Bulk Solids Today October Issue

BULK MATERIALS HANDLING • POWDER HANDLING • QUARRYING • RECYCLING & WASTE NEWS • FEEDERS & CONVEYING • MIXERS BLENDERS & DRYERS MANAGEMENT

FEBRUARY OCTOBER 2017 2021

LATEST UPDATES FROM HYSTER ON GREEN MANUFACTURING AND SOLUTIONS FULL ARTICLE ON PAGE 12

HIGHLIGHTS:

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Dairy Packaging: A Match made in Recycling Heaven!

11

Posi-flate Double Dump Valve Assembly

14 How the Bella Fluidized Zone Mixer Works

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 150

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

COVER STORY

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MIXERS, BLENDERS & DRYERS

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FEEDERS AND CONVEYING

22

SPECIAL FEATURE

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

www.bulksolidstoday.co.uk Bulk Solids Today

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COMPANY NEWS

HAT-TRICK FOR JCB AS HYDROGEN ENGINE WINS TOP AWARD JCB’s super-efficient hydrogen engine has won one of the oldest and most prestigious awards in British automotive engineering honouring technical achievement.

At a ceremony in London, JCB Chairman Lord Bamford was presented with the Royal Automobile Club’s Dewar Trophy for the company’s development of a hydrogen fuel motor. It is the third time that JCB’s innovations have been honoured with the Dewar Trophy.

John Wood MBE, Chairman of the Dewar Technical Committee, said: “JCB has been a pioneer in terms of powertrain development since it started building its own engines in 2004. That ethos has continued with its latest hydrogen-fuelled engines, which are an inspiring combination of current expertise and next-generation technology.”

Anthony Bamford said: “We’re extremely proud that the Royal Automobile Club has chosen to present JCB with the Dewar Trophy for the third time. Our new hydrogen-fuelled engines can be put into production relatively quickly and it’s an important and pioneering step towards a zerocarbon future, and testament to the amazing abilities of our British engineers.”

JCB’s purposeengineered zero CO² hydrogen fuel motor was designed after a challenge to the company’s engineers from Anthony Bamford.

The newly designed motor harnesses JCB’s existing expertise and supply chain infrastructure. The company is investing £100 million in the 4

Bulk Solids Today

project and has two prototype hydrogen fuelled machines on test: a backhoe loader and a Loadall telescopic handler.

Presented to the Club in 1904

by Sir Thomas Dewar MP, and since 1957, the Dewar Trophy has been presented in recognition of ‘an outstanding British technical

achievement in the automotive field during the preceding year’. In 2019 JCB was recognised for the launch of the 19C-1E electric mini excavator.

In 2007, JCB won the Dewar Trophy after the JCB Dieselmax team set a diesel-powered Land Speed Record of 350.092mph on the Bonneville Salt Flats, USA.

COMPANY NEWS

DAIRY PACKAGING: A MATCH MADE IN RECYCLING HEAVEN! CCL introduces certified EcoFloat® polyolefin sleeves for PP dairy cups to boost recycling rates PP cups are mostly the packaging of choice when it comes to dairy packaging.

CCL has launched the perfect product decoration match – a low density polyolefin sleeve that has an ideal performance when it comes to recycling.

“Using a thin plastic sleeve label that is made from the same family as the cup increases the recycling rate.

First of all it is detected as the material it is on the sorting lines and can be successfully recycled afterwards. Most sleeves tend to be removed due to natural friction and de-sleeving during the recycling process but if it stays on it can also be efficiently recycled,” says Norbert Fenkart, Head of Development at CCL Label’s Dairy Packaging Hub in Hohenems, Austria.

Fully Recyclable: Certified by cyclos-HTP The renowned cyclos-HTP institute conducted a test that showed that 92 – 100% of the sleeve could efficiently be recycled with the PP cup, depending on other factors like ink coverage. This earns the EcoFloat polyolefin material the classification “highly to fully recyclable” according to the cyclosHTP rating.

Also the sleeve material is very thin with a density <1 which means that it is very resource efficient and creates less CO2 emissions during transport.

Use sleeves from the same plastic family to avoid composite materials that can hardly be recycled

Paper banderoles have become the product stand out in the sales increasingly popular in the last shelves. years because paper seems a natural sustainable choice to the customers but is a multi-material composition: ON-BOARD EXCAVATOR WEIGHING SYSTEM paper, plastic and the aluminum lid. These are not very often recycled as it is up to the consumer to separate those materials which can be a challenge and obstacle.

Polyolefin Sleeves are a great cup decoration The benchmark for First of all accuracy in difficult it shows great conditions and terrains shrinkage which means that all cup shapes can be covered. It is suitable for highquality printing and offers great possibilities for 360 degree T: +44(0)1453 733300 | info@rdstec.com | www.rdstec.com graphics to make

LOADEX 100

Bulk Solids Today

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COMPANY NEWS

RUSHLIFT GSE WINS GLOBAL CONTRACT WITH MENZIES Rushlift GSE, the specialist airport ground support equipment subsidiary of Doosan Industrial Vehicles UK, has entered into a six-year global framework agreement with airport ground services company, Menzies Aviation, to supply GSE equipment.

Under the arrangement, Rushlift GSE will initially lease 650 brand-new vehicles to Menzies Aviation’s ground handling operations at Heathrow and Gatwick airports. The multi million-pound contract, signed in July, will include the provision of a fleet of pushback tugs and HI loaders from Trepel, mobile conveyor belts and electric baggage and pushback tugs from TLD, and trailers from the UK manufacturer, TBD. The staged rollout, which is already underway, will continue through to Q2 2022 and is timed to align with the expected resurgence in passenger air travel.

Tim Willett, Operations Director at Rushlift GSE, said: “We’re delighted to be working with Menzies Aviation in

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Bulk Solids Today

supporting their operations at Heathrow and Gatwick airports, and for the opportunity to expand our cooperation internationally.

“This contract further underscores Rushlift GSE’s capability to support large corporations. Rushlift are experts in large start-ups, as demonstrated by previous programmes, such as a recent major rollout for easyJet at Gatwick.”

He adds: “In line with Menzies’ environmental objectives, we will be introducing a number of electric GSE vehicles over the six-year term of the contract. We are also exploring alternative fuel options, including Biofuels and Hydrogen. One of the huge advantages of being a subsidiary of Doosan – a

global engineering enterprise – is that we have access to a world-leading team of specialists dedicated to researching sustainable, alternative fuels.”

Stephen Gallagher, SVP GSE and Equipment for Menzies Aviation, said: “The reliability and uptime of our ground handling equipment is absolutely imperative to the service we provide – our reputation depends upon it. We’re confident that Rushlift GSE will provide the GSE and support we’re looking for, both here in the UK and overseas.”

For further information on Rushlift GSE go to https://www. rushlift.co.uk/gse/ or call 0208 564 4949

COMPANY NEWS

DOOSAN NORWAY DEALER OFFICIALLY OPENS NEW SERVICE CENTRE Rosendal Maskin AS, the Authorised Doosan Dealer for Norway, has opened a brand new Service Centre at the company’s headquarters in Askim in Norway. Built for a cost of NOK 35 million (3.6 million Euros), the impressive new 2000 m2 premises houses a predelivery inspection workshop and includes a washing room and welding facility, a new parts warehouse, offices and a small showroom.

Over 100 guests attended the official opening of the Service Centre, including customers, suppliers, service partners and other invited dignitaries. After the ribbon was cut outside the entrance to herald the opening of the Service Centre, Rosendal hosted a dinner and presentation inside the new building.

In his speech during the dinner, General Manager, Tor Anders Høgaas, said: “The opening of the new Service Centre gives us new opportunities and will make us an even better workplace where we can attract the best people to work for us. We are very proud of the new building and we know that by providing an enhanced work environment for our employees will help to take the company further.”

One of the other attractions at the opening dinner was the GT4 class Citroën DS3 R racing car that Rosendal is sponsoring, driven by promising young driver, Niklas Eker Abrahamsen, and emblazoned in the Doosan orange colours and the logos of both Rosendal and Doosan. Niklas competes in the Norwegian GT4 Championship and in the Citroën DS3 Nordic Championship.

Rosendal also hosted a party the next day for all 50 of the company’s employees in the new Service Centre.

Rosendal Maskin AS Established in 1986 by the company founder and Chairman, Kåre Rosendal, Rosendal Maskin AS became a dealer for the Moxy range of articulated dump trucks

(ADTs) the following year. ADTs The company’s factory-trained are still an important product for engineers have many years of the company and became part hands-on experience of repairs of the Doosan range when Moxy and servicing of all types of plant was acquired by Doosan in 2008. and machinery.

As the long-standing Authorised Dealer for Doosan in Norway, Rosendal Maskin AS is responsible for sales and service of the entire Doosan range, both the compact and Tuf-Lok ring grip pipe and tube couplings are heavy lines, rugged, heavy duty, self-aligning and self-grounded including not only couplings with a high end pull. They can be used ADTs, but also for almost any application where pipe or tube ends wheel loaders need to be connected. The Tuf-Lok self-aligning and mini, crawler couplings install quickly and easily with little effort. and wheeled Features excavators, as • Self-aligning well as all the • Self-grounding attachments, • High pressure rated accessories and spare parts • Full vacuum rated available from • Stainless or Doosan. mild steel Customers • Usable on thin benefit from or thick wall pipe or tube the superb on-site service • Low cost network offered • Reusable

by Rosendal, • Absorbs vibration covering • Externally leakproof everything from Tuf-Lok (UK) emergency Tel: +44 (0) 1706 822512 repairs to routine Email: sales@tuflok.co.uk • www.tuflok.com maintenance.

Bulk Solids Today

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COMPANY NEWS

RHI MAGNESITA ORDERS SIX CHAIN BUCKET ELEVATORS FOR LARGE PROJECT FROM AUMUND BRAZIL Global leader in the production and supply of fireproof products and systems, RHI Magnesita, is investing € 30 million in a new rotary kiln line for its mine in Brumado in the State of Bahia, Brazil, where magnesite, one of the raw materials for fireproof products, is mined. To convey the raw material between the magnesite mine and the production facility in Brumado, RHI Magnesita has ordered from AUMUND Ltda six Bucket Elevators with Central Chain type BWZ-L. The AUMUND Bucket Elevators with Central Chain,

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Bulk Solids Today

with heights of 15, 30, 33 and 45 m, were ordered by RHI Magnesita at the end of 2020 and supplied in this year. They will operate in the Pedra Preta magnesite mine in Brumado, where the rotary kiln is designed for processing 140,000 t of magnesite per annum. The new line will bring an increase in production of around 30 percent.

COMPANY NEWS

3SMI APPOINTED BUNTING’S AGENT IN GERMANY, AUSTRIA, AND SWITZERLAND The appointment of 3SMI GmbH as the exclusive agent for Bunting’s magnetic separators and metal detectors in Germany, Austria, and Switzerland significantly strengthens the company’s overseas sales network.

Bunting is one of the world’s leading designers and manufacturers of magnetic separators for the recycling and waste industries. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

The origins of 3SMI GmbH date back to the mid-1980s when Norbert Graef established a consultancy to support mineral processing and ceramics companies. The consultancy morphed into Eriez Magnetics Vertriebs GmbH in the mid-1990s, providing technical advice and support on metal and mineral separation and recovery issues in a wide range of industries including minerals, ceramics and recycling. Norbert Graef’s son, Marcel Graef joined as a Project Manager in 1999, becoming Managing Director in 2009 on the retirement of his father. Marcel Graef launched 3SMI GmbH (Sorting and Separation Solutions for the Magnetic Industry) in July 2020.

Marcel Graef’s experience extends across a number of industries and territories, where he has built a reputation as a leading expert in material separation,

particularly with magnetic and eddy current technology.

The continually expanding range of metal separation technology developed by Bunting provides 3SMI with the necessary equipment to meet the increasingly demanding challenges faced by material processors and recyclers. The new Customer Experience Centre in Redditch, UK, Bunting provides one of the most comprehensive magnetic separation material testing facilities in the world for companies working in mineral processing, mining and recycling.

The appointment of 3SMI follows the establishment of a Bunting Central European sales office with Christopher Gabriel and Dirk Mylich, as well as a Southern Europe office managed

by Stefano Maiaroli.

“This exciting appointment provides us with additional market knowledge and experience in Germany, Austria, and

Switzerland,” explained Simon Ayling, Bunting’s European Managing Director. “Our recently extended manufacturing facility and new customer experience centre provide us with the necessary resources to meet the expectations of customers across Europe. Working with 3SMI provides the perfect platform to further expand our export business.”

For further information, please contact us on press@ buntingmagnetics.com or Marcel Graef on sales@3smi.de or visit our website: Bunting-Redditch – www. bunting-redditch.com

Bulk Solids Today

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COMPANY NEWS

BRÜCKNER MASCHINENBAU PLACES MAJOR ORDER WITH COPERION Brückner Maschinenbau, the world’s leading manufacturer of film stretching lines, has placed an order with Coperion for more than 50 ZSK Mc18 twin screw extruders. These will be integrated into plants for the production of flexible BOPET packaging films, which Brückner will install in China. The ZSK extruders have screw diameters ranging from 70 mm to 177 mm.

Brückner Maschinenbau’s substantial repeat order is based on many years of close cooperation with Coperion. With this order, Brückner is once again putting their trust in proven Coperion technology, which the company has already integrated into numerous film stretching lines. The ZSK extruders are used to melt the compounds that are fed into the lines. Thanks to their high torque, Coperion’s ZSK Mc18 extruders achieve very high throughput rates while maintaining low product temperatures and thus ensuring first-class product quality.

“We are very pleased that Brückner Maschinenbau is once again relying on our technology and know-how,” says Jochen Schofer, Business Segment Manager Recycling & Direct Extrusion at Coperion. “We very much appreciate this familiar, long-standing cooperation with the pioneer for plastic film lines. Our companies pursue very similar aspirations. We both develop high10

Bulk Solids Today

quality technologies for plastics production with very high throughput rates. The efficient use of resources and high recyclability of the end products are important to us.”

Coperion is the international market and technology leader in compounding and extrusion systems, feeding and weighing technology, bulk materials handling systems and services. Coperion designs, develops, manufactures and maintains systems, machines and components for the plastics, chemicals, pharmaceutical, food and minerals industries. Within its two divisions – Polymer and Strategic Markets / Aftermarket Sales and Service – Coperion has 2,500 employees and nearly 30 sales and service companies worldwide. Coperion K-Tron is a brand of Coperion.

For more information visit www.coperion.com or email info@coperion.com.

COMPANY NEWS

POSI-FLATE DOUBLE DUMP VALVE ASSEMBLY The Posi-flate Double Dump valve assembly is a low cost, low maintenance alternative to the traditional rotary airlock feeder.

The air-operated seat inflates to provide a long-lasting high integrity positive seal that that can accommodate either full vacuum or pressure up to 100 PSIG. The Posi-flate Double Dump valve assembly can easily handle high cycling of dry granular or fine powdered materials. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably. The Posi-flate Double Dump Valve Assembly is available in carbon steel and stainless steel in sizes from 2-inch (50mm) to 30-inch (750mm) diameter and in any length desired. Other materials of construction are available upon request. https://www.posiflate.com/products/ doubledump.html

Posi-flate Milton Keynes, United Kingdom +44-1908-622366 E-mail: sales@posiflate.co.uk www.posiflate.com

If you are interested in advertising within Bulk Solids Today or contributing editorial, please do get in touch using the details below: Bulk Solids Today Office - 01933 316931 bst@abbeypublishing.co.uk www.bulksolidstoday.co.uk Bulk Solids Today

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ON THE COVER

LATEST UPDATES FROM HYSTER ON GREEN MANUFACTURING AND SOLUTIONS Hyster Company has set ambitious environmental goals to achieve by 2026. Now at the halfway point, Hyster reveals the progress so far of its green manufacturing initiatives and innovative products and solutions designed to help customers achieve their sustainability goals.

“Part of the overall goal is to significantly reduce our global carbon footprint,” explains Conal McNally, Environmental Engineer for Hyster Europe. “Moreover, environmental targets have been set to reduce carbon emissions, VOC emissions from painting operations, and hazardous waste all by 30%, and water consumption by 20%.

We also aim to achieve zero waste landfill at all sites and to offer a greater range of alternative products that enable customers to cut emissions cost-effectively.”

Most manufacturing processes tend to create waste. As a global manufacturer of industrial products, Hyster recognises the importance of responsible material use and is pushing to mitigate its waste footprint across all aspects of the value chain. The majority of waste created in the

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Bulk Solids Today

manufacturing of Hyster® lift trucks is now being recycled.

For instance, in Nijmegen, the Netherlands, where Hyster Big Trucks are produced, any nonrecyclable waste is incinerated in the Netherlands’ cleanest burning facility, and any excess heat is used for heating in the factory building and nearby homes. Solar panels have also been fitted to provide some of the power to the site.

“We have already achieved our goal of zero landfill waste at our manufacturing site in Nijmegen,” adds Conal. “And the plant producing Hyster trucks in Craigavon, UK, has also been extended with similar green initiatives at the centre of its design and build.”

The new building design includes a smarter approach to heating, a more effective use of natural light, the creation of areas for biodiversity, and a Sustainable Urban Drainage System (SUDS) amongst other important initiatives. 97% of waste from the site is now recycled, and waste to landfill has reduced by almost 45%. A specialist at the site is working to use materials responsibly in the

ON THE COVER

packaging of Hyster products, and to increasingly make packaging recyclable and sustainable.

To further support the reduction in its carbon footprint, Hyster also employs low emission methods to deliver finished trucks to customers, wherever possible. Hyster ReachStackers, for instance, can be transported by barge from the Nijmegen facility to the main port of Zeebrugge in the Netherlands.

Transport on the water reduces the number of trucks on the road, helping save on fuel consumption.

“As well as implementing sustainable manufacturing processes, we are also evolving the complete range of Hyster products towards low or zero emissions with key advances in technology and truck design.,” says Conal. “From Big Trucks used in ports and terminals, right down to low-capacity lift trucks in busy logistics operations, Hyster products increasingly incorporate a range of clean energy solutions.”

For example, innovative applications of lithiumion batteries and hydrogen fuel cells are enabling Hyster to develop zero emission Container Handlers and ReachStackers for the first time.

Plus, Stage V engines that comply with EU emission regulations are introduced for Hyster Big Trucks, with capacities of 8-tonnes or more, helping businesses comply with emissions legislation, while also heightening productivity, and reducing the cost of ownership for the customer.

In 2021 the Hyster® J10-18XD lift trucks were

also launched, featuring lithium-ion battery packs and up to 18 tonnes lift capacity, for comparable performance to ICE trucks, but with zero emissions.

This follows the recent launch of the 7-9 tonne lift capacity, J7.0-9.0XNL series of electric lift trucks, with fully integrated lithium-ion batteries and rapid opportunity charging.

“A big part of our green approach is supporting customers across multiple industry sectors in their own sustainability objectives with the right products, and the right aftermarket solutions, such as carbonneutral lubricants,” says Conal.

Some Hyster Big Trucks for the European market are prefilled with Shell’s carbon neutral engine oil, and it is also in use at the factory producing Hyster lift trucks in Craigavon, Northern Ireland.

“The demand for sustainability is growing across all areas of the materials handling industry, to comply with legislation, company environmental targets, and CSR policies,” says Conal. “Like many of our customers, we are closely monitoring our performance and progress against our own environmental goals and continue to strive for ambitious targets in EMEA. Similar progress is also being made by Hyster in JAPIC and the Americas.”

Talk to your local Hyster distribution partner to learn more about how Hyster can help to support your business sustainability goals.

For more information, visit www.hyster.com.

Bulk Solids Today

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MIXERS, BLENDERS & DRYERS

HOW THE BELLA FLUIDIZED ZONE MIXER WORKS The Bella fluidized zone twin shaft paddle mixer by Dynamic Air achieves fast, high-capacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action with typical mixing times of 15 to 30 seconds. A weightless zone created by low-speed counter rotating paddles generates very low friction without shear.

This makes it ideal for abrasive products and fragile products that cannot tolerate rough handling. Even flakes or spraydried bodies remain intact The Bella mixer consists of twin drums which have two counter-rotating agitators with specifically angled paddles. They overlap at the center and completely sweep the entire bottom of both mixer drums and allow it to be started under full load (Figure 1). The material in the mixer moves in a horizontal counterclockwise direction at the perimeter while simultaneously moving both left and right in the center (Figure 2). The material in Zone B (Figure 1) is in its normal gravimetric state as it is being moved and disbursed. In Zone A, a weightless zone is created which effectively lifts the ingredients to an almost weightless state allowing them to move freely and randomly, regardless of particle size and density. Thus the two zones’ interaction becomes highly efficient as every particle moves rapidly to a highly homogeneous mix, the key to the Bella Mixer mixing technology for fast, precise mixing.

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

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Bulk Solids Today

MIXERS, BLENDERS & DRYERS

AJAX MIXER FOR CEREAL BAR PRODUCTION

Solids handling equipment maker, Ajax Equipment, has supplied a Switzerland based process technologies provider with a heated twin screw mixer with ribbon flights for combining cereal with syrup.

The stainless steel, twin screw mixer includes both a heated casing and heated augers. Using warm water to heat the mixer ensures the condition of the syrup is maintained throughout the mixing process, enhancing the quality of the mix for further processing. The augers are also ‘quick release’, allowing the shafts to be changed out or removed to make cleaning of the augers and mixer easier. The mixer incorporates FDA approved seals and a crevice free internal finish.

“Ajax has supplied a wide range of food manufacturers with solids handling and mixing equipment. Our mixers are ideal for mixing multiple dry ingredients, including cereals, and liquors while maintaining the quality of the ingredients,” says Eddie McGee, managing director, Ajax Equipment.

For more information on Ajax Equipment hoppers and hopper inserts, call +44 (0)1204 386723, email sales@ajax.co.uk and visit www.ajax.co.uk.

If you would like to subscribe to receive a regular copy of the digital edition of Bulk Solids Today magazine, you can subscribe on our website www.bulksolidstoday.co.uk

Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost.

Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong.

• • • • • •

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

www.posiflate.com

Bulk Solids Today

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MIXERS, BLENDERS & DRYERS

ATIK METAL AND A RENOWNED VEHICLE MANUFACTURER BOTH INVEST IN QUALITY AND THE ENVIRONMENT Saving resources and energy with a molding sand preparation system from EIRICH The foundry industry has been hit hard by the COVID-19 crisis, with the economic impact of the pandemic being keenly felt here. In order to meet the challenges of the future and to remain successful in the marketplace, foundries need to develop sustainable, long-term solutions. Renowned companies like Atik Metal have recognized this and are investing in the innovative molding sand preparation technology from Maschinenfabrik Gustav Eirich. The EIRICH mixing system delivers high-quality molding materials – and protects the environment and resources in the process.

Hardheim, October 2021: Foundry technology is highly advanced. In recent decades it has formed the basis of countless further developments, particularly in the field of automotive construction. Cast components are integral to almost all industries. For casting with lost molds, metal foundries often use the important raw material sand as the molding material, together with clay as a binder. This molding sand needs to be specially prepared for the casting process, where it

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Bulk Solids Today

is subjected to high temperatures. Maschinenfabrik Gustav Eirich is the technology leader for costeffective and eco-friendly sand preparation and offers a sustainable solution to the industry: a molding sand preparation system that reduces the number of rejected castings, saves energy, and reduces emissions. For foundries that want to achieve optimum molding material quality with a highly cost-effective solution, the environmentally friendly EVACTHERM® process from EIRICH for cooling of the old sand and preparation of the molding sand under vacuum has been the leading technology for many years in conjunction with the quality system QualiMaster. Here, a single machine – the EIRICH intensive mixer – combines the process steps of mixing, cooling, and bentonite activation all into a single unit. The advantage: During the preparation process under vacuum, the temperature of the sand can be controlled independently of the surroundings.

Thanks to the closed processing cycle, unlike with

MIXERS, BLENDERS & DRYERS conventional evaporation cooling systems no fines are carried away. This saves resources, as valuable raw materials remain in the cycle.

At the same time, this technology reduces emissions and saves costs associated with removal and landfilling.

Quality assurance for the molding material is a central aspect of the EIRICH solution.

The heart of this system is the inline tester QualiMaster AT1. This unit is compatible with the ‘Internet of Things’ and takes samples from every mixture, which it uses to determine control variables such as compactability and shear strength. If the values for the molding material deviate from the requirements, the system initiates an optimization process. The stable, closed-loop process control guarantees continuously high quality of the molding material and ultimately ensures that fewer cast parts are rejected. In addition, QualiMaster AT1 also offers the option of measuring important process values like gas permeability and springback.

With the rising demand for high-quality cast parts, Turkish foundry Atik Metal is currently investing in the construction of a new plant. For this major investment, the company has chosen EIRICH to supply a molding sand preparation system that protects both the environment and resources: “Our vision is to remain competitive and sustainable. With this investment we have chosen to go with our long-term partner, machine manufacturer Maschinenfabrik Gustav Eirich.

By combining our company’s generations of foundry expertise with the technological advantages offered by this company, we will continue to be able to meet the high quality demands of our customers all around the world in the future,” says Can Atik, owner and Technical Manager.

Cast parts will continue to be needed in many areas in the future. In the field of vehicle construction, changes are taking place in terms of how components are being designed. As part of the mobility transformation, average component size is set to go down, while component complexity is going to go up. This means that molding sand preparation needs to more flexible than ever before. For this reason, as well as Atik Metal a renowned commercial vehicle manufacturer is also constructing its new foundry with future-proof technology from EIRICH. The machine manufacturer will be supplying a turnkey solution including not only the intensive mixers, but also the entire system periphery for molding sand preparation. Here, the control technology combines digital solutions such as web-based visualization, condition monitoring, and remote maintenance with decades of experience in process control. From project management to in-house manufacturing of the machinery and assembly, installation, and commissioning of the final system – in this major project, EIRICH will be constructing one of the

biggest and most state-of-the-art plants in the company’s history. By opting for the EIRICH solution, the commercial vehicle manufacturer is building on sustainability and quality for its production facilities.

For more information please visit: www.eirich.de/ de/branchen/giessereiformsand/.

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

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FEEDERS & CONVEYING

MOBILE SANITARY CONVEYOR BAG DUMP SYSTEM A new sanitary mobile TiltDown Flexible Screw Conveyor with Integral Bag Dump Station and Compactor allows the transfer of material manually dumped from handheld bags into elevated process equipment, and the disposal of empty bags, dust-free.

Mounted on a mobile frame with locking castors and a fold-down step, the Bag Dump Station is secured to the floor hopper with quick-release clamps, and features a gasketted bag disposal chute through the side wall of the hopper hood, allowing the operator to pass empty bags directly into the bag compactor.

Dust generated from both dumping and compaction is drawn onto the system’s two cartridge filters. An automatic reverse-pulse filter cleaning system releases short blasts of compressed air inside the filters at timed intervals. This causes any dust built up on the outer surfaces to fall into the hopper, conserving useable product. Filters are readily accessed by removing the interior baffle, and replaced using quick-disconnect fittings.

The compactor employs a pneumatic air cylinder to compress 50 to 80 empty bags into a removable bin lined with a plastic waste bag for dust-free

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tie-off and disposal. The main door, and a flapper door within the bag infeed chute, are equipped with safety interlocks that prevent operation of the compactor unless both doors are closed.

The hopper discharges into an enclosed, 4.6 m flexible screw conveyor that handles a broad range of materials including free- and non-free-flowing bulk solids ranging from large pellets to sub-micron powders, including products that pack, cake, seize, smear, fluidise, or crumble, with no separation of blended products. The flexible screw is the only moving part contacting material, and is driven by an electric motor beyond the point at which material is discharged, preventing material contact with seals.

The Bag Dump Station, support boom and conveyor assembly can be tilted down to manoeuvre through standard doorways and aisles, and around corners for use anywhere in the plant.

The entire unit can be rolled to a cleaning station where a lower clean-out cap on the conveyor tube can be removed to flush the smooth interior surfaces with steam, water or cleaning solutions, or to fully remove the flexible screw for cleaning and inspection.

The system is available in carbon steel with durable industrial coating, with stainless steel material contact surfaces, or in all-stainless steel (shown) finished to industrial, food, dairy or pharmaceutical standards.

Flexicon also manufacture other configurations of bag dump stations and flexible screw conveyors, as well as tubular cable conveyors, pneumatic conveying systems, bulk bag dischargers, bulk bag conditioners, bulk bag fillers, drum/box/container tippers, drum fillers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls..

For information contact Flexicon Europe Ltd, +44 (0)1227 374710, sales@flexicon.co.uk, www.flexicon.co.uk

FEEDERS & CONVEYING

BUNTING LAUNCHES NEW SHREDDER FEEDER CONVEYORS The new Shredder Feeder Conveyor from Bunting-Redditch combines with either a magnetic separator or metal detector to protect a shredder or granulator from metal damage.

Bunting is one of the world’s leading designers and manufacturers of magnetic separators for the recycling and waste industries. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

Specifically designed for recycling plastics, both in-house regrind and from secondary sources, the Shredder Feeder Conveyor provides an even and controlled feed into a shredder or granulator. The design specifically accommodates a metal detector or magnetic separator.

Shredder damage from metal contamination is costly in both repair and production downtime.

Materials fed on the Shredder Feeder Conveyor pass through a metal detector or under a magnetic separator to find and remove such metal. Such protection prevents shredder damage and metal contaminants being reduced into smaller particle sizes, which become more difficult to remove.

Shredder Feeder Conveyors are also located post-shredding and prior to feeding the material into a granulator or extruder. Identifying and removing metal at this stage both protects the granulator and

extruder from damage, whilst also ensuring the quality of the regrind prior to internal use or external sale.

The Shredder Feeder Conveyor design accommodates different designs of magnetic separator including Overband Magnets, Suspension Magnets, Plate Magnets, and Pulley Magnets. The design of the conveyor limits potential magnetisation of the supporting frame to ensure clean discharge of captured ferrous metal.

Different conveyor designs often detrimentally affect the performance of a Metal Detector. The Shredder Feeder Conveyor specifically includes design features to minimise any metal detector interference and ensure optimum detection at all times. The application and nature of the metal contamination determines the selection of either an Underbelt or Tunnel-type Metal Detector. The optional extra of an automated reject system enables the removal of metal contamination without disrupting the material flow. On identifying metal in the material, the metal detector transmits a signal to a reject flap mounted at the end of the conveyor.

The reject flap redirects the contaminated material into a separate collection area.

The Shredder Feeder Conveyor further expands Bunting’s range of equipment for plastics and recycling companies.

For further information, please contact us on press@buntingmagnetics.com or visit our website: www.bunting-redditch.com

Bulk Solids Today

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FEEDERS & CONVEYING

GERICKE SYSTEM COMPONENTS: THE BUILDING BLOCKS TO A PERFECT SYSTEM It is the small details that can make the difference!

Gericke has a number of components and accessories in the range, specifically developed for powder handling applications.

Whether as part of a system or as individual components: Gericke has a broad range of accessories that increase the performance and reliability of powder handling systems.

The Gericke GB Elbows are often used to increase the lifetime of pneumatic conveying lines when working with abrasive materials. Due to the special vortex chamber, the wear rate of bends for pneumatic conveying is drastically reduced.

The lifetime cycle will be extended, and your maintenance and downtime costs will be reduced.

Highly flexible, hygienic and easy to use!

The Gericke GFT Sleeves are ideal for flexible

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Bulk Solids Today

connections using standard Tri-Clamp fittings in many food, chemical and pharmaceutical applications. Available in sizes from DN 65 to DN 200 mm, they are made of VMQ Silicone and comply with ATEX regulations as well as with the requirements of FDA and CFR. The hygienic and convenient Gericke Sampling Valve allows the operator to extract a sample of the product from the production line or reactor and safely store it for transportation to the laboratory where it will be analysed. The sampling valve is designed according to the latest construction standards and recognised safety rules.

More components such as diverter valves, bin aerators and fittings can be found in the respective sections of the Gericke website. www.gerickegroup.com

FEEDERS & CONVEYING

THE AIRSCRAPE® HAS LANDED. IN AUSTRALIA. Kinder Australia Pty Ltd, an Australian developer and supplier of conveyor components, has added the AirScrape® non-contact conveyor skirting solution to its range.

From July 2021 the AirScrape® will be included in the product range of Kinder Australia. The news on the website was headlined: The AirScrape® Has Landed. One of the leading providers for the planning and equipping of conveyor systems in the Pacific region now includes the in-house development of ScrapeTec in its product range. For a long time, Kinder have watched the impressive progress of the AirScrape®. Charles Pratt, Operations Manager at Kinder Australia, was particularly impressed by the YouTube sequences about the use of the innovative side seal. Now an agreement has been reached between Kinder Australia and Kamp-Lintfort, Germany. The AirScrape® as a side seal and the TailScrape® as a back seal of the transfer point effectively complement the Kinder’s range of conveyor ​​ components and seals.

ScrapeTec Trading GmbH has been present in the market for 4 years with the invention of AirScrape® by its founder Wilfried Dünnwald.

The mining engineer has used his decades of professional experience, and with this contact-free side seal for conveyor transfer points has realized a vision. The development of dust during mining is particularly problematic underground. His vision: The development of a conveyor skirting system for maximum dust reduction at transfer points when conveying bulk goods. This is how the AirScrape® came about. Gradually, customers could be convinced over the AirScrape®’s dust-reducing and economical operation. The positive response in the German market was also noticed in the international mining scene. In the meantime, the AirScrape® is in use not only in Europe but also in Africa and America. And now the Asia-Pacific region with Kinder’s reach.

Convincing: the AirScrape® principle In contrast to many side sealing solutions, the AirScrape® works completely contact-free at transfers. This eliminates frictional losses due to belt abrasion and extreme belt wear, because the AirScrape® is mounted at a distance of 1 to 2 mm from the belt. In addition, there are the specially arranged blades in this innovative conveyor seal.

They create the so-called Venturi effect. This is the air suction that is created by the movement of the belt and suction of air in from outside. This prevents dust or fine material from escaping through the gap between the belt and the seal. In addition, thanks to their arrangement, the lamellas convey coarse material that is pushing outwards back to the center

of the belt. These effects have also piqued Kinder’s interest in Australia.

Kinder: Professionalism is a family matter Kinder Australia Pty Ltd has been operating since 1985 in the field of conveyor technology for the mining and bulk materials handling industries. The Australian conveyor component company is still family-run to this day, founded by Neil and Christine Kinder. ScrapeTec Trading GmbH is also a familyrun company, with founder Wilfried Dünnwald in product development and Thorsten Koth in sales, who, as a long-term professional companion, has the necessary closeness and experience. Perhaps it is these soft skills that, in addition to the convincing hard facts about the product, have made the cooperation between the two easily possible.

Kinder offers an extensive range of components for conveyor systems. Starting with the in-house engineering development, to the precise timing of logistics to the installation site. In addition, the field applications team are available for site visits and virtual meetings to discuss maintenance solutions.

Speaking of maintenance: The AirScrape® also makes another important difference here. Due to its contact-free operation with the Venturi effect and the avoidance of friction on the side seal, the maintenance requirement for this type of side seal is zero. A fact that has great argumentative weight towards the customer when calculating new projects for Kinder.

At the other end of the world Despite all the business proximity between the two companies in Braeside, Australia and Kamp-Lintfort, Germany, the important aspect of the distance remains. Both are at the other end of the globe and about 8 hours apart. You have to coordinate well for phone calls and video conferences. And face-to-face meetings are more of a rarity. But as long as the AirScrape® is convincing in use, there is hardly any need to talk.

The AirScrape® has landed in Australia. Just like in Europe, Africa and America with future endeavors in Asia Pacific.

Bulk Solids Today

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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 22

Bulk Solids Today

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 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 dustfree 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

SPECIAL FEATURE 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 railspans 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 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 space-saving 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

Conveyors & Elevators

Powder Handling Systems

“Often copied NEVER matched”

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

Sales office for UK & ROI: SGH Equipment - Entecon® Agent

Tel / Fax: 01270 651611

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

Bulk Storage & Handling

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

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

Remote Silo Monitoring

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

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

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Cleaning

Mixers & Blenders

Dynamic Air Ltd. Milton Keynes England

+44 (0) 1908 622344 www.dynamicair.com

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Bulk Solids Today

If you would like your company to be featured here, please get in touch using the details below : 01933 316931 bst@abbeypublishing.co.uk www.bulksolidstoday.co.uk

BUYERS GUIDE Sieves & Sifters Cont’d

Sack Filling

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Screw Feeders, Mixers & IBC Systems

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Ajax Equipment Ltd Tel: 01204 386723 Fax: 01204 363706

Russell Finex

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

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

www.posiflate.com

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

www.InterBulkGroup.com

InterBulk GROUP

Bulk Solids Today

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Global sieving & filtration specialists The Russell Compact Sieve®

Improves product quality

Fits into smaller spaces

Compact & mobile design

Eliminates dust & fumes

What makes us specialists..?

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

Email: sales@russellfinex.com