BULK MATERIALS BULK HANDLING MATERIALS • POWDER HANDLING HANDLING • FEEDERS • QUARRYING & CONVEYING • RECYCLING • SIZE REDUCTION & WASTE MANAGEMENT
FEBRUARY JUNE 2020 2017
Memory Lane Cakes Creating Creamy Success with Boone Mixers see pages 12-13
HIGHLIGHTS:
4
Community says thanks as food aid project signs off on a high
10
Epoxy crusher backing provides excellent impact resistance
18
Leading the way for the mobile robot takeover
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 142
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
12
COVER STORY
14
FEEDERS & CONVEYING
16
BULK MATERIALS HANDLING
18
SPECIAL FEATURE
20
SIZE REDUCTION
ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2017
www.bulksolidstoday.co.uk Bulk Solids Today
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COMPANY NEWS
COMMUNITY SAYS THANKS AS FOOD AID PROJECT SIGNS OFF ON A HIGH ORGANISATIONS across Staffordshire today said a big thank you to JCB as the company served up its last meal under its ‘Food for our Communities’ initiative. An idea of Carole Bamford, wife of JCB Chairman Lord Bamford, the scheme swung into action in March at the height of the Coronavirus pandemic to support those most in need. Since then, more than 35,000 meals and over 8,000 sandwiches have been delivered to the vulnerable in Stoke-on-Trent, Uttoxeter, Rocester and Biddulph. Dishes made at JCB’s World HQ in Rocester included cottage pies, macaroni cheese and Bolognese. The NSPCC - JCB’s nominated charity - is one organisation which has distributed the meals in Stokeon-Trent, delivering almost 4,000 to families in the Chell, Chell Heath and Fegg Hayes areas. Jennie Hammond, NSPCC Together for Childhood Development and Impact Manager, said: “We would like to thank JCB for such a generous donation at a time when some families might have struggled. The meals have been really appreciated by each family which has received them and the scheme has had a very positive impact on the community.” More than 15,000 JCB meals were also distributed across Stokeon-Trent by the Burslem-based Hubb Foundation to children and families in need. Founder Carol Shanahan said: “The impact of JCB’s ‘Food for our Communities’ project has been immense. It has supported families in Stoke-on-Trent when their need was at its greatest and help like this will never be forgotten.” More than 8,000 sandwiches were made for distribution to the homeless in Stoke-on-Trent and for inclusion in food parcels for vulnerable people in the Uttoxeter and Biddulph areas. JCB also supplied St. Michael’s Church Support Group in Rocester with 100 meals a week for villagers who 4
Bulk Solids Today
were in need. Over the course of the initiative the JCB team used around seven tonnes of potatoes, more than 3.5 tonnes of minced beef and almost two tonnes of both pasta and onions In India – where JCB has factories in Delhi, Pune and Jaipur – the scale of the initiative to support local communities was even greater and more than 175,000 meals were served up during the project. As well as providing thousands of meals, JCB has also donated vital PPE to front line workers. JCB and its employees also volunteered to produce visors for the NHS. Inspired
by these efforts, JCB-sponsored athletes, slalom canoeist Adam Burgess and triple jumper Ben Williams, took on a marathon weight lifting challenge and have so far raised more than £2,400 for the Royal Stoke University Hospital. JCB’s kitchens in Staffordshire were supported with the provision of food from organic farms at Daylesford in Gloucestershire. Daylesford - founded by Carole Bamford - has supplied organic beef mince to the project, with staff working seven days a week to support the food aid initiative. www.jcb.com
COMPANY NEWS
REDUCE PLASTIC & KEEP FOOD SAFE – KICK THE BUCKET! Holmach Ltd and Atlantic Engineering work together to make eco-friendlier manufacturing operations Holmach Ltd’s new partner, Atlantic Engineering of Belgium have developed and patented a solution that aims to cut plastics use, reduce transport costs, waste and improve food quality all in one compact solution. Working together, they are bringing this patented solution that makes eco-friendlier manufacturing operations to the UK market. Aiming to reduce plastics used by 90% when compared with 3, 5 and 10 litre buckets, INNOFILL BY ATLANTIC® is a large preformed pouch filler that can be connected directly to a cooking vessel. A 15 litre bucket version is also currently in development. With hygienic design at the forefront, the flowmeter or servo piston filling of bags mean that every bag has the correct volume, eliminating inaccuracies from time/pressure type systems. Using impulse sealing technology, each bag is safely double sealed creating a high integrity closure without the need to apply heat, with no clips or leaking closures and a tear tab is included so knives are not required for decanting later. There is also a re-closeable spout option available. This hermetic sealing of the bags not only ensures food hygiene and security, but also allows the bags to receive a secondary pasteurisation or sterilisation process if cold filling is preferred. Alternatively, the pouches can be loaded into batch or continuous coolers prior to taking straight into chilled storage. The use of the pouch means that pouches can be shipped in cardboard outers, or in reuseable trays, reducing the space needed to dispose of empty
containers as the pouch can be compacted for disposal. In conjunction with Atlantic Engineering, Holmach offer Lyco Manufacturing Chill-Flow™ continuous pouch cooling technology the food industry and industrial providing rapid heat removal. kitchens whilst optimising product Compared with tumble chilling, quality.” the Lyco system guarantees first in first out handling and complete For additional information control of cooling times. The use please contact Wendy Ford at of heat exchangers minimises the Dupree International via wendy. consumption of water can cool ford@dupreeinternational.com or twice as fast as conventional 01780 757666. technologies. Holmach Ltd’s Director of Sales Lewis Peasgood comments, “We YOUR SIEVING & SCREENING PROCESS continue be at the forefront of process optimisation and environmental WITH SIEVMASTER BY FARLEYGREENE. commitments through our technology, which is why the eco-friendly impact of Atlantic Engineering’s innovative and patented concept is a significant development. Both our companies pursue the same objective of providing ultimate Sieves, screens, sifters. solutions of +44 (0) 1256 474 547 hygienic design, www.farleygreene.com safety and enquiries@farleygreene.com cost-reducing processes in
REDEFINED
Bulk Solids Today
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COMPANY NEWS
PLAST 2021: THE ORGANIZATION PROCESS RESTARTS After the suspension of all non-essential activities due to the Covid-19 pandemic, organization commences for PLAST 2021-international exhibition for the plastics and rubber industries, taking place in Milan from the 4th to the 7th of May of next year. Roughly 450 direct exhibitors (excluding the represented companies) have already confirmed their participation in the fair, reserving an area of 35,000 m². One fifth of subscribers are foreigners, in addition to Italian branches of foreign machinery manufacturers. The effects of the epidemic greatly conditioned worldwide fairs, causing the cancellation of all events in spring-summer 2020 and moving the ones planned for this autumn to 2021. This was the case for various
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Bulk Solids Today
international plastics and rubber industry fairs and also for important events regarding the packaging and converting sector, such as Interpack and Drupa, originally planned for May and June 2020 but postponed to the period between early March and late April 2021. Such changes led to the decision to confirm the next edition of PLAST to 4-7 May 2021 and to reschedule the other four fairs of The Innovation Alliance (IPACK-IMA, MEATTECH, PRINT4ALL, and INTRALOGISTICA ITALIA), also due to the congestion at the RhoPero exhibition district. This decision originates in the extraordinary situation of recent months with the objective of preventing overlaps, which would have caused difficulty for both
companies and operators. The Innovation Alliance project, favouring synergies among complementary sectors, is still a definite go. Although the five exhibitions are scheduled for different times, the organizers have already begun to plan unifying initiatives to assist operators in the planning phase. The PLAST Office is again fully operational and, to facilitate potential exhibitors in the decision process (taking into consideration the obligatory shutdown in March and April), has extended the deadline to 31 July 2020 for benefiting from a 10% discount on the participation fee and priority stand assignments, which will be made starting in September. Organizers are thus confident that they will see reservation numbers similar to the 2018 edition.
COMPANY NEWS
PLAST will be the most relevant European event for the plastics and rubber industry in 2021, a critical occasion for operators to meet and talk and plan new investments. Below, some key figures for the past edition of PLAST, which took place from 29 May to 1 June 2018 in Milan: • total fair area: 55,000 m² net • exhibition sectors represented: 75% machinery, 20% materials and products, 5% services • total exhibitors: 1,510 from 55 countries (57% Italian, 43% foreign; 1,049 direct and 461 via representatives) • satellite fairs: RUBBER (rubber industry), 3D PLAST (3D printing and related technologies), PlastMat (innovative materials) • visitors: 63,000 (27.5% from outside of Italy) representing 117 countries. The upcoming edition of PLAST will once again feature the three
satellite fairs, each dedicated to a sub-sector of excellence and its associated startups: RUBBER (in its fourth edition, dedicated to the world of elastomers, in collaboration with ASSOGOMMA), 3D PLAST (in its third edition, focusing on additive manufacturing and related technologies), and PLASTMAT (second edition, exploring innovative plastics). The list of participants is constantly updated and can be found on the website plastonline.org.
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
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COMPANY NEWS
GYRO EX BIN ACTIVATING FEEDER/ DISCHARGER Accurate Feeding and Discharging
GYRO EX Bin Activating Feeder/Discharger The GYRO EX bin activating feeder and discharger produces a controlled gyratory motion to positively withdraw granular materials from bins, storage silos and hoppers at any desired feed rate for a more consistent and reliable discharge. At the heart of the GYRO EX bin activating feeder and discharger is the drive that produces a radial force creating a uniform circular motion on both the upper activation cone and the lower discharge cone. It is this annular radial vibratory motion which imparts the force to the material, assuring a more reliable and predictable material discharge. A unique feature of the GYRO EX bin activating feeder and discharger is that the stored material load is completely supported by the upper bin activation cone which has a lower cone angle than the discharge cone, assuring an uninterrupted and positive discharge of the stored material. The GYRO EX bin activating feeder and discharger can also be started and stopped as desired because material is not allowed to accumulate or stagnate in the lower discharge cone which might create packing or plugging problems. Irrespective of the particle size, the GYRO EX bin activating feeder and discharger is well suited for almost any size material and the rate can easily be increased or decreased by adjusting the gap between the inlet opening and the upper activation cone. 8
Bulk Solids Today
Features: A. Low headroom reduces height. B. Material stops due to angle of repose. C. Gap is adjustable to increase or decrease feed rate. D. Circular distance of activation cone creates a wide feed zone. E Vibrating lower cone is selfcleaning. F. Exterior mounted vibrating motor. G. High strength reinforced flexible connector.
http://www.dynamicair. com/products/vibratory/ gyroex.html Dynamic Air Ltd. Milton Keynes, United Kingdom Phone: 44 1908 622344 sales@dynamicair.co.uk www.dynamicair.com
COMPANY NEWS
AUMUND SUPPLIES CONVEYING TECHNOLOGY FOR THE LARGEST SUGAR SILO IN THE WORLD Conveying technology from AUMUND is now also in demand within the Dubai based Group, Al Khaleej Sugar, one of the largest sugar producers in the world. The first order is from its Egyptian subsidiary, Canal Sugar, for a CENTREX® Discharge System and two AUMUND Bucket Apron Conveyors. Intense negotiations between the Al Khaleej Sugar Group and the AUMUND Fördertechnik GmbH Branch Office in Dubai led to the award of the order. The two AUMUND Bucket Apron Conveyors will be fabricated in stainless steel. All of the equipment will be on site before
the end of this year. Canal Sugar is constructing a new sugar production plant near Beni Suef. It is the largest agro-industrial project in Egypt since 1952. The Canal Sugar Refinery will be able to process 5.4 million tons of sugar beet per season. AUMUND Fördertechnik already supplied the CENTREX® Discharge System type CTX 8000, which has a diameter of 8 m, in March this year. The CENTREX is in ATEX (explosion proof) design and will be installed in a silo which extends approximately 65 m underground.
The silo holds around 400,000 tons of refined sugar and is therefore the largest of its kind in the world. The discharge capacity of the CENTREX® is up to 300 tph of sugar, which will be transported onwards to the packing plant by the AUMUND Bucket Apron Conveyor type BZB 1400/400. The BZB is approximately 145 m long with a vertical lift of about 103 m. The second AUMUND Bucket Apron Conveyor ordered by Canal Sugar is of the type BZB 1600/400 and has a capacity of up to 400 tph. It will operate as a collecting conveyor under the sugar centrifuges.
GUTTRIDGE COVID-19 STATEMENT In light of the current situation, we would like to reassure all our customers and suppliers that we are continuing to monitor the spread of COVID-19, which is at the forefront of the media. As a company, our doors are still open, but we have put in place certain restrictions in order to safeguard both our employees, and those we come into contact with. Our employees matter to us and it is imperative that their welfare is considered as a priority. Whilst we are closely following government advise and guidelines, it is still business as usual with government recommended exceptions. We will continue to keep our manufacturing facility functioning and are working closely with our suppliers
and transport companies to ensure that risks are minimised. It is important that we can continue to support vital services such as the Food Industry, agriculture and essential manufacturing during these unprecedented times. Our parent company, Mitchells, is based in China. They have worked exceptionally hard to restore the production facility to full capacity, now that 95% of their employees have been cleared to return to work. We are taking lessons learned from them in order to cope with the virus. We would like to thank our customers and our suppliers for their continued collaboration and support at this difficult time, please follow government guidelines and keep
yourselves safe. If you have need of essential machinery or parts, please call our sales office on 01775 765300. Our phones are being manned and you can also contact us at sales@ guttridge.co.uk
Bulk Solids Today
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COMPANY NEWS
EPOXY CRUSHER BACKING PROVIDES EXCELLENT IMPACT RESISTANCE The new LOCTITE® PC 9021 shock-absorbing backing material from Henkel has proven its ability to prolong the service life of gyratory and cone crushers throughout Europe. Now available in the UK, this supremely tough and flexible material minimises downtime and enhances productivity of machinery operating in the harshest of environments. The epoxy product is designed to flow into all cavities between the outer jacket and upper part of the crusher and between its stand, jaws, supporting cone and inner jacket. When cured LOCTITE PC 9021 acts as a highly effective reinforcement and damper layer significantly reducing the effects of impact, friction and vibration during the crushing process. This technology offers distinct advantages over molten metal backing materials that have been traditionally used for this purpose. LOCTITE PC 9021 eliminates the need for melting or special equipment which can be hazardous.
Easy and safe to use, LOCTITE PC 9021 has low water absorption, high compression strength of 107 MPa (15,500 psi) and a shore hardness D rating of 90. Once mixed, it has an open time of 10 minutes at 25°C and cures to provide maximum impact resistance in 8 hours; maximum operating temperature is 77°C. This low-odour, two-part LOCTITE epoxy is formulated to provide a colour change indication when the hardening component is added to the resin so the user can see when the product is thoroughly mixed and ready for application. The low shrinkage characteristic of LOCTITE PC 9021 eliminates the formulation of gaps between backing and liners or support structures. This allows for fast return to service and provides maximum impact resistance. For more information go to: www.henkeladhesives.co.uk
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
THE YANMAR VIO23-6 – COMPACT PERFORMANCE FOR URBAN WORKSITES Designed for worksites with limited access and operating space, Yanmar’s ViO236 mini excavator is ideal for urban environments. With its zero-tail swing design, neither the counterweight or upper frame extend beyond the width of its tracks, offering safe and predictable operation in tight spaces. Powered by Yanmar’s proven 3TNV76-PBV1 engine, the ViO23-6 is quiet, efficient and reliable. Harnessing an indirect injection system and mechanical speed governor, the engine delivers 14.6kW power at 2,400rpm. Auto-deceleration and eco-mode features are included as standard, improving fuel economy and reducing emissions. The ViO23-6 offers exceptional performance for its class, with 13.1/17.5kN of digging force (arm/bucket) to a depth of 2,655mm. Smooth and predictable control is provided by the ViPPS (ViO Progressive 3 Pump System) hydraulic system, which uses three separate pumps – one variable displacement piston pump and two gear pumps – to allow for simultaneous operation of controls.
The ViO23-6 also makes use of a 1,550mm wide extendable folding blade that offers tool-less extension changes. With a variable undercarriage that can be easily extended and retracted with a single lever, the ViO23-6 can access tight spaces, while offering enhanced stability once extended. It can perform on a variety of surfaces, with an operating weight of 2,245kg for the canopy version and 2,405kg for the cabin model. Its low transport weight of 2,270 kg means worry-free towing on a 3.5t trailer, even with a breaker and buckets on board. Operators benefit from a spacious cabin and triple mirrors designed to provide 360° visibility. An adjustable air suspension seat reduces fatigue, while increased legroom and ergonomic arrangement of the operating controls maximises comfort. The ViO23-6 cabin has been designed to meet ROPS (Roll-Over Protective Structure) certification and FOPS (Falling Object Protection Structure) Level 1. A 3.3” digital interface informs the operator in real-time about the machine’s status, including fuel level/consumption, coolant temperature and LED lamp control. The interface also monitors maintenance intervals and functions as a diagnostic tool by reporting error codes to the operator. For more information about the ViO236, or to find your nearest dealer, visit www. yanmarconstruction.co.uk. Bulk Solids Today
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ON THE COVER
MEMORY LANE CAKES CREATING CREAMY SUCCESS WITH BOONE MIXERS Market-leading Memory Lane Cakes in Cardiff, part of the Finsbury Food Group, have replaced old mixing equipment and expanded production capacity with new rotating discharge Horizontal Helical Blade Mixers (HHBM) from John R Boone of Congleton, UK. The HHBM mixers are being used to produce a wide range of cake batters, buttercream fillings and toppings that find their way into branded and own label cakes sold in the majority of the UK’s major retailers. It isn’t easy, keeping pace with the changing tastes of the British sweet-toothed consumer, and the leading supermarkets have a lively programme of product development to continue to excite the shopper with new styles and flavours of cakes. So much so, that Memory Lane have more than a hundred different recipes for buttercream fillings and toppings, and that’s before you even get to the batters that are mixed for the cakes themselves. In production terms, the ‘creams’ present more challenges than the batters. In a domestic kitchen butter would typically be warmed before mixing, but under factory conditions a mixer has to cope with butter in 5kg blocks being added at 8-10ºC. Memory Lane also produce ‘ganache’, a mixture of around 60% chocolate with 30-40% cream, which also present the same issues of quickly ‘conditioning’ the mixture to a homogenous, smooth paste. Memory Lane is a very well established company, and many of the mixers on site were more than 30 years old. Paul Riley, Head of Engineering at Memory Lane, wanted to bring the mixing process up to date and looked 12
Bulk Solids Today
ON THE COVER for a company who could supply mixers costeffectively and who had a good track record in supplying equipment for this application. Following discussions, John R Boone recommended a Horizontal Helical Blade Mixer (HHBM). Paul Riley said: “We contacted John R Boone and we took a mixer on trial. We tested it on every type of mix we make because it mixes in a different way from the ‘lift and throw’ type we had previously”. He went on “We found the Boone mixer to be very quiet and stable in operation compared to the older types.” Mixing times are around 3-4 minutes depending on recipe. The HHBM features four mixing blades forming a double interrupted spiral that create a crisscross material flow and the low-speed motor results in rapid, efficient mixing. The ‘short and tall’ mixer shape combined with the omega shaped shell ensures all the mix is entrained by the blades. The ability to clean the mixers thoroughly between batches is very important, and JR Boone HHBM mixers excel here. The patented mixer arms minimise adherence of the mix, and the rotating trough discharge provides a complete discharge of the mix. As Paul Riley observes: “The Boone mixers are easy to clean, easy to wash down. Once they have been washed they look like a new machine”. The control panel HMI features a simple interface using a hygienic, easily operated colour touch screen and holds all the recipe data, including mix times and order of addition. The system has the capability of being integrated within a factory wide control system although presently the recipe data is stored on a memory card and downloaded as required for the seasons production. The results have clearly been to Memory Lane’s liking, with six JR Boone HHBM mixers already installed and a seventh on order. As Paul Riley put it: “Robust, designed well and easy to work on”.
FOR MORE INFORMATION, VISIT WWW.JRBOONE.COM
Bulk Solids Today
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FEEDERS & CONVEYING
A MARKET WITH POTENTIAL: AUMUND IS INCREASING ITS FOCUS ON CONVEYING SOLUTIONS FOR ALTERNATIVE FUELS The cement, steel and power industries are all energy-intensive, and still predominantly use fossil fuels in their processes releasing carbon dioxide which is damaging to the environment. At the same time these industries have to comply with increasingly stringent domestic and international legal requirements in order to reduce their CO2 emissions. Alternative fuels play a significant role in achieving these targets. The AUMUND Group is therefore convinced of the industry potential of alternative fuels. At EU-level for example, the “European Green Deal” is regarded as the path to a sustainable EU economy. The overriding aim of the concept is that net greenhouse gas emissions are reduced to zero by 2050, and therefore the EU becomes carbon neutral. One of the most important initiatives of the Green Deal is the climate protection law that was introduced in March 2020. It requires EU emissions of CO2 to be reduced by 50 to 55 percent by 2030 compared to1990. On this journey, the use of all kinds of refuse as alternative fuels in energyintensive industrial processes will become more and more important. Alternative fuels can be divided into two groups.
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Bulk Solids Today
The first is biomass, which comprises among other things wood chips, wood pellets, sunflower seeds, coconut shells, soiled straw or hay and sewage sludge. Biomass is carbon neutral because when burnt, it is only re-releasing the CO2 that it had taken out of the atmosphere whilst growing or being produced. The second large group is comprised of materials such as plastics, tyres, medical refuse, and waste from textile manufacturing, shredded paper or bone meal. In many countries it is no longer permitted to dump plastics, but as the possibilities for recycling are limited, plastic is an appropriate alternative fuel. A particularly suitable application is in the cement industry, where high-temperature processes break up the long chain hydrocarbons which are normally released by burning and can cause health hazards. The AUMUND Group offers a wide range of products for handling and conveying alternative fuels all over the world. Many of these are newly developed specialised AUMUND solutions such as the Trailer Docking Station type TES, the Moving Floor type SBA, the Rotating Screw Discharger type RAS, and a modified version of the Drag Chain Conveyor type TKF for alternative fuels. Also suitable are the well-known AUMUND Bucket Elevators, the mobile Samson® Material Feeder and SCHADE Reclaimers. Target markets for the AUMUND solutions are in the first instance various branches of industry in Germany and Western Europe, where there is still a lot of potential, but even more so in Eastern Europe, the USA and Asia, where alternative fuels are only just starting to come into use. Also, many emerging countries are facing considerable challenges with regard to refuse disposal. Enormous amounts of climate-damaging emissions, which could be significantly reduced by utilisation in a thermal process, are released from dumps or incineration plants.
FEEDERS & CONVEYING
DYNAMIC AIR LTD SPECIALISTS IN CONVEYING, MIXING AND DRYING OF DRY BULK SOLIDS Corporate Description 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 44 (0)1908 622344 sales@dynamicair.co.uk www.dynamicair.com Bulk Solids Today
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BULK MATERIALS HANDLING
SABIC AWARDS ABBEY LOGISTICS PLASTICS DISTRIBUTION CONTRACT SABIC Europe has awarded road tanker operator Abbey Logistics a plastic distribution contract to transport bulk polymer granules throughout the UK. Abbey Logistics has added another major plastics producer to its growing list of customers in the plastics sector. The company has secured a bulk polymer distribution contract with Saudi Basic Industries Corporation (SABIC) Europe, one of the leading plastics manufacturers in the world. The contract will see Abbey providing bulk polymer granule distribution services throughout the UK, using its large fleet of speciality tipping silo road tankers. Abbey Logistics’ Business Development Director
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Bulk Solids Today
Mike Ellis said: “All of us at Abbey are excited to begin this contract with SABIC and work together to drive service and flexibility improvements and identify ways to optimise the operations under our management. “This contract is another major milestone for Abbey, establishing us as one of the largest bulk tanker distributors in the polymers sector and indicative of Abbey’s strategic commitment to growing our footprint in the polymers sector. “We are looking forward to playing a key role in safeguarding SABIC’s high quality service to its customers and working with them to deliver a dynamic and sustainable bulk transport solution.”
BULK MATERIALS HANDLING POWDERS
BRIGGS DEFENCE EXTENDS LIFE OF RAF’S CARGO HANDLING TRUCKS
GRANULES
PASTES
BATCH
CONTINUOUS
Boone Mixers
Optimum Mixing
The RAF’s fleet of bespoke air-transportable forklift trucks is Powders or Pastes set to remain Sizes from 2 to 25,000 litres operationally effective for at least Versatile Mixing Machines another 10 years Advanced Plough / Delta Blade: Agglomerates to Paste after undergoing Spiral Blade: Cake Mixes to Mastic a complete refurbishment by Rotary Drum: Rice Flakes to Carpet Fibres Briggs Defence. Complete mixing plant design to commissioning Introduced in 2004, the Dantruck is the RAF’s forklift Test mixers available for production development of choice for Out of Area deployment by No.1 Air Production scale machines for short or long term hire Movements Wing. Used primarily at the Air Head at RAF T: +44 (0)1260 272894 Brize Norton, the 8-tonne forklift features a three-stage hydraulic mast and very low closed height for rapid www.jrboone.com loading of specialist roller pallets for military cargo. e: sales@jrboone.com All 22 of the forklifts have been given a new lease MIXING SOLUTIONS WORLDWIDE of life by engineers at the specialist division of Briggs Equipment. As well as replacing the Detroit power unit and rebuilding transmissions, drive axles and hydraulic systems, they carried out upgrades to the alternator and cooling system. Briggs Defence also created a safety case, which 12296 Solids & Bulk_Chemical_124x86.indd 1 18/03/2016 did not feature on the original Dantruck machine, and redesigned one-off roller tines, supplying 22 pairs. As part of the contract Briggs Defence engineers rewrote the RAF’s Army Equipment Support Publication, Unlike other valves that seal a detailed maintenance manual containing all technical with friction, Posi-flate’s unique data. Civilian part numbers were converted so that parts butterfly valve uses an can now be ordered direct through the NATO parts inflatable seat ordering system from anywhere in the world. to seal with air To keep the Dantrucks serviceable at all times Briggs pressure. Thus it Defence delivered specialist training to RAF engineers, requires less torque whilst a new, bespoke e-learning programme provides all and a smaller actuator, eligible personnel with access to technical information. resulting in lower cost. Gary Clements, Managing Director at Briggs Defence, Plus, the seat automatically said: “This was an important initiative for the RAF and compensates for wear, providing we were able to capitalise on our engineering expertise longer life. Some users have to deliver a cost-effective solution that will prolong the operating life of its Dantruck 2 fleet. reported over six million “Since these forklifts require access to fuel and munition cycles and the valves are dumps, one of the primary objectives of this mid-life still going strong. upgrade was to ensure Cat C certification for storage and marshalling. With the final truck now in operation at • Less friction RAF Brize Norton, we anticipate that our role will switch to engineering support and the delivery of a ten-year • Low torque maintenance programme including parts supply.” • Low maintenance Dantrucks are heavily utilised for rapid loading/ • Lower actuator costs offloading of the RAF’s fleet of military transport aircraft, • Longer valve life including the Airbus A400 Atlas, C17 Globemaster and • More reliable C130 Hercules. Providing vital cargo handling capabilities, the forklifts support not only day-to-day logistics, but also Tel: +44 (0) 1908 622366 military and humanitarian missions. They are in use in the www.posiflate.com Falkland Islands, Cyprus and Ascension Island as well as at RAF bases around the UK.
Other Valves Fight Friction, We Designed it Out
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SPECIAL FEATURE
LEADING THE WAY FOR THE MOBILE ROBOT TAKEOVER INTELLIGENT MOBILE ROBOTS HAVE THE POTENTIAL TO TRANSFORM INTRALOGISTICS PERFORMANCE, WRITES FRAZER WATSON, HEAD OF SALES EUROPE FOR HIKROBOT AT INVAR SYSTEMS. A shift from fixed automation is taking place, as mobile robots are fast becoming a familiar sight within warehouse and intralogistics applications around the world. Autonomous Mobile Robots (AMRs) do not require external infrastructure to navigate a site. Instead they use integral sensors and cameras. With declining costs of this navigation technology and customers seeking solutions offering greater flexibility, global tech market advisory firm ABI Research forecasts that total shipments of AMRs will reach 2.9 million by 2030. The leading AMR producer in China, Hikrobot has been driving the movement to transform intralogistics globally having commenced international installations three years ago. Of the 15,000 Hikrobots deployed globally today, some 2000 are shipped outside of China to markets across Asia, US and Europe. Employing over 1000 staff, including over 800 engineers, last year Hikrobot manufactured approximately 8000 robots, with a current capacity to produce 1000 robots per month. Planned expansion to the production facility will boost capacity to 3000 robots per month, to support a rapidly growing share of markets across the globe. This of course includes Europe and the UK, where the number of companies understanding the productive power and cost efficiency of these platforms is ramping up. Hikrobot’s first UK application is at Superdry. The global fashion brand is leveraging the flexibility of intelligent mini-robot carriers to transform order picking and put-away at its UK hub – just part of a phased rollout of goods-to-person robotics that will boost productivity across its international network of multi-channel fulfilment centres. Ecommerce companies along with manufacturers are the two sectors currently trailblazing the uptake of this technology, but any company, large or small, with a warehouse and requirement for materials handling can benefit – whether they are in retail, apparel, automotive, electronics or third party logistics (3PL). With the AMR platform, robots can be added in stages as 18
Bulk Solids Today
required, meaning companies can start out with a low capital expenditure solution for three critical applications: goods-to-person order picking in the warehouse; movement of materials to production line or around warehouses; and sorting, particularly for parcels in logistics and ecommerce operations. Given that all customers are generally new to this technology, many will ask: what marks out a good AMR? Productivity boosting performance is the prime advantage. The new generation of technology can move high load capacities at great speeds. Labour cost savings and efficiency improvements are clearly demonstrated at a client that is one of the world’s largest security product manufacturers. It operates Hikrobots for a variety of functions such as inbound delivery, outbound delivery, stock transfer, allocation, and inventory for raw materials, semi-finished products and finished products. Compared to a manual warehouse, this smart and agile warehouse solution reduces labour cost by 58% and improves efficiency by 84%. Companies naturally need technology that is reliable. Hikrobot, for example, will only release a solution to the market once it has completely verified its stability. Components and fully assembled robots are thoroughly tested to ensure that each robot shipped to the customer is fully compliant and reliable. AMRs offer a highly flexible solution that is also easy to replicate in warehouses across an
SPECIAL FEATURE organisation. For example, many 3PLs with multiple sites, often globally, can implement the same proven and successful ‘universal solution’ across their estate. Furthermore, if business circumstances change, such as during peaks like Black Friday and Christmas, it is simple to reconfigure the software and add or reduce the number of robots on a site as required. Software is a core technology to manage the robots and maximise control and performance. Getting large warehouse management software (WMS) vendors engaged to write the interfaces for materials handling systems can sometimes present a hurdle for any automation project. This is why most big automation companies offer their own warehouse control software (WCS) with their hardware – in the UK, Invar Systems writes the WCS for Hikrobot platforms. When docking with a company’s upper system intelligent AMRs deliver easy to query digitised warehousing. The AMRs produce standardised data, free from human error to feed AI and big data technology. With this information, companies can optimise business processes such as labour resource management – for example redeploying people to where they can be most productive – boosting operational performance. Such is the case at DHL’s North Asia Hub, located at Shanghai Pudong International Airport.
Here, up to 20,000 documents and 20,000 packages are processed per hour. A Hikrobot warehouse solution, comprising a relatively small fleet of 10 intelligent AMRs, saves time and labour for locating rush-order goods by removing the constraints of having people enter a transfer area to find goods manually. The process now requires only one employee to fulfill a daily operation. The provision of a WCS is particularly important for smaller automated materials handling projects or the first steps of a modular development, where the cost of providing an interface with a WMS can be budget-breaking. Invar can also provide a WMS if a company requires one. And because Invar installs and supports the Hikrobot systems in the UK, we can manage the whole suite of software locally. Customers get a UK phone number and we can get people to site within a couple of hours. Ultimately an AMR platform provides a quick, cost effective, and modular system that improves productivity in a DC at a cost competitive price – and will allow the customer to have an enormous amount of input into configuration. This compelling combination gives the kind of competitive edge that appeals to operations of all kinds around the world. For further information visit: www.invarsystems.com
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SIZE REDUCTION
MOLSON CRUSHING IT WITH MB CRUSHER ATTACHMENTS Molson Group, one of the fastest growing plant and equipment dealers, have been appointed as a distributor throughout Great Britain by MB Crusher, a world leading crushing and screening attachment manufacturer. Molson continues to grow their “Single Source Supply” offering with the addition of MB Crusher buckets to their extensive product portfolio. The MB range of attachments is suitable for 2.8t to 70t base machines, with their crushing bucket range currently dominating the global market with an impressive 90% market share. The brand will be available from Molson Equipment in England and Wales, and Molson Young Plant Sales throughout Scotland. Perfect for on-site crushing of smaller quantities of inert materials, the MB Crusher Bucket takes advantage of the hydraulic system of the excavators, skid loader, loader and backhoe loaders to which it is fitted. An ideal fit for a wide range of applications including demolition, utilities, construction and recycling to name a few. Manufactured in their 180,000 square foot headquarters in the province of Vicenza in Northern Italy, MB manages all phases from research and development to production to sales. The company also controls the complete supply chain to ensure the products are of the highest “Made in Italy” quality. Although
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primarily known for their range of crusher buckets, the company also manufactures a range of rotary and shaft screener buckers and drum cutters that will also be available from Molson. Alongside the MB Crusher range of attachments, Molson Group already distributes a comprehensive range of attachments including, rotating grabs, hydraulic hammers, concrete pulverisers, compactors and many more from NPK, Daemo and Genesis throughout the UK. Jonathan Wilson, joint Managing Director at Molson Group, commented: “MB Crushers are renowned for their strength and durability – a fact proven by their popularity around the world. The addition of the MB range complements the existing range of attachments available at Molson, whilst further increasing our offering to new and existing customers”. MB Crusher consultant, commented: “Molson has generated impressive growth across the UK in many sectors and this, along with the outstanding levels of customer service that they deliver, made it a natural choice to appoint them as a distributor for MB Crushers. We see the UK as a key market and look forward to working with such a progressive and proven dealer moving forward.” www.molsongroup.co.uk
Global sieving & filtration specialists The Russell Compact SieveÂŽ
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SPECIAL FEATURE
TENOVA TAKRAF STORAGE SOLUTIONS FOR SOLID FERTILIZER PRODUCTS By Ralf Katzke, Scraper Reclaimer Technologies, Tenova TAKRAF Dry bulk fertilizer products, whether they be within fertilizer factories or at shipping or receiving points, are mainly stored in stockpiles. Employing a pile instead of a high silo is an economical solution for large volumes. In most circumstances, the stockpiles are covered in order to protect both the environment, as the product is prevented from being blown around, and the product itself as it is shielded from being affected by adverse weather conditions. In most instances where a fertilizer product boasts both a consistent composition and quality from an upstream chemical process, the piles also often function as buffer storage. The piles are thus employed to balance time and volume between production and shipping or to balance reception during interim storage and onward transport to users. In other instances where there is very little or no consistency – specifically when mined ores of varying qualities and/or characteristics arrive at a chemical plant and require homogenization prior to a chemical process – piles can also be employed as a blending bed. This is often the case for large fertilizer storages, especially those with high throughputs for either stacking, reclaiming or both, and are usually equipped with fully automated stockyard machines. LEVERAGING MORE THAN 50 YEARS OF FERTILIZER INDUSTRY STOCKYARD MACHINE EXPERTISE Tenova TAKRAF is a global OEM for mining and bulk handling equipment with a history dating back almost 300 years. The company boasts a successful 50 year plus track record of supplying stockyard machines to the global fertilizer industry, with its first scraper reclaimer (for a potash factory) being supplied in 1966. Since then, the company has designed, manufactured, supplied and successfully commissioned around 400 scraper reclaimers across various commodities with a large majority being employed in the effective handling of potash, urea, phosphates and sulphur. Tenova TAKRAF’s approach to this vast array of global projects is “flexibility”. This means they treat the specific requirements of each project in a unique manner, ranging from the supply of a single machine to various machine packages and/or delivery of a complete bulk conveyor system including storage bin machines, conveyor belts and loading & unloading equipment. Such complete handling systems leverage an extended and well established material handling 22
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portfolio covering stockyard / disposal facilities, loading / un-loading equipment, conveying, port facilities and in-plant handling equipment. STACKING AND RECLAIMING In most instances, a storage facility is fed material through a network of conveyors that efficiently carry the product to be stored. In order to achieve an optimal pile width within the storage area, the stacking of material is carried out via overhead tripper cars. Having supplied machines with capacities of up to 4,000 t/h, Tenova TAKRAF boasts significant experience in the supply of these under-roof tripper cars. For the recovery of product from a pile, scraper reclaimers are the preferred (and dominant) equipment of choice for operators and planners alike. Some of the advantages of these machines include: • Proven robustness and reliability • High efficiency and low operating costs • Simple and steady working movements allowing for full automation • Gentle treatment of material and almost dust-free handling of fertilizer products MAXIMUM STORAGE SPACE IN INDOOR AREAS As a result of general market developments and increasing fertilizer logistic requirements, the global demand for storage volumes and handling capacities is increasing. This growing demand has resulted in large pile widths, sometimes even exceeding 60 m. For such indoor applications, the portal reclaimer, which boasts separate main and auxiliary reclaiming booms, is the preferred solution, as it requires a minimum amount of space due to its shape. This results in the maximum covered storage space for the product stack. Depending on bulk products’ densities, Tenova TAKRAF is able to supply portal reclaimers with handling capacities of up 6,000 t/h and with rail-spans that can exceed 60 m. SPECIAL FEATURES OF STOCKYARD MACHINES THAT HANDLE FERTILIZER As previously mentioned, scraper reclaimers are, due to their method of operation, very gentle in their treatment of material and thus operate with minimal dust creation. This makes them ideally suited to fertilizer material that often comes in granulated form. This gentle treatment of a material, together with the minimization of dust, also applies in principle to all equipment within the fertilizer handling value chain including boom stackers and/or overhead tripper cars. These machines, which generally employ cone
SPECIAL FEATURE
shell stacking for the minimization of dust, can also be equipped with lowering booms or special chutes in order to further improve handling and dust minimization. Nevertheless, depending on the characteristics of the fertilizer product and our customers’ unique requirements, Tenova TAKRAF is able to equip their scraper reclaimers and stockyard machines with special features such as: • Stainless steel design for blades and chutes • “De-lumpers” arranged within the discharge chutes for the breaking up (“de-lumping”) of caked bulk material • Hoses on hose reels for fresh air supply to operator cabins • Life-time lubricated outboard roller chains • ATEX-certified components in case of inflammable / explosive bulk material such as sulphur CRITERIA THAT MAY INFLUENCE THE CHOSEN BULK STORAGE ARRANGEMENT In addition to the globally popular solution of employing portal reclaimers in combination with overhead tripper cars for indoor fertilizer storage facilities, other alternative solutions can potentially also be employed or be even better suited in certain specific instances. Spending the time to properly evaluate all options and making an informed decision based on all factors including the overall space situation, storage shed design & structure and/or on individual mass flows, may mean that the following machine solutions might be an even more suitable choice: • A stacker with tripper-car travelling on ground along the pile • A combined stacker / reclaimer • A circular storage arrangement In addition, the requirement for homogenization may also bear significant influence on equipment selection. Nowadays, very light building structures even for
large shed dimension are available and quite commonplace. Often, these light building structures do not allow for any under-roof installation of incoming conveyors with a travelling tripper car. In such cases, an alternative approach in combination with such a light building structure might employ an on-ground travelling stacker. In such instances where all equipment is installed at a ground level, access to equipment for maintenance is significantly safer and more efficient as an additional benefit. If space at the site is limited, then a circular buffer storage facility may turn out to be the most effective spacesaving solution. Bulk material is stored against a retention wall, with both stacker and reclaimer mounted on a central column. In circular buffer storage solutions, the feeding of the pile is conducted via a boom stacker employing the cone shell stacking method. Reclaiming is accomplished via a cantilever reclaimer, which conveys material into a central chute located below the central column. From this central column, material is then fed, via a feeder, to the outgoing conveyor. In operations where material logistics can be managed in such a manner so as to avoid simultaneous stacking and reclaiming operations, a combined stacker / scraper reclaimer can also be an effective cost saving solution. In this instance, stacker and scraper booms are mounted on the same chassis resulting in substantial cost savings not only for the equipment itself but also in reduced rail lengths and fewer conveyors being required. PRODUCT CONSISTENCY THROUGH HOMOGENIZATION / BLENDING In instances where fertilizer originates from mined ores and/or where variations exceeding the acceptable product range can be expected, material consistency can then be at risk. In order to protect against such consistency issues, the stockpile may, in addition to its buffer function, also be given the additional task of homogenization / blending. Blending beds generally operate in an adjusted combination of chevron-stacking and front-reclaiming. The stockpile is built up according to the so-called “chevron method” in a longitudinal stockpile, or the so-called “chevcone method” in a circular stockpile. In both methods however, stacking is required to achieve a sufficient number of material layers. Reclaiming is then conducted via a bridge-type reclaimer, which takes material from the front side of the stockpile. In this manner, reclaiming achieves a perfect mixture of material, depending on the number of layers and the incoming deviation and/or distribution. For further information, visit: www.takraf.com Bulk Solids Today
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BUYERS GUIDE Aero Mechanical Conveyors
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Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706
Russell Finex
www.ajax.co.uk email: solids@ajax.co.uk
Valves
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WITH SIEVMASTER BY FARLEYGREENE.
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Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions
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InterBulk GROUP
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