Crisplant – part of BEUMER Group and a leading global supplier of automated material handling systems – has been awarded a contract by Swisslog – a leading provider of automated intralogistics solutions for the retail and e-commerce industry – for the design and integration of a high-speed automated material handling system in Scandinavian fashion retailer Varner's new Central Distribution Centre in Vänersborg, Sweden, due to open in the summer of 2016.
The contract was awarded by Swisslog as general contractor for the material handling elements of the new distribution centre. Crisplant's role will support Swisslog's solution to help Varner meet the anticipated demands of future growth.
The Swisslog delivery comprises cranes and conveyors for pallets and light goods, a hanging garment solution, Swisslog’s proprietary warehouse management software and controls systems, and a Crisplant LS-4000CB cross-belt sorter, to serve as the backbone of the sortation system. The sorter will integrate all areas, including inbound, miniload system, order release module (ORM), Swisslog's AutoStore and the shipping lanes. System operation services performed by Swisslog’s on-site engineers are also part of the contract.
To help Varner obtain a scalable, cost-efficient, ergonomic and green distribution solution, Swisslog developed an innovative solution design based on Crisplant's LS-4000CB cross-belt sorter. High availability compared with conventional conveyor system design, and the simplicity of the sorter itself, ensures easy and straightforward understanding of the system's layout and capabilities. This greatly facilitates daily activities for managers and operators handling the system and preparing production.
LS-4000 sorters are well known for their green credentials with proven, low energy consumption of up to 75% less than sorters using conventional technology. In addition Crisplant's modular sorter design delivers reduced maintenance costs compared with conveyor technology.
The modular design also allows future extensions, enabling the system to grow along with demand in the distribution centre. The initial capacity will be 40,000 pallet locations in a high-bay warehouse, 330,000 dynamic locations in the miniload system, and 60,000 bins in an AutoStore small-parts storage system.
Integration of the system is due to start in April 2015 and handover to the customer is scheduled for summer 2016....
Bulk material like building materials, coal, cereals, fodder or mineral compounds are often transported via motorways, railways, waterways or through nature reserves. The large quantities of dust generated during this process can pollute the environment considerably. Dust clouds can also occur during loading, filling and palletising. This not only creates considerable clean-up for the employees, but chemical industry products can also present a health hazard and cause dangerous reactions. With its conveying, loading, filling and palletising systems, BEUMER Group ensures minimal dust emission.
BEUMER Group is a world-leading systems provider for transporting, loading, filling and packaging bulk material. The BEUMER portfolio includes curved belt conveyors for fast and cost-efficient transport of large quantities of bulk material from the quarry or mine to the factory or port. The belt conveyors are able to navigate long distances, high angles of inclination and tight curve radii, and can be adapted individually to the belt or pipe conveyor bulk handling solutions. Depending on the customer's requirements, BEUMER provides either troughed belt or pipe conveyor bulk handling solutions. Open troughed belt conveyors are recommended for larger throughputs, higher mass flows and wider curved radii. Closed Pipe Conveyors protect both transported items from environmental influences and the environment from falling items. Troughed belt conveyors can also be covered or encased to minimise dust formation during transport. This seal guarantees dust-free transport.
BEUMER's portfolio also includes mechanical vertical conveyors such as belt bucket elevators. They are an essential production link in the cement industry. BEUMER reliably seals the shaft casings of these bucket elevators, which stops dust from escaping. Instead, the dust trickles into the bucket elevator boot that is equipped with a dynamic bottom. Wet and sticky material cannot accumulate but is fed back into the transport process.
Loading without spilling
BEUMER Group has developed bulk loading heads for the quick and dust-free loading of bulk transporter vehicles. They are designed according to the double-wall system, where the material inlet and the dedusting unit are separated from each other. When the bulk loading head is placed on a filler neck, its sealing cone is lowered and the outlet spout opens simultaneously. The lowering level of the sealing cone is variable. You can adjust the fill level in the vehicle using the fill level meter. In order to balance out any minor positional deviations of the vehicle, the operator can move the bulk loading head laterally during placement.
The bulk loading head is also available with an integrated compressed-air filter. This allows you to operate the centralised dedusting units independently from the dust transporting devices. The dust removed from the bulk transporter vehicle is fed again to the material flow during loading. The compressed-air filter consists of filter hoses which are positioned between the inner telescopic tube and the outer bellows. The suction is carried out by a fan fastened at the outside. The cleaning is carried out by timed compressed-air shocks.
Dust-free loading of open vehicles
BEUMER offers various types of telescopic loading systems for dust-free loading of open vehicles. With these systems, the bulk loading head is lowered to the floor of the vehicle and the material feed is switched on. A fill level switch in the lower dedusting hood is activated by the rising material. This causes the bulk loading head to be raised automatically. The edge of the dedusting hood always rests on the material cone while it rises, so that no dust can escape. The bellows, or the telescopic tubes for the dust extraction, are connected to a central dedusting air system. Corresponding devices or flow control gates transport the material to the system. The bulk loading heads can also be equipped with fill level indicators. Once the vehicle is loaded, they reliably turn off the material feed. Different types of fill level indicators are used depending on the properties of the material. Some of the criteria used to select the correct switch are bulk density, flow behaviour as well as product temperature.
Mobile loaders for bulk transporter vehicles
In the cement industry, high loading capacities are required. Stationary bulk loading heads are often not sufficient, especially if the bulk transporter vehicle is standing on a weighbridge and may not be moved during the loading process. It should be possible for the operator to move the bulk loading head to each filler neck of the vehicle. Depending on the properties of the materials to be loaded and the length of the vehicle, different sliding or swivelling loading system options are available. These mobile loading systems can be fitted with either one or two loading heads, depending on the space available.
First, the bulk material needs to be filled in bags so that it can be palletised, packaged and sent to the customer. As a single-source provider, BEUMER Group offers an innovative solution with the BEUMER fillpac filling machine and provides equipment and systems for packaging lines. The new machine can be flexibly integrated with existing packaging lines and can be optimally adapted to the customer's situation. What makes the BEUMER fillpac unique is a specific weighing electronics which ensures the weight accuracy of the bags. Rejects caused by too high or too low filling weights can nearly be eliminated. The weighing unit communicates permanently with the filler neck via a specific software. The automatic bag weight adjustment determines the exact filling weight of the bags, thus enabling the exact degrees of filling during the filling process. The filling spout is equipped with a special hood that reduces dust emission to a minimum. There are also suction points on both sides in the area of the filling spout. The dust is sucked off directly where it builds up and fed back into the process. This allows for a practically dust-free filling of the bags. The three-position cylinder that regulates the coarse and fine flow is protected from dust, because it is positioned vertically and outside of the dirty area. The cylinder for bag discharging is also located in the dust-free zone above the filling spout.
The paper, PE or PP bags are then stacked on pallets of different sizes in a flexible, precise and stable way. For this, BEUMER has developed the BEUMER paletpac®, a high capacity layer palletiser. If you want to avoid dust formation, the bags have to be handled very carefully. This is why BEUMER offers the palletiser with a clamp-type turning device or the newly developed twin-belt turning device. They position the filled bags quickly, ensuring their dimensional stability without any deformations. If required, BEUMER Group customer support can simply upgrade existing palletisers with the twin-belt turning device....
At the French packaging exhibition Emballage 2014 (November 17 to 20 in Paris), the BEUMER Group will be presenting its extensive expertise as a full-line supplier of machinery for filling, palletizing and packaging. Visitors to the trade fair will be able to learn all about the new filling machines from the BEUMER fillpac product range, which are distinguished above all by their weighing electronics. Also on display will be the completely redesigned stretch hood system, BEUMER stretch hood A.
The BEUMER Group is a systems supplier which delivers filling, palletizing and packaging equipment from a single source. Using intelligent automation, BEUMER links individual machines and systems in an efficient manner. An example is the innovative BEUMER fillpac, which can be incorporated flexibly into existing packaging lines. The system is equipped with a calibratable electronic weighing unit which ensures that the fillpac always achieves accurate filling quantities. Special software enables the unit to communicate continuously with the filling spouts. This allows users to get the best out of their packaging lines, as it is not necessary to reject bags with incorrect weights from the process.
BEUMER also offers the robotpac, a space-saving, fully automatic articulated robot which is able to perform complex palletizing and depalletizing tasks reliably and efficiently. It stacks containers such as bags, cartons, boxes, canisters and trays safely and economically. BEUMER has developed appropriate, flexibly exchangeable gripper systems for every packaged product.
The flexible BEUMER paletpac high-performance layer palletizer stacks paper, PE and PP bags on pallets of various sizes with accuracy and stability. The intralogistics experts have completely overhauled this product. Users now benefit from improved accessibility, shorter installation time, greater flexibility and therefore lower costs. The BEUMER paletpac is equipped with a clamp or double-belt turning device depending on the product requirements. The double-belt turning device allows bags to be stacked on pallets particularly gently, quickly and accurately. BEUMER’s customer support specialists can easily retrofit existing palletizers with this solution.
The intralogistics specialists have added a new machine to the BEUMER stretch hood model range. The high-performance packaging system has been redesigned from the bottom up. During development, BEUMER analyzed various components and optimized them in terms of function, arrangement and ergonomics. A soft touch panel was added for better menu guidance and the workstations were optimized according to ergonomic principles. The new model also features an innovative film transport system which gently conveys the film to the machine.
BEUMER at Emballage 2014, Hall 5a, Booth L104...
The intralogistics professional has expanded its product portfolio with the BEUMER fillpac filling machine offering, as single-source provider, equipment and systems for packaging lines from one source. The new machine can be flexibly integrated with existing packaging lines and can be optimally adapted to the customer's situation. What makes the BEUMER fillpac unique is a specific weighing electronics which ensures the weight accuracy of the bags. Rejects caused by too high or too low filling weights can nearly be excluded.
The BEUMER fillpac is equipped with a weighing unit that communicates permanently with the filler neck via a specific software. The automatic bag weight adjustment determines the exact filling weight of the bags, thus enabling the exact degrees of filling during the filling process. The user can design his packaging lines more efficiently as it is no longer necessary to remove under or overweight bags from the line. In addition, the quantity indicated on the bag always corresponds to the real volume.
The BEUMER fillpac is designed for capacities ranging from 300 to 6,000 bags per hour and can fill various bag types. If equipped with a special bag placer, it can even fill HDPE bags. The three-position cylinder that regulates the coarse and fine flow is protected from dust, because it is positioned vertically and outside of the dirty area. The cylinder for bag discharging is also located in the dust-free zone above the filling spout. This solution minimises wear and tear on both cylinders and, therefore, ensures longer service life.
Almost all built-in components of the BEUMER fillpac are freely available commercially. This reduces delivery times for spare parts and lowers capital costs for the user. Also, the system is designed so that it is easily accessible for maintenance. The generously dimensioned filling impeller reduces fill times, thus increasing throughput. The BEUMER system is also equipped with an ergonomic control terminal. The improved human-machine interface concept makes work simple and intuitive. Furthermore, BEUMER has designed the system in a way that individual customer requirements or special wishes can be implemented flexibly and cost-effectively....
At Pack Expo 2014 (Nov. 2-5, McCormick Place in Chicago) the BEUMER Group will be presenting its full line of machinery for filling, palletizing and packaging. One new addition to its product range is the redesigned BEUMER stretch hood, a highly efficient system for packaging palletized goods.
BEUMER delivers filling, palletizing and packaging equipment from a single source. Using intelligent automation, the full-line supplier links individual machines and systems to create efficient packaging lines. An example is the new BEUMER fillpac bagging system, which can be incorporated flexibly into existing packaging lines. It is equipped with a calibratable electronic weighing unit which ensures that the fillpac always achieves accurate filling quantities. Special software enables the unit to communicate continuously with the filling spouts. This allows users to get the best out of their packaging lines, as it is not necessary to reject bags with incorrect weights from the process.
BEUMER also offers the paletpac high-performance layer palletizer, which stacks paper, PE and PP bags on different sized pallets flexibly, accurately and stably. BEUMER has overhauled this product so that it works even more efficiently. Users benefit from improved accessibility, shorter installation time, greater flexibility and therefore lower costs. The palletizer can be fitted with a double belt turning mechanism which allows bags filled with bulk materials to be stacked on pallets gently, quickly and accurately. BEUMER's Customer Support specialists can easily retrofit existing machines with this solution.
In addition, BEUMER has redesigned its high-performance stretch hood from the bottom up. As part of this, its experts analyzed and optimized various components. They added a soft touch panel for better menu guidance and optimized the workstations according to ergonomic principles. An innovative film transport system gently conveys the film to the machine. For users this means enhanced performance and better availability.
Visitors to the trade fair will also learn about BEUMER's Customer Support. Experts provide maintenance and service for customers all over the world, ensuring that their systems keep running at all times.
BEUMER at Pack Expo, North Upper Hall, Booth #6007...
BEUMER Group – an international leader in the manufacture of intralogistics systems for conveying, loading, palletising, packaging, sortation and distribution – will be exhibiting at Inter Airport China, being held at the China International Exhibition Centre, Beijing, on 15-17 October 2014.
One of BEUMER Group’s main areas of activity is servicing growing airport hubs where passenger numbers have risen sharply, employing the latest baggage handling technology solutions to fulfil the airports' needs. Recent projects include a CrisBag®-based system for Abu Dhabi International Airport, a tilt-tray system for the newly opened Hamad International Airport, Doha, and BEUMER autover® for Nice Côte d’Azur Airport.
BEUMER Group has a strong, local project management and engineering set-up in China with BEUMER Machinery (Shanghai), and airport projects are handled jointly with BEUMER Group company, Crisplant. Crisplant has operated in China for a number of years and is known for the design and installation of the baggage handling system in Shanghai Pudong's Terminal 2 as well as in Chek Lap Kok International Airport, Hong Kong, Changsha Huanghua International Airport, Guangzhou Baiyun International Airport, Xi'an Xianyang International Airport and Beijing Capital International Airport.
A recently completed project was a baggage handling system designed to raise the capacity of Nanjing Lukou International Airport to an annual 18 million passengers. The system can directly sort bags to all the make-up carousels from any check-in position, so there is no necessity for any check-in desks to be dedicated to particular airlines. This delivers the advantage of smoothing peak processing times, with airlines being able to operate only as many desks as are necessary to ensure good service and short waiting times....
At SyMAS 2014, the international trade fair for the processing, storage and transportation of bulk material and powders (October 29 - 30 in Krakow/Poland), BEUMER Group, a turnkey solutions provider, will be presenting its filling, palletising, and packaging technologies. They will also feature conveying and warehouse management system solutions, all backed by BEUMER's comprehensive customer support team.
BEUMER Group designs, constructs and installs conveying systems as well as filling, palletising and packaging systems that are tailored in detail to the specific requirements of the customer. Belt conveyors are a cost-effective and sustainable solution. They are able to negotiate curves and are designed either as open troughed belt conveyors or as closed Pipe Conveyors. Belt conveyors can be adapted optimally to the environment due to their ability to negotiate long distances and large differences in height. By overlapping narrow horizontal and vertical curves, belt conveyors fit seamlessly within existing terrain.
BEUMER Group's strength lies in its efficient combination of individual installations and systems with intelligent automation. As a systems supplier, the company provides filling, palletising and packaging technology from one single source. This includes the new BEUMER fillpac filling system, which can be flexibly integrated with existing packaging lines. Equipped with calibration-capable weighing equipment, the weighing electronics ensure that the BEUMER fillpac always achieves precise degrees of filling. Special software supports permanent communication between the weighing unit and the filling spout. Users can thus optimise their packaging lines because there is no longer any need to remove bags with an incorrect weight from the process.
To be able to stack paper, PE and PP bags on pallets of different sizes in a flexible, precise, stable and even more efficient way, the intralogistics supplier offers the BEUMER paletpac high capacity layer palletiser, which has recently been completely revised for more efficiency. The user benefits from improved accessibility, shorter assembly period, higher flexibility and, as a result, lower costs. The palletiser can be equipped with a twin-belt turning device, so that the bagged bulk material can be stacked on pallets in a gentle, fast and precise way. If required, BEUMER Customer support can simply upgrade the systems with this solution.
A new machine from the BEUMER stretch hood model range will efficiently package the palletised stacks. The high capacity packaging system was given a complete redesign. Various components have been analysed and optimised by our experts during its development. Feature enhancements include an improved menu system on the machine control via a soft-touch panel, an optimised, ergonomically designed workplace for the operator, and material-friendly transporting of the film in the machine thanks to an innovative film transport system. The result is guaranteed higher system output and improved machine availability for the operator.
BEUMER has developed a Warehouse Management System (WMS) that fulfils key requirements for bulk materials, such as the storage of sensitive materials, batch tracking as well as space-saving and cost-effective warehouse management. The WMS has an interface to all of the current ERP systems. The management of the warehouse, material flow system and process control of the individual machines are integrated into the WMS. This offers the user a comprehensive overview of both production and warehouse operations, providing the possibility to optimally adapt both to current requirements. At the trade fair, visitors will also learn everything about BEUMER's comprehensive customer support.
BEUMER at the SyMAS: booth B30...
The shortlist for the 2014 Postal Technology International Awards has been announced. The awards are designed to honor and reward all the hard work currently taking place in the postal industry.
BEUMER Group is proud to announce it has been shortlisted for the ‘Supplier of the Year’ award at the Postal Technology International Awards 2014.
The results of the awards will be announced exclusively on September 23 at Post Expo 2014 in Stockholm, Sweden and published in the Postal Technology International Showcase....
As a single-source provider for filling, palletising and packaging technologies, BEUMER Group continues to pursue its ambitious goal of offering its customers sustainable solutions. In order to control, coordinate and display these processes, BEUMER Group also provides Group Warehouse Management Systems (WMS). These system solutions are tailored to the customers' individual requirements.
For companies in the food and beverage, construction material, electronics and pharmaceuticals industries, the topic of safety when transporting and storing palletised products has become more and more important. These products must be palletised and filled reliably and securely packed in order to deliver them to the customers without damage. The intralogistics specialist BEUMER has expanded its product portfolio with the filling machine BEUMER fillpac and offers plants and systems for complete packaging lines as single-source provider. The fillpac can be flexibly integrated with existing packaging lines and can be optimally adapted to the customer's conditions. In palletising technology, BEUMER provides a graduated and comprehensive spectrum of high-capacity layer palletisers that form secure load units. The geometric precision and the stability of the palletised stacks enable easy storage and ensure secure conveyance to the packaging system downstream. These plants and systems, in combination with the conveying technology also offered by BEUMER, are meticulously coordinated with each other and have a very long service life. BEUMER adapts these in an optimal manner to individual customer requirements, such as machinery capacities, manufacturing output or storage space. In order to achieve reliable and efficient control of all of these processes, BEUMER provides Warehouse Management Systems (WMS), which can be tailored to the users' requirements.
Warehouse Management System guarantees process control
The BEUMER Warehouse Management System is a web server application which controls and coordinates the entire packaging process, storage and preparation for shipment of products in an optimum manner. Control of materials flow, warehouse management and also the interface to the superior ERP system of the customer are integrated to form part of the system. All information from the packaging line, labelling, storage and shipment converges here. This ensures complete and absolute transparency of all products and processes. All the persons involved in production can access the system, the logistic scheduler, warehouse employees or forklift operators. The functions and graphical user interface can be configured to meet customer-specific requirements. The BEUMER Warehouse Management System ensures financially sensible processes and transparent flow of goods which leads to shorter delivery periods.
If the ERP system receives a picking order, it sends the information to a distributed control system and to the Warehouse Management System. The distributed control system monitors and controls the material flow from the silo, checks the product quantities, bagging, palletising and also securing of loads. The packed load units are then provided with a barcode. In the process, the BEUMER Warehouse Management System is in continual data exchange with the ERP system.
After the load units are delivered to the conveying system, the palletising technology stacks the boxes, bags or trays onto pallets in a secure and space-saving manner. These pallets are then transported on roller conveyors towards the BEUMER stretch hood® high-capacity packaging system. The stretch hood system wraps the loaded pallets with a special polythene film. This extremely weather-resistant packaging ensures the safety of the products during storage and shipment. They are then provided with a barcode.
The Warehouse Management System includes also a main control system for fork-lifts. This ensures that the palletised and packaged goods can be loaded quickly without prolonged intermediate storage. Therefore, the Warehouse Management System checks if the pallet is ready for collection at the belt conveyor, reads the barcode, assigns a specific storage space for the pallet and controls the corresponding fork-lift. In these processes, the BEUMER Warehouse Management System is in continual data exchange with the ERP system.
Any errors that could occur amongst the production, storage and shipment systems are avoided with the BEUMER Warehouse Management System, as are time-consuming searches. As all processes are defined chronologically, an automatic material reservation and provision process is enabled that is timely and tailored to demand. The warehouse and supply process that is positively driven also makes the production throughput clearly faster and more efficient....
BEUMER Latinoamericana Equipamentos Ltda., – part of BEUMER Group, a leading global supplier of automated baggage handling systems – will present solutions for the total integration of all baggage handling processes on Stand 49-B at Airport Infra Expo 2014, 17-19 September, at Expo Centre Norte, in São Paulo, Brasil.
Delegates will see videos of existing airports in which the BEUMER Group has integrated innovative baggage handling systems into new terminals, or upgraded an existing system with virtually no disruption to the normal operation of the airport.
BEUMER Group's baggage handling systems feature a high degree of flexibility which is very crucial to the short-term and long-term baggage handling efficiency. This flexibility also allows their systems to be adapted to reflect future changes such as new demands from airlines, passengers or regulations.
BEUMER Group brings together the Crisplant and BEUMER brands whose combined experience includes designing, manufacturing and integrating high-speed baggage handling systems for airports around the world. A proven, global support network ensures that BEUMER Group baggage handling systems can be maintained, supported and optimised to meet each airport’s changing demands and capacity.
An advanced baggage handling system from BEUMER Latinoamericana Equipamentos Ltda. is currently being installed at the new terminal of Viracopos International Airport, in Brasil. BEUMER Group was also behind the design, manufacture and integration of energy-efficient, high-speed automated baggage handling systems for the new International and Domestic terminals at El Dorado International Airport, Bogotá, Colombia, and also delivers baggage handling solutions to enable the modernisation of regional airports Antofagasta Airport in Chile and Araraquara, Cascavel and Franca Airports in Brazil.
BEUMER Latinoamericana Equipamentos Ltda., will be on Stand 49-B at Airport Infra Expo 2014, 17-19 September, at Expo Centre Norte, in São Paulo, Brasil....
Qatar Airways’ new Hamad International Airport in Doha, Qatar, previously known as New Doha International Airport, has opened with a promise to set a global benchmark in quality and service.
To achieve its goal of exceptional baggage handling, with the shortest possible connection times between flights and no lost baggage, the airport engaged Crisplant – part of BEUMER Group and a leading global supplier of automated material handling systems – to supply a high-speed solution with the capacity to sort 19,500 bags per hour.
Handling baggage for an initial 24 million passengers per year, expected to rise to 50 million per year when the airport is fully operational, requires a specially designed system. The Crisplant system is fully redundant, having two tilt-tray sorting systems with a total of 28 inductions, 172 chutes and 22 make-up carousels. This guarantees that, even in the unlikely event of sorter downtime, passenger bags for this major airport hub, which will handle 80% of its traffic as transfers, will continue to be processed on schedule, with no flight-delaying holdups.
To further streamline the transfer bag process, there are 1,750 fully automated early bag storage positions located below sorter system loops for efficient and timely release and make-up based on flight or time slots.
In addition to this baggage handling system having a notably high capacity, it is also distinguished by having the world’s largest plug-and-play integrated hybrid RFID-barcode scanning system.
To ensure that the baggage handling system continues to operate at optimum efficiency, Crisplant’s Customer Support team will remain on-site to maintain the baggage handling system as part of a five-year service and maintenance contract.
The State of Qatar’s future plans for Hamad International Airport include opening a second terminal in time for the FIFA World Cup in 2022 and the transformation of the area around the new facility into an airport city....
In many industrial processes – as for example in the cement industry – the regularity of the raw materials used plays an important role in the manufacture of products. This uniform consistency is ensured through blending beds located within the storage yard. As a system supplier, BEUMER Group develops stackers and bridge scrapers, the essential components of blending beds, which stack bulk material reliably and guarantee a maximum blending effect. Thus, operators can homogenise large quantities of various bulk materials dependably and efficiently. BEUMER employees can perform the complete engineering of the blending bed systems.
Be it houses, bridges or tunnels: cement is the material that holds everything together. However, a bag of this material has already come a long way before it arrives at the building site. When the component raw materials are mined and transformed into cement at the cement plant, they pass through many different stages. The most important raw materials for cement production are limestone, clay and marl. Workers break them out of quarries or extract them with heavy tools. Wheel loaders and dump trucks transport the raw materials to the crushing facilities. There, the rocks are crushed to the approximate size of road gravel. These rocks then arrive at the cement works via miles long belt conveyors.
A consistent quality must be ensured so that the producers can further process the material to high-quality cement – fluctuations in the material characteristics must not occur. Therefore, a belt conveyor transports the individual raw materials to the blending beds. These storage location systems mix and homogenise the raw materials.
Experts at work
For almost 80 years, BEUMER has been developing tailor-made system solutions in conveying technology for the stone and quarry industry, power plant industry, mining (ores and coal) as well as the logistics industry (harbours and transshipment terminals). Furthermore, the specialists have comprehensive expertise in engineering of blending beds and stockpiles. Through structural analysis of the associated storage depots and calculation of dimensions, BEUMER is able to provide a design. The blending beds are customised according to their requirements. BEUMER proposes either longitudinal or circular stockpile designs. The recommended design shape results from the spatial conditions and the amount of the material to be stored. Depending on the field of application, BEUMER designed blending beds can be used at extreme ambient temperatures, for very high entry conveying capacities, as well as for the highest degree of homogenisation required. Additionally, BEUMER provides material-specific detailed solutions with robust and low-wear equipment. The environmental impacts are also very low as minimal noise and dust occurs during operation. Blending beds can be set up both outdoors and indoors.
Compiled and extracted in layers
The stacker and the bridge scraper are the basis for a blending bed. If they are perfectly designed, the user will obtain an optimum blending effect. BEUMER offers stackers that stack the bulk material efficiently and effectively. In the end, the stockpile has been raised so reliably that its cross-section shows as many layers of equal material as possible. The stackers can be of fixed or mobile types, depending on the requirement. In case of circular stockpiles the stackers are mounted onto a column and with a longitudinal blending bed, they are mounted on rails. The stackers are designed as fixed, raisable and pivotable booms with conveying capacities of up to 4,000 tons per hour. The choice of the right system depends on different factors, as for example, the shape and size of the stockpile, the material, the throughput and the desired mobility.
Lastly, the bridge scraper homogenises the material. It has a mobile rake on each side. The material is removed in layers by stroking the face of the stockpile with the rake. The scraper blades move the bulk material towards the belt conveyor which runs parallel to the stockpile. BEUMER bridge scrapers are not only robust, but they also transport the bulk material so that the product is handled gently. This makes them suitable for a variety of bulk materials. Their continuous and comparably simple working motions allow for a fully automated operation and ensure a constant and steady flow of the bulk material.
In the past, the new BEUMER team has completed remarkable projects in this field. One such example is an installation of a bridge scraper in Russia, which works at an ambient temperature as low as -40 degrees Celsius. The rail width is 34 metres and this bridge scraper is designed for a conveying capacity of 500 tons per hour. Furthermore, BEUMER has developed a stacker for coal mining, which is operated at ambient temperatures of -20 degrees Celsius. This boom has a length of 41 metres and the belt width measures 1.6 metres. It transports 2,250 tons of bulk material per hour. BEUMER also engineered a bridge scraper with a rail width of 55 metres that conveys 1,100 tons of coal per hour....
Crisplant – part of the BEUMER Group and a leading global supplier of automated baggage handling systems – announces that the CrisBag® high-speed baggage transport system, with Smiths Detection’s HI-SCAN 10080 XCT explosives detection system, has been certified to European Civil Aviation Conference (ECAC) Standard 3 for in-tote screening.
This is the first time that a tote-based baggage transport system, with an integrated Explosive Detection System (EDS) has obtained EU Standard 3 certification for both the standard and extended tote sizes. With this approval, the integrated CrisBag® and XCT systems will give airports a significant advantage by delivering high-speed baggage transport combined with benchmark throughput and certified baggage security, in a single, cost-efficient solution.
The ECAC Common Evaluation Process of Security Equipment was carried out as laboratory tests conducted at one of the Participating Test Centres located in ECAC Member States. The tests demonstrated that Smiths Detection’s HI-SCAN 10080 XCT explosives detection system in combination with Crisplant's CrisBag baggage transport system meets the ECAC performance standard.
Crisplant was among the first baggage handling systems manufacturers to introduce in-tote screening to the market with the installation of the CrisBag high-speed baggage transport system in Terminal 2 at Munich Airport, Germany. The concept of in-tote screening and its implementation in the CrisBag system has been widely recognised as a breakthrough in secure and efficient baggage handling. Most lately the CrisBag system was installed in London Gatwick Airport, Düsseldorf Airport in Germany, Changi Airport in Singapore, Bergen Airport in Norway, Abu Dhabi Airport in the United Arab Emirates, and Canada’s Calgary Airport and Ottawa Airport.
In addition to faster baggage transport and system flexibility, CrisBag enables airports to maximise the baggage screening process security by providing 100% track and trace all through the screening and baggage handling process.
In a separate test, the CrisBag system together with Smiths Detection’s HI-SCAN 10080 XCT has proved to process baggage at a maximum throughput rate of more than 1300 totes per hour, setting a new benchmark for in-tote screening capacity....
BEUMER Group – a leading global supplier of automated material handling systems for conveying, loading, palletising, packaging, sortation and distribution – has completed the handover of a sortation system to PostNord AS for its new parcel terminal near Oslo.
Formerly known as Tollpost Globe, now part of the Nordic communications and logistics solutions provider PostNord, the Norwegian company has experienced a boom in its parcel logistics business. The company established the new parcel terminal near Oslo to meet the need for increased capacity in the area around the capital. The location of the new terminal was chosen to make use of the optimised infrastructure in the area to further strengthen and offer a flexible network to customers.
PostNord is no stranger to Crisplant’s sortation systems. Back in 2009 the then-Tollpost was the first parcel distribution company to commission a system with the then-newly released energy-efficient, high-speed LS-4000E sorter. Since that sorting centre opened in 2010, the system has given top-quality service.
In addition to the LS-4000E sorter, the system will include a BEUMER Group software suite system. The entire system is designed to be easily upgradable should there be the need for higher capacity in the future.
As with all PostNord AS' business, the new terminal is part of the company's wish to offer environmentally friendly service and logistics. The facility features a high level of operational efficiency, positive environmental impact and better transport solutions for PostNord's customers.
Property Manager Ronny Grøtvedt, PostNord AS, commented: “Total satisfaction with our original system made the LS-4000 sorter an ideal choice for our new sorting centre. It’s the best solution.”...
BEUMER Group is single-source provider for filling, palletising and packaging technologies. The system supplier continues to pursue its ambitious goal of offering its customers solutions that are sustainable in every respect. To be able to stack bundles such as bags, cardboard boxes, crates, canisters or trays safely and economically, BEUMER Group offers the BEUMER robotpac, a space-saving, fully automatic articulated robot. This fully automatic articulated robot is able to solve even complex palletising and de-palletising challenges reliably and efficiently. BEUMER has developed fully automatic gripping systems that are easily exchangeable and suitable for each item to be packed.
Over the years, BEUMER has established extensive expertise in the design of grippers and control technology. Furthermore, the company offers solutions for filling, conveying, palletising and packaging from one source. This reduces the number of transitions in a project as a whole.
Different Grippers for Different Tasks
The fork gripper was designed for palletising bagged goods and cardboard boxes. It picks up the packaged item from a take-away roller conveyor and secures it using a holding-down device during transport. Once the target position on the pallet has been reached, the gripper opens with a horizontal movement and the push-off plate pushes the packaged item off the fork. The fork gripper features gentle product handling and precise placement of the packaged items. The double fork gripper was also designed for palletising bagged goods and cardboard boxes and picks up two bags simultaneously from a double take-away roller conveyor. Once the packaged item is placed on the pallet, the fork is raised and the tool approaches the target position for the second packaged item. The placement occurs consistently with the first fork's stacking process. Once both forks have placed the packaged items, the tool returns to the pick-up position.
The finger gripper has been developed for palletising bagged goods. It takes the bags from hoist equipment on the take-away roller conveyor and carries it to the target position. Here, the fingers open while the slide plates remain in a closed position. This ensures that the bag is guided along the sides during the stacking process. The double finger gripper is a high-performance tool designed for maximum palletising capacity.
Parallel and Suction Grippers, Combination and Special Tools
The parallel gripper is a special tool for palletising cardboard boxes and other dimensionally stable containers with parallel side walls. The essential components are a fixed plate that functions as a limit stop and a pneumatically activated clamping device that pushes the cardboard box horizontally against the fixed plate.
The suction gripper is fundamentally able to handle all goods with suctionable surfaces. Bagged goods belong to the most frequently palletised products. The suction gripper places its suction head above the product and then lowers the suction head tightly against the product surface. The vacuum pump starts and creates a vacuum in the suction head. Then, the bag is picked up and transported to the target position. Air is released into the suction head and the bag is placed. The suction gripper is used for low palletising capacities.
In addition to these gripping systems, there is a large number of specialty grippers and combination tools. Special tools enable simultaneous processing of secondary tasks, including sheet or empty pallet placement on the conveying systems or barcode reading. Should the needs of the user be so specific that none of the standard grippers is suitable, BEUMER can design a system specifically for such unique requirements. Virtually all products can be palletised with a robot.
High Availability and Gentle Handling
The BEUMER robotpac distinguishes itself through its remarkable precision and availability, as well as through its gentle product handling. An ultrasonic system provides accurate measures of the stacking height, making it possible to calculate the exact placing position of the packaged items and stack these precisely and carefully. This precision guarantees an optimal stack configuration. The latter not only serves as a mark of quality for your customer, it also ensures high stability during shipping and storage.
System and control from one source
That the BEUMER control systems do not require special robot-related expertise - due to their user-friendly design - is also a key advantage. To enable operators to operate the BEUMER robotpac easily and quickly, the intralogistics specialist has equipped it with the BEUMER Group Human Machine Interface (HMI), an operator panel with an optimised user interface and optimised navigation, which creates easily understandable and intuitive interaction, enabling the user to define efficient working sequences. The operator can control the machine safely, independently of prior skills, training and capabilities, this saving time and money which ensures high economic efficiency.
Regulated by complex control mechanisms, the BEUMER robotpac can stack packaged goods of variable dimensions on one pallet. Individual programmes cover all packing patterns, so that complicated and tedious adjustments become a thing of the past. The switch to another programme with the BEUMER robotpac requires a mere push of a button. Thereby, the BEUMER robotpac optimises the material flow quickly and easily adapting itself to products of different sizes and characteristics.
Robust and empirically tested machine components, together with state-of-the-art geared motors, guarantee smooth operation. Therefore, the BEUMER robotpac is not only easy to maintain, but also extremely quiet. The performance can be enhanced cost-effectively. Equipped with an additional drive axle and an integrated motor connected to the control system, the BEUMER robotpac is freely movable on a guide rail. Consequently, it can be used in distribution centres for order picking tasks. The BEUMER robotpac demonstrates its reliability even in dusty environments typical of packing plants and of the building material industry....
The BEUMER Group is one of the world’s leading manufacturers of conveying and loading equipment, filling, palletizing and packaging equipment, and systems for sorting and distribution. The product range of this full-line supplier includes the BG software suite, which allows customers to control their material flows from start to finish. The suite can be adapted to each company’s special needs. Third-party products can be integrated without difficulty.
BG, which stands for BEUMER Group, is the name for the company’s software suite for high-level computer systems. The suite’s modular structure allows users to adapt it to their machinery and equipment and add modules at any time in order to optimize their material flows. The Beckum-based intralogistics specialist also provides the BG Fusion interface, which displays process data, reports and machinery statistics for all parts of the program. Users can call up data on their monitor without having to switch between applications. BG Fusion is fully scalable, meaning it can run on desktop PCs as well as mobile devices like tablets.
Customized for each user
The left area of the interface displays important information in a compact form for all users. The main area is reserved for data relevant to the particular application. Three different desktops are available. Users can store their individual settings so that they can go right to work with the same data when they log in again. The user interface can also be switched between different languages. The web-based interface runs on all current Windows operating systems. Users can export all data displayed on the screen to PDF or CSV files. A screenshot function is also included.
The BEUMER Group Warehouse Control System (BG WCS) module allows the BG software suite to link up with the customer’s warehouse management system or ERP system via a network connection. Thus communication is possible between different control levels.
As a full-line supplier, the BEUMER Group can draw on many years of experience in control and automation technology. It is able to plan and implement complex projects in intralogistics, including intelligent linking of machinery and systems and their integration into existing process control or merchandise information systems. Customers get everything they need from a single source, interfaces are avoided, and possible sources of error are eliminated....
At Powtech 2014, the trade fair for process engineering, analytics and handling of powder and bulk material (Sept. 30 – Oct. 2 in Nuremberg), the BEUMER Group, a full-line supplier for filling, palletizing and packaging technology, will be presenting its expertise. Visitors will learn about conveyor systems, the warehouse management system and BEUMER’s extensive customer support. Whether construction materials or chemical products are needed – the user can get everything from a single source.
Depending on the operating environment, method of handling and anticipated application, the behavior of powders and bulk materials can change completely in conjunction with certain materials. Behavior can depend on the particles’ size and form, bulk weight, compressibility, cohesive strength, moisture, oil content and type of reaction to atmospheric conditions. This affects the flow behavior, which in turn has a significant effect on the correct design of conveyor systems and filling, palletizing and packaging equipment. BEUMER plans, builds and installs systems which are matched to the user’s individual requirements down to the last detail.
With its belt conveyors, the BEUMER Group supplies economical and sustainable solutions for the conveying of bulk materials. The curved belt systems are produced in an open design as troughed conveyors or in an enclosed version as tubular belt conveyors. They can be optimally matched to the environment and overcome long distances and large height differences. This is ensured by their optimum line through the terrain and tight horizontal and vertical curves which can also be laid above one another in the route of the conveyor.
The strength of the BEUMER Group is its ability to combine individual machines and systems by means of intelligent automation for greater efficiency. The BEUMER Group delivers filling, palletizing and packaging equipment from a single source as a systems supplier.
The BEUMER fillpac bagging system can be incorporated flexibly into existing packaging lines. It is equipped with a calibratable scale. The electronic weighing unit ensures that the fillpac always achieves accurate filling quantities. Special software enables the weigher to communicate continuously with the filling spouts. This enables users to get the best out of their packaging lines, as it is not necessary to reject bags with incorrect weights from the process.
BEUMER has completely revamped the BEUMER paletpac high-performance layer palletizer in order to stack paper, PE and PP bags on different sized pallets flexibly, accurately and stably. BEUMER has completely overhauled this product so that it works even more efficiently. Users benefit from improved accessibility, shorter installation time, greater flexibility and therefore lower costs. The palletizer can be fitted with a double belt turning mechanism which allows bags filled with bulk materials with special flow behavior to be stacked on pallets gently, quickly and accurately. BEUMER’s Customer Support specialists can easily retrofit existing machines with this solution.
BEUMER also offers the robotpac, a space-saving, fully automatic articulated robot which is able to perform complex palletizing and depalletizing tasks reliably and efficiently. BEUMER has added a new machine to its stretch hood series for efficient packaging of palletized stacks. As part of this work, it redesigned its high-performance packaging system from the bottom up. During development, the company’s experts analyzed and optimized different components.
BEUMER has also developed a Warehouse Management System (WMS). This system fulfills all the main requirements of the bulk materials industry, such as the storage of sensitive substances, batch tracking and space-saving and cost-efficient warehouse management. The WMS has an interface to all common ERP systems. Warehouse management, the material flow system and process control of the individual machines are incorporated. The user therefore has a continuous overview of his production and storage facilities at all times and can match them to the prevailing requirements. Visitors to the trade fair can learn all about BEUMER’s comprehensive customer support.
BEUMER at Powtech, hall: 1, booth 135...
At CeMAT Russia (September 23-26 in Moscow), the BEUMER Group, a full-line supplier of conveyor and loading equipment, palletizing and packing technology, and sorting and distribution systems, will be presenting its innovations. BEUMER is dedicated to pursuing its mission of delivering sustainable solutions for users' every need - and providing everything from a single source. In this way it is helping companies in the emerging Russian market to efficiently shape intralogistical processes.
In the field of conveying and loading equipment BEUMER provides information on belt conveyor systems with horizontal and vertical curves, belt bucket elevators, heavy-duty belt bucket elevators for particularly large delivery rates and heights, and steel cell conveyors for clinker. As well as supplying all the machines and control systems for the plants, BEUMER often takes charge of the whole process. This includes the planning and design of the complete system as well as the coordination and monitoring of installation and commissioning. The BEUMER Group also offers comprehensive customer support. This service ensures the high availability of all systems from the user's point of view.
The strength of the BEUMER Group is its ability to combine individual machines and systems by means of intelligent automation for greater efficiency. The BEUMER Group supplies filling, palletizing and packaging equipment from a single source. The BEUMER fillpac can be incorporated flexibly into existing packaging lines. The bagging machine is equipped with a calibratable weigher. The electronic weighing unit ensures that the fillpac always achieves accurate filling quantities. Special software enables the weigher to communicate continuously with the filling spouts. This enables users to get the best out of their packaging lines, as it is not necessary to reject bags with incorrect weights from the process.
BEUMER has completely revamped the BEUMER paletpac high-performance layer palletizer in order to stack paper, PE and PP bags on different sized pallets flexibly, accurately and stably. BEUMER has completely overhauled this product so that it works even more efficiently. Users benefit from improved accessibility, shorter installation time, greater flexibility and therefore lower costs. The palletizer can be fitted with a rotary clamp or double belt turning device which allows bags filled with bulk materials with special flow behavior to be stacked on pallets gently, quickly and accurately. BEUMER's Customer Support specialists can easily retrofit existing machines with this solution.
BEUMER also offers the robotpac, a space-saving, fully automatic articulated robot which is able to perform complex palletizing and depalletizing tasks reliably and efficiently. BEUMER has added a new machine to its stretch hood series for efficient packaging of palletized stacks. As part of this work, it redesigned its high-performance packaging system from the bottom up. BEUMER's experts analyzed different components and optimized them.
In Russia the demand for sorting and distribution systems is growing, particularly in the CEP market. Much of this demand comes from e-commerce. To meet this demand, BEUMER has machines in its portfolio that can be equipped with different modules and functions. The BEUMER Group has developed a new high-performance sorter: OptiDrive, a new, efficient force-fit drive system. Pressure is applied in both directions - while accelerating and while braking. In this way the pressing force of the drive wheel is automatically adjusted depending on the amount of power needed. This increases efficiency by up to 85 percent.
Visitors to the trade fair can learn all about BEUMER Customer Support. Highly capable experts located all over the world provide professional repair and maintenance, deliver spare parts and carry out customer training....
The intralogistics specialist from Beckum has developed a new, highly efficient friction drive system for high-performance sorters in the form of the OptiDrive and, as a result, now offers an extremely economical alternative to the asynchronous linear motor drives used previously. What makes the BEUMER OptiDrive so special? Thanks to new and innovative engineering, the contact pressure of the drive wheel is automatically set depending on the required drive force – both for driving and for braking. This boosts efficiency and enhances the service life of the drive wheels. This technology is already successfully deployed in many systems.
According to the Federal Environmental Agency, electrical drives in industrial and commercial applications consume almost two-fifths of all electricity in Germany. Optimised solutions offer users enormous potential for reducing operating costs and conserving resources. The BEUMER Group continually seeks to meet market requirements and to support their customers with sustainable, cost-efficient equipment and systems. Following BEUMER's successful introduction of the new OptiDrive technology back in 2010 for the smaller BS7 high-performance sorter, the intralogistics specialist has now also implemented this for the larger models from the BS25 to the BS60, with mechanically or electrically operated load-bearing elements. "So far we've used double comb asynchronous linear motor drives in these systems," explains Heino Heitplatz, Team Leader Research & Development and Deputy Head of Development at BEUMER. "We wanted to increase the efficiency while at the same time reducing procurement costs. In addition, our goal was to ensure high availability with minimum maintenance and repair costs." BEUMER high-performance sorters are used for sorting and picking a variety of items such as mail, textiles, mail order products, foods or baggage.
For the BEUMER OptiDrive, the contact pressure with which the drive wheel is pressed against the movable friction blade of the circulating carriage assembly is automatically adjusted proportionally to the required driving power. Thus, the drive always automatically operates at the optimal operating point. On one hand, this allows for safe and slip-free starting up of the sorter from a standstill. On the other hand, the efficiency is improved in the predominant partial load range, while at the same time prolonging the service life of the drive wheels. "Without this innovative proportional contact pressure, we would have had to design the contact pressure of the friction wheel for the worst case, that is, for starting up a stationary, cold machine," says Heitplatz."We call this the Monday morning effect." However, the contact pressure for normal operating conditions would then be much higher than actually required and this would clearly impact efficiency and the service life of the drive wheels. The energy consumption has been reduced by up to 80 percent compared to the previously used asynchronous linear motor drive. "With the new OptiDrive BS25/55, we can achieve effective efficiencies of up to 85 percent," Heitplatz reports.
More efficiency, less wear
What is genuinely innovative about the new drive system is its double-acting proportional contact pressure. This works in both directions of action – when accelerating and braking. This means that the new OptiDrive can act as a holding brake. Compared with single sided linear motor drives, this solution does not cause attraction forces between the drive and the carriage, which reduces the load on the carriage and reduces wear. The drive also lines itself up with the carriage. This means that the user does not need to adjust the system.
With this drive method, each carriage has a blade on the underside that acts as a friction blade. The blade is clamped between the friction wheel and an opposite pressure roller and pushed forward. The drive power transitions to the carriage system via this blade. The drive unit is connected to the sorter frame by means of a centre of rotation. This "floating" bearing prevents transverse forces from the drive unit transferring to the carriage at all times.
Patented functional principle
The patented functional principle of the OptiDrive can be explained as follows: the drive motor with directly attached drive wheel is pushed against the blade by a slight spring force. The traction and the applied driving power generate a reaction torque in the motor bracket, which is pivotally borne, and to which the two contract press rolls are attached. These two press rolls, in turn, act on a pivotally borne press arm, on which the pressure roller is mounted. Thus, a contact force is built up on the blade between the drive wheel and the press roll. The force automatically adjusts proportionally to the driving power. The arrangement with two press rolls ensures this function in both directions of action, that is, for driving and braking.
The OptiDrive is equipped with an automatic tolerance compensation system. It compensates for things such as wear and tear on the drive wheel, or component tolerances. To this end, a spring-loaded wedge is integrated between the press arm and the press rolls. Assembly tolerances are compensated for by the pivotal connection of the drive unit. "The drive permanently lines up with the blades and not vice versa," Heitplatz explains. "This means we can allow larger tolerances in assembly and in the components without functional restrictions or transverse forces acting on the carriage system.
Specially adapted for optimal operation
The blades on the BEUMER OptiDrive act like friction blades. To keep the gaps between the carriages as small as possible, thus enabling smooth and silent transitions between each carriage, the blades feature a special contour and arc-shaped ends. BEUMER has been able to reduce gap between the blades to a minimum — and without impairing the mobility of the carriage system in horizontal or vertical curves.
The friction blades are made of extremely light aluminium profiles. This helps to keep the moving mass of the carriages and the motion resistance as low as possible. "In comparison with other systems that need secondary parts on the carriage, for example, for synchronous linear motor drives, where the carriages are additionally weighed down by the permanent magnets, you definitely can reduce the energy consumption. The fact that the moving mass is lower, is independent of the actual drive efficiency," Heitplatz explains.
The OptiDrive is powered by a modern, highly-efficient gearless synchronous servomotor. The drive wheel is mounted directly on the motor shaft. "Because we consistently do without transmission parts such as gears or belt drives, we leverage the maximum efficiency of the drive. In addition, noise sources and potential maintenance points are consistently avoided," says Heino Heitplatz. The direct drive also allows for a very compact design. "Unlike the central converters of the asynchronous linear motor drives, the OptiDrive concept means that each drive has its own controller which is installed locally in the field," says Heitplatz. The controllers are in close proximity to the drive. The individual drive controllers use Profinet to communicate with the sorter controller. The Profinet installation is daisy-chained, as is the power supply to the drives. This reduces the required cable length and the installation overhead. A special control algorithm ensures that all the drives apply the same propulsion power to the carriage system at any given time. This has the advantage that all drives are equally loaded and the force profile is optimised in the carriage system.
The BEUMER OptiDrive BS25/55 is designed for a permanent propulsion power of 600 Newton, and a short-term propulsion power of 1,000 Newton (for acceleration and braking processes) as well as for sorter speeds of up to 3.2 metres per second. The system is monitored by numerous diagnostics systems. Any malfunctions are indicated to the operator in good time. The user can also maintain the drive system remotely. "Thanks to remote access, our experts in Beckum have the ability to remotely access every single drive worldwide, and thus give the customer the best possible support on site", Heitplatz explains.
Placing great emphasis on sustainability
Like in all of our developments, BEUMER's engineers have again placed great emphasis on sustainability for this drive. The BEUMER Sustainability Index (BSI) shows how sustainable a system really is. This is a validation system which the intralogistics specialist can use to systematically and continuously measure sustainability in terms of economy, ecology and social responsibility, both on new machines and existing solutions. The Group has committed to evaluating its products comprehensively on three levels: economy, ecology and social responsibility. The BSI is a points system that rates products on these three levels. Economic performance, market presence, financial opportunities and risks are well-known parameters. Products only become economically sustainable when they, and their corresponding production processes, are tailored to long-term customer use. "For example, we compared the OptiDrive BS25/55 with predecessor and third-party products," as Heitplatz explains.
Economical, ecological and social
This development has allowed BEUMER to significantly reduce the production costs compared to other drives. This also has a positive effect on the customer's investment costs. The lower energy consumption and the more wear-resistant working method also significantly reduces operating costs. The improved degree efficiency means superior results in terms of both economic and ecological sustainability. Large amounts of copper were saved in the production of the motors and supply cables. Furthermore, the double-acting proportional contact pressure means significantly shorter braking distances of the carriage in an emergency stop, which improves employee safety. Since this drive system does not need fans, the operating noise has also been reduced. This makes for a more pleasant working atmosphere.
A company that distributes agricultural machinery, commercial vehicles, spare parts and accessories has opted for the new drive system in a BS 25 Belt Tray Sorter. The sorter has a length of 198.4 meters and is equipped with 248 carriages. The pitch of the carriages is 800 mm and the operating speed two metres per second. The BEUMER specialists installed a total of four OptiDrive units. The system is designed so that the system remains fully functional, even if one of the drives fails. The integrated freewheel function allows individual drives to be enabled or disabled during operation. After about six months, technicians inspected the drives for the first time and evaluated the wear on the friction wheels. "If we extrapolate the wear we measured, we arrive at an expected service life for the drive wheels of about eleven years," Heitplatz concludes. "The actual wear, of course, depends on the operating conditions. The significant variables include the mean driving power, that is, the degree of capacity utilisation, the sorter speed, the ambient temperature and the daily operating hours of the system."
Cost comparison linear motor drive
The potential savings for the user with the new drive system can be illustrated by the following case study. In the project, the intent was to deploy three type BS25 ET Tilt Tray Sorters with a sorter length of about 1,000 metres each and a sorter speed of 2.35 meters per second. Using the OptiDrive technology can help reduce consumption by about 570,000 kilowatt hours per year. At an energy price of twelve cents per kilowatt-hour, this equates to savings of about 69,000 euros per year. "In addition, the emission of approximately 86 tons of carbon dioxide is avoided in power generation," says Heino Heitplatz, explaining the environmental benefits....
The reasons which brought Schwenk Putztechnik to opt for the BEUMER Group palletising technology were longer maintenance intervals, more efficient production and an optimised stack configuration with regard to storage and sales. The single-source provider from Beckum supplied three high-capacity layer palletisers type BEUMER paletpac. Two others were commissioned recently. All of them are equipped with the newly developed BEUMER twin-belt turning device, which enables bags filled with building material to be turned gently and stacks them in the correct position on pallets ensuring their dimensional stability. The twin-belt turning device can be rapidly adapted to various bag sizes.
Dry mortar are prefabricated mixtures composed of mineral binding agents as cement, limestone, gypsum as well as sand, rock dust and further additives. On the building site the craftsmen have to mix them merely with water and they are ready for use. Owing to the avoidance of possible mixing errors, the producer can ensure a constant high product quality of this building material. Schwenk Putztechnik GmbH & Co. KG headquartered in Ulm is one of the leading manufacturers of sustainable and ecological dry mortar. The company has produced its materials for more than 160 years in seven ultra-modern plants. "We place great importance on presenting our products optimally in the building material trade," says Martin Markus. At Schwenk Putztechnik he manages the plants in Eigeltingen and Allmendingen in Baden-Württemberg. As regards the manufacturing process, the company focuses on trouble-free transport, palletising process and packaging.
Safe handling of bags
"Our previous palletising solution caused considerable problems during the turning of bags," remembers Peter Richter, deputy factory manager in Allmendingen. "Due to jerky movements the bags were deformed and sometimes even torn," he says. The building material manufacturer was not able to ensure a proper and constant appearance of the palletised bags. Schwenk Putztechnik not only wanted to achieve an improved and steady stacking result, but also wanted to increase the production capacity, reduce the dust emissions and prolong the maintenance intervals.
During their researches for a suitable supplier, the building material manufacturer found BEUMER Group. The single-source provider from Beckum supplies sustainable systems for filling, palletising and packaging technology from one source. The leading internationally active company can look back on years of experience in the building material industry. "In cooperation with Schwenk Putztechnik we developed a solution which covers the requirements of both production plants," Peter Schmidt reports. As sales manager he was responsible for the project and has managed since January 2014 the Palletising and Packaging Technology business segment at BEUMER Group.
Gentle palletising is ensured
BEUMER Group presented the high-capacity layer palletiser BEUMER paletpac to the building material manufacturer. This construction series enables to stack bags filled with bulk material on pallets exactly layer by layer. Due to the geometric precision during layer and stack formation, stable bag stacks are formed. BEUMER supplied a system able to palletise 1,800 bags per hour as well as a system with a capacity of 2,500 bags per hour. In both plants the employees can adapt the palletiser quickly and easily to different bag sizes without the use of tools. With a pack height of up to 2,400 millimetres, the BEUMER paletpac stacks bags on any commonly used pallet size and in all technically possible packing patterns. A multi-program interface enables the user to set parameters easily and quickly. The new BEUMER Group Human Machine Interface (HMI) ensures a user-friendly operation of the system. This control terminal provides the employee with an easily understandable and intuitive interaction, enabling the user to learn the system very rapidly and to define efficient working sequences after just a short training and introduction period.
Stable stack formation
"In order to turn the bags rapidly and gently to the required position ensuring their dimensional stability, the systems are provided with our newly developed twin-belt turning device. In regards to the stackability, this device offers an immense advantage when compared with conventional turning processes,” Peter Schmidt explains. The system component moves the bags without stressing them from a mechanical viewpoint. Instead, two parallelly driven belt conveyors are used, which during the turning process are driven with different speeds bringing the bags gently into the desired position. The intelligent control of the twin-belt turning device involves the physical properties of the items to be packed in order to achieve an exact positioning preset by the respective packing pattern. In case of changes in bag sizes, all relevant parameters are registered and controlled just via software. For this, the system reverts to an active control loop. The regulation of the drives is carried out by frequency converters, thus developing a gentle, regular rotation and ensuring that the bagged products are not deformed. This results in constant stack results for the whole service life of the system. Ready packed pallets can be stacked on top of each other in space-saving and safe way.
A further advantage is that time-consuming modifications in case of changed bag sizes are no longer required. "The operator only has to enter the bag length and the bag width. Then the system brings the bag into the corresponding position,” explains Bernhard Temming, service manager at BEUMER. Thanks to the modular structure, the twin-belt turning device can be retrofitted even in already existing palletising systems in quick and trouble-free way.
Quiet and efficient
A further reason for Schwenk Putztechnik to opt for the BEUMER systems was their efficient operation. In addition to capital costs, operational costs, spare parts costs and also maintenance costs play an important role. "These are better reduced with the twin-belt turning device than with other turning devices," recognises service manager Bernhard Temming. "The mere automated product change avoids idle times," and as the system component abstains from cost-intensive mechanical components, this optimises the maintenance and repair costs in the long term and reduces the life-cycle costs. "Comparable solutions of competitors for the layer preparation rely on pneumatic elements with correspondingly high operational costs. In our twin-belt turning devices work is done by energy efficient synchronous servomotors," explains Temming. The relinquishment of mechanical parts additionally lowers noises during operation. Peter Schmidt is convinced that this is a strength that happens especially in the day-to-day operations, providing for an improved working atmosphere and inuring to the benefit of the skilled personnel of the building material manufacturer in the daily working sequence.
For this project BEUMER took over the whole handling - from projection up to installation. The experts of the BEUMER Customer Support take care of the optimisation and maintenance of the systems, therefore, they are always available. In case of acute problems, the building material manufacturer can contact the BEUMER Hotline around the clock. An online connection with the machine permits to carry out a rapid fault analyses. "We are very satisfied with the service. This was a further important aspect which led us to opt for BEUMER," says Martin Markus....