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Schiphol Airport signs long term contract with BEUMER Group
Aarhus, 08. October 2019

Royal Schiphol Group has awarded, as a result of a European tender, BEUMER Group one out of two framework agreement contracts covering future baggage handling projects as part of the Group's objective to expand, replace and/or modify Amsterdam Schiphol Airport's baggage handling system over the coming years.

The agreements forms part of a long-term cooperation with two different strategic contractors, both of whom met the requirements and demands set out by Royal Schiphol Group.

The airport is striving to develop Amsterdam Schiphol as “Europe’s preferred airport” and a vital component of that is ensuring that the baggage handling system design is both extremely reliable and meets high levels of availability. Royal Schiphol Group believes that the best way to make this a reality is to opt for a long-term cooperation, which will ultimately guarantee optimum integration between baggage handling systems, whilst at the same time properly aligning implementation of various future projects.

Schiphol Group’s Ron Wever, Manager Baggage, comments, “We are convinced that the outcome of collaborating with the two best in class baggage contractors will result in Schiphol becoming and staying Europe’s Preferred Airport.”

BEUMER Group A/S Managing Director, Klaus Schäfer comments: "BEUMER is well known in the industry for an ethos that places great value on long-term partnerships. Indeed, the company prides itself on the overall reliability of its products and also in the way it makes knowledge and experience available to airport customers so that they can benefit from sustainable system design solutions.”

The agreement will extend for a minimum of five and a half years with the specific aim of maintaining and further strengthening the airport's leading position in Europe’s aviation market.

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BEUMER Group technology helps Kempegowda International Airport, Bengaluru (BLR Airport) meet future capacity challenges
Aarhus, 01. October 2019

BEUMER Group, a leading global supplier of automated baggage handling systems, has been selected by Bengaluru International Airport in India to supply its new second terminal with flexible and efficient baggage handling systems that support increased capacity.

Bengaluru, also known as Kempegowda International Airport, serves the Indian city of Bangalore and is one of the fastest growing airports in the world. Passenger traffic at the airport is growing at an incredible pace, rising to 33.3 million passengers in FY 2018-19. This has prompted airport operator Bangalore International Airport Limited (BIAL) to undertake a Rs 13 billion (US$1.824 billion) capacity expansion programme to cater to the long-term demands of the aviation market in India.

The contract involves BEUMER Group supplying an end-to-end baggage handling system capable of moving 4,500 items of baggage per hour. The system comprises an advanced and super-efficient, high-speed tilt-tray sorter, a kind used by many major international airports worldwide. Furthermore, the system features full redundancy, thereby eliminating any single point of failure, and is controlled by BEUMER Group's proven high-level controls.

BEUMER Group continues to build on its already extensive experience of supplying baggage handling systems and solutions to airports across India. To date, it has supplied either baggage sorters or complete baggage handling systems to all airports in the country that have required automated, high-speed sortation, including Delhi Airport T3, Kolkata International Airport and Mumbai T3.

Nitin Vyas, Managing Director of BEUMER India says, "At Bengaluru International Airport, our focus has been on partnering with BIAL to introduce a baggage handling system capable of moving large quantities of baggage faster, with better accuracy and high efficiently. We have therefore designed a system which combines a low capital outlay with the ability to establish new performance benchmarks.”

The baggage handling system will become operational as part of the first phase opening of the new terminal, which will receive its first passengers in the spring of 2021.

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BEUMER Group hands over 10th project to Australia Post in two years
Aarhus, 24. September 2019

BEUMER Group, leading global supplier of automated parcel and post distribution systems, has officially handed over its latest project with Australia Post; the largest parcels handling and delivery centre in the Southern Hemisphere. Located near Brisbane, the new centre is capable of processing 700,000 items daily.

This is the 10th project so far provided by BEUMER Group to Australia's leading parcel handling company and is the result of the collaboration between the two companies in effect since 2016. As part of this partnership, BEUMER Group and Australia post review the business requirements and BEUMER subsequently designs sortation systems to allow Australia Post to both fulfil its business automation requirements and implement automated parcel sortation systems into the Australia Post network plan.

To date, BEUMER Group has provided parcel sortation systems right across Australia Post’s network, with multiple automation projects delivered each year.

The projects vary considerably in both scope and technology. From one project, implementing High level Control (HLC) upgrades at existing sites to enable StarTrack and Australia Post products to be sorted over the same system; to another, installing small and large parcel processing systems to meet sorting and fulfilment functions.

However, the most significant result of the partnership so far is the new Brisbane site, which will become operational in October 2019. It features state-of-the-art technology, incorporating such diverse elements as robotic inverters, automated singulators, BEUMER’s Parcel Picker, large and small parcel sorting and conveying systems and an AGV fleet for container movements on site.

The agreement with Australia Post also provides for extended Customer Support activities ranging from residential services at some sites to periodical planned inspections at various sites along with full BEUMER Group Hotline support 24x7. BEUMER Group’s experienced teams in addition also support the Australia Post technical teams whom manage most sites on a daily basis and provides for further on-going support, inspections and training on a yearly basis.

Australia Post spokesperson Chris Bresnahan, Operations Director, "Our decision to work with BEUMER Group, in what is a long term partnership, is testament to the dedication the company has already shown to Australia Post, and to the service BEUMER Group provides across a significant number of different areas, including customer support.”

Australia Post is Australia’s leading delivery business, handling over three billion letters and parcels yearly. Around 80 per cent of the nation’s eCommerce is facilitated by Australia Post, which has introduced both more energy-efficient sorting solutions to parcel processing and also more streamlined processes aimed at reducing costs whilst at the same time improving customer delivery service levels.

"We have done a lot of work to cut our carbon emissions: among other initiates, we have adopted the latest technology at all our new sorting facilities including the use of the energy efficient BEUMER Group sorters. This technology has also enhanced our ability to efficiently sort suitable parcels direct to loose loaded trailers which has increased the density of freight in loose-loaded trailers whilst reducing the number of trailers required for the same volumes and cutting transport costs. Chris Bresnahan says “Furthermore, by installing automated sorting equipment at our operational sites in Sydney, Melbourne and Brisbane, we have not only boosted our processing capacity by over 90 million parcels per year we have also ensured we have the capacity to deliver our customers parcels on time during the critical peak periods where parcels volumes can spike by more than 30%.”

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BEUMER Group demonstrate data-driven efficiency with live BHS control room at Inter Airport 2019
Aarhus, 24. September 2019

BEUMER Group - a leading global supplier of automated baggage handling systems – invites visitors to experience a live Baggage Handling System (BHS) control room at Inter Airport 2019.

The control room will demonstrate how BEUMER Group uses data analytics to enable airports worldwide to use data-driven information to optimise operations and drive greater efficiency. The data provides the basis for predictive analytics, 3D visualisation and machine learning.

The data delivers overviews of BHS performance in addition to providing tools and reports for optimisation and planning and BEUMER Group’s data-driven services enable improved decision-making for airport staff in maintenance, operational and management.

“Man-made decisions are not always precise,” explains Klaus Schäfer, Managing Director, BEUMER Group. “The human mind cannot quickly process all the necessary factors, which is why our Management Information System works on three different levels to quickly and efficiently provide informed data to help the airports' BHS operations to make the right decisions".

The developments in data-driven operation support BEUMER Group’s design for the ‘airport of the future’. The airport also features the Ultimate Baggage Handling System and the use of Automated Guided Vehicles (AGVs) for selected baggage handling operations and ULDs.

BEUMER will be on Stand 1154, Hall B5, from 8th to 11th October at Inter Airport 2019, in the Munich Trade Fair Centre, Germany.

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BEUMER Group completes super hub for Hermes
Aarhus, 17. September 2019

BEUMER Group, a leading global supplier of automated material handling systems, has supplied a third sortation systems to what Hermes calls the biggest parcel distribution hub of its kind in the UK, capable of sorting up over a million parcels a day.

The first stage of the Hermes UK Midlands Super Hub in Rugby, consisting of two sortation systems, was completed in 2017 and rapid continued growth in Hermes’ business saw the company placing an order for a third sortation system soon after the hub had been taken into operation.

The second stage demanded BEUMER Group carry out the installation during regular working hours, with no interruption to the operations of the hub, using creative engineering solutions and a rail-based crane system to install heavy components atop a two-tiered structure.

The new BEUMER sortation system in Rugby is similar to the system already installed by BEUMER in Hermes’ hub in Warrington, which ensures close similarity in operational processes, allowing Hermes to continue to operate a highly proficient operation to best support the UK’s retail industry.

Each of the feed-ins to the main sortation system incorporate the latest scanning, volumetric and weighing technologies to ensure accurate identification and accurately profiling of each package. Each parcel is also automatically checked to ensure correct labelling before being transferred onto the sortation system.

Parcels weighing up to 30kg can be sorted in a maximum of three minutes infeed door to outfeed door, exiting the sorting system at any of 60 outfeed boom conveyors or loading into roll cages or pallets.

Martijn de Lange, CEO at Hermes UK, “For the last few years we have witnessed double-digit growth due to our commitment to invest in our world-class network and infrastructure, our innovative fleet and our industry-leading portfolio of services solutions. In addition, our in-house engineering team is constantly optimising our equipment to ensure it is best in class and we will soon be introducing further automation to support our returns process in the coming months.

“Last year, we enjoyed our most effective and busiest peak season to date, whilst, at the same time, achieving record service levels and I’m absolutely confident the third sortation tier in Rugby will put us in the strongest possible position to further support the retail industry over the coming years.”

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Fully serviced in Europe
Beckum, 05. September 2019

BEUMER Group supplies conveying and sortation technology for Inter Cars' new European Logistics Centre to ensure smooth material flows:

BEUMER Group installed the entire conveying, picking and sortation technology for car parts dealer Inter Cars S. A. at its new European Logistics Centre near Warsaw. This includes a warehouse control system (WCS) that manages the entire material flow. Optimising its throughput and minimising costs, Inter Cars gets the spare parts now even faster to workshops and customers all across Europe. For this project, the system supplier BEUMER Group has permanently stationed employees on site as part of its residential service. They take over responsibility for availability and maintenance of machines and systems.

"Inter Cars was one of the most important projects for us to successfully complete in Poland," Sandra Lückmann sums up. She is business development manager at BEUMER Group in Beckum, Germany, and was responsible for the successful handling of this order. What was remarkable: "As system integrator, we designed and installed the entire conveying, picking and sortation technology for the spare parts dealer at its European Logistics Centre, including our WCS, which controls the goods receipt, quality assurance, picking, packing and goods issue."

Spare parts distributor with potential

Inter Cars is one of the leading spare parts distributors for passenger cars, transport vehicles and trucks. The company, headquartered in Poland, has several hundred subsidiaries and branches spread all across the Baltic states and the Balkans. In addition, there is a nationwide network of approximately a thousand workshops. The previous logistics centre in Czosnów, Poland, supplied smaller distribution centres all over Europe who then supplied the workshops and customers. The increasing number of stored and delivered parts, however, started to exceed its capacities. The managers decided to build a new automated European Logistics Centre in Zakroczym, approx. 30 km from Warsaw. The in-house logistics provider ILS was commissioned as general contractor - "and this is how we got involved as system supplier of intralogistics solutions", says Sandra Lückmann. "At the end of 2013, ILS called our Polish subsidiary. At the time, the project was still in its design phase. We only knew how many parts needed to be sorted in a given period of time."

Up to 7 million parts

In January of 2015, BEUMER Group got awarded the contract, installation started in September of 2015, and the start-up process began the following September, with completion in December. Inter Cars closed the previous logistics centre at the end of 2016, the new European Logistics Centre went into full operation in May 2017. "Currently, around 7 million parts like spark plugs, brake disks, V-belts, batteries, but also more bulky goods, like exhausts and hoods, are stored here, basically everything needed for cars," explains Lückmann. The complex is comprised of four warehouses, the largest one with 40,000 square metres, ten metres in height. It is equipped with a four-story shelving rack. The other warehouses have a surface of 5,000 square metres each. Here they store tyres and hazardous material, such as oils and varnishes, that must be kept separate for reasons of fire protection.

The products are divided into different clusters, similar to clothing sizes into S, M and XL, depending on dimension and weight. "Items are picked in two stages," describes Lückmann. With a set number of containers placed on a trolley, the employee drives along the aisles of the shelves, collecting all the components displayed on the hand-held reader. The small and medium parts are taken out of the shelves in batches, consolidating multiple orders into one picking wave. The containers are then placed on the container conveying system and transported automatically to the packing sorter. "Depending on the content, the WCS distributes the incoming containers to one of three induction areas," explains Lückmann. The conveying system transports them to the workplaces where the items are taken out of the containers. Each item is identified with a matrix camera and placed on the sorter. Empty containers are returned to the feeding area by the conveying system. "We provided our BEUMER BS 7 Belt Tray Sorter for this sorting process," explains Lückmann. This system manages a throughput of around 14,000 without presorting, and up to 27,500 items per hour when using the described presorting process.

Destinations ensure gentle sortation

Power and data transmission on the BEUMER BS 7 is contactless. This prevents mechanical friction losses and wear and tear. Compared to conventional cross-belt sorters, this sorter has 50 percent less components, which reduces maintenance costs by 80 percent. Energy requirements are also reduced during production and operation. The distance between the individual conveying elements on the BEUMER Group systems is reduced to a minimum. The use of belt trays makes it possible to have narrower, more closely arranged destinations. Therefore, the sorter requires less square footage. "The special feature of our BS7 are the 361 specially developed destinations that ensure careful handling of the very different spare parts," so Lückmann. Everything must be sorted and discharged while keeping the packaging intact. To this end the destinations are divided in two parts. If the spare part weighs up to 1.4 kilogram, the WCS classifies it as "light", up to six kilograms as "heavy". This way the heavier parts are placed in the container or cardboard box before the lighter parts when the order is packed.

"The XL items from the main storage are handled differently," explains Lückmann. "Their size means that only one spare part fits in one container or box." Therefore, they are conveyed directly to the consolidation area by the container conveying system. The same happens with items from other warehouses like tyres and hazardous material. Together with the items from the packing sorter, the shipping units consolidated in containers and boxes for the respective orders are weighed, compared with the target weight, closed, labelled and then strapped. The container conveying system transports them to the connected shipping sorter that distributes the consolidated orders to up to 50 different dispatch destinations, at a capacity of 2,500 containers per hour.

And what if the spare parts are not working or are no longer needed by the customer? "They go back to the logistics centre in Zakroczym," explains Lückmann. Employees examine the returns: is the part damaged, was it just not needed or was it the wrong choice? If it is still in its original condition, it goes back to the warehouse. The material flow for all these processes throughout the entire distribution centre is controlled by the WCS, from goods receipt to goods issue. The orders are sent from the operator's warehouse management system.

Residential service: BEUMER Group assumes responsibility

BEUMER Group continues supporting the project even after this point. ILS opted for the residential service, a special component of the BEUMER's comprehensive customer support, to focus more on their own core business. "With this 24/7 service, the BEUMER employees ensure availability of the machines and systems," reports Jaroslaw Gorczynski, General Technical Director, Poland. "It must be perfectly coordinated during the entire operating time, so that all processes run smoothly." The team has its own control room, and the workplaces were designed in a way so that potentially critical areas can be reached as quickly as possible.

The BEUMER Group employees also perform preventive maintenance work. Gorczynski explains: "This way, we can avoid unplanned machine breakdowns that can get very expensive for the customer." The team carries out maintenance and inspection work on the systems at defined intervals. They also check the safety devices, electrical components and automation technology. And they can perform repairs that might be necessary in case of an unscheduled failure of components. The team checks the technical installations and maintains them regularly, at agreed intervals. The contract with BEUMER Group runs over five years until 2022.

Guaranteed system flexibility

"Our systems and machines fully met the customer's targets. The system offers high levels of availability, high and precise throughput and can be easily adjusted to changing customer requirements. The same holds true for our modular WCS," describes Lückmann. The owner is very happy with the cooperation: "We were able to accommodate all requirements. Delivery, installation and commissioning went all according to plan." The companies are currently in talks about an extension of the system.

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"We support our customers in growing"
Beckum, 19. June 2019

Interview with Thomas Wiesmann, Director Sales Logistic Systems at BEUMER Group

At LogiMAT in Stuttgart, BEUMER Group presented its newly developed BG Sorter from the sortation and distribution technology segment. The high-capacity system enables precise and controlled processing of a wide variety of packages. The system integrator also has an efficient warehouse control system in its range for optimum flow of goods. In an interview, Thomas Wiesmann explains how users can benefit from this comprehensive competence and what trends they can expect. He is Director Sales Logistic Systems at BEUMER Group.

Mr. Wiesmann, at LogiMAT you showed the newly developed BG Sorter, which BEUMER Group first presented in 2018. How was the high-speed sortation system received in the market?

Wiesmann: Very well. We have already been able to implement some exciting projects since the market launch. This includes, for example, the new distribution centre of Austrian Post in Wernberg in Carinthia. Up to 30,000 parcels are handled on a daily basis. Our BG Sorter is at the heart of the centre. Availability, reliability and, above all, speed are valuable assets in this industry and are of paramount importance to our customers. With our system, Austrian Post will be the only parcel service provider in Austria to deliver parcels six days a week, from Monday to Saturday. The BG Sorter is powerful, energy-efficient and extremely quiet – much to the benefit of the employees.

What makes this high-capacity sorter so special and how do users benefit from it?

Wiesmann: With our BG sorter, operators benefit from very precise and controlled sorting with maximum flexibility. This means that both tilt tray and cross-belt sorters can be used in customer systems. The new sorter family provides the ideal variant for any type of items. The BG Sorter CB ("cross belt") is a reliable solution for sorting a wide variety of articles such as parcels and bags. The so-called "full cross belt design" means that the maximum belt width is ensured. The actual benefit for the customer: More usable belt area is available with the same sorter size. The risk that products remain lying between the belts is reduced. The tilt tray design also offers some advantages. We have designed the tilt trays so as to prevent items from getting stuck between the trays. The so-called "closed deck" closes the gap between them. This function reduces downtimes and avoids possible damage to the sorter or the goods. Users can handle items of different sizes with more flexibility. The tilt tray version can transport items weighing up to 60 kilograms. Furthermore, the construction series is available either with the proven OptiDrive, which is based on servo drives, or the contactless linear synchronous motor as the drive system. Both reduce energy demand and CO2 emissions compared to products offered by our competitors.

With this development, you have combined the best of Crisplant technology with the best of BEUMER technology. Can you give us more information?

Wiesmann: Both Crisplant, which today operates under the name of BEUMER Group A/S, and we have acquired extensive know-how in the development of high-quality sortation systems over decades. Since the acquisition in 2009, we have been able to expand our portfolio, exploit synergies and further expand our strengths in technology. The BG Sorter combines future-oriented features, which set new standards in sorting as large a product range as possible. Providing our customers with this scalable system, we facilitate their future growth and enable them to respond to changes in the market.

What demands do online retailers make on sortation technology today and how have they changed over the years?

Wiesmann: The competitive pressure on postal and CEP companies continues to increase. They must not only save costs, but also adopt a more environmentally conscious approach and follow market trends. Basically, material distribution technology is becoming more complex, and the systems must be able to perform increasingly specific tasks or adapt to changing conditions. Highly efficient processes are necessary to ensure quick delivery of parcels to the customer. Mail order companies are offering more and more products whose dimensions previously made it difficult to transport them automatically. In order to meet the increased performance requirements, more automation is required. In addition, the number of the required sortation and distribution systems is increasing, as more small-scale distribution centres are being built close to customers in order to be able to supply them even faster.

As a system integrator, you offer a flexible and modular warehouse control system (WCS) to control complete material flows in distribution centres from goods receipt to goods issue in real time. What are the features of this solution?

Wiesmann: Our WCS centrally connects and controls material flows from quality assurance, picking of goods and order picking to goods issue, always in accordance with the actual occupancy rate. How effective this system is can be seen, for example, in the new European logistics centre of the Polish automotive spare parts supplier Inter Cars near Warsaw. There it controls the packing and goods issue sorter as well as the put-to-light system in the goods receipt department, coordinates the automatic provision and application of the labels required for shipping the goods, and handles the routing of the individual items on the conveyor lines. This route planning optimises the performance of the system and controls the distribution of the various spare part types.

As an additional module we also offer our BG Fusion system to operators. This visual display system provides the operator with a web-enabled user interface for configuration, monitoring and reporting. It displays system data as alarms in a uniform and centralised way and shows status messages, fault messages and all relevant data. The entire system status can be monitored via the interface to the machine control. BG Fusion combines machine and order data so that the responsible employee can track the current order status in real time.

Why are such software systems becoming more and more important, and what are the concrete benefits for the user?

Wiesmann: The software systems serve as link between the customer's enterprise resource planning (ERP) or warehouse management system (WMS) and the entire material flow equipment. They ensure that the products reach the right place in the desired time within the distribution centre. Operators can perfectly coordinate their processes, increase throughput and reduce costs. With our know-how in sortation technology, we know exactly how to use these systems so that the user gets the most value out of it.

When developing the WCS software, what did you focus on?

Wiesmann: Unlike many competitors, our focus is not on adapting the customer's processes to the WCS. We rather adapt the system with its modular design to the respective needs of the customer on a project-by-project basis.

Outlook for the future: What challenges do you see for the logistics industry, and how must providers develop their IT skills?

Wiesmann: E-commerce is picking up speed and we are expecting double-digit growth per year in this area. In order to hold their own against competitors, the future success of mail order companies and logistics service providers will depend even more on the performance of their distribution centres. To increase performance, digitisation is inevitable.

What does that mean in concrete terms for us as suppliers? To position us for the future, we must complement our expertise in machines and systems, including the necessary software and controls, with digital innovation. We have competence in mechanical engineering. Here in Germany, there are many hidden champions who are global leaders with their products and systems. In my opinion, it is more convenient to adapt digital technologies for the required digital competence. For this purpose, we founded the BEAM GmbH in Berlin. With this autonomous company builder, we want to solve B2B challenges that are unique to the logistics industry in cooperation with start-up teams. For this we are planning on founding three start-ups per year and transfer them, consolidated under BEAM, into a separate company. Our goal is to open up new, but also disruptive business areas in logistics.

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A healthy batch of safety
Beckum, 17. June 2019

Davert opts for BEUMER stretch hood® A for packaging its palletised organic products:

Davert GmbH specialises in organic foods and stands for the continuous further development of processing methods and careful monitoring of these products, from cultivation to packaging. And this is where BEUMER Group comes in. The finished, high quality organic products like rice, legumes and cereal products like sugar, dried fruit, nuts, oilseeds and sprouting seeds must be protected from dust and pests during storage and then transported without damage to drug and health food stores. The system supplier provided the BEUMER stretch hood A for this task. It covers the mixed pallets of bags, cartons and buckets with a highly elastic stretch film, protecting them against external influences, keeping the merchandise secured during transport, even through sudden braking.

Healthy and sustainable nutrition plays an increasingly important role to consumers. Not only because it tastes better and is good for you, but also because consumers are taking a more critical look and want transparency when it comes to the production and processing of their food. Organic supermarkets and health food stores respond to these demands. Davert GmbH is a trading and manufacturing company for high-quality organic products. The company with its 150 employees is based in Ascheberg, in the southern Münster region, right next to the eponymous nature reserve Davert. "With our guarantee of origin, we are committed to fair trade and long-term business relationships world-wide," says Erwin Tenbrink, Technical Director at Davert. The company acts as a consultant for its partners when it comes to product selection and cultivation and coordinates infrastructure projects. For its customers, Davert follows a multi-channel strategy: the merchandise is sold via their own online shop and in in selected drugstores and health food retailers.

Cleanliness has the highest priority

"We are ensuring the highest degree of cleanliness to meet our strict quality standards," explains Tenbrink. Before being shipped out, the legumes, rice etc. have undergone special quality controls. The employees examine the incoming raw products and set up the required cleaning steps. In one mill for example, air flow from the aspiration channel removes stalk remnants, husks and dust from the cereal. Different sized grains are seperated using screens. Weed seeds and light particles like defective grains are also weeded out by the system, an optoelectronic sorter removes the foreign particles. "Another preventive measure is the pressure treatment that we use to prevent any pest infestation from the start," reports Tenbrink. "The sudden pressure release kills off any pests like bugs, moths or mites and their larvae and eggs, without compromising the quality of the product in any way."

In compliance with the quality assurance process, employees pack the merchandise in a variety of ways, depending on the product: rice, flour, linseed and grains are packed into bags, larger storage quantities into big bags. Packaged legumes, nuts, dried fruit and muesli is filled into boxes, honey into buckets. Depending on the store order, the team stacks the various unit loads onto mixed pallets. "Up to this point in the process, we assign the highest priority to cleanliness," explains Tenbrink: "And now it is just as important to keep this level of cleanliness and protect the products from dust and pests during storage in our high-rack warehouse." The units also have to be loaded safely onto the back of the trucks and reach the distributor without any damage. This is where the packaging comes into play.

Reliable and powerful packaging system

The managers were looking for a solution that could meet all these requirements, ensuring fast and reliable operation, high levels of availability, easy maintenance, and a small footprint. They found BEUMER Group. The single-source provider for filling, palletising and packaging technology delivered the BEUMER stretch hood A high-capacity packaging system. "The machine is very easy and safe to operate," describes Volker Feldmeyer, sales engineer at BEUMER Group and responsible for the project at Davert. "In order to make work easier for the maintenance personnel, which also means higher levels of availability, the machine does not require any platform." Maintenance work, such as changing the blades or the sealing bars, is handled at floor level. The operator simply opens a drawer, providing free access. Additional benefits include the compact design and the resulting low height and small footprint.

A film transport system, which is particularly gentle on the material, introduces the previously cut and sealed film hood into the system. On its way to the crimping and stretching unit, the sealing seam on the film hood cools down so that it can be crimped without losing time. Energy-consuming cooling units and delayed cooling times become obsolete. This means that the pallets can be packed in a shorter cycle time. Economical engines and a lower demand in compressed air optimise the energy balance. Environmental considerations are also important to Davert. In order to save resources and produce minimum waste, the company opted for this type of film wrapping. The palletised goods are also clearly visible through the smooth surface of the transparent, highly flexible film. The wrapping protects the merchandise against atmospheric influences and humidity, and ensures an aesthetic appearance on the shop floors. "The elastic film also increases the safety during transport considerably," describes Feldmeyer. At Davert, the BEUMER stretch hood A packages the pallets for high-bay storage systems: the pallet base remains unwrapped, so that the forks of the fork-lift truck won't damage the film. This prevents any remaining film from interfering during the contour check before the pallet is stored in the high-rack system.

Easily operated

The system supplier has introduced the BEUMER Group Human Machine Interface (HMI). This newly-developed operator panel with an optimised user interface and graphical navigation for operating the system offers an even more ergonomic workflow to the user. This easily understandable and intuitive interaction concept helps to define efficient working sequences. "The soft-touch panel uses pictograms to guide the user through the menu of the Siemens SIMATIC S7 machine control," explains Feldmeyer. ""The panel also gives the operator access to all required training programs and content."

"We implemented this project in close cooperation with BEUMER Group," Erwin Tenbrink is happy to report. He is entirely convinced of the great technical cooperation during the planning and installation of the system. One important aspect for him is reliable customer support, as even this high-quality machine needs maintenance and service. "If necessary, we send our service personnel to the plant to check the system and perform any required adjustments," Feldmeyer promises. "This way we can ensure high-levels of availability at any time."

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"Our system solutions are used everywhere"
Beckum, 05. June 2019

Interview with Andrea Prevedello, Global Sales Director CL-Systems of BEUMER Group:

At bauma in Munich BEUMER Group provided information on their system solutions expertise for the mining and raw materials industries and port handling. The portfolio includes curved belt conveyors, blending bed systems as well as ship loaders. Andrea Prevedello explains in the interview how users can benefit from BEUMER Group as a partner and which trends they can expect. Andrea Prevedello is Global Sales Director CL Systems of BEUMER Group.

Mr Prevedello, at bauma you provided information on overland conveyors and Pipe Conveyors. Can you tell us a bit more about a current project?

Andrea Prevedello: What immediately comes to my mind is this very exciting project in the Belgian town of Flémalle. A coal-fired power plant was operated here in the past. The coal residues are landfilled on a fly ash stockpile. We installed a Pipe Conveyor to transport the fly ash to the Maas river for shipment. Its enclosed design prevents the volatile material from coming into contact with the environment and enables a low-noise transport to the destination. This was very important as the system runs over public motorways, railways and residential areas. The transport of the fly ash is carried out in strict compliance with safety standards, taking into consideration environmental protection and the effect of noise pollution on the local residents. It is planned to dissipate the entire stockpile within the next ten years, and repurpose the terrain into a nature park.

What were the challenges during this project, for example with regard to the installation of the system?

Andrea Prevedello: The installation presented itself as quite a challenge, in this picturesque, but also quite hilly environment and as the Pipe Conveyor runs over roads, rails and residential areas we had to comply with public regulations. We set up three teams. We needed a safe conveying system design, that would prevent any environmental impact and noise pollution during the bulk material transport. In the first team employees of the local authorities worked in close cooperation with our experts. The second team was made up of ten BEUMER Group employees that assembled the system. Special cranes and helicopters were used for the assembly work. We assigned the third team for this: the Heliswiss International AG from Küssnacht, Switzerland. They provide transport and construction flights with heavy lift helicopters. Extremely precise flight manoeuvres were necessary so that the technicians could safely assemble the elements suspended from the helicopter to the steel structure. The pilots had to guide the components exactly to the bore holes of the connecting piece so that team II could then bolt them together. The BEUMER Group employees were working on platforms attached to cranes in heights of up to 45 metres. It was quite a sight!

How can you ensure that the customers always receive the best solution that allows them to remain sustainably competitive?

Andrea Prevedello: An essential feature of our transport solutions is that they enable horizontal and vertical curves. This permits us to adapt the sections to the optimum route and we dont't have to use straight line sections to build around obstacles. Angles of inclination of up to 15 degrees are possible, depending on the characteristics of the material to be transported and the topography, with lengths of more than twelve kilometres. Due to the ability to navigate curves, considerably fewer and in some cases no transfer towers are required. The customer gets an ideal solution which allows for substantial cost savings and the system continuously transports the material even over challenging ascending sections and downward slopes - this was a great advantage especially in Flémalle. Using BEUMER calculation programs, we precisely calculate the static and dynamic tractive forces of the belt during the development phase. This is the prerequisite for the safe dimensioning of the curves. BEUMER Group selects the required types of drive technology and conveyor belts based on these calculations. This ensures longevity of the entire system.

Would there also have been alternative possibilities for this task, using trucks for example?

Andrea Prevedello: Mine operators and manufacturers of cement and building materials often rely on trucks for the transport bulk material, even over long distances. These vehicles certainly also have their justification. However, depending on the terrain, they can rapidly reach their limits: they require well-developed roads and fuel, for example and the costs for the construction, maintenance and possible extensions are significant. The ecological aspect needs to be considered as well: new roads and access roads have a serious impact on the landscape. And this was to be avoided especially in the area around Liège with small villages along the Maas river as well as forests and unique landscapes. In addition, there are the emissions caused by truck traffic, which includes toxic substances as well as noise and dust.

Our belt conveyors are provided with environmentally safe electric drives and low-energy belts. The installed motors are mostly adjustable which permits the loads to be optimally distributed on the drive units under various operating conditions. If the belt conveying system conveys downhill, the system works in generative operation. The generated electric energy is fed back into the public network by a regenerative feedback unit. Depending on the project, our belt conveying systems require up to 90 percent less primary energy than comparable truck transports. Users often reduce their operating costs by several million euros per year. If you do not know which solution to choose, a cost comparison will help.

As a system provider you also have stockpile equipment in your portfolio. What does the scope of supply look like, how do you support the operators?

Andrea Prevedello: For this stockpile equipment, we offer the full range of stackers and scraper reclaimers. These can cover different functions as for example simple storage or mixing of the bulk material, and ensure a maximum mixing effect. Users can also efficiently homogenise different bulk material qualities which ensures the uniformity of the raw materials used. My colleagues carry out the entire engineering of the system. They calculate the storage dimensions and provide the design and static calculations of the associated storehouses. The blending beds are customised according to the 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. 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.

In what industries are your solutions needed?

Andrea Prevedello: This can vary a lot, because our system solutions are used wherever you need to transport large quantities of bulk material. This is particularly true for the ore and raw materials industry, but also applies to applications beyond these traditional sectors, such as the transport of cereals. In ports, for example, we ensure that different materials are efficiently loaded onto ships.

What is particularly important when it comes to these loading systems?

Andrea Prevedello: The mobile and swivel-mounted ship loaders have a telescopic chute and a throw-off belt conveyor to make loading as efficient and flexible as possible. The ship loader is also equipped with a dedusting unit which keeps the process emission-free. We also offer bulk loading heads which are used to load bulk materials into silo vehicles quickly and without dust. Special fill level indicators are used, tailored to the bulk density, flow characteristics and temperature of the loaded cargo.

Due to rising living standards, especially in emerging countries and the expansion of key and future technologies, there is a growing demand for most raw materials. How will this development affect plant construction in general?

Andrea Prevedello: The prices for raw materials such as iron ore and copper are rising rapidly. This is why we notice that a lot of companies are willing to invest. In order to cover the increasing demand, there is an overall trend towards larger tonnages and throughputs since larger manufacturing facilities are more efficient. Many users don't want to set up several parallel systems, but want to cover their entire requirements with one line or a minimum number of lines. This trend has a considerable impact on how we develop our systems.

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Economic transportation of cement clinker
Beckum, 29. April 2019

BEUMER Group offers robust belt apron conveyors

Robust apron conveyors (SZFs) are used in cement plants to transport clinker safely and economically from the kiln cooling system to the silos. BEUMER Group is the only manufacturer who offers a special variant, the belt apron conveyor (GSZF): Using a belt instead of a chain as traction element allows higher speeds and a slimmer design while still delivering the same level of performance. The GSZF is therefore particularly suitable for modernisations.

In general, the clinker comes out of the cooler at 80 degrees plus ambient temperature. But during the process, a so-called kiln flash can occur caused by a raw meal flash from the preheater tower or by caked clinker coming off the kiln: Within a few seconds several tons of raw meal or clinker shoot through the cooler. The material to be conveyed cannot cool down sufficiently and reaches the conveyor at temperatures of 500 to 800 degrees Celsius.

With its apron conveyors, BEUMER Group provides robust and reliable solutions. The specific design of the cells allows safe, low-friction transportation of any hot material. Sealed and overlapping side walls and bottom plates in the cells prevent the clinker from exiting and minimise the escape of dust. The traction element in this conveyor is usually a single or double strand sprocket chain. The system supplier is the only manufacturer on the market who offers apron conveyors with the tried and tested BEUMER steel wire belts from the bucket elevator technology instead of a chain as traction element. Here the cells are attached to the long-lasting, steel-wire reinforced belt in a way so that the heat of the clinker in the steel cells is not transferred to the belt. Partition plates are attached in the feeding area below the cooler and can be easily removed for maintenance, protecting the belt against hot clinker in case of a kiln flash.

One decisive advantage of the belt apron conveyor: with speeds of 0.6 metres per second, it can reach double the conveying speed compared to apron conveyors with a chain. This makes it perfect for retrofitting and modernisations. If operators want to increase the kiln capacity for example, they can replace an existing chain apron conveyor with a belt version of the same size – this means double the capacity without having to make any changes to the steel structure or the conveyor bridge. The cement plants also benefit from a new construction application: The thinner, lighter design of the GSZF reduces costs for steel structure and freight. Furthermore, the decreased net weight lowers the static and dynamic loads which affect the clinker silo and foundations for example. A new construction project can be designed for a smaller load and is therefore more cost-effective to build. The lightweight design also lowers operational costs.

Quiet, low in maintenance, reliable

The entire belt lies with its surface on the drive and return pulley which avoids the unwanted polygon effects caused by the chain. The particularly smooth running of the machine also reduces noise emissions considerably. The noise is less than half as loud as conventional SZFs with chains, which is advantageous for both the employees and the environment.

The use of the durable BEUMER steel wire belt lowers the maintenance costs, and extends maintenance intervals. Chains can break, if preventive maintenance is not performed properly, which will lead to the conveyor collapsing. The rubber of the steel wire belt only becomes brittle with age, but it would never completely break. Lubrication is also not required for the belt, whereas used frequently on a chain, if for no other reason than to reduce noise levels. Grease and oil are not only a cost factor, but also detrimental to the environment and the conveyor. The clinker dust gets stuck on it and settles in the chain links, which accelerates the wear and tear.

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BEUMER Group’s tote-based baggage handling solution the preferred choice for Kuwait City’s iconic Terminal 2 international airport project
Aarhus, 09. April 2019

Kuwait International Airport has opted for a tote-based baggage handling system for its iconic new Terminal 2 airport project, which brings together the best of contemporary design and technology. Once operational, it will bring Kuwait to the forefront of global aviation.

The BEUMER Group, a leading global supplier of automated baggage handling systems (BHS), is providing the bespoke BHS based on its technology range. Designed specifically to meet the various demands of the new hub, which includes fast transfer times, the new system will incorporate industry-leading technology such as in-tote hold baggage screening (HBS) and an 1800-position early baggage storage (EBS) CrisStore® function.

The new terminal’s state-of-the-art BHS with the CrisBag® system, will overcome various challenges through the use of BEUMER Group’s advanced high and low-level control system, which will be key to ensuring a flexible and reliable performance when handling major baggage flows.

Explaining Kuwait’s decision to build one of the world’s most innovative and advanced airports, Sheikh Salman Sabah Salem al-Humoud al-Sabah, Kuwait’s Directorate General of Civil Aviation (DGCA), says that the new USD 12 billion mega-hub will meet the rapid growth in air traffic in the region.

In a statement released last year at the Kuwait Investment Forum, he predicted, "Kuwait will witness a rapid growth in passenger and cargo movements in the coming 20 years. To keep pace with this growth, the DGCA has also revamped the existing airport through a number of projects, such as the construction of the new passenger Terminal 2.”

Given Kuwait Airport’s strategic location, the new airport, which is scheduled to be completed by 2022, is expected to serve as the region’s leading hub for traffic flowing between Africa, Europe, Asia, the Americas and the Middle East.

The new passenger terminal will have the capacity to handle 25 million passengers per year and accommodate all aircraft types through 51 gates and stands. Kuwait airport has contracted the BEUMER Group’s Middle East Customer Support Team to provide ongoing residential maintenance functions, with BEUMER Group specialists responsible for all day to day functions of the CrisBag® operation.

Klaus Toftgaard, CEO of BEUMER Group Middle East, applauds this decision, pointing out that this is by far and away the best strategy for the owner of a technologically-advanced BHS to ensure optimum efficiency. He stresses “this is now the solution being adopted by leading global airports, since it draws upon the in-depth knowledge of the system’s designer and builder to ensure that the system will continue to run smoothly, even in the most challenging environments.”

The Ministry of Public Works Kuwait is leading this prestigious project with Foster and Partners in association with Gulf Consult as the designers and Limak Insaat as the main contractor.

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BEUMER Group’s baggage handling system plays important role in the smooth running of Singapore Changi Airport’s baggage operations
Aarhus, 26. March 2019

Changi Airport Group’s (CAG) recently released 2018 performance figures make for impressive reading. The multi-award-winning airport is now handling more than 65 million passenger movements annually.

Behind the scenes, BEUMER Group’s BHS plays a key role in ensuring the overall smooth handling of passengers’ baggage.

"Changi Airport first put its trust in our baggage handling technology in 1998,” says BEUMER Group Managing Director, Klaus Schäfer. He explains that the airport has deployed BEUMER’s baggage handling system in Terminals 2, 3 and 4, and over the years, has also extended the relationship by having BEUMER undertake year-round operational and maintenance support of the BHS as part of the overall care package.

The confidence placed in BEUMER’s technology by CAG has paid off.

Significantly, the company continues to deliver industry leading BHS reliability using the same number of personnel as when the contract first started in 2001. Furthermore, they have put in some truly noteworthy performances.

While the number of bags handled across the whole airport doubled in the last five years, the number of staff employed by BEUMER remained the same. With an average increase of 26,000 bags processed each day, BEUMER’s expertise ensured that the BHS could handle the rising demand on capacity and continued to run smoothly.

BEUMER Customer Support Director, Finn Laugesen, is in no doubt as to why Changi Airport’s BHS can operate so reliably, "We build long term relationships with our customers, so we genuinely understand their needs and are thus able to deliver the required performance. As a direct result of customer understanding, we have demonstrated that peak loads on the system don’t require extra staff. Instead, by combining meticulous planning and rigorous on-going system checks we are able to avoid any surprises.”

He adds that in terms of passenger satisfaction, Changi Airport continues to receive awards.

CAG's Vice President for BHS, Ng Hoe Seng also acknowledges the success of the BHS relies on the strength of the operational relationship between the two companies, " The BEUMER Group has invested time and effort to understand our requirements. They play an important part in our operational ready acceptance tests, most recently at Terminal 4, where the new BHS began operations successfully and on-time, after extensive testing prior to the opening. This included BEUMER Group processing over a million bags in addition to the training of all ground personnel".

The original contract was followed by the installation of a CrisBag system in Terminal 3 which undertakes dual baggage sorting and inter-terminal transfer baggage, linking to Terminals 1, 2 and 3.

Terminal 4, also benefits from the BEUMER Group technology, having its own dedicated CrisBag tote-based system.

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The right packaging
Beckum, 05. March 2019

BEUMER Group supplies entire packaging lines tailor-made for each customer from one single source:

BEUMER Group supplies packaging lines and complementing intralogistics solutions customised to its users and their requirements from one single source. Serving the cement, construction and chemical industries, consumer goods market and logistics sector, the extensive product range features modular designs. One of its customers is the German retail store dm-drogerie markt GmbH & Co. KG, with its logistics centre in Weilerswist near Cologne.

When BEUMER Group installs packaging lines in the (petro)chemical industry, the process may resemble this: bulk materials from the chemical industry are transported from the silo via a conveyor line to the form fill seal system BEUMER fillpac FFS. This highly efficient filling machine forms a ready-made PE tubular film into a bag and fills it with the customer's engineering plastics such as PE, PP, PA or PS granules. Reliable, gentle and sustainable filling is also possible for salts or fertilisers. The bags are then weighed before the filling process. For this, the BEUMER fillpac FSS is equipped with an electronic calibration-capable weighing unit. It ensures that the system fills the bags with a constant quantity of material within the specified tolerances. Then the system seals the bags with a weight of up to 25 kg. It can process 2,600 bags per hour.

For the efficient filling of paper bags with bulk material, particularly cement and construction materials, the system provider offers the BEUMER fillpac R. These systems function reliably, carefully and sustainably while meeting the required throughput. The construction series is equipped with a special weighing unit as well. Depending on the requirements and on the material characteristics such as bulk density, grain size, material density or flow behaviour, BEUMER Group can offer both air and impeller filling machines from the construction series BEUMER fillpac R. The air filling machines are suitable for bagging pourable and coarse-grained products with particle sizes up to ten millimetres, whereas the impeller technology is suited for free flowing and fine-grained products like cement or gypsum. Adding the BEUMER bag placer and a ream magazine to the system makes the filling even more efficient.

Proper and stable stacks on pallets

The filled bags, which are made of different materials like paper, PE or PP and have different sizes, weights and designs (flat valve bags or valve bottom bags), have to be stacked on pallets in a stable and precise way. For this, BEUMER Group offers the BEUMER paletpac. It can be quickly assembled thanks to its modular design, is easily accessible for maintenance, can be operated intuitively and flexibly adapted to different packing patterns. Depending on the product requirements, the BEUMER paletpac can be equipped with a clamp-type or twin-belt turning device which positions the bags smoothly, quickly and exactly. For palletising cartons, boxes, canisters or trays, BEUMER Group offers the BEUMER robotpac. This space-saving, fully automatic articulated robot solves complex palletising and de-palletising challenges reliably and efficiently. The user receives gripping systems suitable for all types of packaged goods, which can be easily exchanged.

Reliable packaging of dm drugstore products

The BEUMER stretch hood high capacity packaging system is at the heart of the packaging lines. It covers the mixed pallet of merchandise with a highly elastic film hood. This can be filled and palletised bags, boxes of detergent, buckets of paint or storage jars. During transshipment and outside storage, the merchandise is protected reliably against environmental influences such as sunlight, dirt and humidity. This is important for the operators who need their products to be transported reliably and in perfect condition to the customers, products like those from dm-drogerie markt GmbH & Co. KG.

The drugstore chain has its own distribution centres, one in Waghäusel in the south-western state of Baden-Württemberg, and one in Weilerswist near Cologne in North Rhine-Westphalia. Here, the employees pre-package cardboard goods for the stores. In Weilerswist, there is also the so-called small parts distribution centre. Here, small and individual products that cannot be securely stored on pallets are packaged in containers and cardboard boxes, and then commissioned, palletised and shipped. Both distribution centres have a combined product range of 12,800 items.

Secure pallet protection

Up to 3,000 pallets of goods arrive in Weilerswist daily. They are registered and checked. They are then transported over a conveyor line to two fully automated high-bay storage facilities. Empty pallets move along 42 aisles on overhead tracks and automated guided vehicle systems. A light signal indicates which product, and how many, are to be placed on the pallet. The merchandise must be secured and protected, so that it arrives at the dm stores in perfect condition. Therefore, high demands are placed on the packaging systems. Two high-capacity BEUMER stretch hood machines are in operation. They package 90 pallets each per hour, but are designed for 100 pallets. Lorries bring the shops their goods approximately 72 hours after ordering.

Playing with colours

The systems run perfectly. The smooth surface of the film hood increases the visibility of the palletised merchandise and the BEUMER stretch hood provides considerably higher levels of availability compared to stretch wrappers; another bonus: they have more colours than other packaging systems. At dm's request, they were painted in several colours. So they fit in the coherent colour scheme of the entire distribution centre: the basic colours yellow, orange, blue and purple run through the entire design. The unique design was created by STOLLSTEINERart&business. The idea behind it is that the colours signal to the employees that all working steps are interlinked.

Like a second skin

Another solution for protecting the bags against environmental factors is the BEUMER bag-in-bag: This system packages one or several filled paper bags quickly and reliably with a weather-resistant plastic film. This ensures that the contents are perfectly protected against moisture, dust or insect infestation when they are transported or stored.
Furthermore, the system provider equips all systems of a line with the same Human Machine Interface (HMI). This operator panel provides users with an easily understandable and intuitive interaction concept, enabling them to define efficient working sequences.

And there is more at the end of this packaging line: With system solutions of BEUMER Group, the full pallets or individual bags can be forwarded to a connected warehouse or directly to the loading space of a truck. The system components are mainly transport technologies such as conveyors or vehicle-based systems. Various solutions for handling and manipulators such as robots, buffer and storage modules are available as well. As BEUMER Group always uses components from a modular system, the solutions can be expanded at any time and can grow with the customer's needs.

Software based on modular design

For best results and to ensure full material and data tracking, the filling, palletising and packaging components as well as other system components must be perfectly matched. For this, BEUMER Group has developed the modular BG Software Suite as superior data processing system. It can be adapted individually to particular tasks and products from other companies can be easily integrated. Users can extend this solution at any time and optimise their material flows. The cross-program user interface BG Fusion shows process data and reports. All available data can be accessed without having to switch between different applications.

With the BEUMER Group warehouse control system the BG Software Suite can be easily connected to the warehouse management system or the customer's ERP solution. This way, BEUMER Group ensures the communication between the different control levels for the user. BEUMER can create an intelligent connection between the individual systems, and integrate them into existing process and inventory control systems of the customer.

Online data access at any time

BEUMER Group has developed the new Operation Monitoring app.  With this application for mobile devices such as smartphones or tablets, the user or the management has an overview on all relevant key figures of the complete packaging line or individual systems. The app shows the status quo of availability, performance and quality levels as well as the energy and compressed-air consumption. This ensures efficient operation of all systems. Customers can adopt the program to their specific requirements. For a better organisation and control of their logistics value chain, the task is to integrate all participants, systems, machines, and products in one dynamic system – horizontally and vertically. Thanks to this increasing networking, highly linked system structures are possible, in line with the ideas of Industry 4.0.

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Beumer-PCL Awarded GTAA Baggage 2025 Master Agreement
Aarhus, 31. January 2019

Toronto, Ontario (January 31, 2019)PCL Construction, one of the largest contracting organizations in North America has, in joint venture with BEUMER Group, a global leader in baggage-handling systems, signed a master agreement with the Greater Toronto Airports Authority (GTAA) for Toronto Pearson International Airport’s​ Baggage 2025 initiative.

To accommodate growth and to improve capacity, reliability, and efficiency at the airport, the GTAA is embarking upon an ambitious upgrade to Toronto Pearson’s baggage-handling operations, with a state-of-the-art, automated system.

The master agreement includes several design-build work packages that together will revolutionize the way the airport operates, enhancing the passenger experience and ultimately moving Toronto Pearson closer toward the vision of being the best airport in the world.

“With over a century of helping our partners succeed, our company takes pride in partnering with the best,” said Dave Filipchuk, PCL president and CEO. “Having successfully delivered a number of projects at Toronto Pearson, PCL is excited to continue building our relationship by partnering with Beumer to deliver a best-in-class solution that supports the GTAA in growing Toronto Pearson’s status as an international gateway.”

The modern and fully automated approach that the Beumer-PCL team will deliver is relatively new in North America but has been more broadly implemented in Europe and Asia.

“BEUMER Group values long-term partnerships, and with this contract we are set for a journey that will last for many years with a clear aim to transform Toronto Airport's baggage handling into a leading airport hub operation,” said Dr. Christoph Beumer, chairman and CEO, BEUMER Group. “We have listened to the GTAA's plans and applied our open mind and creativity to lay out the best solution for developing the airport's baggage-handling process for the benefit of their passengers and their staff."

“As Toronto Pearson’s passenger traffic continues to see significant growth, the GTAA recognizes the importance of planning to meet the demands of a future airport that could grow to welcome over 80 million annual passengers in the next twenty years,” said Howard Eng, president and chief executive officer, GTAA. “With the innovative solutions designed by our partners at BEUMER Group and PCL Construction, the airport will be well equipped to provide efficient, resilient baggage service and ready the system for an estimated 80 million pieces of luggage per year by the mid-2030s.”

As part of the master service agreement, the GTAA will implement Beumer’s automated tote-based baggage transport and sortation system, CrisBag®, at Toronto Pearson. With this solution, each item of baggage remains in the same individually controlled tote and is 100% tracked and traceable at every stage of the baggage-handling process, which is key to complying with the Canadian Air Transport Security Authority (CATSA) requirements for US transborder clearance.

Beumer and PCL look forward to working with the GTAA and partners that include Brock Solutions, B+H Architects, Peter Sheffield & Associates, The Mitchell Partnership, and Mulvey & Banani International. Construction on the first four work packages is set to begin at the end of January, with completion scheduled for 2021.

About PCL Construction

PCL is a group of independent construction companies that carries out work across Canada, the United States, the Caribbean, and in Australia. These diverse operations in the civil infrastructure, heavy industrial, and buildings markets are supported by a strategic presence in 31 major centers. Together, these companies have an annual construction volume of $9 billion, making PCL the largest contracting organization in Canada and one of the largest in North America. Watch us build at PCL.com.

About GTAA

The Greater Toronto Airports Authority (GTAA) is the operator of Toronto Pearson International Airport. The GTAA’s vision is to make Toronto Pearson the best airport in the world. Towards this objective, the GTAA focuses on ensuring the safety and security of passengers and airport employees, enhancing the passenger experience and supporting the success of its airline partners. Toronto Pearson is Canada's largest airport and the second-busiest North American international airport.

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Reliable across rough terrain
Beckum, 29. January 2019

BEUMER Group at bauma 2019:

At bauma, which will take place in Munich from 8 to 14 April, BEUMER Group will provide information on their efficient transport solutions for the mining industry, among other areas. Overland conveyors and Pipe Conveyors transport various raw materials over long distances and often through rough terrain. This is generally faster, more cost-efficient and environmentally friendly than trucking. The system supplier also offers comprehensive technology for the cement and building materials industries and is the only supplier to provide complete packaging lines from a single source – from filling and palletising to transport packaging of the pallet.

The overland conveyors and Pipe Conveyors of BEUMER Group can be used by companies in the mining industry to transport various bulk materials, even over long distances and often through rough terrain. High angles of inclination and tight curve radii enable individual routing adapted to the respective task and topography. BEUMER Group relies on camera-equipped drones for the planning, projection, implementation and documentation of these systems. Using special software solutions, the system supplier evaluates the aerial photographs photogrammetrically to generate digital terrain models.

The product range of the system supplier includes stackers and bridge reclaimers for storage yards, whether with or without blending bed systems. These stack bulk material and guarantee a maximum blending effect. Users can also efficiently homogenise large quantities of different bulk materials and bulk material qualities and thus ensure the uniformity of the raw materials used. For efficient loading, BEUMER Group supplies ship loaders with fixed booms and extendable telescopic belt conveyors, as well as bulk loading heads, which are used to load bulk materials into silo vehicles quickly and without dust.

BEUMER Group will present economic solutions for companies from both the cement and building materials industries at the trade fair. In cement plants, clinker with temperatures of 500 to 800 degrees is transported from the kiln cooling system to the silos. With its belt apron conveyors, BEUMER Group offers robust solutions for efficient transport. A belt instead of a chain as the traction element allows higher speeds and a slimmer design while still delivering the same level of performance. These conveyors are therefore particularly suitable for modernisations.

When it comes to filling, palletising and packaging cement, BEUMER Group offers complete packaging lines from a single source - a unique selling point in this industry. The system supplier offers the BEUMER fillpac filling machine for different requirements in various versions. The unique feature of this filling technology is that it can handle a wide range of materials, from very fine to coarse structures. In addition, various palletising solutions and a high-performance packaging system with sophisticated features are available.

Against the background of the global climate debate, the use of so-called alternative fuels and raw materials (AFR) in the energy-intensive cement production is steadily increasing. BEUMER Group offers tailor-made systems for the entire material flow chain in cement plants - from receiving and unloading the delivery vehicle to storing, sampling, conveying and dosing the solid alternative fuels.

BEUMER at bauma: hall B2, booth 413

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Secure packaging
Beckum, 23. January 2019

BEUMER Group at POWTECH 2019:

BEUMER Group will exhibit its expertise as a system provider for complete high-capacity packaging lines at POWTECH 2019 in Nuremberg from April 9 – 11, hall 1, booth 627. BEUMER Group optimizes the performance of each machine, its components and the high-level controls to ensure high throughput of the lines for (petro)chemical products and building materials.

The behaviour of powders and bulk material can change entirely according to operating conditions, handling methods and the intended use, whether it is for (petro)chemical products or building materials. This impacts the flow behaviour, which has a considerable influence on how to optimally design the conveying, filling, palletising and packaging systems. BEUMER Group designs, constructs and installs systems that are tailored in detail to industry-specific requirements.

The BEUMER fillpac R filling machine fills bulk material from the building materials industry and other industrial pulverized goods into different bag sizes and types like valve bottom and flat valve bags in an efficient and gentle way and with the required throughput. The structure of the materials can be very fine to very coarse. The BEUMER bag placer and the ream magazine supply the rotary filling machine with empty bags to ensure the high throughput. The highly efficient form fill seal system BEUMER fillpac FFS is used in the chemical and petrochemical industries. It forms bags from a prefabricated tubular PE film and fills them with the product. The customers can select the optimal machine performance class from this product family depending on their requirements.

BEUMER Group offers different palletising solutions, depending on the packaged items. The BEUMER paletpac is suited best for bulk material. It is incorporated into high-performance packaging lines to process even sensitive and valuable products as well as products with special flow characteristics in a gentle and efficient manner. Depending on the product requirements, these palletisers can be equipped with a clamp-type or twin-belt turning device which turns the filled bags quickly into the required position for stacking, ensuring their dimensional stability without any deformations.

Products for the (petro)chemical industries are filled in special bags, barrels, canisters, cartons or buckets. To palletise them, BEUMER Group offers its space-saving articulated robot, the BEUMER robotpac. Depending on the packaged items, BEUMER Group equips the robot with the appropriate gripping tools which can be easily and automatically changed, if the packaged items change. The fork gripper for example was designed specifically for palletising cardboard boxes, the finger gripper for bagged goods. For maximum performance, BEUMER Group offers a double gripper for both types. They also offer parallel grippers for dimensionally stable packed items, suction grippers for items with a smooth surface and many other special grippers and combination tools.

Packaged items stacked accurately on pallets can then be transported successfully to the downstream packaging system – for example, the BEUMER stretch hood. It covers the palletised goods with a highly stretchable film. During transshipment and outside storage, the merchandise is protected reliably against environmental influences such as sunlight, dirt and humidity.

BEUMER at the POWTECH 2019, hall 1, booth 627

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BEUMER lands $33 million contract at Aruba’s Queen Beatrix International Airport
Aarhus, 08. January 2019

BEUMER Group has signed an agreement with Aruba Airport Authority N.V. for the design and installation of a $33 million, high-speed baggage transportation and sortation system at Aruba’s Queen Beatrix International Airport. The installation, which also includes BEUMER’s residential program for on-site operation and maintenance, is part of the airport’s Gateway 2030 expansion and modernisation program.

The baggage handling system (BHS) features a tote-based CrisBag® high speed baggage transportation and sortation system, with integration to a full TSA-compliant EDS screening system with in-tote screening functionality, and a Baggage Image Weight Identification System (BIWIS) to streamline the airport’s U.S. pre-clearance process.

The new system will eliminate the requirement to reclaim checked luggage and undergo a second passenger screening process which presently is in place for U.S. travellers. Additionally, the new system will allow U.S and non-U.S. bound flights to operate from a common-use check-in facility. Aruba Airport handles approximately 2.8 million passengers annually, with 67 percent coming from the United States.

The Aruba Airport project is the first airport in the Caribbean and Latin America to showcase BEUMER Group’s integrated ICS system (CrisBag) and bag storage system (CrisStore) to handle the peak flight demands of the airport, according to BEUMER Senior Vice President Barry Lagerstedt.

“The application of U.S. Customs Pre-Clearance as well as the interface with TSA-compliant protocol baggage screening is a perfect application for our integrated CrisBag baggage handling and storage solution and provides the highest reliability and security of any system available,” BEUMER Senior Vice President Barry Lagerstedt said. “Our team has worked very closely with the Aruba Airport programme team to verify system capabilities, operational benefits and future capabilities. We are proud to design a scalable and redundant tote-based system, and we look forward to a successful long-term relationship with Aruba Airport."

The final design of BEUMER’s tote-based CrisBag system will be carried out in collaboration with the airport’s main terminal designer, NACO, and program management consultant Satterfield & Pontikes to ensure that the baggage handling system and the building are properly integrated and that the new system is designed and built with the optimal efficiency.

“We are very pleased to have crossed this important milestone,” said Aruba Airport Authority N.V. CEO James Fazio. “The new baggage handling system is the centerpiece of the airport’s redevelopment project and will allow for the modernisation and streamlining of many of our passenger processes, most notably, a significantly more efficient U.S. Customs pre-clearance operation, improved baggage screening, and a more efficient use of the airport check-in hall capacity. We are very pleased to be partnering with BEUMER Group on this important system and look forward to working on transforming our airport in the upcoming years.”

Installation will begin in Q3 of 2020, with completion expected in Q2 of 2021 in coordination with the opening of the Gateway 2030 project construction phase 1.

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"We have all the opportunities in the world"
Beckum, 22. November 2018

Interview with Johannes Stemmer, Director Digital Transformation at BEUMER Group

Digital transformation is inevitable. Industry, economy and society are already there. How can a medium-sized mechanical engineering company and leading global systems supplier of intralogistics solutions face these changes and get the most value out of it? Johannes Stemmer, Director Digital Transformation at BEUMER Group, is here to give us answers.

Mr Stemmer, how do you understand digital transformation within the context of your company?

Stemmer: It basically comes down to the safeguarding of our future sustainability. We are combining 80 years of experience, which made us one of the leading global systems suppliers in the intralogistics industry, with innovation that is driven by today's challenges from digitization.

What is important for a successful digital transformation?

Stemmer: We are already experiencing digital transformation, not only in our business, but also in our private lives. Almost everybody owns a smartphone, streaming services are taking over and digital platforms are continuously growing. Many of the companies that are active in this field have no relation to standard business models which have existed previously. In August this year, Apple became the first company in the world to have a net worth of more than one trillion US dollars. That is more than the 15 largest DAX-listed companies combined. This switch to mobile end devices also affects the buying behaviour in our society. E-commerce is picking up speed, and we are expecting double-digit growth per year in this area. It is an important business field for BEUMER Group. We have to be fast and flexible in adapting new technologies.

Property rights are an important topic that we will need to examine thoroughly. A traditional technical innovation can be patented, but when it comes to software, things get a littler more difficult, and for business models it becomes almost impossible. For any digital innovation, data plays an increasingly important role. Their value tends to be underestimated in the industrial context. Data, and the resulting efficiency gains, are beneficial for customers and companies and the use of this data can be transferred into new business models. In this regard, other countries are way ahead of us, which has to make us rethink our strategy.

Where is Germany in this process at the moment?

Stemmer: I think that German companies are generally in a better position than it is often portrayed in the media. We have many hidden champions who are global leaders with their products and systems. That is a very good starting position to acquire the necessary digital literacy needed to ensure future sustainability. In my opinion it is easier for a company to adapt the digitization technologies instead of trying to catch up on the know-how lead in the manufacturing sector from a software perspective.

The goal is to complement the capacity of the machines and systems, including the required software and controls, with digital innovation. Especially the B2B environment offers us every chance to play a leading role.

The name "digital transformation" already implies that there is an important change involved. What does this mean for the business world and for the individual, what will be the challenges?

Stemmer: First of all we have to include the people in this, at an acceptable pace. We at BEUMER Group have a large group of different experts. Some of the colleagues work on innovation and software every day, other areas are less affected by this. It is important to make all employees more aware of this topic. Digital transformation is inevitable and it will change our entire business environment. So we should avoid alarmism and find quick and consistent answers instead.

How can you make people more aware of this topic?

Stemmer: One good example are streaming services. Everybody knows Spotify, Apple Music or Netflix. What is new is that we have to look at them as our competitors. Not because they offer the traditional products in the intralogistics field like we do, but because streaming services have changed the entire market mechanisms. Our sortation systems were used for sorting and distributing CDs for the music industry, for example. Within only a few months this entire market was cancelled out, almost no one went to a record store anymore because now there were streaming services. With these business models, the services contributed, within a very short period of time, to the disruption of a market segment that we are active in. This can happen in other segments too.

What are the reactions among the employees?

Stemmer: They can see that there is a lot happening right now. They also see the opportunities, if we respond quickly and efficiently. We can't just ignore the changes. BEUMER Group's core lies in plant engineering. In the past, we focused primarily on physical products and their automation, like a packaging system, a sorter or a belt conveyor. That is our expertise. But over the course of the last few years, software became increasingly important, so that we are now employing more than 200 software engineers in our group. This trend will only continue.

How can this transformation process play out? Are there different steps?

Stemmer: It would be naive to think that we could make this change happen at the push of a button. It is a process that will take several years: we need to prepare our company for the digital age and bring our employees on board. For this we are launching several pilot projects that are aimed towards solving concrete customer problems, improving our processes and targeting new business models with the help of digitization. Depending on the success of the pilot phase, the lessons learned will be integrated and developed further in our processes, products and services.

BEUMER Group wants to be a driver of the digital change and launched two spin-off companies. Can you tell us a little bit about these teams and their fields of activity?

Stemmer: We started BG.evolution at the university location of Dortmund, with the intention to bring digital innovation from outside into the company. The means that the colleagues are working on a customer problem and develop so-called minimum viable products, prototypes that feature minimum equipment, and check, if applicable, their market potential up to marketability. This makes it easier for us to decide quickly whether a new technology will work for the concrete customer problem. Let's take for example the use of smart glasses: if our colleagues on site need the support from other departments at the head offices, for example for a concrete error pattern or maintenance. Here the new technologies can help us to support our service technicians or the customer directly. This is what we are testing the video glasses for. The advantages: with the glasses, the colleagues on site can continue to work hands-free and communicate with everybody involved. The goal of BG.evlution is to validate new technologies for concrete applications in cooperation with the customer.

The second spin-off is Beam GmbH in Berlin. With this autonomous company builder we want to solve problems that are unique to the logistics industry in cooperation with start-up teams. For this we are planning on founding three start-ups per year and transfer them, consolidated under Beam, into a separate company. The goal is to open up new business fields in logistics. One example is that the BEUMER logistics chain at airports ends at the baggage reclaim area. One idea could be to have the bags of frequent flyers or business travellers directly delivered to their hotel. This is not part of the BEUMER core competencies, but a very promising business segment. A young company could accept that challenge and work autonomously on a solution. Our goal is to then successfully establish it on the market. Unlike in Dortmund, the aim in Berlin is to pitch the problem to entrepreneurs and get them interested in working on a solution. What we offer is start-up financing and access to our experts and customers. They get the chance to start their own company.

How do you meet the entrepreneurs?

Stemmer: We launched this process about a year ago at Factory Berlin, the biggest start-up campus in Germany. There is a lot of talent among the 1,500 to 2,000 entrepreneurs. Our Managing Director there is Robert Bach, himself an experienced entrepreneur. In Berlin we are right in the heart of the start-up scene, can benefit from events, give presentations ourselves and arrange offline events to get people's attention. Of course we can also use that framework to advertise for BEUMER Group: Who are we? What is our goal? Who are we looking for and what can we offer young entrepreneurs? It is the perfect platform for us for networking and elevating visibility.

Who are the BEUMER employees in Dortmund and Berlin?

Stemmer: The team in Dortmund is led by Christopher Kirsch. He is an experienced IT specialist and used to work for research institutions and industry projects for many years. Our goal in Dortmund is to bring more software and sensor technology expertise into our company. So we are always looking for new talent in areas like Internet of Things (IoT), sensor technology, full stack development and UX design. All of which are relatively new job descriptions in the plant engineering sector. Let me come back to the smart glasses: we don't only need the hardware in the form of the actual glasses, but they must also be connected and integrated into our existing BEUMER tool landscape. We also need experts that are familiar with the exact conditions on site and can recognise typical error patterns, so that, by using the smart glasses, they can provide better service. This is why Dortmund is working in close cooperation with the colleagues and customers at the head offices, while Berlin has a more autonomous character.

What are your responsibilities?

Stemmer: My task is to build a bridge between BG.evolution in Dortmund, Beam in Berlin and BEUMER Group. I am responsible for BEUMER internal digitization projects as well as the management of BG.evolution. I'm basically the interface between the colleagues in Dortmund, Berlin and the BEUMER Group companies and I support and foster the mutual exchange. I want to make our colleagues more aware of this topic, which is a big part of my job. Communication is probably the most important element when it comes to digital Transformation.

How does the cooperation with Beckum work?

Stemmer: It works very well in general, and we also learn new things every day and try out new formats of cooperating. Several times a year, we organise "Pitch Days" at our locations in Denmark, Beckum and the US, for example. We encourage our colleagues to bring in their own ideas and challenges from their everyday working life. This takes place in a very relaxed atmosphere in the cafeteria. Our goal is to generate new input that we address internally in Dortmund and Berlin, if possible, and include the colleagues and idea providers in the validation process.

BEUMER Group works in different business segments, such as the Center of Competence (CoC) for Logistics and the CoC Airport. Here we participate in central meetings and present our topics, learn about new problems and challenges and ensure a continuous dialogue. We want to keep our colleagues up-to-date and communicate transparently through various in-house events. They are a crucial key element for us. Because there is a legitimate interest in what we are doing and why. We continue to learn every day what format works and what doesn't. For some projects, our colleagues from Beckum can also come to Berlin or Dortmund themselves.

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BEUMER Group automated parcel sorter goes live at Whistl’s super depot in Bolton, UK
Aarhus, 13. November 2018

BEUMER Group, a leading global supplier of automated parcel and post distribution systems, announces the live operation of an automated sortation system installed in Whistl's new super depot in Bolton, UK.

The automated cross-belt loop sorter will ensure faster sortation with greater capacity for e-commerce packets and parcels (cardboard boxes, jiffy bags, poly-wraps) up to the medium size. Cost-effective sortation combined with reduced levels of energy consumption enhance Whistl's commitment to considering the environment, in addition to the competitive and economic factors of each procurement decision.

As the UK’s second largest postal operator, Whistl contracted BEUMER to install the automated sorter in the new super depot. The depot operates as the designated hub for Whistl's sortation operations in the North West of the UK, which is one of the UK’s leading logistics and distribution areas.

Designed to enable Whistl to achieve further expansion to support the soaring e-commerce market, the ergonomic design of the sorter’s man/machine interface also supports Whistl’s drive to provide a clean, safe and secure work environment. In addition to the overall design of the sorter, BEUMER Group tested the interface to ensure that operators would experience minimal twisting and turning and no repetitive stress.

Whistl’s CEO, Nick Wells, CEO explains "The meticulous design of BEUMER Group's sortation system enables Whistl to achieve greater efficiency in the processing of packets and parcels. This is an essential part of Whistl’s growth strategy in responding to the continued growth in the e-commerce market.”

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Through wild nature and populated regions
Beckum, 12. November 2018

Asia Cement Group opts for 13.7 km long BEUMER Group troughed belt conveyor in Sichuan, China:

Sichuan Yadong Cement Co, Ltd. in Pengzhou, China, has been relying on a 12.5 km overland conveyor from BEUMER Group in order to convey limestone from their quarry to their silo. When constructed in 2009 it was the longest belt conveying system in BEUMER history (BEUMER installed a longer system in 2016). The troughed belt conveyor runs through hilly terrain and nature reserves, over streams and unstable ground. The second project includes two additional overland conveyors, with an overall length of 13.7 kilometres, transporting limestone to the cement plant. Unlike the first project, the task here was to build the conveyor across inhabited areas. Noise emission limitations set forth by the government also needed to be considered.

A traditional Chinese proverb says that the roads in Sichuan are hard, harder than climbing to heaven. Depending on the destination, there are rivers and valleys to be crossed and mountains to overcome. The southwestern Chinese province of Sichuan is the source of the majority of different ores in the country, such as titan, lithium and silver and plays a major role economically. The electronics, mechanical engineering, metallurgical, chemical, medical, food and building material industries are all pillars of the economy. One of the cement manufacturers in the region is Sichuan Yadong Cement Co, Ltd. located near Chengdu, the capital of Sichuan. The company is a member of the Asia Cement Group, headquartered in Taipeh, Taiwan.

In 2004, the company decided to build a new cement plant in Sichuan. During the development phase, Asia Cement Group received approval from the Chinese government to use an abandoned railway to transport the limestone. Halfway through finishing the plant however, the government decided to build a new dam. The area intended for the transport was to be flooded, which would have changed the project conditions considerably: roads would be flooded and the trucks would have to take significant detours. Asia Cement Group was also planning on building two additional kiln lines at this location. It was determined, as a time and cost efficient alternative, to install a troughed belt conveyor able to navigate horizontal and vertical curves. For this, the company turned to BEUMER Group. For many years now, Asia Cement has been relying on the system supplier's expertise and are currently operating several of its bucket elevators.

Knowing what the customer wants

BEUMER Group took over the mechanical and electrical engineering and supplied the core components for the overland conveyor and monitored and commissioned its installation. The advantage: The Chinese subsidiary BEUMER Machinery Shanghai can be reached easily and deployed quickly to site. "Our colleagues were able to work closely with the customer. They know the specific local customs, speak the language and are familiar with the particular market and customer requirements," reports Dr. Andreas Echelmeyer, Director of Conveying and Loading Systems at BEUMER Group.

In May 2006, Asia Cement Group awarded the contract for the 12.5 km long system. The overland conveyor can reach a mass flow of 1,500 tons per hour and a conveying speed of four meters per second. "Compared to other conveying solutions, the open troughed belt conveyors are suitable for higher throughputs. Horizontal as well as vertical curve radii are possible," explains Dr. Echelmeyer. They can be adapted to the specific task and topography. Using BEUMER calculation programs, we can precisely calculate the static and dynamic tractive forces of the belt during the development phase of the system. This is a prerequisite for the safe dimensioning of horizontal curves. The type of drive technology and conveyor belts needed are based on these calculations. This ensures longevity of the entire system.

Mountains, soft grounds and extreme heights

The terrain is hilly and covered with dense bamboo forest, parts of which are listed as nature reserve. For this reason, the government did not approve a service route nor deforestation. The ground also presented a major challenge for the BEUMER Group engineers: "The ground is unstable due to previous coal mining. In other areas, the ground consists mostly of granite that could only be partially removed," explains Dr. Echelmeyer. Another section of 1.5 kilometres had to be guided across a river. These framework conditions contributed to the fact that 90 percent of the system was installed manually on site. As it was impossible for trucks to transport the components, they were carried by mules, one part at a time, to the place of installation.

The route of the overland conveyor was coordinated between BEUMER Group and the cement manufacturer. The system supplier calculated the tractive forces of the belt considering the eight horizontal curves with radii of 1,000 to 5,000 metres. The routing was checked for its feasibility on site. The complete route was checked by employees on foot, passing through rough terrain, in order to reliably check the predefined positions for the 460 supports for their suitability directly on site. Whenever technically possible, the routing of the conveyor was adapted to the topography. Height differences of up to 100 metres had to be overcome within shortest distances, so several sections were equipped with bridges of up to 55 metres. One section was realised with a 130 metre long tunnel.

In close cooperation with the customer, BEUMER Group designed the overland conveyor and the bridges. The system supplier developed, built and supplied the core components for the drive and take-up station as well as the belt of an overall length of 25 kilometres, the idlers and the drive technology. Since February 2009, the overland conveyor has been transporting bulk material from the quarry to the bulk loading system. Since commissioning of the first section, the mass flow of the conveyor was increased in two steps. Today, the system conveys a mass flow  of 2,200 tons per hour at a conveying speed of 4.5 metres per second.

The longest belt conveyor in company history

In July 2013, Asia Cement contracted BEUMER Group again for an additional, efficient overland conveyor to replace the trucks transporting the limestone from the bulk loading system to the cement plant. A mass flow of 2,200 tons of limestone per hour was necessary to meet the plant's requirements. For this project, the first conveyor was to be customised to these requirements. "We were planning a second troughed belt conveyor with an overall length of 13.7 kilometres," says Dr. Echelmeyer. This is the longest system in the history of BEUMER.

Projects of that size are often unpredictable, so flexibility was needed from the engineers. During the planning phase, the cement manufacturer acquired another plant in Lanfeng, approximately ten kilometres away. "Now we had to design the system so that both plants could be supplied with limestone," explains Dr. Echelmeyer. The team had to divide the overland conveyor in two parts. After 5.4 kilometres, an additional conveyor can be added to be fed to Lanfeng in the future. In February 2015, the system supplier started with the installation of the conveyor frame.

Both overland conveyors have four horizontal curves with radii of 1,200, 1,500 and 1,800 metres. "We provided the engineering and the individual parts such as pulleys, motors, drive and control technology and the entire automation," describes Dr. Echelmeyer. The installation was monitored by a BEUMER Group supervisor and the wiring of the system was supported by a BEUMER electrical engineer. The system supplier was also in charge of the commissioning in May 2016. The troughed belt conveyor is now supplying three kiln lines, a fourth line is planned.

Reaching the destination - no longer through rough terrain, and quiet

The requirements were different for the two projects: the challenges for the first project were the hilly terrain, instable grounds and crossing through conservation areas and over waterways, for the second project the system had to be built crossing through populated areas. The Chinese government has set out exact regulations on the noise emission levels so that the residents would not be impacted. "We had to minimize the noise to an extremely low level," describes Dr. Echelmeyer. The system supplier took several constructive measures in order to reduce the noise emissions. "We used noise-reducing idlers and customised protective covers on the drive stations," explains Dr. Echelmeyer. In collaboration with the operator, BEUMER Group optimised the conveyor frame and the completely enclosed conveyor Bridge.

For the whole project, BEUMER Group was able to ensure that the limestone is transported safely and quietly, without disturbing the residents or disrupting the surrounding nature.

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