Intralogistic solutions meet high demands of online retailing: Efficient material flows in times of e‑commerce
Beckum, 17. August 2016

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.

At the Khimia 2016, BEUMER will present palletising and packaging solutions for the chemical industry: Success throughout the line
Beckum, 11. August 2016

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.

High quality for high performance
Beckum, 20. July 2016

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 wins contract for the sortation system in Freightways’ new South Island Hub
Aarhus, 11. July 2016

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.

"Demand is more for solutions providers and not so much for product suppliers"
Beckum, 06. July 2016

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 awarded Design & Build contract for the first US tote-based, Individual Carrier System for baggage handling in San Francisco Airport
Somerset, NJ, 29. June 2016

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.

The packaging solution for every industry
Beckum, 27. June 2016

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.

“Intralogistics is a cornerstone of the global economy”
Beckum, 07. June 2016

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.

A powerful global partner
Beckum, 02. June 2016

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 offers virtual-reality tour of the latest baggage handling technology at The British-Irish Airports Expo 2016
Aarhus, 24. May 2016

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.

“The customer will have access to a competent expert twenty-four hours a day“
Beckum, 13. May 2016

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 offers virtual-reality tour of the latest baggage handling technology at Airport Show Dubai 2016
Aarhus, 27. April 2016

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.

Raising the bar
Beckum, 20. April 2016

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 to exhibit sortation solutions that drive profitability, speed and precision at MODEX 2016
Somerset, NJ, 17. March 2016

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.

Customer Support
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 Group awarded an extended Operation & Maintenance contract for the baggage handling system at Viracopos Airport
Aarhus, 15. March 2016

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.

Looking at the world through smart glasses
Beckum, 10. March 2016

BEUMER Group develops smart maintenance system  for customer support:

Augmented reality offers interesting possibilities and potentials, e.g. for maintenance work on intralogistic systems: a head-mounted minicomputer could display all necessary information to the service employee. This would simplify their work, hands-free. The BEUMER Group development department places a high priority on this topic. With an app for smart maintenance on mobile end devices, our customer support technicians can quickly access all important data.

Companies must repair their machines and systems quickly to avoid costly downtimes. This is becoming a more difficult task as systems are becoming increasingly complex, requiring highly qualified service technicians. Even the most skilled technicians sometimes have to read through heavy manuals, open up drawings or struggle with outdated plans. This costs valuable time, and should be so much easier in the digital age. Tablets, smartphones and smartwatches have become indispensable in our private lives. Even smartglasses are increasingly finding their way into our lives. A tourist strolling through Paris, sits down at the Eiffel tower, puts on his glasses and gets all the information he wants, according to his location and true to scale: How tall is the building? What are the opening hours? How did these scene look like 100 years ago? "We take up this technological trend, to complement reality with digital information," says Dr. Andreas Werner, head of the research and development department with BEUMER Group. "This app for smart maintenance will help facilitate maintenance work on intralogistic systems for BEUMER Customer Support employees."

App facilitates maintenance
Through AutoID characteristics on the logistic element, e.g. a conveyor, and the smart maintenance app, information on this element can be displayed, such as maintenance instructions or pin assignments. The service employee focuses on the object with his mobile device. The required data is displayed on the live image of the camera of the device. "The technician looks at the defective part and can immediately call up every related manuals or goods in stock, " explains Dr. Andreas Werner. Every process step is displayed. In the event of very complex processes, he can call a colleague by using the smartglasses and solve the problem together via live stream. Measured values could be recorded at the same time and transferred to the back-end system in real time. Video recordings and photos can document whether an order was carried out correctly and in compliance with the safety regulations.

Smartglasses, tablet or mobile phone?
"When implementing these wearable computer systems into intralogistics, you have to consider aspects like information security, ergonomic user interfaces and suitable IT structures," explains Dr. Andreas Werner. The goal is to ensure a sustainable added value for companies and customers. But which mobile end device is the most efficient? The app can be used on smartphones and tablets for example. They offer the advantage of a high computing capacity. This allows you to process the large amount of data that is required for service tasks. Their interfaces are standardised and always have direct access to the Internet. Their handling is intuitive and easy. One big advantage: these devices are accepted technologies at the workplace because they are already indispensable in our private lives. Smartwatches, however, have a low computing capacity , their interfaces are sometimes specific to the manufacturer and the user requires additional devices. Smartglasses are also very easy to use and their interfaces are standardised. Their availability however is still too low for industrial applications. As with smartwatches, the user requires additional devices. Smartglasses have many operating advantages, but they are still not developed enough to make an industrial use possible.

Smart maintenance at Singapore airport
"Tablets are already used at several airports that operate baggage handling systems from BEUMER Group," describes Dr. Andreas Werner. This includes Singapore Changi Airport. As one of the main hubs for Southeast Asia, this airport is known to be very progressive and passenger-friendly. The baggage handling system was developed and integrated by BEUMER Group. BEUMER Group is exclusively responsible for ensuring trouble-free operation, optimum maintenance and therefore the long-term coordination of the baggage handling systems. This is why 121 employees take care of customer support. They provide 24/7 operation at the baggage control rooms and necessary preventive maintenance to ensure continuous system availability and best performance.

"The maintenance personnel can use the tablets to connect to individual system control components to check for example statuses or carry out modifications," says Dr. Andreas Werner. BEUMER Group employees can scan barcodes from components and look into further data, such as maintenance protocols, using the integrated camera. Maintenance and repairs are carried out a lot faster, and system standstills are reduced. This ensures reliable operation and reduces costs.   Developers are currently carrying out an innovation study with the smartglasses at the airport. The employees receive information on the system layout in 2D via their device, the error history, or device-specific information, and gets VoIP access to customer support. They can access operating and maintenance instructions easily and quickly. All of the information necessary for troubleshooting the system is available. The device can also be connected to the smartphone via Bluetooth.

BEUMER Group wins contract for the Inter-terminal passage between the North Terminal Complex and the South Terminal Complex of Sheremetyevo Airport, Russia
Beckum, 09. March 2016

BEUMER Group - a leading global supplier of automated baggage handling systems – has been awarded a contract for the design, fabrication, delivery, assembly, commissioning and implementation of the automated baggage transportation system for the Inter-terminal passage between the North Terminal Complex and the South Terminal Complex of Sheremetyevo Airport, Russia.

Sheremetyevo is Russia’s largest airport, operating international and domestic flights to more than 200 destinations with more than 31 million passengers in 2015. As part of the Airport’s Master Plan up to 2030, the development of the North Terminal Complex with the capacity to handle 40 million passengers per year is one of the strategic directions of Sheremetyevo airport.

The North and South Terminal Complex will feature almost 2km of new underground tunnels connecting the southern and northern airport areas. These tunnels will be equipped with a BEUMER autover® independent baggage carrier system and provide the capacity to handle future growth in passengers. In addition to this the tunnels and BEUMER autover® system will provide short connection times for passengers and baggage.

“The development project for the North Terminal Complex at Sheremetyevo Airport represents a large-scale and unique project for Russian civil aviation,” explains Evgeny Tumel, Deputy General Director, Chief Engineer of Sheremetyevo Airport. “The underground terminal-to-terminal tunnels under active runways will be the first of their kind in Russia. It will help establish Sheremetyevo as a major hub and will raise Moscow’s transit, tourist and business potential.”

The baggage handling system will integrate a 4.8km BEUMER autover® system and include 187 autoca® intelligent destination coded vehicles (DCVs). The system will support a capacity of 900 bags per hour in each direction. As the BEUMER autover® rail has no moving parts it virtually eliminates the difficult task of carrying out maintenance in very long tunnels.

“By choosing the BEUMER autover® system, Sheremetyevo will keep baggage connection time between terminals to a minimum whilst allowing each item of baggage to be properly processed and allocated to the correct make-up position,” explains Vladislav Dementiev, General Director, BEUMER Russia.

Installation of the BEUMER autover® system is scheduled to start in February 2017.

Crisplant offers virtual-reality tour of the latest baggage handling technology at Passenger Terminal Expo 2016, Cologne
Aarhus, 08. March 2016

Crisplant – part of the BEUMER Group and a leading global supplier of automated baggage handling systems – invites delegates at Passenger Terminal Expo 2016 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.

The hands-on demonstration of the new software controls for Video Coding which has been added to its Airport Software Suite will show how, by adding cameras and introducing a Video Coding System (VCS) into the BHS, the bag does not have to be diverted to an MES as an image of the tag is sent via the VCS to an operator who encodes the information remotely at a workstation or via a tablet.

Delegates will also have the opportunity to meet the experts responsible for Crisplant’s Whitepaper on the IATA Resolution 753. This will allow them 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.

Crisplant will be in Hall: 10.1, Stand: 7035, at Passenger Terminal Expo 2016, Cologne, Germany, from 15th to 17th March 2016.

The solution supplier
Beckum, 08. March 2016

CeMAT 2016: BEUMER will be exhibiting at the world's leading trade fair as a system supplier for sorting and distribution equipment, as well as for filling, palletizing and packaging solutions

At CeMAT (May 31 to June 3, Hanover) BEUMER will be demonstrating the company's extensive expertise as a solution supplier not only for sorting and distribution equipment, but also for integrated packaging and intralogistics systems. To its highly efficient filling, palletizing and packaging installations, BEUMER supplies the matching components for implementing material flow systems for each particular sector. The customer gets everything from one source – including the software.

As a systems integrator, BEUMER supplies complete packaging lines. The company's range includes, for example, the innovative Form-Fill-Seal system (FFS system), known as the BEUMER embapac and used particularly in the chemical industry. The BEUMER fillpac fills a range of materials, particularly those used in the construction materials industry, and can handle structures ranging from very fine to very coarse. Customers can obtain the powerful BEUMER paletpac layer palletizer for stacking the filled bags on pallets. These are equipped with a  clamp or double-belt turning device, depending on the product requirements. The palletized goods can be efficiently secured with a stretch film using the proven, high-performance packaging equipment from the BEUMER stretch hood series. BEUMER will be showing this machine in action – with new and innovative features – to visitors to the exhibition stand in Hanover.

BEUMER is implementing sector-specific applications in the field of palletizing and packaging systems, and is enhancing its packaging lines to create complete intralogistics systems. This is done by fitting the lines with standardized components such as conveyor equipment or vehicle-based systems, a variety of handling solutions and manipulators such as robots, buffer and storage modules, as well as the appropriate software. The customer obtains the complete intralogistics system from one source, and therefore has a single, reliable point of contact. BEUMER will therefore be exhibiting at CeMAT as a system supplier for a wide range of industries.

Efficiently sorted and distributed
Efficient material flows are becoming ever more important in today's e-commerce environment, because the supplier's delivery promise is of crucial importance as online business keeps growing. The BEUMER Group supports mail-order companies and providers with both expertise and with powerful sorting and conveying technology. BEUMER is therefore showcasing models of a variety of solutions – such as the E-Tray Sorter – at the exhibition stand. Energy is supplied to this standard machine contactless. It is available with motor-driven tilt units in sizes BS 25 and BS 55. With the integreted diverter function, the tilt unit enables individually packaged goods to be discharged in two dimensions on both sides of the sorter. Since the tilting movement is independent of the sorter speed, the equipment runs significantly faster than comparable sorters.

A model of the BEUMER Belt Tray Sorter will also be on show. The supplier can fit this with a variety of modules and functions, depending on the application. With a contactless energy supply and a linear motor drive, it sorts goods and conveys them carefully and reliably to the correct destination, regardless of size, shape or the kind of surface. The modular design makes it possible to adapt the equipment ideally to the conditions of a particular building – and without restrictions on performance. A further model demonstrates the Crisplant LS-4000, a high-speed loop sorter used in postal and distribution centers. The cross-belt and tilt-tray sorters mean that the goods are handled quickly yet carefully.

Semi-automatic unloading equipment
Machine-supported bulk unloading of swap bodies rather than manual unloading can be used to increase the capacities of existing logistics centers. A significantly greater gate-throughput is therefore possible. BEUMER launched the first generation of a semi-automatic machine, the BEUMER Parcel Picker, on the market for this purpose, and will be showing it at CeMAT. This bulk unloading machine relieves workers of heavy physical work, increasing productivity at the same time. With this, the staff at postal and CEP companies can unload packages of varying sizes and weights, parcels and shipping units from swap bodies and full trailers, with high-performance. With an average spectrum of packages, and with an experienced operative working the equipment, throughputs of more than 2500 packages per hour can be achieved.

BEUMER Group to deliver sortation system for DPD Russia’s new logistics centre
Beckum, 23. February 2016

BEUMER Group - a leading global supplier of automated parcel and post handling systems – has been awarded a contract to design, manufacture and install the innovative Rota-Sorter at DPD Russia’s new central logistics centre in Domodedovo, Russia.

As an International Courier, Express and Parcel (CEP) service provider, DPD Russia is investing in the Rota-Sorter to provide the additional capacity needed to support a strong growth in demand from the Russian market. The Rota-Sorter was chosen for its ability to sort items across a wide range of shapes, sizes and weights on a single line and at high speed, as well as for its gentle handling of even fragile items.

DPD already uses a Rota-Sorter in its logistics centre at St. Petersburg where the system has delivered a 100% increase in productivity since it began operating in December 2014. This direct experience of the Rota-Sorter was the basis for DPD Russia’s decision to  install a Rota-Sorter in the new logistics centre at Domodedovo.

The Rota-Sorter sorts items ranging in size and weight from plastic bags and catalogues to packages up to 1,200 x 800 x 800 mm in size and weighing up to 31.5 kg. The sortation system at Domodedovo will integrate 15 discharge chutes, barcode scanners and a fully-automated volume measurement system. Despite sorting up to 3,500 items per hour the Rota-Sorter’s gentle handling will help to increase customer satisfaction by minimising damage to parcels, whilst its low-noise operation will also ensure a more ergonomic working environment.

The Rota-Sorter will be equipped with a Scada Supervisory Control And Data Acquisition (SCADA) system as well as BEUMER’s BeSS (BEUMER Sortation System) logistics software to ensure an error-free and efficient operation. A transparent interface to DPD’s host system will also ensure transparent operation across the different systems and controls. This will enable DPD to provide a fast, flexible and reliable supply to customers throughout Russia.

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