BULK MATERIALS HANDLING • POWDER HANDLING • QUARRYING • RECYCLING & WASTE BULK MATERIALS HANDLING • CONTROLS & SENSORS • QUARRYING MANAGEMENT
FEBRUARY 2022 2017
HOW THE BELLA FLUIDIZED ZONE MIXER WORKS FULL ARTICLE ON PAGE 10
HIGHLIGHTS:
6
Need to hire a hoist? Let Hoist & Winch lift the burden
13
Self-Aligning Couplings
14 6X: VEGA’s simple formula for bulk level indication
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 152
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.
CONTENTS 4
NEWS
10
COVER STORY
14
BULK MATERIALS HANDLING
16
CONTROLS & SENSORS
18
QUARRYING
20
RECYCLING & WASTE MANAGEMENT
22
SPECIAL FEATURE
ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2017
www.bulksolidstoday.co.uk Bulk Solids Today
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COMPANY NEWS
INTRODUCING ARMADILLO: THE NEW PROTECTIVE PRODUCT RANGE THAT’S THE “HARD HAT” FOR YOUR IRONWORK LEADING designer, manufacturer and supplier of specialist products for the civil engineering industry Wrekin Products has created Armadillo – an innovative range of products that benefit contractors, housebuilders and the general public alike. It’s common practice for manhole covers and gully grates to be installed in the early stages of construction projects, well before the final tarmac is laid. This either means that the products are installed proud of the binding layer and are, therefore, susceptible to being damaged by construction traffic, or if installed level with the binding layer, must be entirely dug out and effectively installed again if damaged. Both of these scenarios would mean additional time worked, costs incurred and potential complications. Additionally, manhole covers are also specified for the final traffic environment, which means group four D400 covers are commonly installed. However, during the construction phase they are exposed to extreme loads from group five vehicles, including heavy plant and tracked vehicles, which the covers aren’t designed to accommodate. Again, this can result in premature failure and additional costs in materials and labour to put them right before handover. The Armadillo range of protector shells are designed to be placed over manhole covers and gully grates, providing temporary protection from group five traffic during the construction phase of a project. This ensures manhole covers and gully grates start their service life in ‘as new’ condition to optimise longevity. * Armadillo manhole cover protector shell is compatible with both Wrekin Highway and Tristar 4
Bulk Solids Today
manhole covers * Armadillo gully grate protector shell is compatible with Wrekin Tristar gullies The Armadillo manhole cover protector shell is also compatible with Wrekin’s patented ClickLift™, which raises Wrekin Highway and TriStar frames to suit the final surface layer without the need for digging out and reinstalling. The cover and the frame are installed at the binding layer level, thereby reducing the possibility of site damage and then, when the final surface layer is being applied, the manhole cover can be raised with the ClickLift™ frame extender simply and quickly. Together, these products perfectly package up to create a solution that saves house builders and groundworkers time and money – allowing them to completely focus on the task at hand. Gosia Kwapisz, Product Manager at Wrekin Products, said: “We know that for developers and groundworkers time and money is at a premium, which is why we’re constantly pushing ourselves to create new and innovative solutions to the everyday problems that can present themselves during a construction project. “The premature need for replacement or reinstallation of manhole covers and gully grates is an issue we’ve recognised as having a massive impact on the industry due to the disruption and additional costs it causes. A contributing factor to this, and something that’s often overlooked when specifying products for developments, is the damage heavy plant and site vehicles can cause and how it impacts a product’s longevity before it’s
started its actual service life. “The new product has also been specifically designed to present only smooth faces to traffic – making it less likely to cause damage to site or residents’ vehicles.” Gosia added: “The Armadillo range also provides assurance and confidence to contractors that there won’t be a need to replace damaged manhole covers or gully grates at the end of construction, enabling them to remove contingencies for replacement items and saving on the overall tender cost – making prices more competitive. This range delivers a new approach to managing manhole covers and gully grates during construction which not only provides benefits to those who interact with the product but also unlocks the key to longevity of service too. The unique designs are reusable, so contractors can move them on to other phases or future projects. We’re proud to have created Armadillo and look forward to seeing it utilised on sites across the country.” For more information on Wrekin Products, please visit www.wrekinproducts.com.
BORN, WHERE VALUES ARE VALUED. THE 6X®. AVAILABLE NOW! Technology is only as good as the people who make it. That’s why the new VEGAPULS 6X is the result made by over 1,800 valuable employees, 60 years of valued measurement experience and every value that is intrinsic to VEGA.
VEGA. HOME OF VALUES. www.vega.com/radar
COMPANY NEWS
NEED TO HIRE A HOIST? LET HOIST & WINCH LIFT THE BURDEN Alongside its wide portfolio of lifting and handling equipment for sale, Hoist and Winch Ltd is currently promoting its extensive know-how and experience in the hire market. The company is an expert in turnkey hire projects involving air- and electric-powered hoists, overseeing installation, commissioning, testing and certification tasks as part of a complete service package that provides genuine market differentiation. Through its turnkey offer, Hoist & Winch expertly advises customers on the most suitable equipment for their lifting requirements, making precise arrangements to ensure safe and reliable operation. This advice is particularly important for air hoists, where the selection of a portable diesel compressor or the checking of plant air supply is necessary. Here, requirements will include specifying the optimal operating pressure, air volume, and hose length and bore size, as well as preparing and lubricating the air supply. Hoist & Winch completed a notable turnkey hire project over the recent Christmas period. A customer within the building materials industry hired a special 12t swl (safe working load), twin air-powered, trolley-based air hoist for lifting and replacing a large gear weighting 9t. This type of hoist was necessary to spread the 9t load over a greater distance of the monorail beam bottom flange than a standard hoist trolley arrangement would allow. The project was unusual in that Hoist & Winch had to first load, test and certify the monorail beam using two separate 6t swl air hoists and trolleys to support its uprating from 5t swl to the 9t load. This 6
Bulk Solids Today
work was essential before the 9t gear lifts could take place for two reasons. Firstly, the special 12t swl, twin air-powered trolley hoist was not designed for negotiating the curved monorail beam section present just after the test load pick-up point. In addition, the consultant engineer’s calculations showed that the curved monorail beam section was not suitable for bearing the 11.25t proof test load. As a result, the proof test load travelled past the curved monorail beam section separately and divided equally between the two individual 6t swl air hoists/trolleys. In a further project challenge, all hoist unit side and headroom dimensional clearances were very tight and critical. From initial consultation and equipment specification - through installation, commissioning and testing - to issuing the LOLER report, delivering handover training and providing maintenance support for the eightweek hire period, Hoist & Winch acted as the technical partner at every stage of the project. This customer, like all of the company’s customers, find that the turnkey
hire service from Hoist & Winch provides assurance of a highperformance, safety-certified solution delivered on-time and on-budget. Hoist & Winch points out that the option also exists for customers to hire stand-alone airand electric-powered hoists for installation by their own competent personnel, if preferred. Visit www.hoistandwinch.co.uk for further information and to view recent case studies.
COMPANY NEWS
AMAZON ORDERS FLEXI TRUCK FLEET FOR ITS DUBAI FULFILLMENT CENTRE Amazon has ordered a fleet of six Flexi Truck articulated forklift trucks for its DXB3 fulfillment centre in Dubai Logistics City, UAE. The e-commerce site launched in the UAE in May 2019 and, spread over 32,700 square metres and stocked with more than 4 million products, the DXB3 site is Amazon’s largest fulfillment centre facility in the country with in excess of 650 staff employed there. Amazon’s new Flexi Trucks feature digital electric motor technology that allows independent twin front-wheel drive, hydraulic functions and the truck’s unique power-steering motor to be controlled digitally - ensuring the most productive, energy-efficient and safe driving performance throughout the working day. The control systems at the heart of the Flexis deliver higher productivity combined with significantly reduced operating and maintenance costs, while the trucks’ VNA functionality and ability to work both inside and outside the building, make it the ideal choice for Amazon’s UAE operation. Operational efficiency at the Dubai facility is further enhanced thanks to an integrated lead-acid battery charging solution that dramatically reduces Amazon’s overall energy consumption. Featuring ‘call-forward’ alert technology to identify the most appropriate fully charged battery when a change is due, the charge system allows Amazon to operate with only two batteries per truck on a three shift usage pattern to minimise materials handling fleet running costs. Flexi Trucks are built at hubs in the UK and Taiwan by Narrow Aisle Ltd. International sales account for some 40 percent of Narrow Aisle’s business and a global network of partners provides a full range of after sales
support services to Flexi Truck users in some 63 countries worldwide. Narrow Aisle Ltd’s managing director, John Maguire, commented: “The Flexi Truck’s iconic articulated design is ideally suited to the modern fulfillment centre customer order picking duties at operation. lower levels and at the same time Flexi Trucks save space, increase Flexis can stack and replenish in productivity and allow safe access complete safety at height within to any stacking aisle at all times. warehouse aisles.” “The Flexi’s ability to work in very narrow aisles means 30% www.flexi.co.uk more pallet and shelving locations can be designed into storage systems compared with traditional wide aisle operations while comparison tests have highlighted that Flexis are 25 per cent more productive during The Bella dryer/cooler offers thermal a typical shift. efficiencies to 80 percent or better “To achieve because air flows around material while optimum online it is suspended in the weightless zone. order fulfillment performance it The result is a more consistent material. is important to deploy the most suitable materials handling equipment and the Flexi Truck articulated forklift-based intralogistics solution delivers hugely improved productivity and increased safety for warehouse Dynamic Air Ltd. • +44 (0)1908 622344 staff as they carry www.dynamicair.com out a range of
High Efficiency Drying or Cooling of Bulk Solids
Bulk Solids Today
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COMPANY NEWS
SNACK PRODUCER REDUCES FLEET SIZE AND MAKES EFFICIENCY GAINS WITH TOYOTA FORKLIFTS Toyota Material Handling UK has helped the award-winning premium snack producer, Burts Snacks, to reduce intralogistics costs and achieve significant handling efficiency gains across its business. During a review of the company’s materials handling operation, Toyota identified that by replacing counterbalance machines with multi-functional reach trucks capable of operating outside a building, Burts Snacks could not only reduce the number of forklifts within its fleet - with a resultant drop in maintenance expenditure – but also boost productivity and improve on-site safety. Burts Snacks manufactures its growing range of own-brand, licensed and private label snacks from sites in Plymouth and Leicester. At both facilities Toyota recommended switching counterbalance trucks for Toyota Reflex outdoor reach trucks. The Toyota Reflex outdoor reach truck has greater ground clearance than traditional models, which along with rubber wheels with tread and a revised gearbox configuration, allows it to work in yards, block-stacking, servicing outdoor racking and loading and unloading vehicles from the side. It can also perform inside a building and at Burts Snacks’ Plymouth site, the trucks are fitted with Kooi extra long forks with fork cameras to allow pallet loads to be put away within the storage unit’s double deep racking scheme. In addition Toyota provided a mix of electric counterbalance models, powered pallet trucks and order pickers. The equipment at both sites has been supplied on a long-term rental contract that includes service and maintenance. 8
Bulk Solids Today
Burts Snacks’ warehouse manager, Daniel Cresswell, originally approached Toyota to supply new, ultra energy efficient trucks to replace a number of existing electric-powered counterbalance models that had been under utilised for some time and were nearing the end of their fixed contract period. “After seeing the Toyota proposition for our fleet, it was a simple decision for us,” Daniel Cresswell says. All of Burts Snacks’ new machines feature Toyota’s I_Site integrated telematics package as standard. The I_Site system allows truck operating hours to be closely monitored along with battery utilisation across the fleet. This feature has been particularly beneficial at the Plymouth site where the trucks are powered by a combination of Nexus fast charge, lithium-ion and lead acid batteries. “The I_Site system monitors the forklift’s battery and highlights if the power source is being managed incorrectly. For example, if a lead acid battery is opportunity charged, this can cause significant implications to
the battery. The I_Site technology can identify this before any harm is done,” says Mr Cresswell. I_Site also provides valuable data on the efficiency and safety of Burts Snacks’ lift truck operators, as Daniel Cresswell explains: “Because each operator requires his or her own PIN code or smart access card to operate a truck, they quickly realise that they are accountable for their actions during the course of a shift. We find that this accountability prompts forklift drivers to take more care when going about their daily routine, which of course, in turn, results in a safer environment and reduced product, truck or building infrastructure damage.” Keep up-to-date with Toyota: Follow us on Twitter www.twitter.com/ToyotaMH_UK Connect with us on LinkedIn www.linkedin.com/company/ toyota-material-handling-uk Find out more about us on our Blog www.toyota-forklifts.co.uk/ blog
COMPANY NEWS
THE POWER OF DESIGN Introducing the materials handling industry’s first-ever purpose-designed lithium-ion powered pallet truck (PPT) – the 1600kg capacity Toyota BT Levio LWI160. Thanks to the unique modular, compact lithium-ion battery solution, it has opened the possibility to re-think design standards of material handling equipment. The result, a truck with optimised component position, smaller dimensions, light weight, and low energy consumption. How have they been able to achieve this? Unlike standard powered pallet truck designs, the battery compartment has been removed. Because of this the truck is lighter and, with no lifting or lowering of a battery compartment, it is much more energy efficient, leading to maximum uptime and reduced CO2 emissions. Losing the battery compartment also means that the LWI160 is smaller than traditional lead-acid battery-powered PPT models: it is just 419mm long and 726mm wide and weighs only 269kg – which is almost 50 per cent less than the lead-acid version. The dramatic reductions in the truck’s dimensions and weight mean that a low steering force is required, which makes the new model easy to manoeuvre and, therefore, ideal for use within lorries and mezzanine floors or at sites where space is at
a premium, such as retail stores. The new LWI160 offers outstanding slope performance - when operating on inclines is required, and the truck’s compact measurements mean that the operator has an unrestricted view of the fork tips and the pallet load, which reduces the risk of accidental damage to goods. For optimum operational flexibility, lithium-ion batteries can be fully charged anywhere there is a power socket, utilising the onboard charger, which in just over an hour can be fully recharged. And where a larger battery is preferred, external chargers are available, but again can be recharged in just over an hour. Like all models in the Toyota warehouse equipment range, the Levio LWI160 is fitted with Toyota’s I_Site telematics technology. I_Site provides valuable data to ensure productivity and safety are optimised while forklift fleet running costs are kept to a minimum. Toyota Material Handling UK’s Keith Smith, commented: “Our modular approach to lithium-ion batteries has opened the door
for a fresh new approach to the design of materials handling equipment. The LWI160 boasts advances in technology and design, whilst remaining true to what our customers expect from Toyota. A strong, durable, quality product” The LWI160 has won prestigious Red Dot and iF awards for its ground-breaking design. Find out more about the LWI160 powered pallet truck at www.toyota-forklifts.co.uk
Bulk Solids Today
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COMPANY NEWS
HOW THE BELLA FLUIDIZED ZONE MIXER WORKS The Bella fluidized zone twin shaft paddle mixer by Dynamic Air achieves fast, highcapacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action with typical mixing times of 15 to 30 seconds. A weightless zone created by low-speed counter rotating paddles generates very low friction without shear. This makes it ideal for abrasive products and fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact The Bella mixer consists of twin drums which have two counter-rotating agitators with specifically angled paddles. They overlap at the center and completely sweep the entire bottom of both mixer drums and allow it to be started under full load (Figure 1). The material in the mixer moves in a horizontal counter-clockwise direction at the perimeter while simultaneously moving both left and right in the center (Figure 2). The material in Zone B (Figure 1) is in its normal gravimetric state as it is being moved and disbursed. In Zone A, a weightless zone is created which effectively lifts the ingredients to an almost weightless state allowing them to move freely and randomly, regardless of particle size and density. Thus the two zones’ interaction becomes highly efficient as every particle moves rapidly to a highly homogeneous mix, the key to the Bella Mixer mixing technology for fast, precise mixing. The Bella mixer is available in stainless steel for food applications. Custom sizes, finishes and materials of construction are available upon request.
Figure 1 10
Bulk Solids Today
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
Figure 2
COMPANY NEWS
EASY AND SAFE PROCESS INTEGRATION FOR THE GERICKE GNB NIBBLER After the successful launch of the new nibbler and deagglomerator GNB, Gericke has introduced additional executions to simplify fast and safe integration into any powder handling processes. One such example is the sack tipping station. The Gericke Nibbler is a coarse grinder and prebreaker for the size reduction in a broad range of applications. It is used for the deagglomeration, rework and size calibration of various products. Gericke sack tipping and feeding stations are ergonomically designed to provide safe handling for all types of sacks and boxes whilst controlling and reducing dust emissions thanks to integrated aspirators and filters. Access to rotating downstream machinery is prevented by a safety mesh, and optional magnets remove metal parts. The combined sack tipping station and nibbler do not only protect the operator. With the embedded real time diagnostic it also brings metal-to-metal contact detection in this unit. If a contact is detected between the basket and the paddles, a signal is sent to the control system to isolate power to the drive motor. This helps to protect process equipment as well as the process, significantly increasing the production safety and availability!
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Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. • • • • • •
Less friction Low torque Low maintenance Lower actuator costs Longer valve life More reliable Tel: +44 (0) 1908 622366
www.posiflate.com
Bulk Solids Today
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COMPANY NEWS
YALE ENHANCES LITHIUM-ION RANGE WITH SUNLIGHT LI.ON FORCE BATTERIES Yale Europe Materials Handling will offer Sunlight Li.ON FORCE batteries as a power solution for its materials handling product range. Sunlight Group boasts over 12 years of research and development in lithium chemistry. The move marks a deepening partnership between Yale and Sunlight Group, which has previously provided lead-acid batteries for Yale products. Yale Europe Materials Handling is enhancing its lithiumion range with batteries provided by Sunlight Group, one of the world’s top manufacturers of industrial and advanced energy storage solutions. Sunlight Group boasts over 12 years of research and development in lithium chemistry. Yale® will offer Sunlight Li.ON FORCE batteries as a solution for selected warehouse and electric counterbalance trucks, enabling its customers to select the best battery technology to suit their applications. The move marks a deepening relationship between the two companies. Sunlight Group has previously provided lead-acid batteries for Yale products. “Thanks to the success of our collaboration, Sunlight Group has become a trusted partner of Yale, helping us to deliver efficient and productive solutions for our customers,” said Marcus
Rosenkranz, Area Business Director for Eastern Europe at Yale. “We’re excited for the next era of our working relationship, which will see Yale offer Sunlight Li.ON FORCE power solutions in our product line-up.” Powering productivity Sunlight Li.ON FORCE batteries are well suited for intensive and/or multiple shift applications. For industries where clean operations are a must, such as food, beverage and pharmaceutical, Yale products fitted with Sunlight Li.ON FORCE batteries are free of gaseous emissions with no risk of acid spillage. A single battery can replace multiple lead-acid batteries,
meaning customers can benefit from fast opportunity charging during breaks and shift changes. Areas previously needed for battery change can be repurposed as additional working or storage space. The robust Sunlight Li.ON FORCE batteries are maintenance-free with long life cycles. With no battery exchange required, Yale lithiumion products offer more uptime as well as reduced running costs. The charging efficiency of lithium-ion batteries is at over 90% - greater than lead-acid options. “Our Sunlight Li.ON FORCE batteries are the most innovative and revolutionary Smart Battery Solution in the market,” said Dimitris Panagiotou, Sunlight Group Sales Director. “Our values align closely with those of Yale, and we are excited to continue our successful partnership moving forward. Yale customers will reap the benefits of our lithiumion technology, which has been honed and refined over many years of intensive research.” For more information on the extensive range of materials handling equipment from Yale go to www.yale.com.
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Bulk Solids Today
COMPANY NEWS
SELF-ALIGNING COUPLINGS Tuf-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, leak-proof, 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.
Tuf-Lok UK Phone: +44 (0) 1706.822512 E-mail: sales@tuflok.co.uk www.tuflok.com
If you are interested in advertising within Bulk Solids Today or contributing editorial, please do get in touch using the details below: Bulk Solids Today Office - 01933 316931 bst@abbeypublishing.co.uk www.bulksolidstoday.co.uk Bulk Solids Today
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BULK MATERIALS HANDLING
6X: VEGA’S SIMPLE FORMULA FOR BULK LEVEL INDICATION A NEW ERA IN BULK SOLIDS LEVEL SENSING WITH VEGAPULS6X NON-CONTACT RADAR SENSORS. With VEGAPULS 6X, VEGA “re-thinks” radar. The result: A new radar level sensor that can measure in virtually every conceivable bulk-solids application. The time when users had to choose their level instrument from a multitude of options are history. Traditionally, the search for a suitable bulk solids level sensor begins by thinking about questions like: what solution would be best for my application? How can I ensure I choose the correct and most reliable device for a successful outcome for my project? Of course non-contact radar offers great answers for these questions. The customer already knows their own applications, the details of product properties and process they want measured or controlled; temperature ranges involved, standards needed to be met and installation fittings that are available. But, until now, choosing a radar-based level instrument could be a laborious, time consuming and stressful task, matching these process details to myriad radar frequencies, model numbers, part numbers and options on offer. Now this selection process is being simplified by VEGA. With its new VEGAPULS 6X: one device for all and a new selection and ordering method that is
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BULK MATERIALS HANDLING
customer-application focused. Just enter the process and mechanical information and it enables complete, correct configuration and even pre-calibration of the specific sensor required - for any application, whether for liquids or bulk solids. “Ultimately, it’s not the sensor that counts, but what the users can achieve with it in their individual processes,” says Florian Burgert, who, as a product manager, has been closely involved in product development from the very beginning. “Just knowing that they’ve chosen the best possible measurement solution and that they’ll reach their goal faster with it, makes a big difference in their everyday operations.” Over 1 million radar instruments in use worldwide. The success story of today’s world market leader in radar level measurement began 30 years ago. In the meantime, VEGA’s sensors have optimized millions of industrial processes. The story includes milestones such as the world’s first two-wire radar instrument, the first dedicated bulk-solids radar and a worldleading 80-GHz non-contact radar for solids level measurement, which revolutionised radar level sensor performance for customers. Behind these successes are the many people who share a common passion: “At VEGA we don’t do a hundred different things, we concentrate on what we do best: Radar.”, says product manager Jürgen Skowaisa, speaking for all of them.
ALL-ROUND PROTECTION
The new VEGAPULS 6X offers the best that is technically feasible today: a self-diagnosis system that immediately detects damage or interference, that ensures significantly high availability and safety, it also has new radar-chip technology, with expanded application possibilities, better than ever performance and simpler operation. The radar features SIL certification, and compliance with the latest cyber-security standard IEC 62443-4-2, which meets the strict requirements for secure communication and access control. The value lies in making it easier for users to select their device and monitor their industrial processes. The ultimate purpose of VEGAPULS 6X is just that maximum simplification - one sensor that can handle virtually any application. In the future, the customer will no longer have to worry about the technology, model numbers, frequency or instrument version. In many cases, all application-specific settings can be made in VEGAPULS 6X before it leaves the factory, so it’s just left for the user to install, connect, done: It doesn’t get any simpler. More information available at www.vega.com/ radar Bulk Solids Today
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CONTROLS, SENSORS & LEVEL MEASUREMENT
NEW TECHNOLOGY CAPS PHARMA BOTTLING PROCESS A regular customer of Sensor Technology Ltd has switched to its latest range of torque sensors. The new TorqSense SGR530/540, being introduced throughout 2020 and 2021, measures torque using a full four element strain gauge bridge. With this, four separate strain gauges are fixed to the drive shaft of the plant or machinery being monitored. The gauges are aligned so that each measures shaft deflection in a different direction as it rotates under load. Electronics within the sensor collects readings from all four gauges and uses them to calculate the torque value in real time. Sensor Technology has specialised in real time torque measurement for over 40 years, pioneering the use of wireless solutions based on radio frequency pick-ups that do away with the need for hard-wiring and unreliable slip rings. Strict international rules apply to the manufacture and packaging of pharmaceutical products and require that the correct environment is maintained within the bottle or other packaging following capping. To this end, Regulation USP 671 provides a guide to the torque range to be used for screw type containers with varying closure diameters. By ensuring that bottle caps are successfully applied to the bottles within the required torque tolerances, the integrity of the product can be maintained. Over the years Sensor Technology has worked with many OEMs to develop high precision, high speed machines for use in pharmaceutical plants and a range of other applications. One of these, an Oxfordshire neighbour of Sensor Technology, has for over 10 years incorporated TorqSense units into its capping machines. Bottle capping is nearly always performed at very high speed, so that production targets are met. A major advantage of TorqSense is that it does not need to physically contact either the bottle caps or shaft of the torque head it is monitoring, instead using a radio frequency link. This means initial set-up and change 16
Bulk Solids Today
over to new product runs is fast and efficient while operational reliability is not dependent on delicate slip rings. “All you have to do is set up a TorqSense transducer in the capping machine and turn it on.” explains Mark Ingham of Sensor Technology. Significantly, the new SGR530/540 sensors are designed to be drop-in replacements for the older RWT430/440 units they are replacing. They are the same size and shape as their corresponding older model, with the same mounting holes, cables in the same position etc. “All we have had to do to the capping machines is a straightforward swap-out of new for old. It only takes a few minutes,” explains Mark. “Our new SGR TorqSense units are getting a realistic long-term work out on the capping machines, working for long hours at high speed, where they are required to be 100% reliable and consistently accurate.” Fast and accurate torque measurement is becoming more and more important as all sectors of manufacturing automate their physical processes while also needing to improve the recording of production performance data. TorqSense is used in many industries from automotive to materials handling, test and measurement, FMCG (fast moving consumer goods) production, power generation etc. Sensor Technology is working with user-partners in many sectors to assess the new SGR units in a range of working environment.
www.sensors.co.uk
CONTROLS, SENSORS & LEVEL MEASUREMENT
PARKER IQAN-XC4X EXPANSION MODULES NOW CERTIFIED FOR FUNCTIONAL SAFETY Certification facilitates easier system implementation and machine design in mobile hydraulic applications demanding higher levels of functional safety Parker Hannifin the global leader in motion and control technologies, now offers its IQANXC41, -XC42 and -XC43 expansion modules with certification according to IEC 61508 safety integrity level 2 (SIL2). This development makes it possible to use the modules as part of machinery safety functions up to EN 13849-1 Performance level d (PL d). With safety-certified expansion modules, engineers can simplify system implementation and machine design in mobile hydraulic applications demanding higher levels of functional safety. Such applications include those relating to material handling, construction, aerial platforms, and specialty vehicles like refuse trucks, for example. The new development from Parker means that both types of controllers on the latest IQAN platform - MC4x master controllers and XC4x expansion modules - provide several safety-certified versions so that machine designers have many options at their disposal. For instance, design engineers can now assign critical I/O to a module at the best physical location on the machine, reducing wiring complexity and cost. This modularity enables easy upscaling or downscaling with pin-compatible units. An important feature of the XC4x is Parker’s newly designed protocol, which is both safe and bandwidth efficient. The protocol supports both classic CAN (250 and 500 kbps) and CAN FD up to 500/2000 kpbs. Notably, in a system where all outputs that control hydraulic valves are safe to begin with, the application designer does not have to introduce additional components and complexity in order to implement basic stop functions. IQAN is an electronic control system for mobile hydraulic applications with the highest focus on functional safety, precision control and ease-of-use. At the core of the IQAN family is a fully integrated solution of controllers and displays, with the IQAN software toolchain facilitating configuration and maintenance tasks. IQAN is safe, fast, and powerful to use. The IQAN toolchain consists of three core software suites: IQANdesign for application design, IQANsimulate for simulation of the application, and IQANrun for service and diagnostics. Thanks to Parker’s co-development of IQAN hardware and IQAN software, users get to benefit from plug and play functionality and increased safety performance. There are numerous advantages of using IQAN for functional safety. For instance, when using IQANdesign, a high-level graphical tool for quick and easy system layout and machine function design, there
is no need to compile the application or embedded software (Parker compiles and verifies all embedded software and the IQAN application interpreter). Users of IQANdesign can highlight and document safety functions, guided by project check. In addition, designers can easily create the intended function and take advantage of predictable real-time performance. Ultimately, multiple IQAN master modules can be combined seamlessly with Parker IQAN protocols for exchanging safety-related signals with realtime performance between modules. From a safety perspective, it is a great advantage for the developer that the controller and diagnostics tools are designed to work together. It is far easier to provide a reliable and carefully considered interface when everything belongs to the same system of software support tools and controller hardware. IQAN easily implements safety-related devices with generic support from SAE J1939-76 for safe communication with sensors and other input devices. For more information, please visit: https://ph.parker.com/de/en/expansioncontrollers-iqan-xc41-xc42-xc43-xc44
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
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QUARRYING & MINING
GRANITA LOMY ASSEMBLES A FLEET OF 11 DOOSAN MACHINES The Doosan equipment is used in the company’s quarries GRANITA Lomy s.r.o. is one of the most important players in the quarrying and sale of crushed stone in the Pardubice region of the Czech Republic. The company owns and operates six quarries, supplying granite, diorite, granodiorite and rohozec stone. Quarrying of stone like this can only be carried out using heavy machinery and GRANITA Lomy has chosen the Doosan range for these applications, with a fleet of 11 Doosan machines used across the quarries. The key reasons for choosing the Doosan machines were their performance, economy of operation, reliability and, last but not least, the quality service back-up. All of the machines were supplied and are supported by GARNEA a.s., the Authorised Dealer for the Doosan range in the Czech Republic, and service is provided by ZTH s.r.o., GARNEA’s contractual partner from Dobrá Voda near Hořice. GRANITA Lomy decided to buy the first Doosan machines in 2019, when the company bought a large Doosan DL550-5 wheel loader and a DX380LC-5 crawler excavator. The excavator serves as a hydraulic hammer carrier and its task is to prepare
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large pieces of stone for loading using the Doosan wheel loader. Both machines work in the company’s quarry in Chvaletice. The first loader has worked for over 4000 hours and, based on this performance, GRANITA Lomy decided to purchase more Doosan machines. Today, GRANITA Lomy has a total of 11 Doosan machines at its disposal and these machines are among the most popular in their class. THE CHVALETICE QUARRY RELIES ON EFFICIENCY AND ECONOMY
The Chvaletice quarry is the company’s largest operation of its type. It is located between Kolín and Pardubice and has good transport links via Class I and II access roads. This is one of the reasons why stone was quarried here for large projects such as the D35 and D11 motorways. The main type of stone in the Chvaletice quarry is medium-grained biotite granite. Quarrying is carried out by blasting the rock followed by subsequent processing of the stone, which is where the five Doosan machines in the quarry take over. Last year, GRANITA Lomy added another
QUARRYING & MINING
DX380LC-5 excavator and a larger Doosan DX490LC-5 50 tonne excavator for the Chvaletice quarry. Large wheel loaders work in tandem with the excavators, including the DL550-5, which is the second largest model in the Doosan range, with an operating weight of over 30 tonne and a maximum bucket volume of more than 5 m3. Supporting the DL5505 is a Doosan DL420CVT-5, a very economical model, offering significant fuel savings. “It’s a pleasure to work with our latest addition, the larger DX490LC-5 excavator. With a 3 m3 bucket, it’s a real boost and has made quarrying a much more efficient operation. The power of the excavator and its reliability have been amply demonstrated,” says Tomáš Dunda, the Plant Manager at the Chvaletice quarry. USING THE DL420CVT-5 REDUCES FUEL COSTS BY UP TO A QUARTER
The DL420CVT-5 was purchased for the Chvaletice quarry at the end of 2019 and it has worked for more than 3000 hours. It is equipped with a Continuously Variable Transmission (CVT). A CVT transmission is the result of a permanent combination of a hydraulic technology and a mechanical technology which provides a smooth and continuous speed variation. The CVT design combines the benefits of a hydraulic mechanical transmission
and a hydrostatic transmission in the same machine. It allows the DL420CVT-5 to automatically transition from hydrostatic power at low speed to the mechanical system to operate at higher speeds. The complete driving range, forwards and in reverse, is controlled by the CVT system. Low engine speeds ensure a high efficiency and the highest driving comfort irrespective of the traction speed. The power splitting continuously variable technology facilitates moving off softly and hydraulically. Furthermore, with the CVT, a fuel saving of up to 25% can be achieved. “Efficient servicing for all the machines is provided by GARNEA, as part of an extended warranty of 5 years/10,000 hours on all the machines. We are glad that we chose Doosan machines, because we can fully rely on them,” concludes Tomáš Dunda. Bulk Solids Today
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RECYCLING & WASTE MANAGEMENT
WEEE WASTE PLASTIC AND SRF RECOVERY To assist with material decontamination of the waste electrical and electronic equipment (WEEE) material processed at Enva’s plastic recycling and recovery facility in Lincolnshire, UK. Enva employed the services of Impact Air Systems to provide a material separation solution that would remove contamination, improve current capacity, and enable operations to continue to grow. Enva recycles and recovers a large percentage of small domestic WEEE material generated annually in the UK. Its facilities around the UK and Ireland recycle and recover materials ranging from plastics, metals, wood, oil, glass aggregates for re-use in manufacturing and for energy conversion. Enva’s sink float system, used for the processing of plastics, was being compromised with heavy contamination from the material passing through it, so a density separation system was required to remove the light fibres, dust, and other residue from the rigid plastic material stream. The contaminated material was sent to Impact’s test facility for a trial run through the Zigzag Air Classifier (ZAC), a tried and tested solution, popular in the recycling and resource recovery industry for its effective ability to utilise air technology and density separation to clean valuable materials from contaminants. Impact’s test facility provided outstanding results, with the input material being cleaned to an exceptional level, which ultimately resulted in the sale of a ZAC800. For the plastic processing company, the ZAC800 handles up to 14 tonnes per hour at a bulk density of 350kg/m³, however as the ZAC is also available in a 1200mm wide version, compared to the 800mm, and is therefore capable of processing material at an even higher throughput. Project Manager, James Anderson commented on the installation: 20
Bulk Solids Today
RECYCLING & WASTE MANAGEMENT “As an existing customer of Impact Air Systems, it was a natural decision to contact them with regards to the additional requirements of the plastic recovery process. We have a great relationship with Impact and have always been more than satisfied with their solutions. The ZAC works extremely well as part of our process and only took a week to install. The results are impressive and have resolved the issues we were experiencing with the high volume of contaminants hindering the sink float process. The ZAC has also decreased costs due to the contaminants/SRF material being removed earlier in the process before getting wet. We highly recommend Impact’s ZAC for its ability to recover our materials effectively, its low maintenance, ease of use and quick return on investment of around 8 months.” Carl Henson, Technical Sales Manager for Impact Air Systems, sold the system to Enva and said about the solution: “ENVA’s efforts in diverting valuable material from landfill are commendable, so to be involved with the upgrades of its recovery process was a privilege. The ZAC800 was the obvious solution to meet Enva’s requirements of decontaminating the WEEE material stream and the results spoke for themselves. The ZAC has many features that ensures it is robust, reliable, easy to maintain for the customer, making is an easy choice. Quick access points also allow for unblocking if larger parts manage to make their way through to the ZAC or if there is a material build up. This is the ultimate solution for material recovery and with the return on investment being so quick, our customers are always more than satisfied.” Impact Air Systems has developed various cost-efficient systems for the recycling industry around the world. Its innovative system design and well-engineered components ensure maximum efficiency, speeding up the sorting task, improving the throughput and quality of recycled material grades.
Its separation systems provide convenient solutions for waste recovery and sorting scenarios across the waste management sector, making processes efficient and cost effective. Bulk Solids Today
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SPECIAL FEATURE
Q&A ON MINI-EXCAVATOR ATTACHMENTS WITH DANIELE PACIOTTI, EMEA PRODUCT LINE DIRECTOR ATTACHMENTS AT BOBCAT 1. AS THE ATTACHMENT REVOLUTION CONTINUES APACE, WHAT ARE SOME OF THE NEW INNOVATIONS THAT HAVE COME TO MARKET IN RECENT YEARS IN THE EXCAVATOR ATTACHMENT SPACE?
In recent years, Mini-Excavators (MEX) have developed into real Tool Carriers. This is thanks to the application of new technology and improved machine stability due to new designs and a better centre of gravity. At Bobcat attachments, we are always working on new solutions to meet the needs of MEX customers. For example, we have recently put more focus on developing our Depth Check and laser system to support the operator in completing trenching works and to make jobs more efficient. As a result, Bobcat is proud to announce the addition of the updated Depth Check System to our portfolio. This system is a solution that uses three sensors placed strategically on the machine to accurately achieve or sustain the desired grade depth, working from the cab. The Depth Check
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system is fully integrated with the Bobcat panels and display, which offers simple operation and eliminates the need for an add-on Monitor inside the Cab. This simple, durable kit is wired in, so job conditions or the lack of a wireless signal never interfere with digging accuracy, and also remove the inconvenience of lag time with no batteries to replace. The Bobcat Depth Check System is also compatible with the laser receiver, so the operator can ‘bench’ on a laser signal to create slope, or to sustain a grade in multiple locations on a jobsite, which increases flexibility. Bobcat is also offering new Flail Mower and Plate Compactor attachments for MEX. The flail mower has a number of unique features on the market such as the 12 second drum stop after the power is switched off, no need to drain lines as this is integrated in the attachments, a selflevelling system for following the ground surface as a standard feature and the best balanced motor design in order to cut the grass while travelling. The compaction plate attachment is a great
SPECIAL FEATURE
tool to maximize compaction, even where workers cannot go with classic compaction plates, thanks to the great reach of the mini-excavator in all these conditions. Bobcat will continue to bring to the market more attachment solutions to make the Mini-Excavator even more of a real Tool Carrier. 2. WHAT ARE SOME OF THE MARKET NEEDS ADDRESSED BY THESE ATTACHMENTS?
Compact Excavator customers want to work efficiently, with the same solutions as those on the bigger excavators and with easy to use solutions. 3. THERE HAVE ALSO BEEN MAJOR ADVANCES IN COUPLING TECHNOLOGY. WHAT ARE SOME OF THE DEVELOPMENTS YOU HAVE SEEN IN THIS SPACE?
The coupling technology is not moving as fast as machine or attachment technology but is concentrated more and more on safety features, to make the jobsite safer and to avoid any kind of potential accident. One development I see expanding in this area is in hydraulic quick solutions, to reduce spending time in connecting hoses every time you change the attachments and to avoid wasting time getting in and out of the cab.
4. WHICH ATTACHMENTS ARE SEEING INCREASED DEMAND IN THE MARKET AT THIS STAGE AND WHY?
The commodity attachments are always the most requested like buckets and couplers or Breakers, probably because the construction and demolition industry is growing thanks to government subsidies but we also see growth in Hydraulic Clamps, flail mowers and augers due to growth in cleaning and landscaping work. 5. WHAT ARE SOME OF THE INNOVATIONS WE ARE LIKELY TO SEE IN THIS AREA IN THE NEXT FEW YEARS?
Our Attachments team will follow the Market trends and will create solutions to meet these requirements. I’m sure the biggest innovations will come because of three fundamental things: automation, digitalization and recognition. At Bobcat we are working hard on our Long-Range plan to bring the easiest to use and more integrated solutions to the market. Our aim is to make life for the customer as easy and efficient as possible. For more information about Bobcat and Bobcat products, visit the website: www.bobcat.com
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BUYERS GUIDE Aero Mechanical Conveyors
Conveyors & Elevators
Powder Handling Systems
“Often copied NEVER matched”
Suppliers of the Original Entecon® Aero Mechanical Conveyors Other Products: • Sack Openers • FIBC Fill / Discharge Tip or Automatic • Pneumatic Conveyors
Sales office for UK & ROI: SGH Equipment - Entecon® Agent
Tel / Fax: 01270 651611
E: sales@sghequipment.co.uk • www.sghequipment.co.uk
Bulk Storage & Handling
MANUFACTURERS OF SILOS, TANKS AND CONVEYING SYSTEMS Redbrook, Barnsley S75 1HR Tel: 01226 730037 Fax: 01226 730066 Email: info@eb-equipment.com Web: www.eb-equipment.com
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Bulk handling with complete confidence Designers and UK manufacturers of: • Bucket elevators • Chain & flight conveyors • Screw conveyors & bin dischargers • Belt conveyors
Remote Silo Monitoring
www.perryengineering.com Tel: 01404 891400 Fax: 01404 891402
Tuf-Lok (UK) +44 (0) 1706 822512 www.tuflok.com
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Cleaning
Mixers & Blenders
Dynamic Air Ltd. Milton Keynes England
+44 (0) 1908 622344 www.dynamicair.com
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If you would like your company to be featured here, please get in touch using the details below : 01933 316931 bst@abbeypublishing.co.uk www.bulksolidstoday.co.uk
BUYERS GUIDE Sieves & Sifters Cont’d
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Screw Feeders, Mixers & IBC Systems
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Screw Feeders, Mixers & IBC Systems Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706 www.ajax.co.uk email: solids@ajax.co.uk
Valves
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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
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Global sieving & filtration specialists The Russell Compact Sieve®
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
