BEUMER Group Pipe Conveyor ensures dust-free transportation of ore concentrates
Transportadora Callao S.A., the logistics operator of a special cargo terminal in the port of Callao/Peru, relies on a BEUMER Group Pipe Conveyor for the transportation of zinc, copper and lead concentrates of different mining companies from the warehouse to the terminal. With its ability to navigate curves in three dimensions, the conveyor can be optimally adapted to its routing course of approx. 3000 metres. What is even more important: the conveying system prevents the concentrates from coming in contact with the environment and ensures dust-free transport to the ship's holds. BEUMER Group was responsible for engineering and supply, including the steel structure, supervision of the installation and putting the Pipe Conveyor into operation.
Callao is located directly on the Pacific Ocean. With 877,000 inhabitants, it is one of the largest cities of Peru, with the largest airport in the country and one of the most important fishing and commercial ports in South America. A modern ship loading terminal for ore concentrates was built in this port and it is operated by Transportadora Callao S.A. About 75 percent of the imports and exports of Peru, one of the most important mining countries world-wide, are handled in Callao. In order to satisfy the increasing demand for these valuable materials, the Peruvian government decided to expand the port. Besides additional storehouses, the plans also foresaw the largest, most modern ship loading terminal in the country. Peru also wanted to change the way the raw materials were transported to the ship loading areas. Before the construction of the special terminal, trucks were used to transport the concentrates from the warehouses to the port terminal. "Since Transportadora Callao started its operation, they could reduce the truck drives by 130,000 per year," explains Victor Sam, CEO at Transportadora Callao S.A. The company, a consortium comprising five enterprises from the mining and port industries (manufacturers and warehouse logistics operators), obtained a license from the state of Peru for building and operating the necessary infrastructure.
Pipe Conveyor: dust-free conveying
The mines in central Peru transport their concentrates to the warehouses, approx. 3 kilometres from the port. This required an absolutely protected method for the transportation of material, to prevent particle emission into the atmosphere. Transportadora Callao opted for the BEUMER Group Pipe Conveyor. The direct contact person and project partner was Helmut Wolf from BEUMER Group Austria GmbH: "Together with the responsible persons from the customer, we developed a solution that is perfectly adapted to the routing and the ambient conditions."
Due to its enclosed transport, the Pipe Conveyor not only protects the environment against harmful impacts during the transport of the lead concentrate, it also allows conveying over long distances and navigation through tight curve radii. Due to its ability to navigate curves, this belt conveyor requires a lot less or no transfer towers at all, depending on its length and the available curve radii. This results in substantial cost savings for the customer, and allows BEUMER Group to easily customise the system to the individual routing. Durable conveyor belts guaranteeing tensile strength are used. The engineers use different dimensioning programs to determine the ideal belt design. They use them to calculate tractive forces and forces that arise during acceleration and deceleration and also to determine possible curve radii. BEUMER Group provides tailor-made feasibility studies for each project. Another advantage is the reduced noise emission that the system provides. This is ensured by special idlers, as well as low-noise bearings and selecting the right conveying speed. "This improves the quality of the employees' day-to-day work environment," says BEUMER engineer Wolf. Victor Sams adds that the "noise measurements along the Pipe Conveyor resulted in values that are consistently far below the permitted limit values."
Conveying capacity: 2,300 tons per hour
BEUMER Group supplied and installed a Pipe Conveyor with a centre distance of 3,195 metres. "Due to the system design and the required system capacity, we designed it with a diameter of 400 millimetres," explains Helmut Wolf. "The conveyor transports 2,300 tons per hour, at a speed of 4.5 m/s and is driven by 3 motors with a capacity of 650 kW each. We equipped the system with filters, strippers, a dedusting unit and a control system." BEUMER Group was responsible for engineering and automation, and supplied the steel structure and the necessary components. The site managers supervised the installation and put the system into operation.
The process is practically free of faults and, above all, safe: trucks or trains transport the mining commodities from the mines to the ore storages, from where they are transported to the open access station. Here, the concentrates are received by a feeding 43-m belt conveyor that transfers it to the Pipe Conveyor at a height of 6 metres. A dedusting unit ensures that no material is emitted during this process. "We equipped the feeding belt conveyor with a metal detector and an electric magnet," explains Helmut Wolf. "This prevents damage of the downstream Pipe Conveyor by metal parts." At the end of the route, the conveying system runs along the seaside in the naval port of Callao to the transfer tower. Here, the belt opens automatically. It transfers the material to another belt conveyor that conveys the ore to the ship loading system.
Victor Sam: "This modern system, in operation now for 17 months, caused a significant increase in speed by 500 % for loading concentrates and reduced the ship's waiting time until loading by more than 80 %. These advantages lead to savings for the exporters and improve the competitiveness of the country's mining industry."
Trouble-free integration, challenges mastered
"A big challenge for us was integrating the Pipe Conveyor into the existing environment," says Helmut Wolf. The BEUMER system is the connection between the individual belt conveyors from various manufacturers. "When managing the project we had to meet several official requirements," reports Helmut Wolf. The project represents a concession by the state of Peru given to Transportadora Callao S.A., who commissioned Odebrecht Perú Ingeniería y Construcción with the execution, and Buenaventura Ingenieros S.A. with the supervision. Odebrecht commissioned BEUMER Group with the design of the entire line section onshore. The onshore section starts at the "Open Access", where the concentrate is transferred from the warehouses. The Pipe Conveyor then passes a refinery and a military area. "That was the specified routing that we had to observe," explains Helmut Wolf. In the area of the refinery, the systems had to additionally be equipped with fire-proof covers. Due to this impressive engineering work, Transportadora Callao is now able to handle ships for bulk products of up to 60,000 DWT without obstructing the work in the other terminals of the Callao port.
World-wide connected and brought to one point
BEUMER Group has bundled its comprehensive expertise spanning various industries and established different Centers of Competence in order to offer optimal support of their single-source solutions for companies like Odebrecht and Transportadora Callao. The Pipe Conveyor segment is one such Center of Competence. This center is responsible for sales and project management worldwide. It collects and prepares the know-how of each regional group company and passes it on to the group company's global experts, such as Helmut Wolf and his team. "BEUMER's technical team has proven its professionalism and stand-by duty, during construction and operation, and after 1.5 years in operation and more than 4 million tons of transported concentrates, we can attest that the set goals have been reached," explains Victor Sam.
BEUMER Group's extensive Customer Support ensures a high level of system availability after commissioning. Transportadora Callao just signed a teleservice contract with BEUMER Group, so that BEUMER specialists can eliminate possible malfunctions in the system. If necessary, the BEUMER Group service staff will go to Callao in order to make the necessary adjustments and prevent malfunctions and machine breakdowns, which would lead to long downtimes....
BEUMER Customer Support ensures reliable intralogistic processes:
For BEUMER Group, Customer Support is much more than just a service. While it was once enough to "simply" prevent or quickly solve malfunctions and machine downtimes, the intralogistics provider has now significantly extended this service. Approximately 1,000 employees worldwide now work for this business segment. They take care of the customer, starting with the first project discussion, up until the system is in operation. Customer support comprises different types of agreements. With its Residential Service, the group assumes, for example, the responsibility to provide trouble-free operation on site, even for the long-term.
What makes for a good relationship between the user and the supplier? For Kornelius Thimm, the answer is simple. "We have customers that have been loyal to us for decades. This is certainly based on mutual trust," the Director of Customer Support at BEUMER Group is convinced. Because our systems and machines run reliably. His colleagues take care to ensure a high level of system availability for the entire running time. "Our customers know that we would never leave them out in the rain," adds Kornelius Thimm.
As an international manufacturing leader in intralogistics providing customised system solutions in the fields of conveying, loading, palletising, packaging, sortation and distribution technology, BEUMER Group knows the particular challenges posed by the customers. Its clients have ever increasing demands on machine availability and, therefore, on customer support. This is why BEUMER Group has developed and extended its customer support and established it as a business segment in its own right. Due to its global positioning, the group has consistently optimised and extended this segment with specifically trained employees during the last few years. "We're not only providing service products, we really take care," emphasises Kornelius Thimm. This becomes more and more important to users from different industries. It is not always only about preventing malfunctions and machine breakdowns, which would lead to long downtimes. No matter what industry, companies have to meet the ever increasing market demands and improve the capacity of the equipment, for example. "And we take care of this," the service director promises.
Customised like a tailor-made suit
Customer Support offers different types of agreements. They are matched individually to the respective needs of the customer, and the service intervals as well as the response times are agreed by contract. BEUMER employees develop the concepts individually with the customer, and adjust them so they meet exactly their requirements. In the event of a system standstill, qualified Customer Support technicians arrive quickly on site to prevent long downtimes. Customer Support offers around-the-clock telephone support every day of the year worldwide, helping further reduce downtime to a minimum. The technicians perform remote analyses, indicate corrective measures and offer quick and reliable solutions to correct any malfunction. The systems can be put quickly back in service. Additionally, we will also find the cause for the malfunction to prevent it from happening again.
The whole is greater than the sum of its parts
One component of Customer Support is spare parts logistics. If customers decide to use this service, the service employees check the wear parts and spare parts at regular intervals and provide the supplies for the entire service life of the machine. "Already when selling the new system, we advise the customer which spare parts to keep in stock," says Kornelius Thimm. "In case of parts for machine types that are to be discontinued, we inform the customer in time and consult them regarding replacement or exchange possibilities." Personal contacts offer technical support for all inquiries. During the maintenance of the machines, the customer support employees check whether or not there are parts to be replaced. If spare parts are required, BEUMER Group provides a quick delivery.
Customised employee trainings
In order for the machines to run for the maximum operating time, users need to be trained at regular intervals. The performance of the machines also depends on maintenance and on how they are operated by the customer personnel. The employees who work with the machines are brought up to date, and new employees are introduced to the systems. Training is required for the initial installation, as well as a follow-up several months after the system has been running. At this time, the customer has the opportunity to ask questions related to their specific needs. "The training programmes are tailor-made for the customer and their systems", Kornelius Thimm points out. The users' expertise is maintained through the technical consultation by our Customer Support employees.
Customer Support offers basic trainings up to continuing education. They are tailor-made to meet the customers needs and are held for machines and systems of BEUMER Group as well as of other manufacturers. This is how the group ensures high health and safety standards. Experienced specialists impart detailed knowledge and structured procedures for successful maintenance and for the operation of the systems. This is particularly important for machine operators, because mechanics and control technology is becoming increasingly elaborate and sophisticated.
In order to meet future performance and technology requirements, BEUMER Customer Support employees ensure that the machines are always up-to-date. "We make sure that the machines are comprehensively modernised," says Kornelius Thimm. This means higher performance and availability, minimised energy consumption, more ergonomic working conditions, new functions and a better overall system utilisation. For this, the employees can update or upgrade the systems.
Sharing your accountability
A particularly important part of this business segment is the Residential Service. Customers can hand over the responsibility to BEUMER Group for availability, performance and economic efficiency of their filling, palletising and packaging technology, but also for sortation and distribution systems in logistic centres and airports. BEUMER Group employees carry out the maintenance with profound logistical and technical expertise, ensuring high levels of machine efficiency. If required, BEUMER Group appoints a team of specialists which will ensure proper operation and availability of the entire system on site.
BEUMER Group believes that the customer should have access to a Customer Support technician that originates from the same cultural background and speaks the same language. "For this reason we cannot just send colleagues from Beckum to Singapore", says Thimm. Successful customer support requires an understanding of the mentality of the customer: How is the customer positioned? What are his goals and how does he want to develop in the future? These questions require tactfulness and cultural know-how.
Logistics providers offer services for reliable filling, palletising and efficient packaging of products. This can sometimes involve overcoming considerable difficulties, because the products can have very different characteristics. Yet they have to be consistently handled safely and gently throughout the entire process chain. In addition, they need to be able to react to the continually increasing throughput rates of the installations and machines. Another demand to be met: the control, regulation and clear representation of the complete material flow. Kornelius Thimm knows that "if the service provider does not meet all these requirements, a competitor will do it". Customer Support employees make sure that the customer's systems are always perfectly adapted to their tasks, and that all processes run smoothly. They also carry out preventive maintenance, as well as other measures such as applying protective coatings or installing warning devices. Kornelius Thimm adds: "We also develop and implement concepts which enable a long-term and trouble-free operation of the buildings."...
BEUMER Group– a leading global supplier of automated baggage handling systems – will present end-to-end baggage handling and transport systems at Inter Airport China, at the China International Exhibition Centre, Beijing, from 12-14 September 2016.
Visitors to the stand will be able to experience the speed and efficiency of tote-based baggage handling through an immersive, virtual-reality tour using Oculus Rift head-sets. The tour will demonstrate why many airports consider tote-based technology to be the next-generation of energy-efficient baggage handling systems. This is based on the ‘one bag per tote’ concept which provides 100% tracking and traceability of each item of baggage throughout the check-in, sorting and screening processes.
The CrisBag® system is the one of the world’s most widely-installed tote-based systems and is used by a number of international airport hubs including Changi Airport. At Changi, CrisBag® is used as a dual-purpose system for sorting baggage and for extensive inter-terminal baggage transfers between Terminals 1, 2 and 3. BEUMER Group will also supply and integrate the baggage handling system for Changi Airport’s new Terminal 4 building.
In other regions, a CrisBag® system will soon be in operation in Abu Dhabi Airport's new Midfield Terminal, while Calgary Airport Authority, Canada, has awarded BEUMER Group with the contract to integrate a second CrisBag® tote-based baggage transport and sorting system.
Other baggage handling systems from the Crisplant range have been installed by BEUMER Group in airports throughout China, including Shanghai Pudong, Guangzhou, Hong Kong, Changsha and Nanjing.
“This exhibition underlines the boom in China's airport infrastructure,” explains Klaus Schäfer, Managing Director, BEUMER Group A/S. “As the Chinese airports prepare to expand, BEUMER Group is providing guidance on best-practice, and state-of-the-art technology, to support increases in both the capacity and efficiency of the baggage handling systems.”
BEUMER Group will be in Hall 8A, Stand 604, at Inter Airport China, 12-14 September 2016....
Dr. Echelmeyer, you have been Director of Conveying & Loading Systems at BEUMER Group in Beckum for a few months now. What are your responsibilities and what would you like to achieve?
Dr. Andreas Echelmeyer: Since August 2015, I have been the head of the new Center of Competence (CoC) for Conveying & Loading Systems (CL Systems) segment. Under the leadership of the CoC, we would like to globally develop and implement complex system solutions for various industries, such as the mining and raw materials industries, and port handling. In order to achieve this, the customers have to notice us in those fields. BEUMER is known for providing innovative intralogistics solutions. Some are still surprised to learn how fast the BEUMER Group has grown in recent years. Today Beumer now also offers complex system solutions in the raw materials industry, a sector in which business was traditionally limited to sales of single machines. Our goal is to become internationally known as a reliable partner in the area of plant engineering as well. We have fewer inquiries from Germany, and increasingly more from Australia, the Far East, Africa, South America and the US. Our mission is to build an international team for Conveying & Loading Systems that works together on specific projects. In order to ensure a high standard internationally, we must get qualified colleagues from all our local companies on board in all regions.
Qualified means that they have to understand the customers in order to precisely communicate their needs with us and develop the perfect solution together with our team in Beckum. This means that we need to stay curious and open-minded for this type of teamwork.
What has changed now for BEUMER Group with the introduction of the CL Systems segment?
Dr. Andreas Echelmeyer: We are rooted in material handling, which is specifically about the efficient movement of bulk materials. Each industry we serve has very specific requirements however. The cement industry, for example, relies increasingly on alternative fuels and raw materials to reduce the use of expensive primary fuels, such as coal and oil. This can also be achieved with household waste that is processed for a particular application. Due to the differing composition of this material, its handling is often very complex. We consult with our customers based on our extensive knowledge of system solutions and provide entire systems, starting from receiving the material at the factory gate, to storing, mixing, conveying and introducing it into the cement production process via the main burner or calcinator.
How do you define expertise in system solutions for your work?
Dr. Andreas Echelmeyer: In order to customise a solution, we have to listen very carefully and ask the right questions. These are often questions the customer has not even thought about. Some customers can also have very specific ideas about the solution. Together we analyse the task, and in this dialogue the user learns that we can supply the perfect system solution that can sometimes differ considerably from the original ideas. Our main goal is to understand the user. Another important prerequisite for us as a system manufacturer is flexibility. In order to successfully tackle specific tasks, we sometimes have to learn to let go of established solutions and find an entirely new approach, depending on the application.
How do you get in contact with the users?
Dr. Andreas Echelmeyer: Our globally operating colleagues are in close contact with our customers. We are constantly exchanging ideas. Our local colleagues are familiar with the country-specific customs, speak the language and know the market and customer-specific requirements. They can pinpoint the relevant potentials and priority areas. Ideally, the customers themselves approach us at an early stage. Together, we then develop the perfect system. If a new customer comes to us, we will send out experts from our Beckum site in Germany. A team from the local company, accompanied by experts from the CoC, will then discuss the problem in detail with the customer. As a third possibility, the customer sends us a request for quotation. We analyse and examine the request in regards to completeness, and whether all of our questions have been sufficiently answered, and then we evaluate the request. Together with our local colleagues from the responsible group company, we then develop a fitting solution.
Your administrative field is called Center of Competence (CoC), the globally centralised organisation within a matrix structure. Do you also work together with other CoCs?
Dr. Andreas Echelmeyer: In the case of orders from the cement industry, for example, we work closely with our colleagues from the CoC Cement. We can mutually benefit from our respective expertise. Those collaborations are always project-specific.
From which industries do you get requests?
Dr. Andreas Echelmeyer: This can vary a lot, because our system solutions are used wherever you need to transport large quantities of bulk material. This is particularly the case for the ore and raw materials industry, but we also deal with applications outside of these core areas, such as food transport. In ports, for example, we ensure that different materials are efficiently loaded onto ships.
What skills are you looking for in your colleagues?
Dr. Andreas Echelmeyer: As you can imagine, the engineers for this task are very experienced and highly qualified, and are able to think outside the box. Often they need to find new ways in order to find the perfect system solution. Particularly with large conveyor systems, the demands on engineers are becoming increasingly complex. Public acceptance of road transport by truck is declining throughout the world, which means that our conveyors have to deal with greater and greater challenges in overcoming topography. For example, we are designing systems with a length of more than 12 km that transport material over extremely steep inclines and declines – and without transferring material on the way.
If we don't want to send an expedition team first, we will have to use special software that allows us to merge satellite and aerial images of different resolutions with the respective topographical data. The challenge now for my colleagues is to estimate and analyse the project, in order to make a concrete offer to the customer. We usually don't have a lot of time for this. It is only possible with an excellent global team.
What experiences do you bring into your new position?
Dr. Andreas Echelmeyer: I am familiar with the system manufacturing side, as well as the user side. I was working in the cement industry for eight years. As production manager, I had to oversee complex systems that manufacture more than 13,000 tons of steel per day. This is how I am familiar with the demands on system manufacturing coming from the users. I then switched sides and have now worked in systems manufacturing for twelve years. During this time I have set up a global customer support division, among other activities, and I therefore know the expectations of customers: they have ever increasing demands on machine availability and, therefore, on customer support.
How would you assess the current development for plant design in mining?
Dr. Andreas Echelmeyer: The prices for raw materials like iron ore or copper have been extremely low for the last two or three years now. This is why the market situation is very difficult at the moment. We feel the effects of companies cutting investments and stopping projects. We expect this low level of investment to continue for another two, three years, until the market stabilises. What else has changed? There is a general trend towards larger tonnages and throughputs because larger production 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 as few as possible. This trend influences considerably the development of our systems.
Today, the trend is towards a comprehensive product portfolio in order to offer complete solutions for the entire production process to the customer. Do all components come from BEUMER?
Dr. Andreas Echelmeyer: We want to offer comprehensive services to our customers, so that we can also avoid unnecessary interfaces. This is why we deliver everything from one single source. For many of the components that are not part of our portfolio, we always ask ourselves whether to purchase or manufacture them in-house. For gear units and electric motors, as well as systems to quantify material flows, we use selected partners. We also attend trade shows to get a clear picture of the current market developments. It's the only way to make sure to provide the perfect solution to our customer in terms of profitability. It is not uncommon for plant manufacturers to purchase many of the components. This way we focus on our core competence and always provide the perfect solutions. Our goal is to always supply turn-key systems that allow the customer to work efficiently.
Are you planning on becoming an EPC (Engineering, Procurement and Construction) company for bulk material – or even an EPCM (Engineering, Procurement and Construction Management) supplier for large-scale plants, also in order to avoid interfaces?
Dr. Andreas Echelmeyer: Not necessarily. As plant manufacturers, we want to focus more on the required system solutions and less on industrial construction, excavation and concrete construction. In addition, climate conditions and legislation can vary greatly from China to Tierra del Fuego, Australia or Alaska. This is why for every project we decide if we will be the single provider or if we will work together with a reliable partner in the region. Local partners are familiar with their environment and the pricing, and are usually well connected. We always want to be well aware of the interfaces. We usually decide on a case by case basis whether or not to use a local partner. We keep a very close eye on the EPC topic, however.
Our customers appreciate that we are a competent expert. They don't want to buy a tunnel or a foundation. They want a system that solves their problems....
In times where online retailing is constantly growing, the delivery promises of suppliers are becoming increasingly important. Customers expect their order to arrive in time, as ordered, and at the correct destination. If these requirements are not met, customers can choose to simply change suppliers, and often also even share their dissatisfaction on social media. High reliability requires efficient intralogistics, from warehousing to sortation and transportation. Intralogistics need to be versatile, capable of managing complexity while increasing their efficiency. BEUMER Group supports online retailers and shipping providers with competence and with efficient sortation and conveying technology.
Online shopping continues to grow in popularity. It's easy, quick and simple. Buyers appreciate the convenience and flexibility. Online stores don't have set operating hours, so the customer can shop at any time from any place, computer, tablet computer or smartphone, provided they have internet access. Once the products arrive at home, you can test them out, and, if not satisfied, just send them back. E‑commerce is primarily used for selling books, audio/video devices, clothing and shoes, consumer electronics or computers.
In 2014, turnover of German companies in this industry totalled 66.5 billion EUR. This year's estimates are up to 90.5 billion. The market is growing by 20 per cent every year. However, this also leads to cut‑throat competition among online retailers. The most successful e‑commerce companies are those who can provide a wide range of products and the necessary reliability. This, however, increases the expectations of a limitless supply of goods at low cost and with immediate and fault‑free delivery.
How to fulfil customer expectations
In order to stay competitive as an online retailer and reach new audiences, you have to look towards new trends. This includes individual delivery times and same day delivery, whereby the customers order and receive products on the same day. This option may to finally bring e‑commerce on the same product availability level of local retailing. This special type of express delivery however only covers certain regions, depending on where the online store is based. It is offered within the urban logistics of large cities and is more expensive than regular delivery. Even though there is a high demand for this in the industry, only few retailers offer it as a delivery option. In typical e‑commerce orders, deliveries are often atomised. The customer orders more often, sometimes several times a day, and in smaller quantities. This leads to smaller, but more frequent deliveries, which is very challenging for the manufacturers of intralogistic systems and for operational logistics.
Finding the perfect intralogistic solution is crucial
Overall, as the material distribution technology becomes more complex, intralogistic equipment and systems are required to be more flexible in order to handle different tasks and be able to adapt to changing local conditions. Highly efficient processes are therefore necessary to ensure quick delivery of packages to the customer. Tracking and tracing of deliveries is becoming more important as well. Delivery status can be tracked, allowing the customer to determine the current location of their package and its estimated arrival time.
As a system integrator, BEUMER Group supports its customers from planning through commissioning, to ensure fast, safe and fault‑free sortation, distribution and control of very different goods such as parcels, bags and bulk goods. Our product base includes modular high‑speed sortation systems that give the users a competitive advantage and prepare them for future growth in their own mail‑order business.
Concept of an order‑picking system
BEUMER Group has already realised numerous projects in cooperation with partners from the intralogistics sector. Shuttle warehouses with a storing and taking out frequency of more than 10,000 units per hour are best suited for handling receptacles and cartons for A, B and C items with high availability. When handling small parts automatically, these storage solutions are well‑established for these applications and are particularly suited for fast growing companies that store different types of products. A cross‑belt sorter ensures the connection between goods receipt department, the shuttle warehouse, the order‑picking stations and the goods issuing department. This sorter solution achieves a high distribution rate of more than 10,000 receptacles per hour. Besides distributing receptacles and cartons, cross‑belt sorters are ideal for the gentle handling of all types of products, regardless of their size, shape or surface characteristics. These characteristics help meet the specific requirements of mail‑order businesses. Due to contactless energy supply and data transmission, the BEUMER Belt Tray Sorter requires little maintenance. Its modular structure permits adaptation into existing buildings without any loss of performance.
The cross‑belt sorter consists of several mobile flat belt conveyors. They are arranged perpendicular to the direction of run of the belt. This allows the transported items to be fed or discharged either to the right or to the left of the direction of run of the belt. The products are fed onto the cross belt at a speed adjusted to the sorter speed and the angle of induction. For the discharging process, the conveyor belt moves towards the discharge and the item is guided gently into the destination.
Placing great emphasis on sustainability
BEUMER Group equips the sorter with modules for order‑picking stations. Additional sensor technology is often installed to detect and eliminate potential errors and increase the successful sortation rate. Safe and reliable sorting processes are guaranteed at all times. Complete order containers are automatically moved to the goods issuing department, while incomplete order containers from each module are moved back to the shuttle warehouse and empty containers go back to the goods receipt department to be filled again.
The delivery from the goods issuing department to your doorstep, or to the collection boxes, is usually ensured by service providers. They provide a comprehensive network of sortation centres, offices and delivery service. Their systems are primarily aimed towards the traditional package range. The fact that delivery quantities are increasing and delivery sizes decreasing at the same time usually leads to their capacity being exhausted. Delivery windows are becoming increasingly more narrow and sortation periods shorter. In order for the service providers to meet the requirements of e‑commerce, they have to increase their capacities.
From manual to machine‑aided unloading
The capacity in existing buildings can be increased by replacing manual unloading with machine‑aided bulk unloading. This enables much higher throughput per gate. BEUMER Group has brought the first generation of semi‑automatic machines to the market, the BEUMER Parcel Picker. It relieves the physical burden of the employees, and at the same time increases productivity. The personnel working for postal operators and CEP companies can use it to unload packages, parcels and delivery units of different sizes and weights from swap bodies and trailers at a high capacity. The unloading capacity increases with smaller deliveries.
For the bulk stream to be efficiently processed, the packages need to be automatically separated. This is why BEUMER Group has developed the Automatic Parcel Singulator, which is matched to the discontinuous mode of operation of a loop sorter induction unit. It has a compact design and its required capacity is adapted to requirements of the induction unit. Its operation is low in noise and in maintenance. A typical application proposes two BEUMER Parcel Pickers that supply one Automatic Parcel Singulator. The result of the separation is monitored by an image sensor. Correctly separated packages arrive at the sorter via a discharge unit, whereas incorrectly separated deliveries are automatically returned to the Automatic Parcel Singulator....
BEUMER Latinoamericana Equipamentos Ltda., - part of BEUMER Group, a leading global supplier of automated baggage handling systems - announces the completion of the contract to refurbish the Baggage Handling System (BHS) at Terminal 2 (T2) of Aeroporto Internacional Tom Jobim (RIOgaleão), Brazil, meeting the deadline for the BHS to be fully operational for the Olympic Games 2016.
The upgrade is part of the investment to improve the overall services at the Aeroporto Internacional Tom Jobim (RIOgaleão). In a joint effort between the airport and its partners, including BEUMER Group and BNP, these improvements were designed to ensure high levels of passenger satisfaction for the international athletes, delegates and visitors using the airport during and after the Olympic Games.
The team created a custom layout designed to enable the airport to meet the peak demand throughout the Olympics as well as future growth forecasts. To achieve the new layout, BEUMER refurbished the existing baggage handling system and re-integrated part of this existing system with state-of-the-art equipment to enable higher capacity and efficiency.
With the deadline for the BHS to be fully operational for the Olympics 2016, BEUMER scheduled the refurbishment to be completed to an extremely tight timescale of less than seven months.The scheduling of the project also took into account that there should be no disruption to the normal operation of the airport throughout the integration process. This challenging deadline was achieved due to the meticulous planning, experience and commitment of the BEUMER project management team working in close cooperation with the airport.
The new BHS will handle baggage for departures and arrivals as well as for transfers. For departures, the airport now has seven baggage lines and make-up carousels, which include the addition of two new lines and carousels; the ten existing arrival baggage reclaim carousels have been relocated and augmented by two new carousels and a new recheck-in line and transfer carousel.
BEUMER was also responsible for the complete integration of new SCADA automation and supervisory software. This will help to ensure uninterrupted operation and reliability across the entire baggage handling system in the airport's new Terminal 2 and South Pier. Following the integration of the BHS, BEUMER personnel will remain resident on-site at Terminal 2 until the end of 2016 to provide a full range of services under an operation and maintenance contract awarded to BEUMER by the airport.
The completion of the BHS, and the inauguration of the South Pier in May 2016, marked the end of a major stage in the overall investment plan for Aeroporto Internacional Tom Jobim (RIOgaleão). The airport has already started to welcome the 1.5 million visitors and competitors who are expected to attend the Olympic Games 2016 in Brazil....
At the international chemical industry and science trade fair, Khimia (19 to 22 September, Moscow), BEUMER Group will present complete packaging lines. Along with comprehensive customer service, the intralogistics provider supplies highly efficient filling, palletising and packaging systems, which fulfil the complex requirements of manufacturers from the chemical sector.
A packaging line provided by BEUMER Group for the chemical industry could look like this: bulk material passes from the silo along a conveyor line to our innovative form fill seal system BEUMER fillpac FFS. This filling machine is fitted with an integrated, high-precision weighing unit which ensures that the weight of the bags is accurately reproduced. High-performance palletisers from the BEUMER paletpac range then stack the bags on pallets with maximum efficiency. Depending on the product requirements, these palletisers can be equipped with a clamp-type or twin-belt turning device which turns the filled bags into the required position for stacking. Even bags filled with pellets can be gently palletised, ensuring their dimensional stability. The handling of bags filled with PE pellets, which have special flow characteristics, or of bags exposed to high temperatures and increased air humidity is very demanding. In these cases, BEUMER uses ventilated layer stacking tables with a special coating. The ventilation generates an air cushion between the bags and the layer stacking table. As a result, the bags do not stick to the surface and can be palletised in a dimensionally stable manner.
Customers use the high-performance BEUMER stretch hood packaging systems to secure loads. For many customers in the chemical industry in particular, the efficient packaging of their palletised goods is a deciding competitive factor. In order to guarantee protection during transport and load stability, the stretch film adapts to any product that is stacked on the pallet. The film is very stretchable during the packaging process and its contracting forces keep the goods tight together. Contrary to shrink wrapping, since no heat is used in the packaging process, the film will not glue to the product. This also reduces the fire hazard considerably, increases operational reliability and therefore minimises insurance rates. Thanks to the high transparency of the film, the packaged goods are clearly visible and barcode labelling is quickly and consistently recognisable. A sheet placed on the pallet offers additional protection against external influences on six sides of the stacked goods. It allows for clean and dry outdoor storage of industrial products as they are reliably protected against environmental impacts, humidity, insects and UV rays.
Additionally, BEUMER Group will present its warehouse management system (WMS) that fulfils key requirements of the chemical industry, such as the storage of sensitive materials, batch tracking or space-saving and cost-effective warehouse management
Visitors will also be informed about the comprehensive BEUMER customer support, with a main focus on residential service. With this service, companies can hand over the complete responsibility for availability, performance and economic efficiency of their systems to employees of BEUMER, who are on site to ensure trouble-free operation.
Collectively, these capabilities will deliver customers a complete solution from a single source and only one - reliable and competent - point of contact for the entire job....
BEUMER provides Turkish cement manufacturer with 13 bucket elevators and 6 apron conveyors:
General contractor Bilim Makina has commissioned BEUMER to supply and mount at its cement plant in Elazig, eastern Turkey, 13 bucket elevators for the transport of cement, clinker and raw meal, as well as 6 apron conveyors and 13 silo discharge systems for clinker transport. The greenfield plant is expected to achieve a capacity of 5,000 tons per day. Sycs Insaar Cimento Madencilik is the user of this plant.
Two high-capacity belt bucket elevators with a centre distance of 133 meters each are included in the scope of supply. They are used for feeding the preheater tower with raw meal. Owing to the size of this plant, a conveying capacity of 500 tons per hour is achieved. High-quality BEUMER steel wire belts with a particularly high strength class ensure this capacity.
The supply of the comprehensive technology has been completed. A team of BEUMER staff members are now mounting the plant. At BEUMER, the Center of Competence (CoC) for the cement industry is responsible for the project. The CoC enables the single-source provider to supply suitable systems at a constant high quality level anywhere in the world. Andre Tissen, Director Business Unit Cement at BEUMER Group says: "Working with us, the user is also provided with global service and a competent contact person."...
BEUMER Group - a leading global supplier of automated parcel and post distribution systems - has been awarded the contract to supply an automated material handling system in Freightways’ new South Island Hub at Christchurch Airport, New Zealand.
BEUMER Group’s automated sortation system will be based on a state-of-the-art, energy-efficient LS-4000CB cross-belt sorter with the capacity to handle up to 15,000 items per hour. The system has been specifically designed to enable efficient handling of the high volume of items in a short window, including wine boxes and fresh fish polystyrene containers which are shipped through the Freightways Courier Network.
“The decision to award the contract to BEUMER Group was influenced by the fact that they took the time to understand our business and operations, and transferred that knowledge into a system design that met and exceeded our operational requirements,” explains John Charles, National Operations Manager, New Zealand Couriers, part of Freightways. The Freightways group, which also includes Post Haste, Castle Parcels and Now Couriers, is New Zealand's largest independent courier network.
“In addition to industry-leading energy-efficiency and high-speed sortation the LS-4000CB sorter will provide the flexibility to enable Freightways to increase system capacity to meet future growth forecasts,” says Stephen Clark, Sales Director Logistics Systems BEUMER Group Australia.
The new hub will provide Freightways with direct airside access when it goes live in June 2017....
Gregor Baumeister, Manager of the Palletizing and Packaging Systems Division
Mr. Baumeister, you have been Manager of the Palletizing and Packaging Systems Division at the BEUMER Group in Beckum since October 2015. In this function, you control and coordinate the global competence center in this sector. What are your tasks and which goals do you want to achieve?
Gregor Baumeister: With the management of the Palletizing and Packaging Systems Division, I have taken on a highly exciting and varied task. In this position, I control and am responsible for all global sales activities via the competence center. Together with my team, I am also responsible for developing and expanding the comprehensive solutions portfolio. I can formulate my goal very simply: I want to continuously promote the worldwide growth of this business sector. To achieve this, we must establish ourselves in a regionally balanced manner to enable us to support our customers throughout the world in the best possible way. We concentrate on industries with potential but with different economic cycles. And with our intelligent solutions, we will continue to address sectors in which we are firmly established, such as construction materials, chemicals and consumer goods.
Can you explain the procedure within the competence center in more detail? And how do customers throughout the world benefit from this?
Gregor Baumeister: In our target sectors, we integrate packaging and intralogistics solutions for industry-specific applications. A good example is integrated packaging lines for the chemical industry. The bulk material passes from the silo along a conveyor section to our innovative Form-Fill-Seal system (FFS system). The bagging machine is fitted with an integreted, high-precision weigher. This ensures that the weight of the bags is accurately reproduced. Our reliable high-performance palletizers from the BEUMER paletpac range then stack the bags efficiently on pallets. Our customers use the innovative high-performance packaging systems in the BEUMER stretch hood series to secure the load. All machines in this line used the same Human Machine Interface (HMI). This makes it easier for the user to operate, and considerably reduces familiarization time. But there is more to come at the end of this packaging line. With our system solutions, we ensure that the palletized and packaged product is forwarded to a connected store – or directly to dispatch. At the same time, our systems ensure continuous material and data tracking.
We have combined the appropriate solutions and expertise required to realize this material flow in our intralogistics team. The customer is therefore provided with complete solutions from a single source. The team also develops special solutions for very demanding tasks. For example, we have installed a highly redundant application for the rubber industry, which enables an efficient material flow, and complex packaging systems, which are used by wood-processing companies throughout the world.
What experience do you bring to your new position?
Gregor Baumeister: In my professional life, I have acquired extensive experience in intralogistics which I will be putting to outstanding use in my current position at BEUMER. For example, this includes several years abroad. This has shaped my multicultural understanding. Among other things, I have held responsible posts in design and sales for renowned packaging line and intralogistic system providers. Most recently, I held an international sales management position for a provider and manufacturer of logistics systems, logistics software, workstation equipment and storage technology. The thing that appeals to me in particular about the new job at BEUMER is the all-embracing scope of work which is associated with managing this business sector.
How have the requirements for intralogistics and in particular in filling, palletizing and packaging equipment changed over the years?
Gregor Baumeister: I also see a clear trend towards integrated systems in this sector. Customers also want a complete solution from a single source and therefore only one – reliable and competent – point of contact for the whole job. Demand is more for solutions providers and less for product suppliers. However, this does not mean that we will no longer be selling individual machines. We have only established, particularly with very large organizations such as building material or chemical concerns, that they prefer to combine the responsibility and have only one point of contact for their whole line.
Controlled, fault-free and above all appropriate handling of products is required. To what extent has the importance of the control equipment in intralogistics changed as a result?
Gregor Baumeister: You have raised a very wide ranging subject. The control equipment is a central part of every mechatronic system. Furthermore, the trend towards parallel material and data flows, which has already been around for many years, is consolidated particularly within the Industry 4.0 environment. Here, we see an evolution which we are approaching positively and with an open mind. The advantages which the user has from self-optimizing and controlling systems are obvious. For example, they automatically detect blockages in the material flow and select alternative routes. Or, workpieces carry all important information in the form of parameters relating to the production process in themselves. They know who they are and can ‘converse’ with the system via RFID technology.
How do you ensure that users are provided with reliably controlled and regulated material flows?
Gregor Baumeister: This always depends on how complicated the task is. Many applications can be implemented solely at PLC level. Others, in turn, require high-level material flow computers or Warehouse Control Systems. Although every system that we plan and install is based on standard modules, the solution is specifically matched to the customer. This is because no customer requirement is exactly the same as another.
BEUMER has developed from being a machine builder to a system integrator and software provider. How do your customers benefit from this?
Gregor Baumeister: One is inseparably associated with the other – and companies really only want one point of contact. The system integrator must therefore also provide the associated software. If we supply a complete packaging line with connected block storage for a customer, he gets from us a fully functioning system with all mechanical and electrical components as well as the associated software program. We often see software-based strategies as being the key to increasing performance or energy efficiency. Take, for example, the “Sport” and “Eco" gear selector in a car. The changeover is not mechanical but is undertaken by software. And it is exactly the same with the different operating states in intralogistics systems.
What do these intralogistics systems consist of and what are the specific benefits for the user? In which industries are they used?
Gregor Baumeister: As far as the users are concerned, we are problem solvers, and this is also how we want to be seen by the industry. This is what we will be showing with these systems. We are not bringing so-called “me too” solutions to the market, but extremely efficient and specific systems which overcome quite individual challenges. I have already mentioned a highly redundant application for the rubber industry. This is a very good example. With this application, after cutting, the rubber bales must be film-wrapped and packed in large containers. The special challenge here is that they must not stop on the conveyor as otherwise the rubber would flow and it would no longer be possible to transport them. We have developed a system for the customer which ensures a continuous material flow in all operating states. We have implemented this with components from our proven portfolio. At the same time, we are also using technologies from other sectors – for example, we transfer solutions from the Airport sector to the tire industry. As we work across different sectors, we are able to offer our customers quite different perspectives.
Which components are these systems built from and can they be expanded in a modular fashion?
Gregor Baumeister: The components are substantially transport technologies such as conveyor equipment or vehicle-based systems. Added to these, for example, are various handling solutions and manipulators such as robots, buffer and storage modules. As we always use our system building blocks, the solutions can be expanded at any time and can grow with the customer’s business. Furthermore, good planning always provides for different growth scenarios. We therefore plan potential expansions in right at the design phase....
BEUMER Corporation – part of the BEUMER Group, a leading global supplier of automated baggage handling systems – has been chosen to partner with San Francisco International Airport (SFO) and its design-build teams to provide schematic design services for a new common-use individual carrier system (ICS) for baggage handling. As part of the airport’s Terminal 1 (T1) Redevelopment Program, this is the first tote-based baggage handling system to go into operation in a US airport.
The design-build teams will take the airport's Development Plan for the baggage handling system through design and construction. Using an iterative design process, the teams will develop and implement a tote-based system solution which meets the requirements of the airport and all other stakeholders.
Currently, Terminal 1 has multiple baggage systems, each of which is independently operated by a separate carrier, which is a legacy model from when airlines owned, maintained and operated their own baggage systems. Many airports around the globe are now migrating to a common-use model. This allows airlines to share the cost of using a single system, while providing a more efficient operation for the airport, greater flexibility for the airlines and a consolidated security checkpoint for compliance with Transportation Security Administration (TSA) regulations.
This is the first time in the US that a baggage handling system provider has been invited to participate in the programing phase of a baggage handling project. BEUMER Group’s role will be to help to recommend the system components that should be used at each stage of the baggage handling process....
At CeMAT, BEUMER showcased high-capacity packaging systems for various applications:
Whether handling detergents, paint buckets or barrels on pallets - the high-capacity packaging system BEUMER stretch hood efficiently covers all kinds of products with a highly stretchable film hood, while fulfilling the requirements that are specific to the industry: In case of outdoor storage the goods are protected from environmental influences such as sunlight, soil and moisture. When using a non-transparent film, the goods are protected from prying eyes. If designed as an inliner, the film hood prevents the goods from coming in contact with the transport container. In this context, BEUMER Group also presented the world's first Easy Opening film hood: Users can remove the film easily and quickly without any cutting tool. At CeMAT, BEUMER presented this versatility with different demo pallets.
The BEUMER stretch hood A is the result of the intralogistics specialist completely redesigning its tried-and-trusted packaging system. During its development, BEUMER specialists analysed various components and combined them optimally in terms of function, arrangement and ergonomics. This includes a soft-touch panel that guides the user intuitively through the machine control menu as well as material-friendly transport of the film in the machine. Its throughput is higher and its floor space is reduced by more than 40 % compared to previous types of this machine series. Gregor Baumeister, who manages the palletising and packaging technology business group at BEUMER Group in Beckum since October 2015, explains: "There had not been a packaging system for pallets on the market, that did not require the operator to open the film with a cutting tool." From now on, it will be easier for employees in retail stores or logistic centres to unpack or repack goods. With common opening methods, employees may cut themselves with the cutting tools or even damage the products. Baumeister knows the industry: "This can be expensive for companies and, of course, increases the risk of accidents." In order to find a solution, BEUMER has developed a technology that allows the film to be opened along a precise tear line. By using the Easy Opening, employees can tear the film hood easily and quickly without any tools being required, increasing the unpacking productivity significantly.
Various requirements - one machine
"At CeMAT we did not only showcase this innovative solution", says Gregor Baumeister. "Above all we wanted to show the variety of markets in which our machines are used." The BEUMER stretch hood A is used by clients from the cement, construction and chemical industry, as well as in the consumer goods market and logistics sector. Every industry has its own requirements. In cooperation with the Sales Department, the developers have analysed various customers' specifications and system requirements: "To this end, we brought clients, as well as packaging and pallet manufacturers on board", explains Baumeister. The result is a packaging system with a very attractive price/performance ratio and a high throughput. It requires little space, is highly flexible and offers an easy operating and maintenance concept. BEUMER showcased different demo pallets with a variety of products at the stand.
Efficient use for commerce
When it comes to commerce, BEUMER stretch hood A is an efficient solution for securely packaging consumer goods for transport and storage. Baumeister says: "We showcased a mixed product pallet of the large drugstore chain dm as well as a pallet stacked with detergents." When food and consumer goods are palletised, the film hood must guarantee product protection. An increasingly important aspect is tamper protection: Unauthorised persons cannot take goods from the pallet without damaging the film.
In order to guarantee protection during transport and load stability, the stretch film adapts to any product that is stacked on the pallet. The film is very stretchable during the packaging process and the contracting forces in the film keep the goods tight together. Since no heat is used in the packaging process, contrary to the shrink wrapping, the film cannot glue to the product.
The pallet can be packed for high-bay storage systems, with understretch, various base reinforcements, as well as with package sleeves. Thanks to the high transparency of the film, the packed goods are clearly visible and barcode labelling is quickly and consistently recognisable. Logos and text can also be printed on the film to be used as an advertising medium. A sheet placed on the pallet offers additional protection against external influences on six sides of the stacked goods. It allows for clean and dry outdoor storage of industrial products, as goods are reliably protected against environmental impacts, humidity, insects and UV rays. Baumeister adds: "In addition, stretch hooding has a very high throughput and packs at least 200 pallets per hour."
Stretch hood in a metal container?
Yes, that is possible! For example if the contents are not to come in contact with the surface of the container. This is the case for lubricants and adhesives, antifreezes, resins, brake cleaners, as well as for bulk material such as pellets. The inside of the container is lined with a film hood. To showcase this, BEUMER had prepared a metal container on a pallet.
"We also had two other pallets", says Baumeister. "On one, we packaged buckets for construction material, on the other, we presented a non-transparent film. The demand for this is steadily increasing especially for high-priced goods, such as spirits, or high-quality consumer goods such as razor blades....
Dr. Beumer, what can you tell us about trends that are currently important in intralogistics?
Dr. Beumer: Intralogistics is a cornerstone of the global economy. For companies it is no longer a necessary evil; it is crucial for gaining a competitive edge and creating added value. Moreover, it opens the way to new business models, such as e-commerce and customization of products and services. We’ve all discovered how convenient it is to order goods via the Internet. Online shops are open all the time, and customers can shop anywhere and at any time from a computer, tablet or smartphone. If they don’t like what they’ve bought, they just send it back.
What new challenges has this created for intralogistics?
Dr. Beumer: The demand for reliable, flexible delivery is steadily growing. In online retailing same-day delivery has almost become standard, especially with groceries. Customers expect to get what they ordered right away, whether it’s frozen pizza, strawberry ice cream or lettuce. This trend is accompanied by an atomization of orders. Businesses and private individuals have no notion of the effort involved when they order a product and then a second one a few minutes later and expect the two to be combined in a single delivery – oh yes, and when the package comes to the house, please ring only once. The increasing flow of goods in e-commerce, along with the problem of handling returns, has led to greater connectivity, automation and system integration. For me, these are the key areas that are providing solutions.
Could you explain that in more detail?
Dr. Beumer: Supply chains nowadays are organized and interconnected from end to end – from the source of raw materials to the consumer’s door and continuing on to returns, disposal and recycling. The driving forces are the expectations of consumers and industrial customers. For consumers, what counts is the benefit they expect from products and services. Products and services must be tailored to their individual interests and needs. For industrial customers, whose main concern is high productivity, efficient production processes are paramount. Here reliable, cost-effective logistics is indispensable. But the new emphasis on individuality has set the bar so high for logistics that stackers and high-bay warehouses by themselves are no longer sufficient. Technical solutions at the starting points and connection points, in other words value-added services, are becoming increasingly important, plus software control.
How important is flexibility in supply chains?
Dr. Beumer: It is critical. Globalization is bringing about lasting changes in markets and the economy. The economy is becoming more international, but also more regional. On the one hand, customers in Europe configure their laptops on the web and have them assembled in Texas, while their summer clothes are sewn in Vietnam. And they want to receive these products at the front door within 48 hours. On the other hand, they want to buy locally grown organic food. The same is true for businesses. They order products on the global market, but they still want to have their specialized suppliers in the vicinity. All companies, large and small, must adjust to these new patterns of procurement, production and sales. This is leading to far-reaching changes in the supply chain and it will require enormous flexibility. Without efficient intralogistics none of this will be possible.
The theme of CeMAT 2016 was “Smart Supply Chain Solutions”. What does this mean?
Dr. Beumer: The theme was a very good choice. It calls attention to the fact that future processes in logistics will be automated and interconnected. Increasing digitization will bring about fundamental changes in value chains, and entirely new business models will emerge. The adoption of digital technology and the associated changes in people’s thinking will create new challenges not only for logistics companies, but also for service providers of all kinds. For them, success in the future will depend even more on the capabilities of their logistics centers. Intralogistics and digitization are inseparably linked. Industry 4.0 is already a reality, as is the internet of things, which in many areas has become part of everyday life. The opportunities are enormous because we’re talking about highly scalable systems. Intelligent solutions are already available, but the possibilities of this technology are by no means exhausted. For example, increasing numbers of logistics companies and warehouse operators are opting for autonomous in-house transport systems that select their own routes, and for warehouses that detect empty stocks in real time and fill them.
Companies have been using driverless transport systems for some time now. Do you see a trend here?
Dr. Beumer: Yes, a clear one. The trend is away from heavy, inflexible handling equipment to small, multifunctional vehicles. The latter are much more versatile when it comes to in-house transport and warehouse operations. The vehicles independently agree on which of them should do which job and what routes to take. I see a direct correlation here with the growing trend towards small load carriers and goods packed in cartons. These are being used more and more as a result of e-commerce and atomization. In addition, lean concepts are becoming more important in assembly, in combination with smaller inventories and order quantities. Intralogistics is undergoing a radical transformation.
What must be done to cope with these changes?
Dr. Beumer: We must plan processes with the future in mind and devise safe and reliable technical systems. This will mean more and more processors, user controls, software and control units. All of these elements must be integrated into a harmonious, ergonomic, efficient and user-friendly system that is able to handle the gigantic quantities of data. The complexity of logistics makes IT indispensable; it is the only means of intelligently controlling the flow of goods. We will need smart solutions for the supply chain. The performance of IT systems and components will have to be continuously improved. This applies to more than storage and distribution; it extends to areas such as manufacturing and the supplying of assembly workstations, and it also includes the consumer. In all parts of the supply chain value creation and profitability will thus increase. There will also be benefits for mechanical and systems engineering. In many companies software already accounts for half of the new solutions being developed, or even more.
What does this mean for you as a manufacturer of equipment and systems for intralogistics?
Dr. Beumer: Nowadays, unless we decide to alter machinery and equipment, we can often only achieve increases in performance and efficiency by creating better software. This opens up an exciting area of activity for us, one with great benefits for our customers. We have grown from being a component supplier to become a system integrator. We equip our systems with intelligent software and control units from the very start. This is a big advantage for users. Their processes are more flexible, and they are efficient even with a batch size of one. With a comprehensive database our customers can optimize their processes from start to finish and achieve significant savings thanks to greater transparency.
What did CeMAT hold in store for visitors?
Dr. Beumer: CeMAT presented solutions for all of these trends and highlighted areas of potential. The focus of the exhibition, logistics IT, was important owing its relevance to all areas of logistics. Software has a bearing on all areas and connects them. CeMAT therefore was a must not only for IT experts, but also for logistics specialists, production managers and business managers throughout the world. They had an opportunity to survey the entire market and discover what will be in the production facilities and logistics factories of tomorrow....
Conveying & Loading Systems: Beumer develops and implements complex system solutions for the bulk materials industry throughout the world
The BEUMER Group uses its newly created Conveying & Loading Systems (CL Systems) division to develop and implement complex system solutions throughout the world for different industries, such as mining and the cement industry. The team is made up of experienced staff from the branches distributed around the world who work together on the projects. What they all have in common is that they understand the user, which means that they can develop tailor-made solutions. This is demonstrated by three impressive completed projects.
Dr Andreas Echelmeyer, who has headed the Conveying and Loading Systems division in the BEUMER Group at its headquarters in Beckum since August 2015, stated that “We can use our comprehensive expertise in system solutions to advise our customers and provide them with complete plant systems. Each industry poses its own unique challenges”. The most important point is to listen carefully to the customer and then ask the right questions. This can only be done locally. Employees positioned around the world are therefore in close contact with the customer. They are familiar with the specific customs of the particular country, understand the language and are wise to the particular requirements of the market and the customer. They identify appropriate potential and any possible need for action. The operators for whom BEUMER has successfully commissioned conveying plants includes the TPI Polene Public Company Ltd. The third largest cement producer in Thailand uses this complex system solution to transport crushed limestone from the quarry to the blending bed.
Difficult environment safely overcome
Dr Echelmeyer was aware that “The challenge lay in the nature of the ground between the quarry and the cement plant”. It was exceptionally demanding. We had to make allowances not only for numerous obstacles but also for a steep downhill section of the conveyor”. The team designed a complex, but above all cost-effective, integrated system comprising a total of eight belt conveyors covering a distance of 6,129 metres. BEUMER also supplied a PLC plant control system, transfer stations, filter systems and foreign body collectors.
The system is designed for a conveying capacity of 2,200 t/h. The key items in the limestone transport system are two downhill belt conveyors operating in the generator mode followed by a troughed belt conveyor with horizontal curves. The material passes from the crusher discharge belt the first two troughed belt conveyors. The material is then transferred to a long overland conveyor with a speed of 4.5 meters per second by an accelerator belt with a speed of 2.6 meters per second. Three more conveyors finally transport the material to the blending bed.
Cost-effective operation guaranteed
One particular feature of the downhill conveyors is their power generation. With a total of 640 kW/h generated energy that is fed into the power grid they make a substantial contribution to the cost-effective operation of the overall system. “We have a great deal of experience with conveying systems that can negotiate horizontal and vertical curves and operate in the generator mode” explained Dr Echelmeyer. During the development it was necessary, for example, to ensure safe and carefully controlled stopping of the large belt system to avoid problems during unavoidable events, such as a power failure.
BEUMER supplied four further belt systems with a total length of 989 metres to deal with the discharge from the blending bed and supply the material to the raw mill feed hopper. The conveyors were all built and installed in only eleven months. The commissioning phase, lasting three months, was followed by performance tests. The team then handed over the entire plant to the customer. Dr Echelmeyer emphasized that “We supervised and monitored the installation and commissioning to ensure long-lasting, trouble-free, operation. This always forms part of our service”. The standard scope of supply also includes intensive training of the operating and maintenance personnel.
Complex and curved
Cong Thanh, the Vietnamese cement producer, also relies on the system solution expertise of the BEUMER Group for transporting crushed limestone from the quarry to the blending bed. The CL team discussed the various technical options intensively in a joint workshop held with the producer. Various routes were worked out and compared on the basis of the narrow terrain that was available. Dr Echelmeyer explained that “We have appropriate software for this, with which we can match satellite and aerial photographs with topographical data”. One conveyor section that drops steeply in some places with numerous obstacles in the terrain and seven road crossings was particularly challenging.
A total system consisting of four conveyors with a combined length of 3.5 kilometres is now in use, BEUMER also supplied a PLC plant control system. The main component is an overland conveyor with three horizontal curves and a total drive rating of 600 kW. It is designed for a continuous conveying capacity of 2,200 t/h.
The heaped material is transported in trucks from the quarry face to the crusher. The limestone that has been pre-crushed to less than 100 millimetres is then transferred by discharge conveyors to an accelerator belt that feeds the long belt conveyor.
The troughed belt conveyor for downhill transport is one meter wide, with a distance between centres of 3,200 metres, and drops 70 metres. The conveying speed is 4.5 meters per second. The low operating costs are a special feature. Due to the downhill section the operation of the fully loaded conveyor is virtually energy-neutral. Its consumption during continuous operation is less than 200 kilowatts, which means that not even 0.1 kilowatt is required per tonne of transported material. According to Dr Echelmeyer “This, together with the low maintenance and repair costs, contributes substantially towards cost-effective operation”. After the installation and commissioning his team submitted the plant to a performance test that it passed successfully on all points.
Through the middle of the rainforest
The CL Systems division of the BEUMER Group has also been very successful in Indonesia. The plant construction company Sinoma International Engineering Co. Ltd. was awarded the contract by the Indonesian end customer, Cemindo Gemilang, to supply a turn-key cement plant to Java. It should reach a daily clinker production of 10,000 tonnes. Sinoma commissioned BEUMER with the design and supply of an overland conveyor between the quarry and the plant.
The challenges in this project were not only the demanding topographical routing but also the evergreen rainforest. Joint discussions were held between the BEUMER team, Sinoma and the end customer. The team worked various routes out and compared them. “The very narrow corridor of land in addition to the tropical climate required a complex and sophisticated design” explained Dr Echelmeyer. Among other things his team designed a solution with tight horizontal curves that fitted optimally into the landscape.
The entire system now comprises six conveying plants with a total of length of 7.6 kilometres. BEUMER also supplied acceleration and discharge conveyors and a PLC plant control system.
Controlled loading ensured
The system is designed for a maximum continuous conveying capacity of 3,000 tonnes per hour. The main component is a 7.4 kilometre long overland conveyor. Upstream of this troughed belt conveyor is an intermediate hopper with a capacity of about 120 tonnes. The material passes from this hopper via a variable-speed discharge conveyor to a downstream acceleration belt that feeds the overland conveyor. This controlled loading system ensures cost-effective operation of the plant, especially during the start-up phase. It also has a favourable effect in the dimensioning of drive components and the belt, and reduces the operating costs.
According to Dr Echelmeyer “The acceleration belt with a speed of 4 meters per second protects the belt of the overland conveyor and increases its service life”. For further protection there are also upstream units for collecting any iron and non-ferrous metals. The limestone is then transported to the blending bed on short troughed belt conveyors.
The troughed belt conveyor has a width of 1,200 millimeters and a distance between centres of 7,381 metres. One tail drive and two head drives are installed, each with a rating of 545 kilowatts. The plant conveys the material at a speed of 5 m/s and negotiates a height difference of minus 188 metres.
Protection of people and animals
The conveying system also runs past villages and for long sections passes through rainforest that deserves to be protected. The CL Systems team has taken numerous design measures to reduce the noise impact on people and animals. Dr Echelmeyer explained that “Among other things, we have used low noise idler rollers and appropriately dimensioned protective hoods at the drive station” . This means that the limestone passes through the rainforest in virtually silent mode. The construction time lasted only one year....
BEUMER Group UK invites delegates at British-Irish Airports Expo to experience a virtual-reality tour of an advanced CrisBag® tote-based baggage handling system. In addition, delegates will be invited to participate in a hands-on demonstration of a Video Coding System to optimise the baggage handling process for no-read labels on transfer baggage. Delegates will also be able to meet the experts behind BEUMER Group’s recent Whitepaper on IATA Resolution 753.
“Future baggage handling systems must be capable of transporting and sorting an extremely wide portfolio of baggage products and must also feature increased security to meet the key requirement to 'track & trace' all baggage items handled within the system,” states Peter Gilks, Managing Director, BEUMER Group UK's Airports Division. “The new IATA Resolution 753 requires all IATA airports to work with their partner airlines and ground handling companies in assessing possible upgrades in order to comply with this new regulation. As the BEUMER Group Whitepaper explains, if an upgrade is required, this can also be seen as an opportunity for all stakeholders to drive down costs by accessing the new levels of efficiency offered by modern baggage handling equipment and controls.”
The virtual-reality tour of a CrisBag® tote-based baggage handling system will show why many airports consider this the system of the future. By use of the latest Oculus Rift technology viewers, BEUMER Group has created a virtual reality experience of being "inside the system" to experience first-hand the power of a high-speed baggage handling system.
Delegates will also have the opportunity to discuss their own airport’s strategy for compliance to IATA Resolution 753 and explore how compliance can be used as part of a cost-down process....
Andre Tissen is Director Business Unit Cement at BEUMER Group in Beckum, Germany:
BEUMER Group established the Center of Competence (CoC) for the cement industry in order to provide optimal systems and installations, becoming a full-range supplier to customers all around the world. It is designed to optimise communication among the BEUMER experts worldwide. Andre Tissen, the director of this business segment since 2013, manages and coordinates this global competence centre.
Mr Tissen, could you tell us more about your tasks and the goals you have set yourself?
Andre Tissen: As the head of the Center of Competence (CoC) for the cement business, a centre with global responsibility, I am responsible for developing this business segment. This includes optimising and expanding the range of products we offer, as well as supporting the individual group companies. Because only by cooperating with our international group companies can we offer comprehensive support to our customers and expand into new markets.
Can you give an example on how the customers can benefit from the CoC?
Andre Tissen: We have experts in the cement industry with extensive know-how who are located all over the world. The CoC helps us to bundle their knowledge and make it accessible to the individual group companies. This will benefit customers in the Unites States, as well as users in the Philippines or in Germany. The CoC allows us to offer global support. The customer will have access to a competent expert twenty-four hours a day.
You mentioned the continuous development of products. What are you working on at the moment and what does the current situation look like?
Andre Tissen: We continue to optimise all of our machines and systems. One of the trends is that more and more clients want to receive their systems in a turnkey state. They want the systems to come from one single source that means not only individual machines, but a combination of several machines, a complete system where the individual components are perfectly compatible. This means that automation will become increasingly important. BEUMER Group is very well positioned, which is a big advantage for us. Our sortation and distribution systems have a high degree of automation and are successfully used in distribution centres world-wide. We are one of the global leaders in this business segment. Experiences gained in one sector can often be used and transferred to another.
BEUMER Group provides the customer with complete turnkey packaging lines. We design, install and commission the machines and systems, and, if necessary, integrate the products of subcontractors. Our customers entrust us with the complete responsibility. In addition, there are changing types of problems, cement manufacturers, for example, are using more and more secondary fuels, such as tyres and household waste. Our systems constitute the appropriate conveying solutions for this kind of material.
What does the Chinese market for your solutions for the cement industry look like?
Andre Tissen: China remains an important market for us. It has calmed down a little though, because the clinker capacities in China are reaching their saturation limit. There are two major general contractors in China that are currently building about 70 percent of new clinker production lines world-wide. Those companies sell their products to more than 20 countries, with a main focus on the Middle East, Africa and Asia. For several years now, they are relying on different BEUMER Group systems such as apron conveyors, bucket elevators and palletisers.
Where are the current growth markets for the cement industry?
Andre Tissen: Core regions for us are currently Africa, the Middle East and south-east Asia. One interesting customer in Africa, for example, is the cement manufacturer Dangote Cement PLC. It is a worthwhile investment here, even for small companies, because the demand for cement is continuously rising due to the persistent construction activity in many parts of Africa. The demand for large-scale plants is particularly high. The US market is getting more and more interesting as well because it is becoming more stable. We still believe the Russian market shows great promise. We are expecting a strong demand as soon as the political situation has stabilised. Our Russian group company is represented in almost every region of Russia and the states of the former Soviet Union. Despite the political events of the last months, we want to continue our successful cooperation with the Russian partners based on mutual trust.
What does the market situation look like in Germany?
Andre Tissen: There is a lot more going on now here in Germany than in previous years. They are mostly modernisation projects of existing cement plants. There is, for example, a strong demand for conveying systems for alternative fuels.
What are the most requested BEUMER products in the cement industry at the moment?
Andre Tissen: There are our bucket elevators, filling systems, palletisers and the high capacity packaging system BEUMER stretch hood®. We sell it to companies in all industries, but particularly to the building material industry, where it is used to package palletised bags filled with cement, mortar, limestone and gypsum. Our innovative BEUMER fillpac® is in high demand too. It's an efficient and optimised filling technology. Our bulk loading heads are often used to load bulk materials quickly and without dust. They are designed with a double-wall system, separating the material inlet and the dedusting unit. Our loading and palletising systems, for example, can automatically load bags of bulk material directly onto the trucks. A very efficient option which would otherwise require several workers. This is particularly interesting for emerging market nations, where the transshipment of bagged bulk goods is increasing and labour costs are climbing. We offer our curved belt conveyors as troughed belt conveyors and pipe conveyors that can transport different types of bulk material over long distances and through oftentimes rough terrain.
Can you tell us something about the competitive situation in the cement industry; are there many global companies that you are competing with?
Andre Tissen: Our main competitors are predominantly from Germany and our neighbouring European countries. If we want to keep our leadership position, our systems and machines always have to be one generation ahead of our competitors. This is the standard we have set for ourselves. One of our unique selling points is definitely that BEUMER Group is one of the few companies that covers the entire portfolio, from the quarry to the palletised and packaged cement bag.
How do you stay up to date with the customer's needs in order to remain competitive in the future?
Andre Tissen: Our employees from our branches world-wide keep their fingers on the industry pulse. They are permanently in touch with the customers. This is how we can react quickly to emerging trends. We also hold regular workshops with the leading cement manufacturers. One of the advantages of being a global company is that we can react to regional differences. Automation is one of the topics that is very important to our European users to remain competitive. It plays a smaller role in other countries and regions. Our employees know the local particularities and will find the most suitable solution.
How have the demands changed over the years?
Andre Tissen: More and more customers want the worry-free package. This can be the deciding factor for keeping the competitive edge. Our customers expect us to assume the responsibility for the entire project and, upon completion, just "hand over the key", so to speak. A comprehensive customer service becomes increasingly important. During machine downtimes, customers expect us to respond quickly. The service agreements are individually tailored to the customer's needs. They can range from only maintenance and inspection to a long-term placement of our service personnel on site. The "Residential Service" includes technical support, preventive maintenance and inspection, emergency plans, system and process analyses and optimisation as well as spare parts and facility management. The relationship with the customer becomes more and more important. I like to compare it to a good friendship that is based on mutual trust. We are not only a supplier, but also a partner. A good relationship, in my opinion, is based on giving and taking. It should always be a win-win situation. The two partners should be able to maintain an open dialogue.
How do you handle systems from third parties?
Andre Tissen: We support our customers in all matters, even with the repair of third party systems. We also modify and modernise systems from our competitors.
Is the purchase price more important to customers than the long-term costs?
Andre Tissen: The cement market is in a harsh situation due to the global crises. This is why many customers are basing their decisions on price. We are trying to counteract this trend by offering sustainable solutions to our customers, so that they can reduce their costs in the long term. We want to be able to offer our products at a better price while maintaining the same quality. One major advantage for our customers: our systems and machines come in a modular system. So depending on their individual requirements, they can add modules to extend our basic version....
BEUMER Group Middle East invites delegates at Airport Show Dubai to experience a virtual-reality tour of an advanced CrisBag® tote-based baggage handling system. In addition, delegates will be invited to participate in a hands-on demonstration of a Video Coding System to optimise the baggage handling process for no-read labels on transfer baggage. Delegates will also be able to meet the experts behind BEUMER Group’s recent Whitepaper on IATA Resolution 753.
“These are very dynamic times for the airport industry,” states Klaus Schäfer, Managing Director, Crisplant. “The new IATA Resolution 753 requires all IATA airports to work with their partner airlines and ground handling companies in assessing possible upgrades in order to comply with this new regulation. As the Crisplant Whitepaper explains, if an upgrade is required, this can also be seen as an opportunity for all stakeholders to drive down costs by accessing the new levels of efficiency offered by modern baggage handling equipment and controls.”
The virtual-reality tour of a CrisBag® tote-based baggage handling system will show why many airports consider this the system of the future. By use of the latest Oculus Rift technology viewers Crisplant has created a virtual reality experience of being "inside the system" to experience first-hand the power of a high-speed baggage handling system.
Delegates will also have the opportunity to discuss their own airport’s strategy for compliance to IATA Resolution 753 and explore how compliance can be used as part of a cost-down process....
BEUMER supplies world's highest bucket elevator to Indian cement manufacturer:
The ACC Ltd., part of the Lafarge-Holcim Group, is also benefiting from the construction boom in India. The Indian cement manufacturer has therefore expanded the capacity of its factory in Wadi in the south Indian state of Karnataka to 13,000 tonnes per day. The BEUMER Group as main (EPC) contractor has got a repeat order on turnkey, for high-performance belt bucket elevator, type HGBW-HC 1250 x 175.3 m. With a distance between centers of 175.3 meters, this is currently the highest in the world.
ACC’s decision is the result of the reliable performance of the bucket elevators supplied by BEUMER Group to the same client in the past with heights of 174 m and 171m. The enormous size of this system enables a flow rate of around 600 tonnes per hour to be achieved, ensured by high-quality steel wire belts of particularly high strength....
BEUMER Group, a leader in sortation, distribution, palletizing and packaging systems, will exhibit at MODEX 2016 in booth 4137 with a broad range of flexible, high-speed and low-maintenance energy-efficient sortation and distribution solutions, including its automated BS 7 cross-belt sorter and an interactive “video wall” featuring several BEUMER Warehouse & Distribution solutions. Additionally, BEUMER will introduce its latest offering, the Rota-Sorter®, suitable for handling a vast range of items on a single line at top speed.
The Modex 2016 show runs April 4-7 at the Georgia World Congress Center in Atlanta, Georgia.
BEUMER highlights at the MODEX 2016 show include:
Rota-Sorter®, the latest solution by BEUMER, can handle a vast range of items on a single line at top speed. Its unique discharge technology makes sortation extremely gentle. The system also distinguishes itself through its flexibility and economic efficiency.
The Rota-Sorter® can sort a great variety of items, whether large or small, tall or flat, of different weight categories and in different packaging, on one single line. The range extends from flat lightweight items with dimensions of 120 x 60 x 5 mm to large packages with a format of 1,200 x 800 x 800 mm weighing up to 31.5 kg. High-speed operation is a matter of course: the Rota-Sorter® can sort an impressive 5,000 items per hour on one line. The sorter can be expanded to up to three lines arranged above each other, thus achieving a maximum capacity of 15,000 items per hour.
Warehousing & Distribution Solutions
To give booth visitors a unique and original “perspective” on the key capabilities and advantages offered by BEUMER for Warehousing & Distribution, Sortation Experts will be on hand to discuss key issues impacting customer’s operations, including order accuracy, omni-channel fulfillment strategies, improving throughput and service levels and peak season planning. To illustrate these solutions and connect them to business requirements, BEUMER experts will guide booth visitors through an interactive, touchscreen video wall, providing visibility into the full line of BEUMER cross-belt and tilt tray sortation systems.
Additional BEUMER Sorter Models on Display
For those that prefer a hands on-approach instead of a virtual one, the booth will also include actual samples of several BEUMER tilt tray and cross belt sorter models including the BS-7 and BS-25. Attendees will get an in-depth look at the robust parts and decades of engineering built into the industry's leading sortation products.
For BEUMER Group, Customer Support is much more than just a service. While it was once enough to "simply" prevent or quickly solve malfunctions and machine downtimes, the intralogistics provider has now significantly extended this service. Approximately 1,000 employees worldwide now work for this business segment. They take care of the customer, starting with the first project discussion, up until the system is in operation. Customer support comprises different types of agreements. With its Residential Service, the group assumes, for example, the responsibility to provide trouble-free operation on site, even for the long-term.
BEUMER Latinoamericana Equipamentos Ltda. (BLE) has been awarded a second Operation & Maintenance (O&M) contract for the baggage handling system at Viracopos International Airport, Brazil. The original 24 months O&M contract was awarded by Aeroportos Brasil Viracopos when BLE completed the supply, installation and commissioning of the baggage handling system in the airport’s new international terminal. The new contract extends the existing agreement and ensures that BLE will continue to operate and maintain the system for a total of 5 and a half years (66 months).
During the first year of the O&M contract BEUMER Latinoamericana Equipamentos’s on-site employees completed a number of work orders for preventive maintenance without a single work order required for corrective maintenance while the BEUMER Group baggage handling system handled the baggage from 4,400 flights with zero delays resulting from baggage handling.
Viracopos’ baggage handling system in the new Terminal 1 consists of 72 check-in stations; 2200 meters of belt conveyors; 6 standard 60-metre baggage-reclaim carousels and an 80-metre carousel to handle high-capacity planes such as the Airbus A380. The system also integrates a fully automated LS-4000 tilt-tray sorter with the capacity to sort up to 4,400 items of baggage per hour.
The O&M contract allocates full responsibility for the operation and maintenance of the baggage handling system to BEUMER Latinoamericana Equipamentos. This includes monitoring and supervision of the system via SCADA; monitoring the baggage flow and resolving operational anomalies.
“The new contract was awarded to BEUMER Latinoamericana Equipamentos due to the successful, error-free operation of the baggage handling system throughout its first year of operation and the close collaboration which has developed between BEUMER Latinoamericana Equipamentos and Viracopos Airport,” explains João Scharam, Maintenance Manager, Viracopos Airport.
BEUMER Latinoamericana Equipamentos Ltda. is part of the BEUMER Group, a leading global supplier of automated baggage handling systems....