safety interlocked to prevent operation of the compactor unless both doors are closed. The hopper discharges into an enclosed Flexicon flexible screw conveyor for dust-free transfer of freeand non-free-flowing materials to an elevated destination with no separation of blended products. The company also manufactures tubular cable conveyors, pneumatic conveying systems, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, drum/box/container tippers, drum fillers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls. For information contact Flexicon Europe Ltd, +44 (0)1227 374710, sales@flexicon.co.uk, www.flexicon.com.co.uk



hen constructed and fully commissioned Hinkley Point C will provide added security to the mix of electrical generation capacity in the UK. In its own right nuclear power can be viewed as one of the greenest forms of reliable, long-term electrical energy available. The project will secure power for the U.K. for the foreseeable future, reportedly at least 60 years. Nuclear power is also one of the renewable energy forms that produce less CO2 than traditional fossil fuel systems. However, before even generating one kilowatt hour of electricity the project is already establishing its “green” credentials for all to see. Much of the construction material, mainly aggregate and cement required to build the project is to be delivered by sea. This will save thousands of vehicles, over the 10 year construction period, having to use the roads surrounding the site. This is especially significant in the tourist areas of the North Somerset coast. Not only will it reduce


Bulk Solids Today

(Photograph courtesy of BYLOR)

vehicle pollution but it will also avoid traffic congestion. Fairport Engineering’s part of the overall Hinkley Point C project is to provide a facility to receive and store aggregates, sand and ground granulated blast furnace slag (GGBS). These materials will then be used by any of four concrete batching plants for the civil engineering aspects of the project. Fairport Engineering is to design, supply and install the entire covered conveyor system for aggregate and sand along the 500m jetty, into a compartmentalised storage building. Additionally a 5,000t silo is to be provided for GGBS cement. All necessary electrical and control systems will be provided. Installation, commissioning, handover and training are also included in Fairport’s scope of works. Whilst Fairport Engineering is based in Adlington, Lancashire and the project is key to Britain, its supply chain spreads across Europe, including Germany and Italy; thus mirroring the wider diversity of stake-holding partners for the project as a whole. Not withstanding Fairport’s European suppliers jobs have also been created in the UK supply chain, due to Fairport’s design, procurement and project management of the project. Fairport Engineering is managing the project with BYLOR (Bouygues TP and Laing O’Rourke) and has their project delivery team based on site in order to safely manage the installation under the C(DM) 2015 regulations. Currently good progress is being achieved. For further information please contact Fairport Engineering’s Communications Manager, Mrs Linda White lwhite@fairport.co.uk


BARDYKE CHEMICALS CHOOSES AJAX INCLINED SCREW FEEDER Solids handling specialist, Ajax Equipment, has supplied copper chemicals producer, Bardyke Chemicals, with a 4m long inclined screw feeder for its factory in Blantyre, South Lanarkshire. Bardyke Chemicals manufactures a range of copper-based chemicals including cuprous oxide and cuprous thiocyanate for applications from marine paints to pharmaceutical production.


he production process requires the Ajax screw feeder to be inclined at 25°. Screws inclined at an angle greater than 20° can lead to material back-spill, increasing the cross sectional loading on the feeder. To prevent back-spill, Ajax has combined specially selected flights and appropriate rotational speed to generate effective conveying, driving the material forward. The stainless steel screw feeder features Lynflow™ ribbon flights with variable pitch. Ajax’s Lynflow™ ribbon and paddle flights have been specifically designed to counter the adhesion of materials to the shaft and blades.

“Bardyke has worked with Ajax Equipment on several solids handling projects in recent years, all of which have contributed to the consistency and reliability of our production line. Ajax’s understanding of solids handling ensures the material and process are the foremost factors during design, resulting in effective and efficient equipment,” said Duncan Norman, Managing Director, Bardyke Chemicals Ltd. For more information on Ajax Equipment screw feeders call +44(0)1204 386723 or email: sales@ajax.co.uk

Bulk Solids Today



GREATER RELIABILITY IN COOLING LUBRICANT FILTRATION VACUBELT® filter belt sets new standards in central system of automotive supplier


ith its sophisticated product portfolio, the Schaeffler Group ranks among the world’s leading technology companies, specializing in precision components and systems for engines, transmissions and chassis, as well as roller bearing and plain bearing solutions for industrial applications. At the Schweinfurt location, the cooling lubricant filtration of three lateral grinding machines used in transmission bearing manufacture has now been sustainably optimized. In the central filter system, a VACUBELT® 3354 polyester filter belt from GKD – Gebr. Kufferath AG replaces the plastic belt previously used. With considerably better durability, stability and service life, the new belt type helped the company achieve significantly higher supply and process reliability. This now qualifies it for use in further filter equipment at the integrated automotive and industrial supplier. As one of the world’s largest family businesses with 85,000 employees and 170 locations in over 50 countries, Schaeffler manufactures precision products that make a key contribution to the mobility of tomorrow in a multitude of applications. Whether in the drive train of motor vehicles, in highspeed trains, wind turbines or innovative solutions for the aerospace sector: high-tech-bearings from Schaeffler facilitate leading-edge motion in over 60 industry sectors. Yet impressive performance does not depend on component size, as miniature bearings measuring just a few millimeters are just as important in the production spectrum as large bearings with an external diameter of several meters. Beside these precision components, Schaeffler develops and produces complete system solutions for engines, transmissions and chassis that are used in numerous industrial and automotive applications. At its site in Schweinfurt, Schaeffler Technologies AG & Co. KG produces spherical roller bearings with a diameter of up to 1,600 mm for wind turbines, high-precision spindle bearings for machine tools, as well as a broad range of roller bearings for industry and the automotive manufacturing sector.

30 PRESSURE BELT FILTERS IN CONTINUOUS USE In principle, a roller bearing comprises one outer ring and one inner ring with caged rolling elements – balls, pins or cylinders – sandwiched between the two that move on tracks. The cage keeps the rolling elements at an equal distance and thereby prevents them from touching one another. This design therefore transmits a load between two surfaces running in counter-rotation with little frictional resistance. Grinding is a key process in bearing ring production. Beside a precise system design, optimum cooling and lubrication performance 32

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are of central importance in ensuring the quality and costeffectiveness of this process. The cooling lubricant dissipates the heat occurring during the machining process, reduces friction between the grinding discs and the workpiece, while at the same time removing the swarf and corundum particles released. To achieve high quality surface finishes and a long service life, the cooling lubricant needs to be permanently regenerated. For continuous cleaning and preparation of the cooling lubricants, Schaeffler therefore uses twelve central filter systems with around 30 pressure belt filters, each of which serves between five and one hundred systems depending on the respective process. They prepare 150 to 600 cubic meters of cooling lubricant per hour. Depending on the system size and application, the filters at Schaeffler operate with a fill quantity of 40 to 100 cubic meters. The throughput performance depends on the required viscosity of the cooling lubricant, the material to be machined, the type of machining and the required tolerances – for example less than 1 μm for spindle bearings. Schaeffler uses water-based emulsion as the cooling lubricant.

IT ALL HAPPENS IN RING MANUFACTURE In transmission manufacturing, a pressure belt filter supplies three lateral grinding machines. On these systems, the lateral surfaces of the bearing rings (between 50 and 100 millimeters in length) are ground on the top and underside. The prepared cooling lubricant must therefore contain no more than 50 milligrams of dirt load per liter following its treatment. The target level is actually ten milligrams per liter. In addition to this, the cooling lubricant is heated to a defined temperature for process reasons. The increased viscosity created by this improves adhesion of the rings on the grinding machine’s magnetic chuck. The coolant, loaded with abraded material and swarf, is transported from the manufacturing operations to the pressure belt filter’s dirt tank and from there via a pressure pump into the filter chamber, where it is distributed on the belt

TRANSMISSIONS & COMPONENTS using nozzles. The pressure forces the suspension through the filter belt, while the dirt particles are retained on its surface and form a filter cake. The cleaned cooling lubricant is then pumped from the clean tank back to the machining tools. The differential pressure rises with increasing thickness of the filter cake, which can reach a height of up to six centimeters. At 0.7 bars, supply of the cooling lubricant loaded with abraded material is automatically interrupted for regeneration of the filter. To this end, the filter cake is dewatered with compressed air for around two minutes, reducing its residual moisture content down to 40%. The pressure belt filters do not operate with closed, revolving filter belts. Instead, the system is fed from a roll of 50 meter long and 1.30 meter wide filtration mesh. After the filtration process, the soiled mesh is removed and cleaned. This filter surface is then drawn back into the filter. Only when the degree of soiling means that effective filtration is no longer guaranteed is the belt rolled up behind the system, exposing a clean and unused section of the filter belt ready for use in the system. To ensure the requisite process reliability, at least a pair of belt filters is fitted in each central system. While one system filters, the other is on standby ready for use at any time. This also allows periods of filter regeneration or downtimes during belt changes to be bridged, making what is actually a discontinuous process continuous.

FILTER BELT STABILITY PREVENTS KINKS AND TEARS In the past, Schaeffler always used a polypropylene belt in its pressure belt filter. However, regular problems with bent edges or irreversible longitudinal kinks in the belt which reduced its useful life motivated the production engineer responsible, Ralf Kuberek, to look for alternative solutions in the market. During this search, he got talking with the filter belt experts from GKD at the end of 2015. He was so impressed by the company’s product presentation and consultancy expertise that he immediately decided to install a test belt on the central filter system for the lateral grinding machines. The belt was delivered just two weeks later and then installed in the pressure belt filter at the start of 2016. The VACUBELT® 3354 filter belt was ultimately chosen, as its pore size of 150 μm met Schaeffler’s requirements perfectly. This belt type allows efficient filtration without addition of filtration aids. With air permeability of 1,300 l/m²/s, it is highly permeable. The smooth surface of the specific mesh design made of polyester monofilaments also guarantees easy cleaning, as well as good cake discharge. For Ralf Kuberek, however, the benefit that tipped the balance in favor of the VACUBELT® was its high degree of lateral stability thanks to the significantly thicker weft wire. At 0.9 millimeters, the belt is more than twice as thick as the belt type previously used. Initial fears that the thicker monofilaments might potentially compromise the seal of the filter chamber proved completely unfounded, as did the worries that the sealing flaps would lead to irreversible kinks in the mesh. It was possible to readjust the chamber seal accordingly without any great effort. The higher weight and transverse stability make the VACUBELT® significantly more controllable than the softer cloth previously used, which is of key importance for this system design. After all the belt is not fixed in place, but is instead only positioned tautly in the filter chamber. Outside the chamber, it is only held at the side by lifting beams.

Kinks, such as those regularly encountered with the old filter belt due to a lack of control, made the belt narrower and thereby more difficult to fix in position. As such, there was always a risk of leaks occurring. Thanks to its greater material thickness, the new belt retains its shape and directional stability permanently without kinks. Problems with bent edges due to skewed running or even formation of tears, such as those regularly encountered with the previous belt type, are now a thing of the past with VACUBELT® 3354. Due to the relatively large ball passage of the filter pumps, rings used to find their way into the filter again and again, where they would cause tears in the thinner cloth previously used. A tear in the center of the cloth would typically go unnoticed until the filter failed or was only discovered when the cloth was at the top by chance during a visual inspection – with the result that grinding sludge kept reaching the clean tank unhindered until the tear was fixed. Unlike the previous filter belt, the welded edges of the GKD belt do not fray.

GREATER RELIABILITY AND LESS CONSUMPTION MEAN GREATER EFFICIENCY While the previous belt had a maximum useful life of seven months, the VACUBELT® filter belt is still performing its task to the complete satisfaction of Ralf Kuberek after almost a full year. The new belt is also significantly more efficient in use, as the 50 meter long filter cloth previously used was totally spent after seven months, while the VACUBELT® filter belt of the same length was only around 60 percent used up after the same period. As a consequence, the number of cycles that can be completed before the used filter belt section is no longer capable of providing the necessary differential pressure is significantly higher with the GKD product – while delivering comparable results in residual dirt analyses. Ralf Kuberek is therefore very positive in his summary of the product: “The GKD belt meets our expectations of improved stability in full.” The sustainable kink resistance demonstrated in the test run means significantly higher process reliability in real world operations. Together with the discernibly increased supply reliability resulting from the significantly longer useful life, the VACUBELT® filter belt meets cost-effectiveness and efficiency requirements in an unprecedented scope. Ralf Kuberek’s conclusion is therefore clear: “Given these properties, the belt could potentially also be used for some of our other filter systems.” The excellent cooperation with the filter belt experts at GKD is also essential: “They provide me with prompt and professional advice that I can rely on in any situation,” he comments.

GKD – WORLD WIDE WEAVE The owner-run technical weaver GKD – Gebr. Kufferath AG is the global market leader for metal and plastic woven solutions as well as spiral fabrics. Four independent business divisions bundle their expertise under one roof: Industrial Mesh (woven metal mesh and filter solutions), Process Belts (belts made of mesh and spirals), Metalfabrics (façades, safety and interior design made of metal fabrics) and Mediamesh® (transparent media façades). With its headquarter in Germany and five other facilities in the US, South Africa, China, India and Chile – as well as its branches in France, Great Britain, Spain, Dubai, Qatar and worldwide representatives, GKD is close to markets anywhere in the world. www.gkd.uk.co

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BUYERS GUIDE Aero Mechanical Conveyors

Conveyors & Elevators

Mixers & Blenders

â&#x20AC;&#x153;Often copied NEVER matchedâ&#x20AC;?

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

Bulk handling with complete confidence Designers and UK manufacturers of: â&#x20AC;˘ Bucket elevators â&#x20AC;˘ Chain & flight conveyors â&#x20AC;˘ Screw conveyors & bin dischargers â&#x20AC;˘ Belt conveyors

Dynamic Air Ltd. Milton Keynes, England

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Tuf-Lok (UK) +44 (0) 1706 822512 www.tuflok.com



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FIBC Dischargers


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BUYERS GUIDE Sieves & Sifters Contâ&#x20AC;&#x2122;d

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


T: +44 (0)1487 711114

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



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6:(&2(XURSH Vibratory & centrifugal Solids/solids or liquid/solids separations Standard and custom designs Industrial, food, pharm. designs


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Primasonics 7

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Sieves & Sifters

ntitled-2 1

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Vortex Valves


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InterBulk GROUP

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NORD DRIVESYSTEMS Intelligent Drivesystems, Worldwide Services

Maxx MaxxDrive Drive The MaxxDrive TM range of Industrial Gears are designed to our tried and tested Unicase principle of a one piece housing, into which all the bearings are integrated providing the highest levels of precision, rigidity and strength. This produces a compact, lighter unit that can be mounted in any position and with the use of larger roller bearings guaranteeâ&#x20AC;&#x2122;s a long operating life. There are 9 sizes in the range with ratings of 25,000...250,000Nm, covering motor powers 2.2...2,200kW and with gearbox ratioâ&#x20AC;&#x2122;s of 5.54...1,600 : 1. Shown below on a base frame with a fluid coupling between motor and gearbox for soft start functionality. The product is fully flexible and can be adapted to suit all applications.

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Member of the Global NORD DRIVESYSTEMS Group

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