Bulk Solids Today October 2020

COMPANY BULK MATERIALS SHOWCASE HANDLING • MIXERS, • POWDER BLENDERS HANDLING & DRYERS • QUARRYING • SIEVES, •SIFTERS, RECYCLING SEPARATORS & WASTE MANAGEMENT & SCREENING

FEBRUARY OCTOBER 2020 2017

HOW THE BELLA FLUIDIZED ZONE MIXER WORKS

see pages 16

HIGHLIGHTS:

4

Briggs Equipment delivers new JCB machines to The Port of Liverpool

8

Port of Tyne unveils £1 Million investment in cargo handling

20

Farleygreene’s Ultra Hygienic Sack Tip Station

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

MODU-KLEEN BIN VENT FILTER

SWITCH RECEIVER

CONVEYING LINE

®

BLENDCON SILO BLENDER

TM

BULKBUSTER BULK BAG UNLOADER

STORAGE SILO

STORAGE SILO

STORAGE SILO

TM

VIBRA-JET BIN AERATOR

BULK BAG

®

GYRO BIN ACTIVATING FEEDER TM

DYNA-SLIDE HIGH PRECISION AIR-ACTIVATED FEEDER

WEIGH HOPPER

®

BAGBUSTER BAG BREAKER ®

BELLA TWIN SHAFT FLUIDIZED ZONE MIXER

®

BLENDCON AIR BLENDING HEAD

TRANSPORTER MANUAL HOSE SWITCH

Less degradation

Cost effective

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

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

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

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

BellaTM Twin Shaft Fluidized Zone Mixer

GYRO EXTM Bin Activating Feeder

Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: sales@dynamicair.co.uk

www.dynamicair.com

Dense Phase Transporter, J-Series

BulkBusterTM Bulk Bag Unloader

Issue 144

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 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

CONTENTS 4

NEWS

12

FEEDERS & CONVEYING

14

MIXERS, BLENDERS & DRYERS

16

COVER STORY

18

SPECIAL FEATURE

20

SIEVES, SIFTERS, SEPARATORS, & SCREENING

22

COMPANY SHOWCASE

All contents © Abbey Publishing Ltd 2017

www.bulksolidstoday.co.uk Bulk Solids Today

3

COMPANY NEWS

BRIGGS EQUIPMENT DELIVERS NEW JCB MACHINES TO THE PORT OF LIVERPOOL The Port of Liverpool has taken first delivery of two new cutting edge shovel loaders which will replace an existing fleet of machines at the Animal Food Stuffs (AFS) warehouse.

The new JCB 457 loading shovels are the latest JCB built machines from Briggs Equipment and include cutting edge machine technology. The new machines have been selected and specified with additional safety features including: hivisibility hand rails, Ardent Vehicle Fire Protection, Camera System, Illuminating Chevrons and Tier 5 engine technology, reducing harmful emissions by eliminating ultra-fine particles of soot in diesel exhaust known as sub-micron level particles. This is extremely important and in alignment with Peel Ports clean air quality strategy.

A further four new machines will be delivered over the coming weeks which will include another two JCB 457 and two JCB 437 loading shovels.

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Bulk Solids Today

The new equipment will be used across the bulk terminals at Mersey, specifically the AFS and Merlin General Bulk Stores, and will allow the port to continue to provide its customers with a reliable and competitive service.

Phil Hall, Port Director (Liverpool), Peel Ports said: “The addition of these cutting edge machines have been well received by the team. They are highly reliable pieces of equipment which will further enable us to deliver our customer needs more efficiently due to an increased cubic capacity bucket.

“We have a great working relationship with Briggs Equipment who are our strategic wheeled asset partners. They have a strong track record for safety and customer service.

Putting our customer service first is paramount to Peel Ports, this investment will minimise machine down time supporting our operational capability to customer service satisfaction”.

Tony Worrall, National

Account Manager, Briggs Equipment, said: “We are delighted to have completed this latest delivery of JCB equipment to Peel Ports.

“We have worked closely with Peel Ports to understand their specific requirements and the solution that we’ve delivered ticks every box. The fast-paced working environment at the Port demands equipment that is strong, reliable and suited to high-intensity workloads and these new machines will provide exactly that.

“The additional safety features were a key requirement for Peel Ports and the new Tier 5 engine technology demonstrates their clear commitment towards sustainability in their work.

“We’re looking forward to continuing our work with Peel Ports and seeing the positive impact that these new machines will have on all aspects of their operations.” www.briggsequipment.co.uk

COMPANY NEWS

B&B ATTACHMENTS INTRODUCE AN EXCITING NEW ADDITION TO ITS RANGE OF TURNING ATTACHMENTS B&B Attachments continues to drive its innovative solutions within the material handling industry by introducing its new box turning attachment. Several features immediately make the new produce box turning attachment a sound investment for the user. This high visibility unit with its robust construction is a low maintenance solution to handling and rotating a range of different box sizes.

This attachment is intended exclusively for the transport and lateral discharge of produce and Dolav boxes. It improves productivity through speed of rotation and elimination of dropped loads.

The specially positioned arms are fitted directly to a KAUP 360 degree rotating head. The arms secure the box load at both the top and sides, providing a safe and secure hold on the load. The arms are manually adjustable to handle different box sizes securely and are fully bushed to ensure smooth arm movement.

There are several different types of top and side arm options available. The attachment can be supplied with a side arm on either one or both sides of the rotator.

This attachment can be fitted with a rear spacer to help the truck discharge produce closer to the centre of vehicles or when its receiving hoppers, ensuring safety and increased productivity with every lift. The arms can also be made as ‘quick release’ which allows the operator to revert to a standard rotator and forks in under two minutes, allowing all other palletised loads to be handled by the same forklift truck.

The rotator is rated 3200kg

at 500mm load centre.

All capacities, sizes and types are available through B&B Attachments.

B&B Attachments has been established for 40 years.

It prides itself on providing solutions to the most demanding material handling tasks.

Its technical support and fully inclusive maintenance and service contracts ensures full service support at every stage of equipment selection and use.

YOUR SIEVING & SCREENING PROCESS

REDEFINED WITH SIEVMASTER BY FARLEYGREENE.

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

Bulk Solids Today

5

COMPANY NEWS

HYSTER DOUBLE CONTAINER HANDLING SOLUTION HELPS BOOST PRODUCTIVITY AT PORTS With a Hyster Empty Container Handler, port operations can benefit from time and cost savings by handling two empty containers simultaneously. This double-handling capability provides advantages as organisations scale to handle growing demand, while controlling efficiency and costs.

“The quantity of containers shipped worldwide continues to grow, and we are seeing increased use of dedicated empty container yards,” says Richard Root, EMEA Big Truck Director for Hyster. “With such scale, double handling of empty containers can unlock efficiency gains that can

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Bulk Solids Today

make a meaningful impact on the bottom line.”

For instance, double handling may help improve terminal throughput and reduce congestion at ports – both inside the terminal and on roads. This helps reduce waiting times for lorries, resulting in shorter queues and optimised

traffic flows. With greater speed and efficiency, double empty container handling could increase throughput by up to 30%, driving down the cost per container moved and boosting profitability.

Using Hyster® Empty Container Handlers for double handling can also contribute to a low cost of ownership. By decreasing driving distances, operations can reduce fuel usage and tyre wear, while maximising the quantity of containers moved.

The Hyster® H9-H11XM-ECD truck series lifts loads of up to 11-tonnes and enables operators

COMPANY NEWS

For more information on contributuing or advertising within Bulk Solids Today magazine, please feel free to visiit our website www.bulksolidstoday.co.uk or get in touch by emailing james@bulksolidstoday.co.uk

to build stacks up to nine high, significantly increasing capacity.

This optimises yard space and is both cost and time efficient.

For maximum productivity without compromise on security, the spreaders available for Hyster® Empty Container Handlers all lock the second container. The truck also has an intuitive digital display so that operators can check that containers are seated and secured correctly. Meanwhile, operators get a strong sense of stability, competitive levels of forward visibility and a comfortable experience, thanks to an ergonomic seat and controls.

Even where difficult weather conditions, local policy or other constraints prevent operations from stacking nine high, increasing stacks from five to six containers with a Hyster® Empty Container Handler can still result in a capacity increase of up to 20%.

With a lift capacity of up to 11-tonnes, it is also possible to handle two reefers at once with a Hyster® Empty Container Handler, even if the containers have a wet floor or the load is ‘imbalanced’ with cooling units positioned on the same side.

“The right choice of truck always comes down to the specific application – no two container terminals are exactly the same,” says Richard. “However, our global network of local Hyster® dealers has the expertise to advise whether double handling can help optimise the operation for greater efficiency and profitability.”

See double handling with a Hyster® Empty Container Handler in action: https://youtu. be/3uxvCsx_ XK0 For more information on the benefits of contact a local Hyster® distribution partner or visit www.hyster.com.

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

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

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

Bulk Solids Today

7

COMPANY NEWS

PORT OF TYNE UNVEILS £1 MILLION INVESTMENT IN CARGO HANDLING The Port of Tyne, one of the UK’s leading deep-sea ports and a major employer in the region, has today announced a £1 million investment in its wood pellethandling operations.

The investment sees state-ofthe-art equipment installed and a range of measures put in place to help combat dust emissions from the dry wood pellets it handles into the UK. The actions put Port of Tyne at the forefront of technology and systems at UK ports, and underlines its position as a key player in the growth of offshore renewable energy industries in the North East of England. In May, the Port announced that it is to become the base for the world’s largest offshore wind farm, Dogger Bank, in partnership with Equinor and SSE Renewables.

Matt Beeton, Chief Executive at the Port of Tyne, said: “These measures ensure that we are doing everything we possibly can to decrease dust emissions to the

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Bulk Solids Today

lowest level possible.

“We have, over recent months, been carrying out a range of proactive investigations and have engaged the services of the best external, independent, professional advice to support our improvements.

“We were aware the situation needed improvement and this investment in the very latest innovation and state-of-theart equipment underlines our determination not just to meet standards, but to go over and above them, with best practice in every area of the business.

“We are working closely with our stakeholders and thank them for their support.

“Noticeable improvements have already begun, and more will follow.”

The improvements at Port of Tyne include: •Dust bosses, which create a continuous water mist spray to

prevent dust particles flying into the air •Pyramid covers, which enclose the top sections on the eight cargo grabs •Skirting on hoppers, which increase airflow and reduce dust emissions.

•A micro-fogging system at strategic points within the warehouse and on the ventilation units, making dust fall to the floor In 2021 the Port will also be the only one in the UK to have a hitech water spraying system, which will be installed at the end of the Quay.

The work builds on the back of the announcement in May that the Port was to become the base for the world’s largest offshore wind farm, Dogger Bank, in partnership with Equinor and SSE Renewables.

The investment comes despite a difficult year coping with the effects of the global COVID-19 pandemic.

COMPANY NEWS

FIRMS URGED TO ACT NOW TO TAKE ADVANTAGE OF TAX RELIEF Companies are being urged to act quickly to ensure they take full advantage of tax relief for the purchase of plant and equipment.

Currently the full cost of such purchases can be off set against tax through the Annual Investment Allowance (AIA), up to a maximum of £1 million, following a temporary increase introduced by the Government.

From January 1st, 2021, the AIA limit will reduce to £200,000 but for some businesses, the limit could be even lower – costing some firms hundreds of thousands of pounds in reduced tax relief.

Now Paul Jennings, Managing Director of JCB Finance, is urging customers to take full advantage of their AIA before it’s too late.

He said: “While the AIA is due to revert to £200,000 on 1st January 2021, businesses whose year-end is not 31st December could see their AIA allowance drop even lower, in some cases to as little as £50,000 if they don’t time their purchases

right. “The temporary increase to £1 million is only available for qualifying expenditure incurred in 2019 and 2020. If companies have a 31st December year end, then the position is straightforward, as a December 2020 year end will coincide exactly with the decrease in the limit. Put simply, firms would receive £1 million potential relief in 2020 and £200,000 potential relief in 2021.

“For companies with a year-end other than 31st December, things become much more complicated.

Due to how the available AIA relief is calculated, for businesses whose financial year spans the calendar year, their effective AIA limit restricted to significantly less than £200,000. That’s why it is important that companies act now to take full advantage of their AIA.

Bulk Solids Today

9

COMPANY NEWS

STOCK CHILLERS WITH NO FRILLS In direct response to increased market requests, Motan Colortronic Limited have increased stock holdings of standard, stand-alone Reglochill chiller units.

“The RC models from 4-40kW, designed to fulfil basic cooling requirements while offering maximum performance and low energy consumption, are filled with high quality components to ensure long, trouble free use.

The control is easy to use and new stock levels carried at our 2 acre Chesterfield facility allows us to respond to the complete needs of our Customer, where fluid chilling and heating are required” states Karl Miller of Motan Colortronic Limited.

These smaller stand-alone chillers are complemented by the medium to large size Reglochill DCW airblast chiller and the unique

IESG integrated chiller systems with free cooling and without glycol with typical sizes of 60-1,500 kW.

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

Bulk Solids Today

COMPANY NEWS

BRITISH OFF-ROAD MACHINERY OPERATORS URGED TO ADOPT STAGE V COMPLIANT GENERATORS British off-road machinery operators have the opportunity to radically improve air quality and minimize their green-house gas (GHG) emissions, thanks to a series of Stage V generators that meet the Non Road Mobile Machinery (NRMM) emissions standards for mobile power.

Developed through a collaboration between a specialist provider of generators; Power Electrics, and the UK’s leading provider of GreenD+ (paraffinic HVO fuel), Green Biofuels.

Air quality is a critical factor in the UK’s health, and Stage V Generators offer a huge advance in emissions reductions. The Department for Environment Food and Rural Affairs reported in July 2020 that the mortality rate caused by air pollution is equivalent to 28,000 to 36,000 deaths a year[1].

Independent tests have confirmed that the New Stage V generators, developed by the two companies as part of an ongoing partnership, have the lowest emissions on the market thanks to the use of the high performance paraffinic alternative HVO fuel, Green D+, supplied by Green Biofuels. Using GreenD+ reduces GHG emissions by up to 90%, when compared to regular diesels.

Power Electrics are commencing a rolling conversion of their 2,500 generator fleet to Stage V compliant generators which can all run on Green D+. The aim is for these to form the backbone of the Power Electrics fleet of rental generators, giving off-road machinery operators the opportunity to access the UK’s lowest emission rental generators and reduce GHG. This means that emissions contributing to climate change can be reduced, as well as pollution affecting the local air quality. The London Greater Authority has reported that since March 2020, the particulate emissions (PM2.5) of nearly all sites in London and regional background sites, exceed the average guideline limit of 25 μgm3 set by The World Health Organisation[2].

Power Electrics has been using GreenD+ for 12 months and has used 3 million litres of GreenD+. The total emissions savings in this time have been calculated as: 8,612mt of NOx and 31.3mt of Particulate Matter.

In addition, a total saving of C02e over regular diesel of 8,190mt of C02e (equivalent to 1,688 single flights London/Sydney) has also been achieved. When combined with the rolling conversion to Stage V, these savings will see the Power Electrics hire fleet contend for the title of lowest emission and highest GHG saving fleet in the UK. Green D+ has already been widely adopted in the UK as a drop-in diesel replacement by centrally fuelled fleets – on-road, off-road and in back-up power applications, where it helps to meet the Medium Combustion Plant Directive (MCPD) and the Non-Road

Mobile Machinery requirements for improved air quality.

Green Biofuels also recently announced a collaboration with Volker Fitzpatrick, a leading construction company operating in the rail infrastructure sector, who estimate they will reduce 4,000mt of CO2e over the coming 12 months thanks to the use of Green D+.

Green D+ is aligned with each of the Mayor of London, TFL and Network Rail’s separate policies to reduce transport’s contribution to climate change with the use of, amongst other initiatives, biofuels. Specifically, in line with the Mayor’s proposal for solutions which are price competitive with conventional technology, Green D+ enables construction and infrastructure operators to switch from conventional road vehicles to low CO2emitting transport and low carbon fuel sources without any change to equipment or fuel tanks.

Andy Pullin, Managing Director of Power Electrics, has commented: “We are delighted that through the hard work and dedication of our team and the outstanding GBF technical team we have achieved a remarkable thing. To be able to launch a Stage V generator with the lowest emission fuel providing the best local quality and a GHG saving is something of which we are hugely proud. We look forward to being able to deploy our fleet of Stage V generators where they will make the biggest impact and help improve air quality and reduce carbon.”

William Tebbit, CEO Green Biofuels, has commented: “We are delighted to continue to work with Power Electrics to deliver the best air quality and GHG savings possible in mobile generators. Increasingly our customers are recognising that without any capital expenditure any diesel engine can use our fuels and immediately improve air quality and reduce GHG. “Many are still talking about plans for battling climate change, but we believe now is the time for action. Green D+ can be used instantly with no capital expenditure to hugely reduce emissions and greenhouse gases. As a lot of our customers say – it’s a no-brainer; as we say it’s a solution for HERE and NOW. Bulk Solids Today

11

FEEDERS & CONVEYING

NEW GENERATION STORMAJOR® COMBINES SAMSON MOBILE MATERIAL FEEDER WITH OUTLOADING BOOM AUMUND Asia Ltd, located in Hong Kong China, is acting in the Asia Pacific Area and sells AUMUND, SCHADE and SAMSON equipment in all kinds of key industries such as Cement, Mining & Minerals, Chemical and Fertilizer Industry, Ports & Terminals and many others more. Synergies within the AUMUND Group of companies consistently lead to successful outcomes: In May 2020 AUMUND Hong Kong won an order from PT Asahimas Chemical, Java/Indonesia, for the New Generation of STORMAJOR®. The project was technically supported by SAMSON Materials Handling Ltd/UK leading product company in the AUMUND Group for mobile bulk handling solutions. The pre-assembly of the STORMAJOR® takes place in the workshops of AUMUND Foerdertechnik GmbH, Rheinberg/ Germany. The delivery is planned for December 2020.

The new designed STORMAJOR® is the combination of a Mobile SAMSON Material Feeder and an Outloading Boom, both mounted on the same chassis. The diverse options for stockpiling and loading offered by the STORMAJOR® were the compelling factor in the order from PT Asahimas Chemical, a company which operates several chemical production plants in Cilegon in Banten Province, Java, Indonesia. In 2018 it built its own power plant, where the first New Generation

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Bulk Solids Today

STORMAJOR® will operate, serving an important purpose in minimising spontaneous combustion of coal by stockpiling the coal externally and bringing it back inside once it has cooled down.

CHALLENGE: DANGER OF SMOULDERING COAL FIRES CAUSED BY GLOWING NESTS

PT Asahimas Chemical is concerned about embedded hot bodies, which occur frequently causing the coal to catch fire in covered storage areas of the power plant. Currently the glowing nests are removed with diggers from the stockpiled coal and transferred to an external storage area about 50 m away by dump trucks, where the coal is left to cool down before being taken back into the covered storage areas using the same diggers and dump trucks.

The new generation of STORMAJOR® both simplifies and speeds up the process of moving the coal. The machine is placed centrally between the stockpile and the covered storage area, from where it can both receive the coal from the diggers and stockpile it outside the covered storage area via the STORMAJOR® Outloading Boom. When the coal has cooled down the STORMAJOR® turns in the opposite direction, receiving the coal back from the digger and transporting it back into the covered storage area. This new process of utilising the STORMAJOR® also decreases the amount of times the coal has to be handled, which reduces the material degradation keeping the quality of the coal intact, whilst operating at 300 tonnes per hour. The STORMAJOR® therefore increases the efficiency and productivity of the complete process cycle.

PT Asahimas Chemical selected a 450 Series STORMAJOR®, which is the medium-sized model, for its

FEEDERS & CONVEYING

operation in Indonesia. The bucket capacity for material discharge is approximately 4.5 t and a conveying length of 11.5 m.

The Outloading Boom is 27 m long, has a luffing range from 2 to 30 degrees and a slewing range of 80 degrees (40 degrees in each direction). This STORMAJORÂŽ forms stockpiles of up to 11.75 m in height.

through a total of 19 locations in Asia, Europe, North and South America and a total of five warehouses in Germany, USA, Brazil, Hong Kong & Saudi Arabia.

The AUMUND Group is active worldwide.

The conveying and storage specialists have special expertise at their disposal when dealing with bulk materials. With their high degree of individuality, both its technically sophisticated as well as innovative products have contributed to the AUMUND Group today being a market leader in many areas of conveying and storage technology. The manufacturing companies AUMUND FĂśrdertechnik GmbH (Rheinberg, Germany), SCHADE Lagertechnik GmbH (Gelsenkirchen, Germany), SAMSON Materials Handling Ltd. (Ely, England), as well as AUMUND Group Field Service GmbH and AUMUND Logistic GmbH (Rheinberg, Germany) are consolidated under the umbrella of the AUMUND Group. The global conveying & storage technology business is spearheaded Bulk Solids Today

13

MIXERS, BLENDERS & DRYERS

HIGH-SHEAR, HIGH-SPEED MIXING SUCCESS FOR ST RATED POWDER A British designed and built horizontal delta blade mixer from Boone Mixers has helped contract cosmetics manufacturer Surefil to produce a range of powder products, mixing pigment int a very light powder within an ATEX Zone 22 area ad achieving a 75% reduction in mixing time compared to pre-project estimates.

The HDBM model 1250 supplied to Surefil has a working capacity of 1100 litres and is modified to work within the Zone 22 parameters the HDBM’s “short and tall” mixing shell along with the unique ‘delta’, shape of the high-speed, high attrition mixing elements rapidly disperses a small percentage of pre-milled pigment into the absorbent bulk material The Delta Blade Mixer is easy to clean requiring only a single short clean down at the end of each day.

Compared to pre-project estimates, the Boone Delta blade Mixer has completely exceeded expectations, reducing mixing time estimates by three-quarters – or put another

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Bulk Solids Today

way. Surefil have been able to operate as much as four times faster than expected. As Matt Waring put it “As with any new project, you start out hoping that it will pay for itself” Now we’re looking for opportunities to expand production. We are installing a vacuum sack lifer to allow us to move the raw materials more easily and quickly. If it leads to us requiring a second line, we’ll definitely come back to JR Boone’s for it” St Helens based Surefil is a successful and growing business whose versatility and cando attitude has seen them working with major retailers and brand owners throughout the UK. Surefil’s R & D laboratories develop new cosmetic products from the ground up, each formulation being individually crafted for each particular customer and their range includes lipsticks, powder compacts, eyeshadows and nail varnish, with ATEX Zone 1 required for nail varnish and eau de toilette production.

For their new development Senior Factory Manager Matt Waring wanted the reassurance of well-engineered, fully ATEX-approved mixing equipment and contacted Boone’s after reading some of the testimonials on their website. He said “We were keen to buy British and we really liked the open-door policy at JR Boone’s so we were able to visit early in the process and see how they work,” He went on to say “You can immediately tell that there is solid engineering being done. We were able to test the product at Boone’s factory on their test rig so we were confident that we could scale up up. Boone’s gave us great support through the project and whenever we have had a question since then, and were very price competitive too. www.jrboone.com

MIXERS, BLENDERS & DRYERS

AUMUND PENETRATES STRONGHOLD OF BIOMASS HANDLING IN JAPAN Taiheiyo Cement Corporation, Japan’s largest cement producer, fires its new power plant in Ofunato with both biomass and coal.

Until now conveying of biomass in Japan has been dominated by domestic manufacturers, but the AUMUND Hong Kong team successfully convinced its customer of the merits of the conveying technology solutions offered by AUMUND for both of these types of fuel. An order from Taiheiyo Engineering Corporation for three AUMUND Bucket Elevators and an AUMUND Drag Chain Conveyor was the result.

AUMUND Drag Chain Conveyor type LOUISE TKF for handling alternative fuels in Taiheiyo Cement’s Ofunato Power Plant in Iwate Prefecture, Japan (© AUMUND) The customer chose two identical AUMUND Bucket Elevators with Central Chain type BWZ and an AUMUND Drag Chain Conveyor type LOUISE TKF for its biomass conveying, all with capacities of up to 150 tph. The AUMUND machines transport palm kernel shells (PKS) and palm empty fruit bunches (EFB), which are used as alternative fuels in the Ofunato power plant.

The conveying concept is designed so that the different materials are kept apart and enter the silo buffer tanks separately.

High Efficiency Drying or Cooling of Bulk Solids

For coal handling Taiheiyo decided upon an AUMUND Bucket Elevator with Gravity Discharge type BWZ-S and a capacity of up to 35 tph.

The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone.

The result is a more consistent material.

Dynamic Air Ltd. • +44 (0)1908 622344

www.dynamicair.com Bulk Solids Today

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MIXERS, BLENDERS & DRYERS

HOW THE BELLA FLUIDIZED ZONE MIXER WORKS The Bella fluidized zone twin shaft paddle mixer by Dynamic Air achieves fast, high-capacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action with typical mixing times of 15 to 30 seconds. A weightless zone created by low-speed counter rotating paddles generates very low friction without shear. This makes it ideal for abrasive products and fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact The Bella mixer consists of twin drums which have two counter-rotating agitators with specifically angled paddles. They overlap at the center and completely

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

The Bella mixer is available in stainless steel for food applications. Custom sizes, finishes and materials of construction are available upon request. http://www.dynamicair.com/ products/mixer.html Dynamic Air Ltd. Milton Keynes, United Kingdom +44-1908-622344 E-mail: sales@dynamicair.co.uk www.dynamicair.com

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Bulk Solids Today

MIXERS, BLENDERS & DRYERS POWDERS

PRECISION MIXING CONTAINS COSTS FOR PRODUCT DEVELOPMENT

GRANULES

PASTES

BATCH

CONTINUOUS

Boone Mixers

Optimum Mixing

A pre-pilot mixing plant is using wireless TorqSense transducers for ultra-accurate viscosity measurement of high-value compounds.

The plant is used to prepare small batches of compounds from shampoo and detergent to cosmetics, therapeutic and medical preparations. Some of the ingredients in the compounds are very expensive, so product developers are loath to make large batches early Powders or Pastes in the formulation process.

Sizes from 2 to 25,000 litres Instead, they start with 850 millilitre samples for the early stages of each project, then once the recipe is wellVersatile Mixing Machines proven, move on to pilot-scale work where the samples Advanced Plough / Delta Blade: Agglomerates to Paste are measured in thousands of litres. The final stage is, of Spiral Blade: Cake Mixes to Mastic course, full-scale production where volumes may be truly Rotary Drum: Rice Flakes to Carpet Fibres enormous.

The TorqSense transducers were supplied by Sensor Complete mixing plant design to commissioning Technology Ltd of Banbury, whose Mark Ingham explains Test mixers available for production development the design of the pre-pilot plant: “It can take three hours Production scale machines for short or long term hire or more to make a single sample, each produced with T: +44 (0)1260 272894 precision accuracy – and development programmes www.jrboone.com need a great many samples. Clearly this cannot be e: sales@jrboone.com done manually. Automating the basic mixing process is in principle straightforward; for this the plant has four MIXING SOLUTIONS WORLDWIDE workstations based on paddle mixers, each of which is monitored by a TorqSense.”

TorqSense constantly assesses the level of torque in a driven shaft. Often, this is used to measure the power being provided by the drive motor. However, in this case12296 Solids & Bulk_Chemical_124x86.indd 1 18/03/2016 it is the opposite – TorqSense is used to calculate the drag being exerted on the paddle and shaft by the liquid being mixed.

“The mixing process changes the viscosity of the liquid, Unlike other valves that seal which is what causes the drag,” says Mark. “In the first with friction, Posi-flate’s unique instance the TorqSenses are looking for the viscosity to butterfly valve uses an stabilise to a steady value that won’t change any further no inflatable seat matter how much more mixing is done. to seal with air “Then they measure that very accurately. The viscosity pressure. Thus it is what gives the final commercial product its sense of requires less torque quality: a low viscosity and the product feels watery, and a smaller actuator, cheap and ineffective; overly high viscosity and it is resulting in lower cost. unpleasant and greasy.

Plus, the seat automatically “There is an optimum point where the product feels compensates for wear, providing luxurious and high quality, which is what needs to be longer life. Some users have identified for each formulation. In the past this was reported over six million done manually, so was completely subjective and cycles and the valves are unquantifiable: TorqSense has changed this to a precise still going strong. and scientific procedure.”

TorqSense is a wireless sensor, which is not physically connected to the mixer shaft by slip rings. Instead, it • Less friction monitors the torque via radio waves.

A shaft deforms very slightly when it rotates, the amount • Low torque of deformation being proportional to the torque. TorqSense • Low maintenance measures the deformation so that it can calculate torque.

• Lower actuator costs To do this two tiny piezoelectric combs are glued to the • Longer valve life surface of the shaft at right angles to one another; shaft • More reliable deformation will expand one comb and compress the other. The radio frequency signal emitted by the TorqSense Tel: +44 (0) 1908 622366 is reflected back by the combs, with its frequency changed www.posiflate.com in proportion to the combs’ deformation. www.sensors.co.uk

Other Valves Fight Friction, We Designed it Out

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SPECIAL FEATURE

BOOTS RAMPS-UP ECOMMERCE PACKAGING PERFORMANCE UK health and beauty retailer, Boots UK, has significantly enhanced ecommerce packing performance by deploying two Quadient fit-to-size automated packing machines. An unforeseen benefit from the investment was the ability to respond swiftly and efficiently to the doubling of online orders following the COVID-19 lockdown.

Boots is the UK’s largest pharmacy-led health and beauty retailer with over 2,500 stores in the UK, ranging from community pharmacies to large destination health and beauty stores. Over its 171 year history, the business has experienced phenomenal growth and now, with 15.8 million active Boots Advantage Card members, the business supports a vast customer base across its omnichannel operations.

Boots.com is a fast-expanding part of the business, supported by an advanced ecommerce fulfilment centre in Burton. Preparing online orders for home delivery or in-store collection demands highly efficient order picking and packing processes. Critically, during peak these systems must be flexible and agile enough to cope with a huge increase in order volumes, and this can place a great strain on the packing area, where manual labour is traditionally increased during peak to cope with demand.

Tracey Clements, COO for Boots in the UK and Ireland, says: “As consumers are spending more time

online, we are seeing tremendous year-on-year growth on Boots.com and to meet the growth of online sales and customer expectations, we had to innovate the way that our supply chain works, and the answer was automation.”

THE DUAL CHALLENGE Faced with the dual challenge of recruiting more and more people every autumn for peak season and a shrinking pool of available labour, in 2019 the business decided to look at the potential to boost productivity by increasing the level of automation used in the packing operation. A simple mechanise packaging system was in use for the majority of off-peak orders, but the system did not offer the flexibility or capacity needed for Black Friday and peak season. In addition, a large number of manual packing benches were necessary to fulfil the volume of orders received during the peak season – a major financial and administrative commitment.

Ian Murfin, Customer Relationship Manager at Boots, explains: “In order to support the fast growth in online sales, we wanted a solution that would increase efficiency, boost capacity and enhance the productivity of our labour force. We realised packaging technology had become much more sophisticated, offering far greater performance, speed, accuracy and importantly, reliability. And that’s exactly what we needed to increase capacity.”

HIGH-VELOCITY, FIT-TO-SIZE PACKING INNOVATION After a review of the latest packaging technology available, Boots took the decision to invest in two state-of-theart automated packing machines from Quadient that tailor-make parcels at highspeed. Quadient’s CVP Impack is unique in

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Bulk Solids Today

SPECIAL FEATURE seamless and continuous flow of orders, from order-totes arriving, to complete, perfectly sized packages, weighed and labelled, ready for despatch.

that it has the potential to construct bespoke individual cardboard boxes to the exact size of an ordered item at the rate of up to of 500 boxes per hour – combining multiple items, as required.

The CVP Impack measures, constructs, tapes, weighs and labels each parcel in one seamless process. The operator simply places the item(s) to be packed onto the machine and scans the order. The system identifies the order and automatically conveys the items to a 3D scanner to measure and calculate the minimum box size required. The cardboard is then cut and folded to create a snug fit around the goods and tape is applied on just two sides to secure the box. Then an in-line scale checks the weight against the order and, finally, the box is automatically conveyed to a label printer where a carrier compliant label is created and applied.

The whole process, from start to finish, takes just thirty seconds with a custom made box configured every seven seconds.

Adam Coventry, Head of Warehousing for Boots. com, comments: “At our Dot Com warehouse we have created a hi-tech and fully automated operation for goods in and out. We have the safety of our colleagues, efficiency, and sustainability at the core of what we do. Every year we pick, pack and ship over 43 million products to our customers.

“Once the items have been picked by the cobots they arrive at our CVP Impack packaging solution – the latest addition to our high tech warehouse operations. This has genuinely revolutionised the packaging process for Boots.com, reducing the need for extra packing stations and increasing the items packed to up to 500 items an hour per machine, helping us to meet the high demand for online orders.” He adds: “We are able to use 100% recycled Boots branded cardboard and no longer need to use any additional filler material.”

The installation of the two CVP Impack machines took place in late September 2019, just in time for the Black Friday season, and both machines were designed for dual operator feed, the first to be supplied to the UK market. Having two operators per machine facilitates a

PEAK BENEFITS “We were impressed by the speed and efficiency with which the two Quadient machines performed over the Black Friday peak,” says Ian Murfin. “The CVP Impack machines have delivered significant cost and environmental benefits too, with reduced material use and volume savings on transport.”

In fact, following the installation of the two CVP Impack machines, Boots has also been able to reduce the transport journeys – a significant cost saving and environmental benefit. The business is also expecting to buy around 30% less cardboard for the same volume of packages produced by the pre-existing system.

There are important customer benefits too. By creating custom sized packaging for each order, the customer receives a compact, right-sized box, which is more convenient to carry, eliminates ‘consumer distress’ over wasteful packaging and delivers a positive environmental message. A further advantage of the fitto-size cardboard packaging is a snug fit to the product, which prevents items moving around, providing better protection without the need for bubble-wrap or void-fill.

However, perhaps the most unforeseen benefit of the investment in Quadient technology has been Boots’ ability to respond efficiently to the sudden demands placed upon the business through the boom in online orders following the Coronavirus lockdown.

“With a surge in ecommerce orders, up 100% since the lockdown, and a dramatic change in order profiles, the agility and speed with which the CVP Impack machines can create individually-made packs have proved their worth in abundance,” says Ian Murfin.

“And critically, this unexpected challenge has been met without needing to scale up the operation, which would have been extremely difficult at this time, with all the complications of social distancing.”

He adds, “The core driver for this investment was increased operational efficiency – and we certainly achieved our goal.”

Tracey Clements, concludes: “The customer experience is extremely important to Boots, so as we continue to see high demands online, we know that packing automation is not only supporting our supply chain but also ensuring that we can continue to meet the needs of all our customers so they receive the same care outside our stores as they do within.”

A short video of Quadient’s CVP Impack at Boots.com is available here: https://packagingbyquadient.com/ customers/case-study-boots/ or You Tube: https://www.youtube.com/ watch?v=oDKAQRRCFq8 Bulk Solids Today

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SIEVES, SIFTERS, SEPARATORS & SCREENING

FARLEYGREENE’S ULTRA HYGIENIC SACK TIP STATION Farleygreene UK manufacturers of industrial sieves, have designed an ultra-hygienic version of their Sievmaster Easilift Sack Tip Station for the food and beverage industries. This new model features a sack tip hood with fewer crevices and externally mounted hinges, the overall design on the Ultra is intended to reduce the risk of bug traps and improve product flow Avoiding food contamination and increasing product safety are all key concerns for food and drink manufacturers, and a necessary part of protecting brand reputation. All Farleygreene sieving equipment is constructed using FDA compliant materials, conforms with EC 1935/2004, French ANIA regulations, and is ISO 9001 approved The Easilift Ultra’s hygienic design ensures contamination is more visible and can easily be cleaned, improving product quality and safety.

The Ultra is operator safe, can be stripped down effortlessly without tools, and is designed for low level lifting. The Easilift Ultra design has a fold out sack tip table to aid the user in sack dispensing, as well as forming a hygiene barrier between sanitary and nonsanitary environments. The optional integrated dust extraction system also lowers the risk to the operator associated with airborne dust particles. The redesigned tubular frame greatly

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Bulk Solids Today

reduces flat surfaces to minimise the risks of microbial contamination and increasing accessibility to the underside of the machine for removing connections and cleaning.

A single piece of removable metal detectable gasket creates a seal between the hood and the door - in place of permanent silicone bonding.

This quickens gasket changes and eliminates the chance of silicone bonding entering product flow. The Easilift Ultra door has been designed without welding to reduce deformation and provides a flatter sealing surface, ideal for dust suppression and WIP/CIP applications.

The hood design features pneumatically assisted door lifting with quick catch (as standard) and is safety interlock ready. The internal rounded edges and 45-degree product contact surfaces improve flow and minimise residual powder build ups.

Used in combination with the Slimline check screener, the Easilift Ultra can process up to 25kg worth of food powders at once, dispensing into containers, static weigh bins or incorporated into convey systems. Special finishes are also available to deal with individual product flow characteristics and reduce product build up.

Please visit the Easilift Ultra product page for further information and to request a quote.

Global sieving & filtration specialists

SIEVES, SIFTERS, SEPARATORS & SCREENING

The Russell Compact SieveÂŽ

Improves product quality

Fits into smaller spaces

Compact & mobile design

Eliminates dust & fumes

What makes us specialists..?

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

Email: sales@russellfinex.com Bulk Solids Today

21

COMPANY SHOWCASE

COMPANY SHOWCASE Welcome to the latest edition of the Bulk Solids Today Company Showcase.

This special feature has been designed to highlight a few individual companies who have excelled within their respective industries, providing outstanding service to their customers. We believe each company in this showcase to be a leader in their own markets. The companies in this showcase are : • Dynamic Air • J R Boone • Farleygreene

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Bulk Solids Today

COMPANY SHOWCASE

DYNAMIC AIR LTD SPECIALISTS IN CONVEYING, MIXING AND DRYING OF DRY BULK SOLIDS Dynamic Air is a manufacturer of pneumatic conveying systems, vibratory equipment, and process equipment. We provide manufacturing, sales, technical, and service support to customers and representatives worldwide with offices in: • St. Paul, Minnesota U.S.A., • Milton Keynes, England, • Brazil, • China, FULL SCALE TEST FACILITIES

Our state-of-the-art full-scale test facilities are available to perform: • Full pneumatic conveying testing • Blending • Mixing • Agglomerating • Coating • Bin discharging • Dust collection DYNAMIC AIR PROVIDES:

• Complete electrical and mechanical design • Engineering • Start-up services SIXTEEN CONVEYING CONCEPTS:

We offer sixteen different pneumatic conveying concepts • Four different vacuum conveying systems • Twelve different pressure conveying systems.

Each system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Our 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. Capabilities include the handling of difficult abrasive to very fragile granular materials at capacities exceeding 400 ton per hour and distances exceeding 1500 m in length.

MARKETS SERVED

• Cement • Ceramics • Chemical • Dairy • Feed • Food • Foundry • Glass • Mining • Petrochemical • Pharmaceutical • Plastics • Power • Pulp & paper • Railroad • Refinery • Refractory • Rubber • Steel • Wastewater Dynamic Air Ltd. 26 Peverel Drive Milton Keynes, United Kingdom Phone: +44 (0)1908 622344 E-mail: sales@dynamicair.co.uk www.dynamicair.com

Bulk Solids Today

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COMPANY SHOWCASE

JR BOONE LTD SPECIALISTS IN INDUSTRIAL MIXERS, BLENDERS AND MIXING SYSTEMS JR Boone Ltd is the number one leading designer and manufacturer of industrial mixers, blenders and mixing systems in the UK. Our innovative and efficient mixers are used worldwide in the production of powders, granules, pastes, liquids and many more applications in the Food, Chemical and Mining industries.

The versatility of the Boone Industrial mixer ensures that our machines can mix a wide range of products from Tea, coffee, Cake mixes, Sugar Paste, Cereals, spices, fine chemical powder, adhesives, detergent powder, metallic powders, welding flux, agglomerated pigment, floor screed, grass/bird seed and many more. We would advise and discuss your requirements to ensure the right machine suits your requirements following tests at our site or in house.

With this we provide supporting services to protect your investment in our technology, for mixer or blender hire for development work to refurbishment, maintenance, spares and repairs. These are designed to ensure top mixing performance can be maintained at all times.

This is possible as our engineers who research and develop our mixing equipment work closely with our clients to ensure that we understand their industry needs and deliver innovative solutions for their application.

For more details on our Boone’s Industrial Mixers and the sizes we can offer on our product range for the Horizontal Helical Blade Mixer, Delta Blade Mixer, Paddle Blade Mixer or Rotary Drum Blender please contact us. www.jrboone.com 24

Bulk Solids Today

COMPANY SHOWCASE

FARLEYGREENE LIMITED SPECIALISTS IN SIEVING TECHNOLOGY FOR THE PROCESS INDUSTY WHO ARE WE Since 1976, Farleygreene has been providing excellence in the manufacture and supply of sieve, sifter, screener and separator machinery to some of the largest companies across the Globe.

From food to pharmaceuticals, and everything in between, Farleygreene’s Sievmaster range of sieves are designed to cover all aspects of sieving and screening applications. Their Sievmaster sieves are built to solve production issues and give customers total confidence that their end products will meet quality control specifications. Farleygreene work alongside their customers to develop a solution that meets customer’s specific requirements and performs exactly as required.

DISTRIBUTING WORLDWIDE Based at their factory in Hampshire UK, Farleygreene work closely with their growing network of distributors to ensure that high quality sieving equipment is available to companies of all sizes around the world.

QUALITY SIEVES BUILDING YOUR TRUST

Farleygreene’s commitment to maintaining strict working practices has been recognised with an ISO 9001 certification, guaranteeing a high level of quality throughout the build process.

Farleygreene also provide full and free certification in compliance with ATEX, FDA and EC regulations, with every completed project. All their machinery is made in the UK, making them part of the Made in Britain campaign that promotes and contributes to UK manufacturing.

WHAT WE DO

Product sieving is an essential requirement in nearly all industries. To obtain a quality-controlled end product not only requires diligent constituent choice, but careful handling and processing.

Removal of any substandard or unwanted matter

is therefore of prime importance. Farleygreene’s standard range of sieves are designed to cover all aspects of sieving; check, grading, linear, centrifugal, vacuum/pressure and batch sieving – all machinery is designed with the customer in mind.

Farleygreene deliver many benefits to their customers: • Instead of taking a “one size fits all” approach, Farleygreene adapt their machines to suit customer’s processes. This provides improvements in both efficiency and quality.

• Farleygreene sieves can be stripped down without tools which ensures there can be no associated contamination or health and safety issues.

FREE ONE WEEK TRIAL

Choosing the correct sieving equipment is not always straightforward, and some products can be particularly tricky to process. That’s why Farleygreene offer a week’s free trial of their machinery at the customers premises, so they can be sure to choose the correct sieve for their requirement.

As well as this, Farleygreene have a fleet of machines available for hire and demonstration. Due to current social distancing measures, they also offer the option to perform and film the test for customers alongside a full report.

OUR GUARANTEES

While Farleygreene’s Sievmaster sieves are designed to give customers total confidence that their end product will meet their quality control specifications, they go further to unconditionally guarantee against breakdown or malfunction for 24 months. Customers are also offered a full spares and service agreement which will ensure years of problem free operation.

Farleygreene also provide a re-meshing service for existing rings or frames, irrespective of the original supplier.

For specific product information and a copy of our brochure, please visit www.farleygreene.com.

Please phone us directly on +44 (0) 1256 474 547 or email enquiries@farleygreene.com Bulk Solids Today

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BUYERS GUIDE Aero Mechanical Conveyors

Conveyors & Elevators

Mixers & Blenders

“Often copied NEVER matched�

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

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

Tel / Fax: 01270 651611

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

Bulk Storage & Handling

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

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

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

Powder Handling Systems

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Remote Silo Monitoring

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

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Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706

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

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Tuf-lok 7

WITH SIEVMASTER BY FARLEYGREENE.

www.farleygreene.com

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

www.posiflate.com

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

www.InterBulkGroup.com

InterBulk GROUP

Bulk Solids Today

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