BEUMER Group - a leading global supplier of automated parcel and post sorting systems - will showcase innovative automated sorting technologies at PARCEL-EXPO Asia Pacific 2015. These technologies will include products which have already been installed by BEUMER Group China and Crisplant Singapore to help major companies within the Asia Pacific region to achieve leading-edge speed, capacity and energy-efficiency from the sorting process.
The BEUMER Group will also present papers at PARCEL-EXPO Asia Pacific's two-day conference on business development, productivity and innovation in the Asia-Pacific region:
- 'How automated identification can boost tracking capabilities' Wednesday 13 May, 'Innovation & Trends' moderated by Derek Osborn, CEO, Whatnext4U.
- 'Automating the parcel distribution centre in a world of e-commerce' Thursday 14 May, 'Parcel Hub Development and Logistics' session.
"The sorting technologies being presented at this exhibition combine two of the leading names in automated sorting technologies, BEUMER and Crisplant. The innovations introduced by these BEUMER Group companies are already being used to achieve unprecedented capacity and energy efficiency to companies throughout the Asia Pacific region. These companies include the Singapore post office, SingPost; express parcel courier, SF Express; and two of China's leading online retailers, JD.com and VIPshop," explains Martin Mossinkoff, Managing Director, Logistic Systems, BEUMER Group.
BEUMER Group companies, BEUMER Group China and Crisplant Singapore, will be on Stand No. 4025 at the second PARCEL-EXPO Asia Pacific which will be held in Singapore on 13 - 14 May 2015....
For many companies in the chemical, building material or food industries, the efficient packaging of their palletised goods is a deciding competitive factor. Some of the crucial factors are transport security, anti-theft protection, display characteristics of the packaged goods, as well as weatherproofing for outside storage. Further key factors are process efficiency and cost reduction (energy and material consumption), as well as the system output (the number of pallets that can be packaged during a specific amount of time). All of these factors need to be taken into account in order to determine the perfect packaging technology. Stretch hooding has proven to be particularly efficient in comparison with other techniques.
Palletising and packaging play a particularly important role, in any industry, for delivering your goods in optimum condition to your customers. If the required stability is not provided, goods such as glass, stone or bricks stacked on trucks can detach from the palletised unit and break. This can cause tremendous costs, depending on the product. Materials such as cement, flour or cocoa powder need special protection against atmospheric influences and humidity during transport and storage. To accommodate this, there are different packaging solutions available to the customer. It is important to find the most economical and environmentally sustainable solution. There are currently three different palletising packaging techniques on the market: shrink hooding, stretch wrapping and stretch hooding.
Efficient packaging with shrink film
Film packaging for pallets was developed by a German chemical producer in the mid-1960s, based on using shrink film. The film is produced as a tube using blow head extruders with tubular dies, which are then further processed or slit open to become a flat film. Hot air heats the film during the shrinking process up to the softening point. The film is shrunk to fit perfectly around the palletised goods, which, after cooling down, creates the necessary stability to secure the load. The heat required for the shrinking process is produced by the packaging system either electrically or with gas. If required, the pallet can be packaged leaving its base open for the skids of the fork-lift. This allows high-bay storage. It is also possible to draw the film over the pallet base. The shrinking method is particularly suited for products that are sensitive to elastic packaging stacking, such as glass. The goods are reliably protected against environmental impacts such as snow, rain, UV radiation, dust and insects. However, the shrinking process causes the film to become milky, which makes it difficult to see the packaged goods or imprinted barcodes. Additional disadvantages: polyethylene (PE) bags might weld to the packaging film and the heat effect can be a fire hazard.
Or opt for wrapping instead?
A decade passed before a US-based crude oil refiner and chemical resins supplier discovered the ingredients for a stretchable film, and the stretch wrapping technique was born. This packaging technique is still one of the most popular solutions with many companies, due to the low initial investment costs for the machines compared to shrink or stretch hood systems. The consumption of stretch wrapping film in Europe alone is estimated to be 1.4 million metric tons per year. This technique, however, requires a lot of material which means that the operator has to change the film roll frequently. This makes the technique suitable for low production rates.
The stretch wrapping film's elasticity allows solidifying the palletised goods during packaging. This technique, however, only provides little vertical tension force to the load, which is needed to provide stability for the transportation loads. This technique is not suited for materials with sharp edges, such as stones or bricks. Another disadvantage: additional plastic film is required to protect the goods against environmental impacts and humidity. The film overlay prevents an optimal display of the products and barcodes on the film cannot be read easily. And because the film is wrapped, you cannot print on it. Additionally, the film attracts dirt particles due to its adhesion properties and the products collect dust during longer storage periods. The film also does not offer any protection against theft, as unauthorised persons can remove goods from the pallet without ripping the film. Another problem: projecting film remnants, typical with this packaging technique, can disturb the sensor system of the conveying technology or the rack feeders. This causes repeated error messages. Due to the many setting parameters, the quantity of the film required for the packaging cannot be calculated exactly.
High transport security with stretch hoods
The stretch hood technology is a combination of the film hood and stretch wrapping techniques. BEUMER installed the first stretch hood system in Belgium in 1988. But the largest breakthrough for this pallet packaging technique only came about 15 years ago. The availability of improved raw materials allowed the quality of the film to be considerably increased. Like shrink hooding, the stretch film adapts to any product that is stacked on the pallet. And similar to wrapping, the film is very elastic and therefore solidifies the material via contracting forces. This technique guarantees high load stability. The packaging film does not get glued to the product during the process. It is possible to pack the pallet both for high-bay storage systems and with understretch. The smooth film surface ensures high visibility of the packaged goods, and therefore provides an excellent display of the packed goods at the Point of Sale because barcode labelling is quickly and consistently recognisable. The used film is recyclable. Stretch hooding does not use heat, which reduces the fire hazard considerably, increases operational reliability and therefore minimises insurance rates. Less film and energy are required, which means less damage to the environment. In the majority of industrial and consumer product applications, stretch hooding offers the best possible protection for palletised goods. A sheet placed on the pallet offers additional protection on six sides against external influences with this packaging solution. It allows for a clean and dry outdoor storage, as goods are reliably protected against environmental impacts, humidity, insects and UV rays.
Packaging solutions compared
The BEUMER portfolio includes innovative solutions and systems for all these packaging techniques. But in order to stay competitive in the long run, companies should not only consider the total cost of ownership when making investment decisions. A comprehensive approach is necessary to determine the perfect packaging method. By considering the total value of ownership (TVO), the efficiency of the operating investments can be specified more comprehensively and in more detail. This is why BEUMER Group considers economical, ecological and social aspects when developing their plants and systems. This allows our customers to plan their investments strategically.
Double your throughput with stretch hooding
Besides load securing, another important factor for most companies when choosing the perfect packaging method, is the protection against environmental impacts. This is why the BEUMER experts compared shrink hooding to stretch hooding and found a clear cost advantage for the stretch method. They took a palletised stack of 1,630 millilitres in height for test purposes. Systems that use shrink hooding to package palletised items can process 35 to 70 pallets per hour. With this process, the film strength lies between 120 and 180 micrometres. By using the stretch hooding method, throughput is nearly doubled with 100 to 120 pallets per hour. The film that is used is also thinner, only 70 and 140 micrometres. Less material is required due to the elasticity of the film.
In 2014, the market price for shrink film was at 1.70 EUR per kilogram. The packaging costs for a film hood were approx. 1.02 EUR. The film costs for 300,000 pallets per year were approx. 306,000 EUR. The film used for stretch hooding is currently slightly more expensive with 1.90 EUR per kilogram. To form a film hood, however, you only require materials totalling 57 cents. This leads to a remarkable cost difference of approx. 159,000 EUR for the same amount of pallets per year. The customer can achieve cost savings of approx. 52 percent.
The systems also differ in regards to their energy demands. The gas consumption for shrink hooding is at approx. two kilowatt hours per pallet. The energy required to form a stretch hood costs six cents. For the calculated 300,000 pallets per year, the total cost is 18,000 EUR. Due to the fact that the stretch hood system works without gas and the costs for energy consumption are almost identical for both techniques, the user can save those costs by implementing the stretch hood method.
The maintenance costs for shrink hooding can vary, especially for older machines, between 2,000 and 8,000 EUR per year. We used 4,000 EUR as the basis for our calculation. The calculated average costs for the stretch hooding method are between 1,000 and 3,000 EUR per year. Assuming an average value of 2,000 EUR, the user saves 2,000 EUR per year in maintenance costs. This means significantly lower costs per year when using the stretch hooding technique.
The BEUMER stretch hood® A is the result of the intralogistics specialist from Beckum redesigning its tried-and-trusted packaging system from scratch. During its development, our specialists analysed various components and optimised them in terms of function, arrangement and ergonomics. This includes an intuitive 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 new system also features improved system performance and requires far less floor space.
Each product has its own handling characteristics, which require a careful analysis by the user. This analysis is necessary to determine the pallet packaging requirements. BEUMER provides the operator with an online configurator to calculate and evaluate the economic efficiency of different packaging techniques, as well as the added value for their company. In addition, BEUMER experts will create a presentation that is individually tailored to the customer's requirements. The customer gets a reliable comparison between the different packaging methods, the individual energy consumption, as well as the maintenance, investment and system costs....
BEUMER Latinoamericana Equipamentos Ltda. - part of BEUMER Group, a leading global supplier of automated baggage handling systems - announces the completion of the contract to design, manufacture and integrate a new energy-efficient, automated baggage-handling system at Tefé Airport, Brazil.
The city of Tefé, on the southern bank of Lake Tefé in the heart of the Amazon rain forest in northern Brazil, can only be accessed by plane (1h 10min) or boat (16h) from Manaus - the capital of the state of Amazonas.
Tefé Airport, administrated by Brazilian airport operator Infraero, which manages 60 airports across Brazil, is one of the main gateways to the interior of northern Brazil and plays an important role in development and commercial activity in Tefé as well as in the surrounding cities. It is likewise socially important, in that it serves as a base for transporting humanitarian missions from neighbouring countries. Currently the airport operates regular regional flights as well as military aircraft of the Brazilian Air Force, Army and Navy.
The new baggage handling system for the departures area is part of the modernisation and expansion of the airport terminal, which has been extended from 590m² to 4,000m² The system integrates check-in scales and take-away conveyors with a complete baggage handling conveyor system. The new system is designed to shorten baggage processing times and help the airport improve its operational efficiency and deliver an enhanced passenger experience.
Due to the geographical location of the airport, Infraero takes the responsibility to increase the quality of life in the vicinity very seriously. To this end - and as expected from BEUMER Group equipment - the baggage handling system minimises energy consumption, operating and maintenance costs and environmental impact.
The contract underlines BEUMER Group's strong foothold in the South American regional airport market. In addition to the Tefé Airport contract, BEUMER Latinoamericana Equipamentos Ltda is also installing baggage handling systems at Antofagasta Airport, Chile, and the Brazilian airports Araraquara, Franca and Cascavel.
Tefé Airport expects its new baggage handling system to be in operation in the spring of 2015....
BEUMER Group - a leading global supplier of baggage handling systems - will demonstrate high-efficiency, fully-automatic and semi-automatic baggage handling systems on Stand 6704 in the German Pavillion at Dubai Airport Show 2015, from 10th to 12th May.
The BEUMER Group stand will highlight the industry's first, high-speed tote-based baggage transport system to be certified to the European Civil Aviation Conference (ECAC) Standard 3 for in-tote screening using standard and extended tote sizes.
"With a choice of screening machines from the industry's leading manufacturers, Crisplant CrisBag® provides airports with a fully-integrated high-speed baggage handling and ECAC3-screening system," explains Klaus Schäfer, Managing Director, Crisplant. "With its compact footprint, high speed and 100% tracking and traceability of each item of baggage, CrisBag can be installed as a new system or as an upgrade and is currently being installed in Abu Dhabi International Airport's new Midfield Terminal."
Visitors to the stand will also be able to collect a copy of the BEUMER Group's recent white paper: 'Assessing the Impact of ECAC3 on BHS - Considerations for upgrading existing ECAC2 systems.'
BEUMER Group is a global company, working with airports around the world through a network of local offices. To provide close partnership and effective communication with airports throughout the region, BEUMER Group Middle East has offices in Dubai, Abu Dhabi and Qatar....
BEUMER Corporation, a leader in sortation, distribution, palletizing and packaging systems, will exhibit at ProMat 2015 in booth 1231 with a broad range of flexible, high-speed and low-maintenance energy-efficient sortation and distribution solutions, including a fully operational demonstration of its automated BS 7 cross-belt sorter and an interactive "virtual sortation tour" featuring several BEUMER sortation solutions. Additionally, BEUMER will introduce its latest offering, the Automatic Parcel Singulator (APS) for handling a variety of parcels.
The ProMat 2015 show runs March 23-26 at McCormick place in Chicago.
BEUMER's booth will present several innovative products and systems that help improve distribution center productivity and efficiency. The company is also participating in an educational seminar presented by the Material Handling Institute (MHI) with a BEUMER sortation expert sharing insight on the latest advances in material handling equipment, systems and controls.
BEUMER highlights at the ProMat 2015 show include:
BEUMER BS 7 BT Cross-Belt Sorter
The company's main exhibit features an operational and interactive BS 7 high-capacity cross-belt sorter, which is the same type used by Chico's, DSW, Land's End and other leading entities in their e-fulfilment, retail/wholesale replenishment and parcel operations. Attendees will be able to induct product and test the system performance via three sample discharges (direct to bag, direct to tote, and accumulation chute). BEUMER's display will also include an integrated high-speed camera system working with a wide range of products and packages such as clothing, shoe boxes and bagged items.
The BEUMER cross-belt sorter has a contactless energy/data supply with linear induction motor drives to sort a variety of items safely and gently to the right destination, no matter the size, shape or surface characteristics of the product being handled. BEUMER's industry-leading dynamic induction line will also be in action, capable of inducting items from small accessories o large parcels to the center of every belt tray. This results in a system that guarantees 99.99+ percent sort accuracy while reducing maintenance costs by as much as 80 percent compared to competing systems.
New Automatic Parcel Singulator (APS)
The Automatic Parcel Singulator (APS) transforms a bulk flow of parcels into a flow metered for high-capacity loop sortation. Designed to handle a wide variety of items, the APS is BEUMER's newest offering for sortation and distribution. The APS handles parcels, flats, totes and sealed bags - minimizing the need for manual handling and supervision during normal operation. The APS features a compact, energy efficient, low maintenance design that is ideal for new loop-sorter parcel systems or retro-fitting into existing loop-sorter systems.
BEUMER Group Software and Controls: Introducing BG Fusion
Software and controls from the BEUMER Group provide the most efficient sort engine to optimize throughput, availability, visibility, and operational performance, delivering the highest level of ROI for our customers. Across multiple sites, we are currently beta testing our latest visualization software, BG Fusion, which provides a web based user interface and visually rich reporting and system monitoring. We will showcase this latest offering, along with the BEUMER Sorter Control (BeSS) via an in-booth demo, featuring real time dashboards and operational data from a major retail distribution system. The dashboards allow supervisors to proactively re-balance labor, efficiently transition between waves, and minimize problem-order resolution based on the current status of the sorter and peripheral operations such as picking, induction, pack-out and shipping.
Interactive "Sortation Virtual Tour" Presentation
To give booth visitors a unique and original "perspective" on the key capabilities and advantages offered by BEUMER's full line of cross-belt and tilt tray sortation systems, special interactive "virtual sortation tours" will be given in the booth. Using an interactive touch screen approach, visitors will have the ability to create a custom journey through a BEUMER sorter system based on their own specific distribution processes. Tours include sortation applications for e-commerce, retail fulfilment, omni-channel, wholesale/cross-dock and shipping or parcel handling.
Additional BEUMER Sorter Models on Display
For those that prefer a hands on-approach instead of a virtual tour, the booth will also include actual samples of several BEUMER sorter models including the BS-25 tilt tray, the Crisplant LS4000 E-tilt, and Crisplant LS2000 mechanical tilt tray. Attendees will get an in-depth look at the robust parts and decades of engineering built into the industry's leading sortation products.
Material Handling Institute Classroom Session
Show attendees can also get up to speed on the latest material handling equipment, controls, software, and integrated systems developments in a 45-minute educational session sponsored by MHI's Integrated Systems and Controls Group - featuring BEUMER's Chief Sales Officer, John Sarinick, and John Hill, Director at St. Onge. This seminar will discuss innovative solutions ranging from simple to complex for both smaller and larger companies with details on applications, operational benefits and financial justification. Full details are below:
Date: Monday, March 23, 2015
Time: 11:15 AM - 12:00 PM
Location: Theater F
For more information on BEUMER's sortation and distribution solutions and services visit booth 1231 at ProMat 2015, or go to www.beumergroup.com....
BEUMER Group Middle East - a leading global supplier of automated baggage handling systems - will demonstrate its end-to-end in-tote baggage handling systems at the Bahrain International Airport Development Forum, Manama, Bahrain, from 1st-2nd April 2015.
The demonstration will highlight how the BEUMER Group enables airport hubs to support sharp increases in passenger numbers by using the latest baggage handling technology to meet the individual needs of each airport. Recent projects have included a CrisBag®-based system for Abu Dhabi International Airport; tilt-tray systems for Hamad International and Doha airports; as well as tilt-tray and autover® Destination Coded Vehicle (DCV) baggage handling and transportation systems for Dubai International Airport.
With a strong local project management and engineering team, BEUMER Group Middle East has regional offices in Dubai, Qatar and Abu Dhabi. Globally, BEUMER Group works with airports through a network of local offices which provide the close partnership and effective customer communication which are essential for successful projects worldwide.
BEUMER Group will be on Stand A25, at the Bahrain International Airport Development Forum, held at the Gulf Convention Centre, Manama, Bahrain, from 1st-2nd April 2015....
BEUMER Group - a leading global supplier of automated post and parcel handling systems - has been awarded a contract by UK Mail Group PLC - the UK's largest independent express delivery company - to install a fully automated parcel sorting system in UK Mail's new state-of-the-art Midlands Hub which is scheduled to begin operation in 2015.
Equipping the new Midlands Hub with a state-of-the-art parcel sortation system will enable UK Mail to ensure high levels of service to end-users throughout the UK. The decision to award the contract to BEUMER Group was based on the reputation for developing and delivering innovative parcel sorting systems combining the flexibility to handle parcels across a wide range of shapes, sizes and weights, with the scalability to increase capacity in line with future growth.
"The automation of UK Mail's parcels operation is an essential part of their strategy," explains Martin Mossinkoff, Managing Director, Logistic Systems, BEUMER Group. "Crisplant's expertise in designing systems which combine high efficiency with ultra-low energy consumption and maintenance costs will make a significant contribution to enabling UK Mail to drive down the cost per item by increasing the capacity of their centralised sortation system."
Richard Wenham, Network Development Director, UK Mail, explains "Our continuous growth has been driven by a particularly strong increase in the volume of parcels in the B2B and B2C parcel markets. This is being driven by expansion in the number of home deliveries from Internet-based companies. We estimate that this segment of the market will continue to grow and therefore we are maintaining our focus on combining competitive pricing with strong service levels."
The new parcel handling system will integrate two Crisplant LS-4000 cross-belt sorters which achieve up to 70% reduction in energy consumption, compared to conventional sorter technologies. They also provide a single system capable of ensuring the safe and efficient handling of parcels of different dimensions from induction to discharge. The reduced energy consumption will reduce the product life cycle costs in addition to helping UK Mail to meet environmental goals for reducing carbon emissions....
Skechers, a two-billion-dollar global leader in the high performance and lifestyle footwear industry, designs, develops and markets more than 3,000 styles for men, women and children. Skechers' success stems from its employees, high-quality, varied product offering, diversified domestic and international distribution channels, and targeted multi-channel marketing.Skechers has recently expanded its European Distribution Centre in Milmort, Belgium. BEUMER Group provided the BS 7 BT Belt Tray Sorter that has now been put into operation. Skechers wants to increase its throughput and further strengthen its customer support.
Skechers' products are manufactured worldwide, shipped to the distribution centre in Milmort and then distributed to the Skechers retail stores, wholesales customers and retailers. "In the past years, we have seen an increasing demand for our products", explains Sophie Houtmeyers, head of the logistic centre. "This is why we had to consistently expand our logistic centre. Sales continue to grow in the future. "We want to offer exceptional service at competitive prices", emphasizes Sophie Houtmeyers.
The fully automatic sortation and distribution system from BEUMER is modularly designed and particularly suited for accurate and quick sortation of large numbers of items. "One of the reasons for choosing the BS 7 BT was its long service life and high reliability", explains Thomas Wiesmann, sortation and distribution technology sales manager at BEUMER Group. The entire system was mounted on a platform. The engineers designed the destinations to make the operation faster and more efficient, but also to handle the products more gently....
Crisplant - part of the BEUMER Group and a leading global supplier of automated baggage handling systems - will launch a hybrid check-in system at Passenger Terminal Expo 2015, on 10-12 March, in Paris, France. MyCheck™ is a flexible solution which can be used as a fully-automated check-in and bag drop for the passenger; as an automated check-in by the passenger and bag drop at a manned counter; or as a conventional check-in and bag drop at a manned counter. MyCheck™ complements the CrisCheck range of check-in conveyors already available.
This flexibility not only provides a multi-function check-in for space-constrained airports, but also allows the airport to achieve a much higher level of asset usage. The ability to switch between different check-in options will help airlines to manage long queues more effectively and reduce the pressure of under-manning in the departure hall during peak periods.
For passengers, the MyCheck™ self-service check-in and bag drop is both easy to use and offers an ultra-low conveyor height which allows bags to be lifted easily for added comfort and safety.
For airports, a lean and functional design makes MyCheck™ suitable for new terminal designs as well as for retrofit installations and it can be used as an easy extension to Crisplant's CrisCheck™ conveyor. Vital security and safety features include tamper detection, to prevent bags being switched during check-in; double detection to ensure that every bag is checked; and also motion detection to monitor for the presence of a child or passenger on the conveyor. Seamless integration with the airport and airline IT systems provides immediate barcode verification during the reconciliation of the passenger, passport and ticket. MyCheck™ also reduces maintenance costs by allowing all maintenance tasks to be carried out by a single operator.
"MyCheck™ represents a significant advance in the flexibility which airports can expect from their check-in systems," explains Klaus Schäfer, Managing Director, Crisplant. "It will enhance the efficiency and productivity of the check-in procedure even in the most space-constrained airports."
Crisplant is launching MyCheck™ on Stand 4040 at Passenger Terminal Expo 2015, 10-12 March, Paris....
BEUMER Group with Crisplant - a leading global supplier of automated baggage handling systems - has published a white paper which assesses the impact of the European Civil Aviation Conference's ECAC3 hold baggage screening regulations on European airports.
Written for Airport Operations Executives and Airport Design Consultants, the paper presents an objective analysis of the implications of upgrading existing ECAC2-compliant baggage handling and screening systems to the ECAC3 standard.
"ECAC3 provides airports with the opportunity to make improvements in the performance and efficiency of their baggage screening process," explains Klaus Schäfer, Managing Director, Crisplant. "Using experience gained over 35 years, Crisplant helps airport operators to make informed decisions and achieve the full benefits of the upgrade to ECAC3. In addition to enhanced baggage handling, these benefits include ensuring the optimum use of assets such as Explosive Detection Systems (EDS) to optimise the baggage handling process."
The paper covers topics which include:
- System design, capacity, redundancy and layout
- A comparison of the ECAC2 and ECAC3 technologies
- Compliance and operation
- CAPEX and OPEX costs
The European Civil Aviation Conference's (ECAC) Standard 3 threat detection test is the highest standard set by ECAC for the detection of explosive threats in passenger hold baggage. The ECAC3 protocol supercedes the ECAC2 hold baggage screening standard for all new baggage handling systems installed after September 2014. Existing ECAC2 systems must be upgraded to comply with ECAC3 before September 2020....
Crisplant - part of the BEUMER Group and a leading global supplier of automated baggage handling systems - will be showcasing the CrisBag® high-speed baggage transport system on Stand No 4040 at Passenger Terminal Expo from 10-12 March 2015 at Porte De Versailles, Paris.
Crisplant will also partner Smiths Detection in a joint presentation, "ECAC3 - a great step forward for aviation security," on Thursday 12 March 2015 at the Passenger Terminal Conference.
The combination of Crisplant's CrisBag® high-speed baggage transport system, with Smiths Detection's HI-SCAN 10080 XCT explosives detection equipment created the first system to be certified to the European Civil Aviation Conference (ECAC) Standard 3 for in-tote screening using standard and extended tote sizes. CrisBag has also subsequently been approved for the integration of CrisBag with detection equipment from L3 using standard tote sizes.
"CrisBag provides airports with a single, compact and cost-efficient system for high-speed baggage handling and full integration with state-of-the-art ECAC3 screening," explains Klaus Schäfer, Managing Director, Crisplant. "With its compact footprint, high speed and 100% tracking and traceability of each item of in-tote transported baggage, CrisBag can be installed as a new system or as an upgrade for airports."
On Thursday 12 March 2015, at the Passenger Terminal Conference, Crisplant and Smiths Detection will present an objective review of the impact of the ECAC3 screening standard and its effects on the baggage handling procedures, systems and equipment in airports of all sizes. This presentation will draw on information presented in the recent Crisplant whitepaper: "Considerations for upgrading existing ECAC2 systems."...
BEUMER Group, a leading global supplier of automated material handling systems - will be demonstrating the innovative Tire Tray System on Stand number 2040 at Tire Technology Expo, Cologne, Germany, from 10 to 12 February 2015. The Tire Tray System automates the management and handling of green and cured tires throughout the production process to provide increased capacity and productivity within existing production facilities.
Based on three decades of experience as an industry leader in advanced automation systems for the airport and warehouse sectors, Crisplant's development of the Tire Tray System introduced a paradigm shift in the tire manufacturing process. The system offers high-speed, high-capacity transportation, sortation and storage of green tires, from tire building to the curing presses, combined with careful and accurate manipulation which is achieved without ever gripping the tire.
For cured tires, all quality inspection, warehousing and outbound sorting processes are integrated into a single LS-4000CB cross-belt sorter loop which provides the flexibility and capacity required by high-volume tire manufacturing facilities to support increased capacity.
"The compact and highly-configurable Tire Tray System can easily be installed in existing tire production facilities to replace manual handling of tires with a fully-automated process. This enables tire manufacturers to significantly increase workplace safety and productivity," explains Klaus Schäfer, Managing Director at BEUMER Group company, Crisplant.
High RFID read-rates allow the Tire Tray System to provide end-to-end traceability and tracking of each tire throughout the production process, including the integration of release agent spray systems, as well as the buffering and curing processes. It also offers advanced features such as fully automated loading and unloading and the ability to handle a wide range of tire sizes within a single system.
The LS-4000CB loop-sorter has proven its value with some of the world's most demanding customers and sectors. Within the tire manufacturing sector, BEUMER Group is currently designing and manufacturing the first Tire Tray System to be installed in a major tire manufacturing facility in South America.
Delegates can see a demonstration of the Tire Tray System on Stand number 2040 at Tire Technology Expo, Cologne, Germany, from 10 to 12 February 2015....
BEUMER Group UK with Crisplant - a leading global supplier of automated baggage handling systems - has been awarded a portfolio of prestigious baggage handling system projects at Heathrow Airport, London, UK. This portfolio of projects, known as "Q6", was awarded to the BEUMER Group UK by the main contractor Balfour Beatty and includes the installation and integration of over thirty Standard 3 Hold Baggage Screening (HBS) machines. Balfour Beatty completed a robust tender selection process before awarding the contract to BEUMER Group.
The Q6 portfolio of projects consists of upgrading the existing Hold Baggage Screening (HBS) machines to meet Standard 3 legislation; the installation and commissioning of a new Crisplant LS-4000E tilt-tray baggage sorter; and major asset replacement of the baggage handling control systems. These projects will take place in Terminals 1 and 4. Also included in the Q6 portfolio is the task of installing and integrating nine new Standard 3 HBS machines into T2, The Queen's Terminal. BEUMER Group will also ensure that all high-level baggage IT controls and systems, such as the Sort Allocation Computer (SAC) and SCADA, interface seamlessly with the new baggage handling assets and the HBS Standard 3 screening machines. During the Q6 project delivery BEUMER Group will install and integrate a total of thirty-two Standard 3 HBS machines into the Heathrow Airport baggage handling system.
"The Q6 portfolio of baggage projects requires very detailed and extensive project phasing and an operational mitigation plan plus an integrated testing regime using comprehensive system emulation," comments Peter Gilks, Managing Director, Airports Division, BEUMER Group UK. "This proven BEUMER Group methodology will ensure that the live Heathrow Airport operation will be protected during the delivery of this wide portfolio of Q6 baggage projects."...
BEUMER Group with Crisplant - a leading global supplier of automated baggage handling systems - will present end-to-end baggage handling systems which integrate conveyors and tilt-tray sorters at Inter Airport SE Asia, Singapore EXPO, from 21 - 23 January 2015. The stand will also include a demonstration of the innovative CrisBag® tote-based transport and scanning system.
The CrisBag® system, which was developed by BEUMER Group company, Crisplant, uses the 'one bag per tote' concept to provide 100% tracking and traceability of each item of baggage throughout the check-in, sorting and screening processes. It is one of the systems to have been installed by Crisplant during its long-term partnership with Singapore's Changi Airport which began with the installation of a tilt-tray sorter in 2002. Crisplant has also installed a CrisBag® system at Changi Airport. This provides a dual-purpose system for sorting baggage and for extensive inter-terminal baggage transfers between Terminals 1, 2 and 3.
The partnership between Changi Airport and Crisplant will continue when Crisplant supplies and integrates the baggage handling system for the new Terminal 4 building for which construction began in November 2013.
"This exhibition brings together two powerhouse brands within baggage handling - Crisplant and BEUMER Group," explains Klaus Schäfer, Managing Director, Crisplant. "Together, these brands have an unmatched track record of integrating innovative baggage handling systems, including a long-term partnership with airport operator, Changi Airport Group, which has seen a number of systems installed by Crisplant to increase the airport's baggage handling capacity and efficiency."
BEUMER Group with Crisplant will be on Stand no A02, in the German pavilion, at Inter Airport SE Asia, Singapore EXPO, from 21 - 23 January 2015....
The BEUMER Group received one of eight coveted Innovation Awards for its new fillpac bagging system at the French packaging exhibition Emballage 2014. The award was presented at the special Pack Innovation show on November 17. The bagging machine is notable in particular for its electronic weighing system, which ensures that it always achieves accurate filling quantities. 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.
A panel of twelve experts selected the eight winners from a large number of entries. The experts came from international corporations in a wide range of sectors, including the food industry, capital goods industry and healthcare sector....
SCHWENK Zement KG is replacing its old drag chain conveyor line with a modern Pipe Conveyor from BEUMER Group. Requiring a solution that would transport alternative fuels such as crushed plastic material, textiles and paper from the warehouse to the feeding system of the oven in their cement plant in Bernburg, Germany, this fully closed conveying system makes transporting bulk material more environmentally friendly and energy efficient. Maintenance costs are also considerably lower and the system can be optimally adapted to the ambient conditions.
SCHWENK's product diversity and production capacity make the cement plant in Bernburg one of the largest and most efficient building material plants in Germany. The production of cement along the river Saale has a rich history due to the prevalence of high-quality deposits of limestone in this area. The plant has been in existence since 1960. SCHWENK took over the plant in 1990 and tore down the existing systems to build an entirely new plant. Today, SCHWENK's product portfolio includes a wide range of efficient, specialised cement marked by consistently high quality. The company produces the ideal product using modern mixing technology, as required for tunnel, road and well construction, as well as for geothermal and environment engineering.
One topic of great importance to the SCHWENK plant is sustainable production. Production of cement has always been one of the most energy-intensive operations. This is why SCHWENK minimises the use of primary fuels such as coal and oil and focuses increasingly on substitute fuels. These substitute fuels are mainly a mixture of high calorific waste materials, comprised mostly of plastic and packaging residues and textiles. They are processed to high-grade fuels with defined product parameters in external processing plants.
For the manufacturing of cement, limestone is quarried, crushed and homogenised with additional raw materials. Belt conveyors then transport the crushed material with other materials from the blending bed to the plant. It is ground to the necessary grain size in the raw mills and then dried. The raw meal is then homogenised and temporarily stored in large silos. To obtain Portland cement clinker, a coarse intermediate product, the raw meal is first transported into the cyclone preheater, then into the calcinator, both powered by alternative fuels. The limestone portion of the raw meal is deacidified at temperatures of over 950 degrees Celsius. The material then moves into the rotary kiln where it is burned at temperatures of approx. 1,450 degrees Celsius.
Up until now, SCHWENK relied on a drag chain conveyor line for transporting the fuels from the storehouse to the feeding systems of its main burner. The baffle plates on these mechanical continuous conveyors are mounted to an endless chain, transporting the bulk material in a trough. "We had been using this system for more than ten years. This meant that we had to put more and more maintenance work into it", says Dirk Fabian, production manager at SCHWENK in Bernburg. Another problem: after further development of the dosing technology, the drag chain conveyor was no longer able to transport enough bulk material, with a density of only 0.2 tons per cubic metre, to the weigh feeders (and thus to the main burner). "We were looking for an alternative solution that would be ecological as well as low in maintenance", explains Dirk Fabian. In addition, the new conveyor should also be optimally adapted to the curved routing in the plant.
Comprehensive expertise, optimum support
For the building material manufacturer, BEUMER Group was their first choice supplier of the optimal conveying technology. SCHWENK has a long-standing and close partnership with BEUMER as an internationally operating system supplier. BEUMER has provided SCHWENK Putztechnik GmbH & Co. KG, headquartered in Ulm in southern Germany, with several BEUMER paletpac® high-capacity layer palletisers, equipped with the newly developed twin-belt turning device. BEUMER has been well-established in the building industry for nearly 80 years as a supplier of conveying technology solutions. BEUMER has bundled its comprehensive expertise in the building material industry and established different Centers of Competence, in order to offer optimal support for global building material manufacturers by offering single-source solutions. The "Pipe Conveyor" segment is one such Center of Competence. These centers are in charge of worldwide project management and sales. They collect and process the expertise from the individual local group companies and pass it on to the global Group experts in each respective field.
High level of environmental protection, low level of maintenance
"Together with the management team in Bernburg, we developed a solution that is tailored exactly to match SCHWENK's requirements", says Michal Mikulec, managing director at BEUMER Group Czech Republic a.s. and supervisor for this project. Our first idea was to combine a new drag chain conveyor with several open belt conveyors, but it was quickly abandoned. It became apparent that a Pipe Conveyor was the best solution offering environmental protection and low maintenance. "Its closed design protects the environment from transported goods falling down. Another advantage is the lack of dust development on the running line", explains Michal Mikulec. These conveyors offer many other advantages. They are able to navigate long distances and tight curve radii. Due to their ability to negotiate curves, considerably less transfer towers are required compared to other belt conveyors. This results in substantial cost savings for the customer and delivery of a system customised for individual routing. BEUMER Group supplied and installed a system with a diameter of 200 millimetres and a length of 230 metres. It conveys up to 15 tons of material per hour. BEUMER was also responsible for the design of the system and the entire steel structure.
Durable conveyor belts guaranteeing tensile strength are used in the SCHWENK solution. "To find the ideal belt version for SCHWENK, we calculated the tractive forces as well as the forces that occur during acceleration and deceleration – always considering the net weight of the belt and the transported item", reports Michal Mikulec. The engineers also precalculated the belt positions in different curve radii for the empty and loaded belt. Another system advantage is the reduced noise emission of the Pipe Conveyors. "Special idlers as well as low-noise bearings and electric motors work very quietly. This improves the quality of our employees' day-to-day work environment and ensures the people living near the plant are not disturbed", says Dirk Fabian.
Cranes pick up the treated substitute fuels in the storehouse and unload them into the discharge bunker with the discharge system. From here, the chain belt conveyor continually transports the material to the new Pipe Conveyor that then transports it to the weigh feeders of the main burner.
BEUMER was able to optimally customise the routing of the conveyor to the plant. Another requirement met by the experts: no supports underneath the Pipe Conveyor that would otherwise obstruct vehicles. This is why the technicians mounted the first support directly to the storehouse. The conveyor take-up system was designed by BEUMER as a take-up tower. It is located right next to the feeding station.
It took only eight months from the time the contract was awarded until commissioning of the new system in February 2014. "We have been working with the BEUMER system for several months now", says Dirk Fabian. "We are very satisfied. It is very robust and we no longer have any failures."...
As a single-source provider for filling, palletising and packaging technologies, BEUMER Group continues to pursue its ambitious goal of offering its customers solutions from a single source. Therefore, BEUMER has fundamentally reengineered its high-capacity layer palletiser BEUMER paletpac. The user now benefits from a better accessibility, a shorter assembly period, higher flexibility and, as a result, from lower costs. The BEUMER paletpac is incorporated into high-performance packaging lines to process even sensitive and valuable products in a gentle and efficient manner.
With the layer palletiser series BEUMER paletpac, the intralogistics specialist supplies high-capacity machines, which stack bags filled with bulk material on pallets gently and exactly layer by layer. The products include cement, mortar, pellets, industrial salts and fertilisers filled in paper, polyethylene or polypropylene bags. Owing to the geometric precision during layer and stack formation, stable bag stacks are formed. Multiple pallet loads created with the BEUMER paletpac can even be stacked one on top of the other to save storage space. To make the BEUMER paletpac even more sustainable, BEUMER has redesigned it. Due to the optimisation, BEUMER was able to lower the production costs, which is reflected in the purchase price. Furthermore, the optimised model also brings about a reduction in operating costs.
Trimmed to improve efficiency
Until recently, the system was equipped with large drives. Now small motors carried out as servo drives are used and optimise the energy consumption needed for the lifting movement. In addition, these motors need less maintenance thus further reducing the costs for the user.
With regard to the overall structure, BEUMER has made various improvements. For starters, there is now better accessibility and therefore easy cleaning underneath the machine is ensured. Another important modification is that the external frame elements can now be folded, allowing the whole palletiser head to fit into one transport container. The palletising head doesn't have to be dismounted and the total amount of containers sent to the customer can be reduced. This alleviates the transportation costs and shortens the assembly period on site.
The pallet pusher that automatically provides the hoist unit with empty pallets has also been modified by the BEUMER specialists. They have modified the guides for the pallet side plate, introduced a new lateral guide system, changed the drive performance and decreased the system width. Now the user can quickly and easily adapt the palletiser to different pallet sizes without the use of tools. The BEUMER paletpac palletises bags up to a pack height of 2,400 millimetres, in all technically possible packing patterns and on any commonly used pallet size - including intermediate sizes such as 1,400 x 1,200 millimetres. A multi-program enables the user to set parameters easily and quickly. The BEUMER paletpac can be provided with a bar-type or clamp-type turning device or with a newly developed twin-belt turning device to position the filled bags quickly, ensuring their dimensional stability.
To enable operators to operate the BEUMER paletpac 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, thus saving time and money which ensures high economic efficiency.
These innovations demonstrate BEUMER Group's commitment to the total value of ownership (TVO) approach, enabling a company to work efficiently through tailoring, facilities, systems and pertinent production processes to long-term customer use. A product is considered not only from an economic viewpoint, but also from an ecological and social one. This includes, for instance, ergonomic Human Machine Interfaces. This way, operators can describe the effectiveness of their operational investments in a holistic and especially significant way. They are able to determine not only their direct costs, but above all the 'Total Value' of the solution to be provided over the whole operating time. Three equally important factors are involved: market development, risk management and sustainability.
For use in any branch of industry
With the BEUMER paletpac, users can palletise up to 2,500 bags per hour, and up to 5,500 bags per hour by using the high-capacity version. It doesn't matter if the industry is chemical, building material, food, peat or rock and associated products, with the BEUMER paletpac, BEUMER fulfills the constantly increasing market and customer requirements, especially with regard to throughput rates and reliability. In particular, paper, PE and PP bags are perfectly palletised. All current bag dimensions and bag types as well as packing patterns can be processed without any problem with the BEUMER paletpac. The modular structure permits adaptation of the BEUMER paletpac to special market- and customer-specific requirements. The bags stacked accurately on pallets can then be transported without problem to the downstream packaging system, for example, the BEUMER stretch hood.
BEUMER implements the entire process chain: from bagging, bag transport and palletising to full pallet transport and packaging....
Companies should take into account more than just overall operating costs if they want to be competitive in the long term. An integrated approach is far more important. By looking at the Total Value of Ownership (TVO), the effectiveness of business investments can be described more comprehensively, from the right perspective, and therefore more meaningfully. It is important to include economic as well as ecological and social aspects when developing machines and systems, as the BEUMER Group does, making it not just a supplier but a strategic partner for postal and CEP companies.
“The pressures on postal and CEP companies in a competitive environment are increasing. Not only must they save costs but they must also reduce environmental impact and respond to influential market trends,” describes Martin Mossinkoff, globally responsible director of the business segment “Logistics Systems”. These include new technologies, the increasing use of new sales channels such as e-commerce – which raises high customer expectations for immediate deliveries – and also growing globalization. As a result, the demand for more efficient sortation and distribution systems continues to grow throughout the world.
For example, the gross domestic product in many countries in Asia is steadily increasing which, in turn, is leading to an increase in wages. This is particularly noticeable in China and India. A new middle class has come into being which is significantly changing the consumption pattern of the population in the developing countries. The volume of trade is increasing and purchasers are demanding ever-shorter delivery times. “This is also affecting the working environment, for example in distribution canters. Here too, it is becoming necessary to think and act more globally whereas local orientation of such service providers is reserved for niche markets,” says Martin Mossinkoff. Postal and CEP companies must therefore be able to adapt flexibly and dynamically to changing requirements in order to survive in the marketplace.
Investment for improved competitiveness
“The trend towards automation continues to be important for the survival of service providers, and is therefore strongly increasing in distribution centres. Material flow technology is becoming more complex, and systems must be able to carry out more flexible tasks or be adapted to suit changing local situations,” Mossinkoff explains. Highly efficient processes are required to enable parcels to be dispatched to customers quickly.
For example, e-commerce and mail order companies have recently also been offering products which, up to now, have been difficult to transport automatically because of their dimensions. However, the automation of existing solutions or the integration of new machines and systems is usually accompanied by significant costs for the user. To enable them to make these strategic investment decisions in a targeted manner, companies must analyze all direct and indirect costs in advance in order to calculate the Return on Investment. In doing so, they should set their sights on more than just the procurement and operating costs.
To enable companies to work efficiently, their machines and systems and the associated production processes must be directed towards long-term customer benefits. “That’s why we develop all solutions with an integrated approach, the Total Value of Ownership (TVO),” says Mossinkoff. “While the Total Cost of Ownership (TCO) exclusively takes into account the economic aspect of a product, TVO is based on and includes ecological aspects such as energy-saving operation or resource-conserving production as well as social factors.” Examples of these include sorters which run very quietly and therefore produce only a small amount of vibration. This makes for a more pleasant working atmosphere and less noise pollution.
The systems also simplify the sorting of goods of all kinds, and this is carried out automatically instead of by hand. This enables our customers to describe the effectiveness of their business investments holistically and more meaningfully. Companies are not only able to determine their direct costs, but, above all, the ‘Total Value’ of the solution to be supplied over its entire operating life. For this purpose, we identify three interacting factors: market developments, risk management and longer term sustainability.
Adapting flexibly to increasing demands
“To enable companies to flexibly convert or adapt their machines and systems, for example to accommodate changes in consumer behavior or to adapt to trends such as the increasing use of e-commerce, we collaborate with the users to work out which solution is able to accomplish the required task and whether it will also be capable of meeting future requirements,” Mossinkoff describes. The decisive factor here is whether performance can be increased without also increasing the costs in the long term such as in the case of inefficient sorter drives or if maintenance is frequently required.
An important point is therefore the availability and usage of machines and systems that have been supplied and installed. Malfunctions and machine shutdowns frequently lead to long downtimes, especially in intralogistics. Production and delivery can come to a complete halt. Possible risks must be clearly identified, analyzed and evaluated. “As a strategic partner, we therefore take care of our customers from the initial project meeting to the running system and beyond. As part of this service, we offer flexible agreements, an efficient supply of spare parts and comprehensive training for users of our systems,” states Mossinkoff. As an example, these agreements can include upgrading of the systems by our customer support staff as soon as new sorting technologies and software controllers are introduced. It is important to BEUMER not only to rectify faults, but also to help companies to satisfy future performance and technology demands. For example, as the mechanical parts of a sorter wear out over the years, staff must respond immediately at the first signs to prevent possible consequential damage. The BEUMER Group is therefore in a position to offer high system availability over the whole working life. “Our objective is always to make processes even smoother in order to ensure a value-added material flow,” Mossinkoff adds.
The third factor relates to sustainability. This subject, in particular, represents a particular challenge for intralogistics. In order to find a clear answer to the question of sustainability of a system, machine or drive, BEUMER has developed a validation system in the form of the BEUMER Sustainability Index (BSI). We use this to systematically and continuously measure sustainability on every new machine and also on existing solutions. Each of the three levels, economy, ecology and social, is divided into five categories for evaluation purposes using the BSI. These include “efficiency and effectiveness”, “lifetime”, “operating costs”, “production-related raw material consumption” and “training and development standards”. These categories are evaluated with up to five points. The total of these is used to provide a classification into the levels “excellent”, “very good” and “suitable for improvement”. If a product is classified as suitable for improvement, BEUMER subjects it to reengineering to ensure that it achieves a higher level.
Designed for growth
BEUMER’s product base includes modular high-performance sorting systems, which enable widely varying goods – such as parcels, products in bags and bulky goods – to be sorted, distributed and checked in large quantities quickly, reliably and accurately. For example, a customer who wanted to fulfill his global commitment to sustainability and environmental protection in his distribution centre through efficient sorting technology also approached us with a requirement for fast and accurate sorting. “We installed our energy-saving Cross Belt and Tilt Tray Sorters. After all, most of the energy in this center was used in operating the sorting and conveyor equipment,” Mossinkoff reports. “Because our solutions use linear synchronous drive technology, the energy consumption is 75 percent lower than that of sorters with conventional technology.”
The process here is sophisticated. Workers place the boxes with the products from the warehouse on a conveyor belt. This takes them to an in-line sorter, which transports the parcels to one of three possible positions, depending on whether the goods are to be dispatched in batches or mixed in newly assembled boxes. At one station, boxes are sent directly to the dispatch sorter. Another station receives boxes that contain items in certain batches, which are then sent to the infeed unit of the pre-sorter. The third station is designed for boxes containing items that are brought together for mixed deliveries. These are delivered directly to the warehouse, where workers remove the items from the boxes and place them on shelves. They can then be taken as required and placed in plastic trays on the conveyor system. The conveyor transports the trays to a further conveyor on Level 2 of the building. The trays and the boxes with the batches are brought together and emptied. Workers place the items on the Cross Belt Sorter. This automatically sorts the goods from the plastic trays into defined containers, which are discharged in the tilt area. From here, they are transported by a system of conveyor belts to the workers, who place the items manually on the final sorter, a Cross Belt Sorter. The chutes are equipped with batch divider flaps. These are activated when a complete batch has been delivered. The batch is thereby isolated and can subsequently be packed in a box by the operator. The box is pushed onto a roller conveyor, which transports it to the Tilt Tray Dispatch Sorter. We have integrated the system and device controllers for the machines seamlessly into the user’s warehouse management system. This prevents bottlenecks, and the customer achieves faster throughput.
Long-term service ensures reliable operation
BEUMER has entered into a three-year service contract with the customer to offer maximum operational reliability. As part of this agreement, service engineers are stationed on site, with responsibility for the support and preventative maintenance of all material flow equipment and for management of the local spare parts stock. This agreement also includes upgrading the systems when new sorting technologies and software controllers are introduced which illustrates how total value of ownership can be more important than just the cost of the equipment.
Thanks to the sorting systems and software controllers used, the distribution centre works more efficiently than conventional installations. The company has also achieved a number of important objectives, including greater operational efficiency, flexibility and freedom from errors on dispatch. The handling costs and the energy costs have decreased, and the environmental impact of the operations has also been reduced....
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....