Bulk Solids Today June Issue

BULK MATERIALS HANDLING • POWDER HANDLING • QUARRYING • RECYCLING BULK MATERIALS HANDLING • PACKAGING • VALVES & WASTE MANAGEMENT

FEBRUARY JUNE 2021 2017

SCHÜTZ GREEN LAYER – UN-APPROVED IBCS AND PLASTIC DRUMS MADE WITH HIGH QUALITY RECYCLATE

see pages 20-21

HIGHLIGHTS:

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specialist set to exhibit

activating feeder/

the whole package

at Advanced Materials

discharger

Dust extraction

Show 2021

GYRO EX bin

Thin walling delivers

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

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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 149

BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley

CONTENTS

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.

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NEWS

12

BULK MATERIALS HANDLING

16

SPECIAL FEATURE

18 PACKAGING 20

ON THE COVER

22 VALVES

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

www.bulksolidstoday.co.uk Bulk Solids Today

3

COMPANY NEWS

AGGREGATE INDUSTRIES URGES BUSINESSES TO PRIORITISE SUSTAINABLE MATERIALS AMID NEW NET ZERO RULES FOR UK GOVERNMENT CONTRACTS • From September, firms bidding for £5m+ government contracts must be committed to Net Zero by 2050 • Leading construction materials supplier Aggregate Industries says low-carbon concrete and asphalt will be vital for successful tenders • Last year, parent company LafargeHolcim became first construction materials firm to sign Net Zero Pledge Leading construction materials supplier Aggregate Industries has welcomed the news that firms looking to bid for UK government contracts worth more than £5m will need to prioritise sustainable building materials as a new rule requires them to commit to achieving net zero carbon emissions by 2050.

Earlier this month, the UK government announced that from September it will require businesses to commit to net zero by 2050 and publish clear and credible carbon reduction plans before they can bid for major government contracts1.

Contactors will also need to demonstrate how they will manage their impact on the environment throughout the contract.

Welcoming the new measures as a ‘major leap forward for sustainability’, Aggregate Industries, whose parent company LafargeHolcim last year became the first construction materials company to sign the Net Zero Pledge, is pressing firms to make the most of emerging sustainable materials such as low-carbon concrete and asphalt.

Kirstin McCarthy, Sustainability Director at Aggregate Industries, comments: “Given the billions of pounds the government spends on construction schemes each year, these new rules are a major 4

Bulk Solids Today

leap forward for sustainability – positioning the UK as a worldleader.

“However, it also means that companies hoping to win these lucrative government contracts must demonstrate a credible, robust and ambitious plan for achieving net zero carbon emissions.

“The good news is that Aggregate Industries have invested heavily to innovate and develop low-carbon materials in recent years including concrete, concrete blocks and asphalt. The speedy adoption of these will be fundamental to any successful tender, hence, we’d urge those that haven’t done so already to prioritise the use of sustainable building materials now.”

The advice comes as for the first time, the UK government will require companies to report some scope-three emissions, including transportation, distribution, and waste from their operations as well as suppliers – which often represent a significant proportion of an organisation’s carbon footprint.

As part of a long-term strategy to decarbonise its operations, Aggregate Industries recently announced that its Cauldon Plant

in Staffordshire will undergo a £13m investment project to reduce its carbon footprint. This will be achieved by building a new pre-processing plant for the storage, handling and feeding of solid alternative fuels, that would otherwise end up as landfill.

Kirstin adds: “While reaching Net Zero remains a big challenge for the construction sector, we’re seeing tangible progress. For instance, at Aggregate Industries not only are we committed to removing as much transport from roads as possible through the use of rail and water transport but we’re also leading the way in helping clients to make sustainable design and purchasing decisions by providing carbon calculations.

“By working with suppliers truly committed to Net Zero, contractors will be well-placed to demonstrate their environmental credentials to help them secure public sector projects in the coming years.”

Aggregate Industries has a growing portfolio of low-carbon building materials, including ECOPact low carbon concrete and Superlow carbon neutral asphalt.

For more information, please visit: https://www.aggregate.com/ sustainability/climate.

COMPANY NEWS

WAREHOUSE EXTENSION PROVIDES EXTRA CAPACITY FOR MEDICAL SUPPLIES DISTRIBUTOR Medisave is one of the UK’s leading distributors of medical supplies to the NHS and healthcare professionals. Based in Weymouth, Dorset, the company’s range comprises over 30,000 product lines, including top branded stethoscopes, diagnostic sets and medical furniture as well as a comprehensive choice of medical disposables.

The heart of the company’s operation has always been its warehouse, where stock worth an estimated three million pounds is stored ready for next day despatch to hospitals, GP surgeries, medical students, nursing homes and, in fact, anyone with a need for medical equipment.

Clients have the option of placing their orders online, by telephone or, if they prefer, by fax and goods are picked, packed and on their way within 24 hours.

Even before the onset of the pandemic – which, of course, led to a massive spike in demand for all forms of personal protection equipment (PPE) and other medical instruments and kit – Medisave had been experiencing a sustained period of significant growth. To keep pace with the demands of its client base, the company opted to extend its existing warehouse unit by an extra 60 per cent.

The new building has been fitted out with modern very narrow aisle (VNA) racking to maximise storage capacity, while a mezzanine provides valuable extra office space as well as an area dedicated to small parts storage.

Additional pallet and order picking locations have been provided by the development – which, in effect, has increased the site’s storage capacity by close to 100 per cent.

Altegra Integrated Solutions Ltd - Medisave’s long-term intralogistics solutions partner - specified a fleet of Flexi Digital articulated forklift trucks to serve the facility.

Because Medisave’s warehouse extension is significantly taller than the original unit – the highest racking beam is nearly eight metres in the new part of the

store, whereas the top beam in is prominently located within the the existing building stands at 5.5 original building. metres – the new Flexi trucks are “The closed height of a fitted with four-stage ultra low-lift conventional three-stage mast masts that extend to a height of would have been too tall, but the eight metres but have a closed Flexi trucks’ four-stage ‘Quad’ mast height of just 2.9 metres. overcame the mezzanine underThe use of four-stage ‘Quad’ clearance issue and enabled the masts allows the Flexis to safely trucks to travel between the old travel and operate below the three and the new parts of Medisave’s metre high mezzanine floor which is warehouse unhindered, reach the a feature of the existing warehouse. uppermost racking beams of the The safety of warehouse new building comfortably and, most personnel is further enhanced by importantly, operate safely beneath the fact that the ‘Quad’ mast’s the mezzanine.”

HiVis design ensures that the Flexi The Flexi trucks deployed at operators enjoy best-in-class Medisave feature digital electric forward vision as they shuttle motor technology that allows all throughout the extended store. independent drive, hydraulic and “The extra height that the new unique power-steering motor building provides helps to increase functions to be controlled digitally Medisave’s capacity considerably.

- ensuring the most productive, But, of course, because the existing energy-efficient and safe driving unit is some 2.5 metres lower than performance throughout the the extension, Medisave’s original working day. trucks – which were also Flexis – did not have the lift height to YOUR SIEVING & SCREENING PROCESS reach the highest racking beam level within the extension,” explains Altegra’s WITH SIEVMASTER BY FARLEYGREENE. area sales manager, Darren Palfreeman.

He continues: “Medisave has operated Flexis for several years and for the new project they needed Flexi articulated truck technology with the lift height to reach the upper racking levels in the new part of the store. But the trucks also had to be able Sieves, screens, sifters. to pass safely +44 (0) 1256 474 547 and operate www.farleygreene.com underneath enquiries@farleygreene.com the existing mezzanine floor structure that

REDEFINED

Bulk Solids Today

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SPECIAL FEATURE

ADVANCED DESIGN EXPERTISE ENSURES SUCCESS OF ULTRA-LONG OVERLAND CONVEYOR FOR MAJOR ALUMINA PRODUCER TAKRAF India outlines the design features and challenges overcome in designing an overland conveyor, the “life line” for Utkal’s alumina plant, supplying bauxite ore from mine to plant.

The successful completion of the approximately 19 km overland conveyor system for the green fields Utkal Alumina project in Tikri, Raigada, in the Orissa state of India, marked yet another TAKRAF milestone development for the global conveyor industry.

The contract from Utkal Alumina International Limited (UAIL) called for an overland conveyor system to transport bauxite from the mines to a new 4.5 mtpa alumina plant.

This also included the longest single- flight conveyor system to be installed to date within Indian territory.

With the best quality bauxite as its input, and tightly integrated logistics between the mines and the refinery, Utkal Alumina’s operating cost per ton of alumina is among the lowest in the world. The bauxite for Utkal Alumina is sourced entirely from the Baphlimali mines, some 16 km (aerial distance) from the plant site in the Doragurha village. Prior to being conveyed overland to the processing plant, the bauxite is crushed to a size of -150 mm, with the fixed crushing package having been provided in 2012/13 by a

6

Bulk Solids Today

sister company, the then Bateman India (acquired by Tenova in 2012).

CONVEYING ORE FROM MINE TO PLANT

The scope of the overland conveyor project covered design, basic and detailed engineering, procurement and fabrication, right through to erection, which included civil and structural work, commissioning, performance guarantee test runs and handover of the 2,850 t/h conveyor system.

An intermediate transfer point and unloading station, including silos and buildings, were also supplied with complete electrical and instrumentation systems.

The system design brief called for the primary crushed bauxite ore of size -150 mm to be fed from the mine end junction house, through a chute to an overland conveyor of 14.5 km. This overland conveyor, ending at an intermediate junction house, in turn feeds an overland conveyor of 13.6 km. The latter, shorter conveyor ends at a plant end junction house, feeding a 500 t material surge hopper via a twoway chute. The overland system

comprises 2,000 and 4,000 tensile strength steel cord conveyor belting, with a minimum belt safety factor at a steady state of >5.5, supported on a series of underslung-type idlers. These, in turn, are supported on a structural system made up of ground modules and gantries, with the overland conveyors routed partly along the ground and partly along an elevated portion. From the surge hopper, material is fed either directly to plant conveyors or to a stockpile through stockyard conveyors supplied by others.

ADVANCED DESIGN AND ENGINEERING

The execution of the project represented a group-wide effort, drawing on the global overland conveying expertise of TAKRAF Group, with the length of the required conveyor system and the challenging topography along the conveyor path calling for state-ofthe-art design and engineering.

Industry-leading software was used to maximize routing and equipment utilization and specifications. The conveyor design was supported by horizontal curve analysis and dynamic analysis to optimize the long-distance conveyor power and belt tensions. Global procurement was also followed in order to optimize costs but at the same time source the most advanced and reliable components.

Initially, two technologies were considered, overland trough belt conveying and cable belt, with the client selecting the former due to its many advantages in such inhospitable and remote terrain.

In addition, a major advantage of using trough belt conveying was that almost all the components and spares for trough belts are available in India, with a very small percentage of imported components.

SPECIAL FEATURE DESIGNING FOR A COMPLEX TERRAIN

In its final configuration, the system’s two conveyors traverse a highly undulating and complex terrain. Dropping in total by 250 m over its course from material loading to discharge, the conveyor system passes through 11 nalas (branch rivers), the Ratachuan River, one forest stretch of nearly 470 m in length, a high voltage line crossing, 37 road crossings, a paddy field adjacent to the plant boundary with a stretch of approximately 2.5 km, eight hills and several villages. The elevated structures were provided with cage ladders spaced at approximately 150 m, and pile foundations were provided for the river crossing and one of the downhill crossings.

As a result of the topography and due to the conveyor length, the conveyors were designed with head and tail drives, and multiple, very tight compound horizontal and vertical curves. In total, the conveyor system features 10 right hand curves, 4 left hand curves and horizontal curve radii of 2,500 m across all locations but one: a critical zone on the shorter conveyor where the horizontal curve is 1,800 m. This portion of the conveyor passes over a hill and through the plant boundary.

The longer conveyor has a ground module and a graded portion.

The ground module comprises 17 straight sections, 1 left hand curve and 1 right hand curve section, while the graded portion consists of 12 straight sections, 2 left hand curves and 4 right hand curves. The overland gallery on both conveyors together features 403 straight sections, 154 right hand curves and 61 left hand curves, with a maximum gallery length / support interval of 49.5 m and standard gantry length of 27 m.

The idler spacing for the straight and inclined portions of the galleries on both conveyors is 4.5 m for the carry idlers and 9.0 m for the return idlers, except for one section on the longer conveyor where the carry idlers are spaced at 3.5 m and the return idlers at 7.0 m. On both conveyors, the carry idler spacing for the horizontal curved galleries is 2.25 m; and the return idlers are spaced at 4.5 m.

system passes, as well as the need With an installed power of 6x850 to blast and excavate a suitable kW and 2x850 kW, the conveyor route through the hilly region of system features 6 drives at the tail the conveyor path. Approach end and 4 at the head end on the roads for erection of elevated longer conveyor, while the shorter structures on the hilly terrains also conveyor has 2 drives at the head had to be provided. With major end only. There are 2 belt turnequipment such as heavy cranes overs on each conveyor, 1 at the and excavators used for erection of tail end and 1 at the head end. the elevated structures, particularly Each conveyor features a fail-safe in the challenging hilly terrain, hydraulic disc brake at the tail end.

TAKRAF India placed particular A take-up winch with capstan brake focus on safety, strictly conforming arrangement has been provided at both to TAKRAF’s global promise of the head end of both conveyors.

Zero Harm and to the client’s safety The intermediate transfer protocols. point between the 2 conveyors is Performance guarantee testing located in hilly terrain and, since was carried out over nearly one the 4 head end drives of the longer week, with the system consistently conveyor are also located there, achieving its present capacity of the conveyor drive and take-up 1,500 t/h.

As a result, the conveyor areas are mounted on a portal system could be handed over to steel structure. These lightweight but the client in December 2016 at a high strength structures provide the special event where celebratory design flexibility to accommodate Pooja rituals were carried out in the terrain. Advanced material the presence of top management flowability testing and modelling of both companies. The successful was used in the design of the completion of this project is transfer chutes at the intermediate testament to TAKRAF’s ability transfer point and the plant end to employ their long-standing junction house to minimize risks experience in designing conveyors such as environmental pollution to meet new challenges. and spillage, accelerated belt wear and blockages.

To facilitate maintenance, approach roads and a mine road Unlike other valves that seal were made with friction, Posi-flate’s unique available all along butterfly valve uses an the conveyor inflatable seat length, with the to seal with air cage ladders pressure. Thus it provided on the requires less torque elevated structures and a smaller actuator, enabling ease of resulting in lower cost. access.

Other Valves Fight Friction, We Designed it Out

CONVEYOR ERECTION FOCUSES ON ZERO HARM

Erection of the conveyor system was complicated by the requirement to accommodate and minimize disturbance of the population of the various villages through which the conveyor

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

7

COMPANY NEWS

DUST EXTRACTION SPECIALIST SET TO EXHIBIT AT ADVANCED MATERIALS SHOW 2021 Dustcontrol UK has announced it will be exhibiting a range of its highly effective extraction equipment at this summer’s Advanced Materials Show 2021.

Taking place on Wednesday, 7th and Thursday, 8th July at the National Exhibition Centre, Birmingham, the Dustcontrol team will be showcasing the firm’s extensive range of both fixed and mobile cyclone-based dust extractors and air cleaners at stand 17312.

The DC 11-Module for example, which comes in several models, is an optimised stand-alone unit for source extraction and industrial cleaning. It has been designed to service up to six normal extraction points or several cleaning outlets at a time, and is modularly built, meaning it can be tailormade to suit any manufacturing and production environment.

As with all of Dustcontrol’s UK equipment, the DC 11-Module can be fitted with Hepa 13 filters, meaning exhaust air can be safely returned to the work environment.

James Miller, Managing Director of Dustcontrol UK, said: “We’re excited to be showcasing a range of our most efficient extraction equipment on our second attendance to the Advanced Materials Show.

“As well as showcasing centralised systems, we’ll be exhibiting a range of H Class mobile air cleaners and cyclone-based vacuum units.

A selection of ATEX-approved models and accessories will also be on display to complete the extensive range.

“In addition, we look forward to further demonstrating the versatility and durability of our mobile machines, which have been meticulously designed to provide easy transport and be simple to maintain.”

The company, based in Milton Keynes, has over 45 years of experience in developing dust extraction solutions and centralised vacuum systems to fit client requirements in the manufacturing and production industries. They are experts in capturing dust at its source – both where and when it’s created.

With more than 300 exhibitors and 3,000 visitors expected to attend next month’s show, the event promises to offer an unmatched insight into current and future materials development, with a specific focus on high-performance materials 8

Bulk Solids Today

technology, innovation, design and use.

James concluded: “The Advanced Materials Show will provide us with a platform to show trade users first-hand how our elite dust extracting equipment can help to create safe and healthy working environments.”

For further information on Dustcontrol UK’s products, please call 01327 858001, or email sales@dustcontrol.co.uk.

Alternatively, for further information on Dustcontrol UK, visit www.dustcontroluk. co.uk, or for more information on Advanced Materials Show 2021, visit https://www.advancedmaterialsshow.com/.

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9

COMPANY NEWS

RTITB TO LAUNCH NEW FORKLIFT OPERATOR ID ECARDS RTITB will become the first accrediting body to issue lift truck operators with electronic ID cards, as opposed to physical photo ID Cards, starting from 12 July.

Materials Handling Equipment (MHE) operator ID cards are important as they help to quickly identify the operator and ensure the person named on the training certificate is one and the same.

“We are committed to improving the safety of everyone in the supply chain,” explains Laura Nelson, Managing Director for RTITB. “So, just like our existing physical National Operator Registration Scheme or ‘NORS’ ID card, the new electronic eCard shows employers that an operator has received the required training and obtained the necessary qualification to support safe operating practices.”

“During the pandemic there was huge demand for lift truck operators, and businesses had a need to get qualified operators up and running quickly and safely,” says Laura. “Whatever happens going forward, the new eCards will help speed things up, thanks to an average four-hour delivery time and our ability to dispatch them anytime, even during a national lockdown.”

From 12 July, on successful completion of RTITB Counterbalance Lift Truck Operator training, or similar courses, the training provider will be issued with a link to the eCard via email. For data security reasons, a separate email will go to the employer or operator with a code to access and download the ID card. This means that if the training provider sends the email to the wrong person, no personal data is compromised.

“We are also very aware that these are difficult times for many businesses, so the new eCard allows us to reduce the cost of ID cards, with the added benefit of Covid-safe fast delivery as well as being more environmentallyfriendly,” says Laura. “This change 10

Bulk Solids Today

will help prevent pollution by reducing the amount of new raw materials used, as well as saving energy and reducing greenhouse gas emissions”.

Operators can use either an Apple or Android smartphone to save the card to their preferred digital wallet (Apple Wallet or Google Pay), and view, save, and print a PDF version of their card if they wish. A PDF eCertificate will also be an option for those without a smartphone. Once an operator has been issued with their RTITB eCard, any subsequent new or updated qualifications will be added to their card.

To help employers, training providers, and operators transition to eCards, RTITB will provide full support in the set-up, providing helpful guidance documents and videos.

Information on the eCard will include the operator’s photo, name, and RTITB registration number, logos for RTITB and the Accrediting Bodies Association for Workplace Transport (ABA) logo, ABA truck code, where applicable plus the training provider’s name and website address. The course title and a QR code to easily verify operator qualifications will also be included.

“Also, with safety and infection

control bound to remain a priority for the supply chain long after restrictions are eased, the eCards reduce contact points, while offering a secure, easy to update, and robust system that helps employers ensure only correctly qualified operators are using a lift truck,” says Laura.

The new RTITB eCard is the latest digital transformation for RTITB, following the launch of a wide range of innovative eLearning solutions and the unique MyRTITB TrainingFriend android app, which enables lift truck operator testing to be 100% paperless, while improving operator testing standards and training record compliance. RTITB also recently switched most of its Training Materials to USB, instead of hard copy and is working towards all training materials going digital, instead of being on paper.

These new digital options are developed with the environment front of mind. The eCard will help reduce the use of single use plastic, just as the other solutions help remove unnecessary paper usage from training and administration.

For more information about the new lift truck operator eCards, please contact us on solutions@ rtitb.com or +44 (0)1952 520200 or visit www.rtitb.com.

COMPANY NEWS

GYRO EX BIN ACTIVATING FEEDER/DISCHARGER Accurate Feeding and Discharging 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.

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. https://www.dynamicair.com/ products/vibratory/productsv.html Dynamic Air Ltd. Milton Keynes, United Kingdom Phone: 44 1908 622344 E-mail: sales@dynamicair.co.uk www.dynamicair.com

Bulk Solids Today

11

BULK MATERIALS HANDLING

DUST EXTRACTION SPECIALIST LAUNCHES TRIO OF POWERFUL VACUUM CLEANERS Dustcontrol UK has officially launched its new, all-in-one range of powerful three-phase turbo vacuum cleaners.

The latest addition to the DC Tromb family, the DC Tromb Turbo offers optimum quality, containment and performance.

One of the major updates is the three-phase turbo motor that has been designed specifically to target heavy-duty cleaning.

The new range has also been developed with a thermal protector that activates at high temperatures, while a simpler filter change has also been included for easier and quicker removal.

The DC Tromb Turbo is available with Direct Start or a Frequence inverter (VFD), while those working in ATEX zone 22 can benefit from the EX model.

The DC Tromb Turbo with direct start is suitable for source extraction from medium-sized power tools such as grinders, jackhammers and saws, while the VFD model gives 50 per cent more Hepa filter area than its predecessor. For instance, it can remove dust during polishing of glass fibre, carbon fibre and epoxy with a hand-held sander. New safety features such as overheating protection is also added. Both models can be equipped with either a steel container, plastic bag or a Longopac bag.

The EX version is certified to

IP65 standard, ATEX Zone 22, meaning it can operate in explosive environments. Like the other two versions, the EX Tromb Turbo has a tall cyclone, large filters and powerful motor package, allowing it to handle large amounts of debris.

James Miller, Managing Director of Dustcontrol UK: “We’re delighted to launch our new and improved Turbo Tromb range.

The new models are not just more powerful, robust and effective than previous Tromb cleaners, but also incredibly resourceful.

The powerful vacuum cleaners can handle an array of fine dust and materials on construction sites, created from cutting concrete, sanding, grinding or drilling floors or walls, as well as dust from many other industrial factory processes.”

The company, based in Milton Keynes, has over 45 years’ worth of experience in developing dust extraction solutions and centralised vacuum systems to fit client requirements in the aerospace, food and drink, construction, engineering, and manufacturing industries. They are experts in capturing dust at its

source – both where and when it’s created.

James concluded: “Ultimately, the new range ensures those working in hazardous environments where dust is prevalent can carry out their jobs as safely and efficiently as possible.”

For further information on Dustcontrol UK’s products, please call 01327 858001, or email sales@dustcontrol.co.uk.

Alternatively, for further information on Dustcontrol UK visit www.dustcontroluk.co.uk.

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BULK MATERIALS HANDLING

HYSTER-YALE GROUP CELEBRATES 40 YEARS OF MANUFACTURING IN NORTHERN IRELAND AS PLANT EXPANDS In 2021, the Hyster-Yale Group proudly celebrates 40 years of manufacturing lift trucks at its plant in Northern Ireland as it announces the expansion of its Craigavon site.

The facility, which was officially opened on 7th April 1981, was built and equipped with the most up-to-date robot systems and equipment. Over the years the plant has grown to be the largest volume forklift plant in the UK, manufacturing thousands of electric, diesel, and LPG forklifts each year for export throughout Europe, the Middle East and Africa.

The site, around 30 miles from Belfast, employs hundreds of people from the local area, which the company credits as key to its success story. This year, five team members will also celebrate the milestone of 40 years with the company, while more than 100 current employees at the site have 30 years or more of service.

“The success of our plant at Craigavon is driven by our people, where we see incredible dedication, perseverance, and loyalty from the team at all levels, with an average length of service of 17 years,” says Jim Downey, Plant Manager for Hyster-Yale Group EMEA in Craigavon. “Over the last four decades, our people have worked together to conquer challenges, embrace new opportunities, and maintain forward momentum, and that is why our facility continues to succeed, evolve, and grow.”

Transformation remains key to the Craigavon facility, where expansion of the 500,000 sq.ft site is currently in progress, in preparation for future manufacturing demands and product lines. The company has invested millions over the past 2 years developing the factory, which incorporates leading technologies and up-to-date automated systems.

The extension will also create dozens of new jobs, including continued investment in apprenticeships.

“We have great confidence in the talent pool in Northern Ireland and are fortunate to have so many long-standing employees that bring with them significant expertise, including many of our management team who started their careers here on the shop floor,” says Downey. “However, at the same time, we are keen to optimise our operations with automation and new ways of working that best support our workforce and deliver the quality our customers need,” Quality is key to the facility at Craigavon, which has been the recipient of numerous awards throughout its history. Among the team’s achievements is ISO 50001 certification for its commitment to energy efficiency, and sustainability continues to be a key driver for the company during its latest site expansion.

The new 60,000 sq. ft. extension to the factory will 14

Bulk Solids Today

be known as the Sands Building, in honour of Harry Sands, former Senior VP and Managing Director, EMEA, for Hyster-Yale Group based in Craigavon, who retired in 2020 after 40 years with the company.

It has been built with environmental specifications and ambitious objectives in mind. For instance, it incorporates a completely new approach to lighting which harnesses more natural light, decreasing electricity consumption and reducing CO2 emissions.

A biomethane fuelled plant on the site will also be used to provide 80% of the electrical power required, with the heat by-product also used on site.

In line with the Hyster-Yale Group 2026 Corporate Responsibility Objectives, the site aims to reduce carbon emissions by 30%, in addition to targets for reducing water consumption, waste, and landfill.

Waste to landfill from the facility has already reduced significantly, with 97% now being recycled, and a number of other waste reduction initiatives exist on the site, everywhere from the canteen kitchen to the packaging line.

The Craigavon plant also continues to be committed to biodiversity, encouraging rare wildlife in its grounds as a result. The latest plant extension incorporates a Sustainable Urban Drainage System, which mimics natural drainage and is more environmentally friendly.

“Throughout its 40 years the Craigavon facility has continued to innovate and build capability to be an agile and flexible facility, that is able to meet and exceed customer expectations through automation, people and processes,” says Downey.

“Now is an exciting time as ever, as we adapt our assembly lines, connect with new technologies, and develop our product ranges, laying the foundations for future growth and many more decades of success,” he concludes.

BULK MATERIALS HANDLING

ABBEY LOGISTICS FORMS STRATEGIC PARTNERSHIP WITH CISTERNAS AMARILLO S.L Abbey has formed a new partnership with Cisternas Amarillo S.L (Amarillo), a large bulk powder road tanker company based in Seville, Spain and part of the full-service logistics company, Pantoja Grupo Logistico.

The partnership is designed to provide continuous movement of customers’ products between the UK and Spain and provide customers with a faster more reliable and cost-effective transport solution through a well-managed joined-up approach that optimises the reach of the two businesses.

The partnership combines Abbey and Amarillo’s extensive knowledge and experience in bulk food road tanker transport and maximises their collective fleet capabilities to provide a reliable flow of feedstock ingredients between the two countries.

Utilising multimodal transport links, the tanks are reloaded for the return journeys, minimising empty miles and fully utilising both company’s vehicles and drivers to ensure products move on a continuous basis.

Paul Laverick, Head of Abbey’s Powder Division said: “This new partnership further demonstrates Abbey’s unique ability to support road tanker companies in Europe thanks to our scale and network capability in the UK. Amarillo is highly regarded for its skills and experience in bulk dry food grade products and we are delighted to begin working together as we maximise the vast experience our combined businesses have for the benefit of our customers.”

Lars Stendahl, Amarillo’s Operations Director said: “Abbey Logistics is well known to us and their reputation for customer service and flexibility together with their specialist knowledge of the products we carry, made them a natural fit for our operations and customers.

“We look forward to expanding our work together and building on the partnership we have formed.”

Abbey Logistics is committed to delivering costeffective, dependable and responsive road tanker logistics for bulk liquid & powdered products in the UK and Europe.

The Group also provides warehousing and

materials handling services on the Wirral in the UK, and multimodal transport solutions throughout the UK and Europe.

Visit www.abbeylogisticsgroup.com for more information about Abbey Logistics Group.

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

The result is a more consistent material.

Dynamic Air Ltd. • +44 (0)1908 622344

www.dynamicair.com Bulk Solids Today

15

SPECIAL FEATURE

ERGONOMICS AND MANOEUVRABILITY AT THE HEART OF NEW YALE PLATFORM PALLET TRUCK • New MPX Series platform pallet trucks offer impressive ergonomics designed around the needs of the operator.

• The MP20-30X trucks are ideal for medium to high intensity applications and can manoeuvre comfortably even in the tightest of working environments.

• A range of innovative options enables the MPX Series trucks to be tailored to the specific nuances of an operation.

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Bulk Solids Today

When it comes to maintaining high levels of productivity, comfortable employees can make all the difference to a company’s operation.

The machine should be able to work in perfect harmony with its operator, requiring minimal effort to execute the task at hand. The new MPX Series platform pallet trucks from Yale Europe Materials Handling embodies this philosophy, offering impressive ergonomics and exceptional manoeuvrability.

“The YaleⓇ MP20-30X platform pallet trucks have been designed around the needs of the operator during horizontal transportation of loads,” explained Gianbattista Scaramuzza, Senior Product Strategy Manager, Warehouse Products at Yale. “Even in the most congested of spaces, these new low lift trucks can work effortlessly. For businesses looking to reduce operator fatigue and increase productivity, the

SPECIAL FEATURE MPX Series trucks are the perfect addition to a fleet.”

Ideal for medium to high intensity operations, the MP20-30X can be used in the loading and unloading of trailers, working around the dockside, order picking and cross docking.

The MPX Series tiller head has an ergonomically shaped handle, fitted with an integral hand guard, and will automatically return to the vertical position when released by the operator. The large butterfly control buttons are engineered to support natural thumb movement, with all dash panel components within easy reach.

Rather than forcing the operators to adapt to the same driving style, the MPX Series trucks feature driver mode selection to suit different operators’ skills.

Cushioned support MPX Series trucks are available in three configurations. For operations managers who would prefer the versatility of switching between ride-on and pedestrian mode, the MPX Series is available with a foldable platform and side arms for support. There are also two fixed platform options: one with permanent rear protection for the operator, and one with permanent side protection. To meet the needs of specific applications, a foot sensor can be installed on trucks with permanent side protection, which will only allow the truck to be driven with an operator on-board.

“The operator platform on the new Yale MP2030X Series trucks is designed to support a number of comfortable driving positions, while the rubber floor mat delivers extra grip while in transit,” explained Gianbattista.

The MPX Series trucks have a number of new features that allow operators to move loads smoothly and efficiently. The new, robust design of the foldable side arms provide stability and security when the truck is in motion, while also reducing maintenance costs and improving productivity.

As well as its ability to work in tight spaces, the MPX Series trucks can transfer loads across extended distances and offer a wide capacity range of 2 to 3 tonnes. The new fork design is available in a range of lengths, with customers also able to choose from two fork heights to suit their specific needs. The extended forks option allows the MP20-30X to transport up to two

pallets or three Europallets crosswise per journey.

Operation managers can choose the power solution that best fits their needs with lead acid and lithium-ion batteries offered for the MP2030X trucks. Its durable design combined with a low energy consumption helps keep ongoing running costs under control.

A range of innovative options The MPX Series can be tailored to applications with a range of additional options.

A smart lift option can elevate loads and begin transporting pallets before its load arms are at full lift, eliminating the need for the operator to continually hold down the button.

A height adjustable tiller is suitable for a wide range of operations. Simply by adjusting the position of the tiller, operators can adapt the truck into a driving position that they find comfortable.

For low-light environments, a working light package on the Yale MPX Series illuminates the load area. A cold store solution enables the MPX Series trucks to cope with temperatures as low as -30°C without any effect on its performance.

“We’re really proud to unveil our new MPX Series trucks. Yale has worked hard to identify features in which we can offer comfort and ease to the operator to help them be as productive as possible during a shift in a busy environment. We believe the MP20-30X accomplishes this and would be an asset to any warehouse operation,” concluded Gianbattista.

For more information on the extensive range of materials handling equipment from Yale go to www.yale.com.

IF YOU ARE INTERESTED IN SUBSCRIBING TO BST MAGAZINE, PLEASE DO GET IN TOUCH BY VISITING WWW.BULKSOLIDSTODAY.CO.UK OR EMAILING US AT BST@ABBEYPUBLISHING.CO.UK

Bulk Solids Today

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PACKAGING

THIN WALLING DELIVERS THE WHOLE PACKAGE CURRENT MARKET FOR THIN-WALL MOULDED PRODUCTS?

Global forecasts for the thin walled plastic packaging market is rising significantly. According to a report released in 2020 by Research & Markets, it will be worth an estimated USD 71 billion by 2027 expanding at a CAGR of 4.5% between 2019 to 2027. Food and beverage, and more widespread adoption of thin walled packaging in developing economies, will drive this growth. PE is projected to be the largest-growing segment during this forecast period. Light-weighting and consumer convenience are important factors in this expansion, with the combination of environmental pressures, improvements in recycle rates and high polymer prices placing increasing pressures on packaging manufacturers.

Wider adoption of bio-based and recycled materials is also expected to boost market growth.

GROWTH APPLICATIONS

For several decades now light-weighting and consumer convenience have given packaging manufacturers the strong commercial incentive to do more with less. No strangers to responding to demographic and lifestyle changes and balancing a wide range of variables, including cost, increased strength, recycle rates and functional requirements, lightweight formats have become the industry norm. Especially in food and medical packaging.

More recently, the market has been moving more towards novelty solutions that improve performance, functionality and shelf impact.

The Covid-19 pandemic has forced yet another re-think to our way of living and future reliance on packaging. While food and medical packaging saw rises in demand, other categories softened. As public health concerns gradually ease, we suspect demand for reusable and sustainable solutions will swiftly resume. The exact timings will be very much determined by consumers. Understanding how

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people interact with packaging and the channels they purchase through will be a clear driver, ensuring consumer safety, product security and future sustainability are evenly balanced.

MAIN TRENDS

Sustainability (including environmental, social and governance (ESG) performance) and personalisation are expected to be among the key trends. Sustainable packaging will form a critical part of brand storytelling and consumer unboxing experiences.

As a material, plastic is inextricably linked with energy and resource savings. Its low weight makes it both cost effective and flexible to use, adding to the sustainability score when measuring ESG. If anything, the Covid-19 pandemic has presented retailers, brand owners and packaging manufacturers with the opportunity to review, realign and reinforce the value of their packaging.

CHALLENGES AND SOLUTIONS

As packaging changes, so do packaging processes and equipment. Speed and lightweighting remain probably the most dominant trends. Efficiency and throughput are inextricably linked.

From a machinery performance viewpoint, thinner wall sections bring changes in processing requirements. Among them, higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements. These process changes need to be factored into the mould, machinery, and packaging component design.

Even when using less raw material, packaging forms the protective layer so still needs to be engineered to provide strength. Choosing the best machine for your packaging application is critical.

Understanding the melt stability and how the plastic will perform as an end product should form the basis of all decisions.

In caps and closures, the tethered market is a

PACKAGING big focus area. As of May 2024, EU producers, retailers and manufacturers, as well as importers to EU countries will be obliged to implement tethered closures on all beverage containers up to three litres. Looking specifically at the moulding processing conditions, these in theory won’t change considerably.

Providing the material isn’t altered, melt stability will be the same. The main investment outlay will be in mould tool design, which may require increasing the mould space of injection moulding machinery or opting for a larger tonnage packaging machine.

LATEST PACKAGING TECHNOLOGIES FROM SUMITOMO (SHI) DEMAG

Economic viability is just as important a consideration for packaging moulders. Low unit costs, high output coupled with energy savings all need to be factored in. That’s why so many packaging manufacturers today are prepared to invest in new high-performance plant.

Our moulding machines will always be aligned to the market trends. Breaking these down, 2020 has seen increased demand for thin-wall applications due to rising in-house consumption of food and beverages throughout the COVID-19 pandemic. In 2021 we anticipate this continuing, and the additional trend of tethered caps being addressed with the EU Directive deadline due in 2024. Demand for tethered cap applications will continue to accelerate in 2022, and we anticipate high demand for stabilised packaging formats. By 2023, attitudes towards circular packaging will inevitably shift back and we envisage renewed focus on recyclable packaging materials once more.

Any packaging moulding machine selected will be dictated by mould design and the cavitation layout.

With regard to auxiliary equipment, higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements are all important factors that need to be considered when developing turnkey lines.

Another way to achieve thinner yet stronger packaging containers is to apply injection compression techniques to stack moulds. With this, packaging moulders can increase output while reducing the wall thickness of containers and lids from 0.45mm to 0.35mm. This saves around 25% in raw polypropylene materials compared to the standard injection moulding process, while maintaining comparable mechanical properties.

EL-EXIS SP DEVELOPMENTS

The latest generation of EL-Exis SP’s are specifically designed to withstand the higher stresses and injection pressures that are so critical in achieving repeatability, particularly in thin walled products.

Capable of delivering a cycle time of less than two seconds, Sumitomo (SHI) Demag’s El-Exis SP remains the fastest injection moulding machine series for packaging manufacturers on the market today. The series also offers exceptional process consistency through acceleration, mould movement

and deceleration. Having this additional control during the manufacturing process saves moulders and converters money by lowering operational costs and delivering energy savings of around 15%.

Being able to adjust the accumulator charging to the injection pressure required for the exact moulding process not only lowers energy usage, but also reduces wear and tear on parts. Additionally, to help factories make informed and conscious energy consumption decisions, the machine now includes an integrated energy monitor as standard.

Mould safety is another feature that can save money. Given that mould tools can be one of the costliest elements, protecting moulds from damage by foreign objects and any damage caused by general wear and tear without incurring cycle time penalties can significantly reduce the frequency for scheduled machine and mould maintenance.

The new generation of packaging El-Exis machines can all be equipped with an OPC Unified Architecture (OPC/UA) interface, offering broader scope for connectivity.

ENERGY MONITORING DEVELOPMENTS

Many of our customers are keen to opt for more energy efficient systems. But until recently, machinery suppliers have struggled to quantify and compare performance data in relation to energy consumption, investment and planned maintenance costs, mould wear, output quality etc.

To help with these, Sumitomo (SHI) Demag UK launched a new testing service. The company was already undertaking more than 300 performance measurements for customers annually. Due to its popularity, Sumitomo (SHI) Demag invested in three new Fluke energy monitoring devices to extend this service. Plugging the tool into existing machines, including legacy and competitor moulding systems, the company conducts the energy tests on-site using a real production scenario. Calculating the energy used in kilowatts for each kilogram of raw material converted, the team then provides the customer with a credible comparison if they were to purchase a newer Sumitomo (SHI) Demag machine.

In order to get a like-for-like comparison, our engineers run the same product before and after new kit is installed, with all ancillary equipment plugged in. As well as examining energy performance, the tests also examine other factors including the parallel movements and the impact of drive cycle times on output. The results are compiled into a comprehensive report that presents companies with robust data that can be included in annual CSR reports McLaren Plastics used Sumitomo (SHI) Demag’s new test service to measure the energy savings realised after replacing two legacy hydraulic machines with two all-electric IntElect machines.

One of the performance benchmarks was for a packaging black end cap. The investment resulted in the Midlothian business slashing 60% off their energy bill, saving them in excess of £7,000 a year.

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ON THE COVER

SCHÜTZ GREEN LAYER – UNAPPROVED IBCS AND PLASTIC DRUMS MADE WITH HIGH QUALITY RECYCLATE Selters (hds). As a pioneer of the circular economy in industrial packaging, Schütz has for decades been setting standards in the conservation of natural resources by saving, reusing and recycling materials and components.

The company’s Plastic drums offer the highest quality, safety and performance – while at the same time providing a low operating weight.

The IBCs, which are developed in-house and manufactured around the world, owe their leading global position to the highly efficient and environmentally friendly combination of reusable and disposable systems. In the new Schütz Green Layer versions, the eco-balance of both types of

packaging has been taken to a new level. In the multi-layer extrusion process, the IBC inner bottles and drum bodies are produced with 40 per cent high-quality plastic recyclate. This material is generated by Schütz through its worldwide collection and reconditioning programme.

Another key feature is that the IBCs of the Green Layer series also have UN approval.

Ecological Packaging as a comprehensive concept Multiple use and recycling, the two factors that sit at the heart of the circular economy, have always been a core concept of Schütz IBCs. The entire life cycle of the packaging is geared towards ensuring maximum environmental friendliness. During reconditioning as part of the Schütz Ticket Service, the inner bottles of collected IBCs are removed from the steel grid and treated in a complex recycling process during which they are ground, cleaned and finally regranulated.

Special degassing extruders ensure a low-odour, homogeneous quality.

The company uses the HDPE recyclate obtained in a closed cycle: 100 per cent flows back into the internal production of plastic packaging components, including corner protectors and plastic pallets. This is why Schütz IBCs have always had an exceptionally high proportion of recycled material. Depending on the type of pallet, the proportion is between 36 and 55 per cent of the plastic in the entire IBC. Additional CO2 saving: more than eight kilograms per IBC With the new Green Layer IBCs, Schütz has increased this proportion even further, taking resource preservation to a new level. For these containers in particular, high-quality recycled material is also used for the production of the inner bottle. The IBC container in the innovative Green Layer design contains 40 per cent recycled material alone. This corresponds to an additional CO2 saving of at least eight kilograms per IBC. The recycled

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Bulk Solids Today

ON THE COVER HDPE is extruded only into the middle layer of the container.

The inner and outer layers are made of virgin HDPE material.

This way, Schütz ensures that both the filling product and the environment only come into direct contact with virgin material, making a significant contribution to protecting the quality of the filling product.

Equipped with a full-plastic pallet, the total content of recycled plastic in this particular IBC model is as high as 73 per cent.

Sustainable IBCs and PE drums with UN approvals With its ecological packaging and low CO2 footprint, Schütz supports its customers in achieving their sustainability goals. And there is another benefit: the new Schütz IBCs have UN approval and are therefore also suitable for a wide range of dangerous goods applications. The new containers also impress with their uniform appearance.

The outer layer is completely black, thus avoiding colour variations that often occur when recycled material is used in IBC inner bottles. Transparent view stripes enable the user to monitor the filling level in Green Layer IBCs at all times.

Schütz also uses multi-layer extrusion for the production of drums, combining maximum safety with a maximum content of recycled plastic. The F1 tight-head drum in 220l and the S-DS1 open-head drums in sizes 30l to 220l are also produced as Green Layer models using the three-layer extrusion blow-moulding process with recycled HDPE in the middle layer. The recycled content here accounts for 40 per cent of the drum body and the entire product range has dangerous goods approvals.

Market launch in Europe with pilot projects With the European Green Deal and the Action Plan for the Circular Economy, the European Union has defined the goals and framework conditions for resource-saving economic growth. The future legal requirements for the use of recyclate in packaging are already met by the new Green Layer products. In order to

ensure a constant supply of IBCs and drums with recycled plastic material, Schütz emphasises how important it is for customers and returners of used industrial packaging to actively cooperate.

A corresponding supply security can only be guaranteed, if there is a sufficient supply of recyclate from the Schütz Ticket Service, the global system for the reconditioning and recycling of industrial packaging by Schütz. The market launch of the Green Layer products therefore requires close coordination with customers and is initially limited to Europe, where pilot projects have been successfully launched. Future expansion into other regions is possible and intended thanks to the global production network of Schütz with state-of-the-art multilayer extrusion blow moulding equipment.

Bulk Solids Today

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VALVES

PUMP AND VALVE INNOVATOR FINDS A TEST RIG TECHNOLOGY THAT TALKS THE TORQUE To analyse the long term performance and reliability of hard working valves and pumps, serial innovators Manchester-based Bifold Group has adopted radio frequency based torque transducers from Sensor Technology Ltd for two of its specialist test rigs.

An inter-generational commitment to advancing science and engineering has seen Bifold transform from a 19th century mining lamp maker into a leading manufacturer of instrument valves and accessories, piping valves and pumps for the oil, gas and wider industrial markets. It has particular expertise in subsea and wellhead control systems and has also developed market leading technology in areas such as solenoid valves with ultra-low power requirements.

Its corporate development is just as impressive as its technical advancements. Over the last 10-15 years it has consistently grown profits by 50% a year, and is on course to clear £33m this year. During this period it has moved into bespoke premises, created about 250 high value jobs, developed new products and technologies and entered high tech markets around the world. Today 95% of its output is exported.

By using the power of computer aided design many of Bifold’s products are built to custom designs, yet they are produced to very short lead times thanks to the efficiency of internet communications.

To maintain this standard, sample products and components are comprehensively tested so that their reliability and capabilities are never in doubt.

Bifold is as innovative in developing its test regimes as it is in advancing its product technologies and business systems. So when it wanted to assess the effects of wear on its long-life valves it set about

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Bulk Solids Today

designing a special test rig. Engineer Andrew Laverick recalls: “We wanted to measure the power required to operate the valve to see how it changed over time and with long term use. It was clear that the best way to do this was to measure the torque input over an extended period.”

“We were open to any design concept for the test rig, but soon found ourselves gravitating towards a TorqSense solution because the Sensor Technology engineers were so helpful and really knowledgeable about test rigs.”

TorqSense transducers lend themselves to test rig uses because they are non-contact measuring devices.

Attached to the surface of the transducer shaft are two Surface Acoustic Wave (SAW) devices, when torque is applied to the shaft the SAWs react to the applied strain and change their output. The SAW devices are interrogated wirelessly using an RF couple, which passes the SAW data to and from the electronics inside the body of the transducer.

Sensor Technology’s Mark Ingham explains: “All you have to do is set up a TorqSense transducer in the test rig and fire it up. The SAW frequencies reflected back are distorted in proportion to the twist in the test piece, which in turn is proportional to the level of torque. We have some clever electronics to analyse the returning wave and feed out torque values to a computer screen.

“TorqSense has been used on many test rigs over the years and I was delighted to hear the Bifold engineers say how easy it is to use and how robust the software is.”

Laverick again: “As a test engineer you are almost resigned to long set up procedures and software that falls over at the drop of a hat. But Sensor Technology has designed these problems out of their TorqSense equipment, with the result that we were able to complete our long term test procedures with the minimum amount of fuss and heartache and well within the allotted time schedule.”

In fact Bifold has since bought a second TorqSense which is being fitted to a new test rig used to assess the performance of mission critical chemical injection pumps, as used at oil and gas wellheads and on process pipelines.

“This project is proceeding well,” says Laverick, “and is allowing us to further develop our abilities to quickly provide bespoke equipment for ultra demanding applications, safe in the knowledge that it will perform faultlessly over a long working life.”

VALVES

REDUCE FOREIGN BODY CONTAMINATION WITH GERICKE’S ROTASAFE

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.

• • • • • •

Gericke RotaVal have launched an enhanced version of their class leading RotaSafeTM system for their rotary valves. Designated the RotaSafe RS1 it has been developed in close cooperation with key customers.

The rotor protection system RotaSafe is designed to instantly detect any contact between the rotor and valve housing while at the same time sending a signal to the control system to isolate power to the drive motor. It will primarily be of interest to customers where product contamination due to metal to metal contact is a significant issue.

For many years Gericke RotaVal has continuously improved its foreign body and contact system. This latest version provides additional functionality, flexibility, and optimized responsiveness for the end user. The first systems have been delivered and are in full operation, protecting the process equipment and the products.

About Gericke The Swiss Gericke Group has been designing and manufacturing equipment and systems for modern bulk material processes, as well as providing design and consultation services, for more than 125 years.

Gericke bulk materials processing technology can be found throughout the world in many sectors including the food, chemical, pharmaceutical, plastics and construction material industries.

Gericke’s fully owned group companies employ more than 300 experienced professionals and are located in Switzerland, Germany, Great Britain, The Netherlands, France, USA, Brazil, Singapore, Indonesia, Malaysia, Thailand and China.

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

www.posiflate.com

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

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

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

Bulk Solids Today

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SPECIAL FEATURE

COPERION SUPPLIES TWIN SCREW EXTRUDER TO GHENT UNIVERSITY FOR CHEMICAL PLASTIC RECYCLING Coperion is supplying an extrusion system to Ghent University in Belgium for comprehensive research and development tasks in chemical recycling of mixed plastic waste. Coperion designed this laboratory system, built upon a ZSK 18 MEGAlab twin screw extruder, especially for chemical recycling of postconsumer waste within a throughput range of 1-10 kg per hour. Along with the extruder, it includes a feeder from Coperion K-Tron as well as a vacuum unit.

Plastic waste, especially packaging waste, is generally a mixture of materials with a high degree of contamination. Recycling this raw material is usually difficult, as sorting and cleaning of waste is in many cases neither economically viable nor technically feasible. Chemical recycling is a promising process to recycle these material streams into chemicals, waxes

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Bulk Solids Today

or liquid energy carriers.

As a trailblazer in the development of chemical recycling of plastic waste, Ghent University has laid the foundation for many forward-looking developments in the field that are paving the way to more sustainability in the plastics industry. Chemical reaction engineering in general and the kinetics of

SPECIAL FEATURE chemical reactions are major axes of the research done at the Laboratory for Chemical Technology (LCT) of Ghent University. These include, among other applications, optimization of existing industrial processes and development, intensification and scaleup of novel technologies aimed at minimizing waste streams and energy consumption.

TWIN SCREW EXTRUSION FOR EFFICIENT ENERGY ADDITION

Coperion’s twin screw extruder technology is particularly well suited for chemical recycling of plastics. After post-consumer waste, either shredded or compacted, is reliably added to the extruder’s process section by the Coperion K-Tron feeder, a great deal of mechanical energy is introduced into the material in shortest time thanks to the continuous surface renewal as well as intensive dispersion and shearing along the twin screws.

Within about 30 seconds, a homogeneous, highly devolatilized melt with a temperature of up to 350°C is produced, into which the energy has been introduced very efficiently.

Further materials, such as catalysts, can be added and mixed in as needed. In some cases, residual water or chlorides from PVC are introduced into the extruder in minute quantities along with the plastic waste. Both are reliably extracted via vacuum devolatilization on the extruder’s process section.

Twin screw extruders possess numerous advantages that are especially beneficial in chemical recycling. The technology covers a broad range of throughputs. On larger ZSK extrusion machines, throughputs of up to 20 t/h can be realized using this process. Polymers of various viscosities are reliably plastified thanks to the highly effective mode of operation of the twin screws. Plastic energy dissipation takes place in no time. When needed, corrosion and wear protection of all productcontact parts within the process section can assure long extruder lifetime even when processing very aggressive materials.

RECLAMATION OF RAW MATERIALS

Within the reactor, the melt, which was previously heated to up to 350°C in the twin screw extruder,

is further heated. At up to 500°C pyrolysis of the polymers takes place, the splitting of polymer chains into shorter units in an oxygen-free environment. The pyrolysis of polymers utilizes the random scission mechanism, where free radicals are generated. At the same time, chain reactions are initiated which lead to cracking polymers into a broad mixture of hydrocarbons in liquid and gaseous phase. The most important factors for driving this process are residence time, temperature, and the type of pyrolysis agent.

Most of the inorganic components of the postconsumer waste remain in the reactor’s sump and are removed. The polymers’ organic hydrocarbons evaporate. They are transformed into monomers, petrochemical raw materials, or synthesis gases and then processed further in a destillator into marketable products such as oil, heavy fuel, or waxes.

Chemical recycling is a very active research topic at Ghent University. Even though it is already shown that mechanical recycling of plastics is an easy method of plastic valorization, certain limitations were encountered due to the impracticality of waste separation. However, with chemical recycling, these limitations may be overcome.

The Coperion ZSK twin screw extruder will be part of a new setup for chemical recycling at Ghent University. It will be among others coupled to a vortex reactor; thus the molten plastic will flow directly into the reactor. Different technologies for the conversion of plastic waste to chemicals may be applied like catalytic pyrolysis and thermo-chemical processing (cracking).

“We are proud to be able to support the renowned Ghent University with our expertise and technology in their research and development activities involving chemical recycling. We see chemical recycling as a trailblazing process for reclaiming raw materials from mixed plastic waste. With this process we will succeed at preserving our valuable resources in the long term.

As soon as the recycling system featuring the ZSK twin screw extruder is in operation at the Ghent University, it will also be available to our customers for testing,” said Jochen Schofer, Business Segment Manager for Recycling & Direct Extrusion at Coperion. www.coperion.com

If you are interested in advertising within BST magazine, please feel free to get in touch using the details bleow: Bulk Solids Today Magazine bst@abbeypublishing.co.uk www.bulksolidstoday.co.uk Office - 01933 316931 Bulk Solids Today

25

BUYERS GUIDE Aero Mechanical Conveyors

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

Powder Handling Systems

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