The international parcel and express service provider DPD has opened a new superhub in Hinckley in the southwest of Leicestershire, England. The purpose is to meet the increasing demand for its services and be prepared for future growth. The new distribution center is able to handle up to 720,000 parcels a day. To achieve this capacity, the company installed innovative sorting, distribution and conveyor equipment from the BEUMER Group over a length of three kilometers.
The new Hub 4 of the DPD Group UK just recently went into operation. BEUMER delivered and installed three BS 25 ET parcel sorters with a total length of 2,700 meters. It also installed two BS 7 BT sorters totaling 270 meters in length for small items, plus feed-in units with induction lines, end-point conveyors and two carousel systems for goods that cannot be put on conveyors. Cameras and scanners with downstream OCR and video coding reduce the number of no-reads on the sorters to a minimum. In order to optimally direct material flows, BEUMER equipped the system with the modular BG software suite. The BG Fusion user interface provides users with access to all available data without having to switch between different applications. The interface also includes a comprehensive statistics package.
Installation and commissioning took only 18 months. Thus DPD was able to connect the Superhub 4 to its national distribution network almost two months earlier than agreed in the contract. On its first day of operation the system sorted 92,000 packages and parcels. The number will go up to more than 500,000 per shift when the startup phase is completed, making the hub ready for the peak season at Christmas.
The new Hub 4 is 470 meters long and almost 40 meters wide. There are 264 loading ramps. The sorting equipment is designed so that packages leave the building three to seven minutes after entering it. Employees in the outgoing goods area load them manually onto trucks or semitrailers.
Dwain McDonald, CEO of DPD: “Everyone involved contributed to the success of this project. We have invested systematically in our network. The superhub will give us plenty of space to expand in the years ahead and respond to the growing need for our services.”
“We are glad to have helped DPD implement its expansion plans in the English market,” says Martin Mossinkoff, director with global responsibility for the BEUMER Group’s Logistics Systems Division. “We’ve worked very successfully with the DPD Group UK for ten years and are happy to have this close business relationship.” The BEUMER Group also delivered and installed sorting and distribution equipment for Hubs 2 and 3....
Calucem d.o.o., a member of Calucem Group and based in Pula, Croatia, is a manufacturer of calcium aluminate cements that are predominantly used in the refractory industry. The company is now replacing its previous packaging line with BEUMER filling, palletizing and packaging systems. This BEUMER solution will help simplify the process of moving material into the packaged units and is a more energy-efficient option. BEUMER provided an entire line from one single source. Instead of a turbine filling machine, which is typically used in the cement industry, a pneumatic filling system was used to allow for a quick material change without any loss.
Pula is located at the southernmost tip of Croatia. The town with its 57,000 inhabitants is known with tourists for its amphitheatre, the Temple of Augustus and the Arch of the Sergii, built between 29 and 27 BC. The climate is mild, the sea is blue and calm. Many of its inhabitants make their living from producing wine, fishing and shipbuilding. But there is something else produced in this city steeped in history, calcium aluminate cement. Calucem d.o.o. is one of the leading suppliers of this building material that is sometimes also referred to as high-alumina cement. "It is resistant to high temperatures, chemical substances and corrosion", explains Alfred Blažina, managing director of the cement plant. "Due to these properties, it is used in the refractory industry, foundries, kilns and combustion chambers as well as in the building industry." Calcium aluminate cements can be found in rapid repair mortars, ceramic adhesives and sealing material. This hydraulic binder is also particularly important for refractory concrete. It influences the rheology, the setting characteristic, the sifting properties and the chemical resistance. "We export our cement to more than 60 countries and are the world's number 2 supplier in this market", emphasises Alfred Blažina.
The required solution: compact, low in maintenance and energy-efficient
Calcium aluminates are produced when limestone or bauxite is burned in furnaces at temperatures above 1,500 degrees Celsius. "The chemical composition changes depending on the application", explains Alfred Blažina. There is a growing demand for more resistant high-performance products. HiPerCem is a new addition to the product portfolio, used for the formulation of highly sophisticated refractory concrete. "The very innovative concept is based on a high calcium content, combined with an optimised grain size distribution", explains the managing director. Additionally, there are products for conventional ramming mixes and casting compounds.
After manufacturing, these different mixtures are ground, filled into bags, then palletised, packaged in film and transported to customers and retailers. "Up until now, we had used systems that were high energy intensive and high in maintenance", says Alfred Blažina. Calucem employees were responsible for changing the filling system from one cement mixture to another, which was never a trouble-free process. Depending on its composition, the material can be more fine or coarse. After a mixture change, large amounts of dust were generated, meaning material was lost. In search of a new solution and a suitable business partner, Calucem quickly found the intralogistics expert BEUMER. "Our product has very specific properties", explains Alfred Blažina. "We needed a supplier who we could develop a solution with for our particular product."
From filling to packaging - everything from one single source
As a single-source provider for filling, palletising and packaging technologies, BEUMER Group supports its customers with sustainable solutions from a single source. "We installed the entire line ", says David Žargi, BEUMER representative for the Western Balkans and supervisor for the Pula cement plant. The specialists integrated the machines and systems using intelligent automation and linked them efficiently. Calucem needed compact systems that work efficiently, require little maintenance and can be operated intuitively and easily by the employees", says David Žargi.
Air instead of turbine filling machines
"The cement industry normally uses turbine filling machines", explains Stefan Bonenkamp, commissioning engineer at BEUMER. "They are particularly suited for free flowing products, such as cement." But in order to guarantee loss-free filling of varying compositions, BEUMER technicians installed a BEUMER fillpac filling machine with two spouts that operates according to the air filling principle. This particular material can be finer than regular Portland cement, but it can also be pulverised or gritty.
Air filling machines are especially used in the food industry. They use a blower to fluidise the material that is to be filled, e.g. flour or cacao powder. These products can then be filled into bags, gently and precisely, "without mechanical stress and at minimal air consumption", explains Stefan Bonenkamp. The product is filled according to the gross weight principle, i.e. the bags are weighed during the filling process. The BEUMER fillpac is therefore equipped with calibration-capable weighing equipment. This electronic weighing ensures exact filling degrees for the BEUMER fillpac. Special software supports permanent communication between the balance and the filling spout.
The product is then transferred through a rotary flap into the filling boiler. The ventilation of the boiler floor and of the upper part of the boiler can be regulated separately, which guarantees a continual product discharge. It creates a steady product flow with minimal compressed-air consumption. A special filling nozzle is equipped with a vent duct and an ejector that operates in cycles, extracting air from the bag during filling. After each filling process, the filling nozzle is cleaned by air pressure. This prevents the filled bag from being soiled. "The quantity of the conveying air can be adjusted separately, depending on the product", says Bonenkamp.
Space-saving, reliable and energy-efficient palletising solution
Calucem needed a compact and energy-saving solution for the fully automatic, efficient and above all, fast palletising of the bags. As a single-source supplier, BEUMER provided the fully automatic BEUMER robotpac, solving complex palletising and de-palletising challenges reliably and efficiently. It distinguishes itself through its remarkable precision and availability, as well as its gentle product handling. An ultrasound system ensures the precise measurement of the bags before they are palletised. This way, the position of the item can be exactly calculated and the bags can be placed precisely and gently. The precision guarantees an optimal stack configuration. This is not only representative of brand quality to the end customer; it also ensures that the stack remains stable during shipping and storage. The BEUMER robotpac palletises up to 600 bags per hour. Two gripping tools are used: a suction gripper, that places a paper sheet on the pallet, and a fork gripper, that palletises the bags in the exact position on the carrier. "The flexibility of the BEUMER robotpac allows the customer to implement even complex processes with varying frame parameters", explains David Žargi. In addition, the robotic palletiser is very robust which ensures a secure operation even under extreme conditions. "The drives work reliably, highly efficiently and quietly. Which was an important precondition for the cement manufacturer", remembers the BEUMER expert.
Compact, fast and practical packaging
Roller conveyors transport the palletised bags to the packaging system. "In order to keep the entire line compact and energy-efficient, we use the BEUMER stretch hood A at this point in the line, a new machine from our portfolio", says David Žargi. The high capacity packaging system from the stretch hood series was given a complete redesign. We analysed and optimised different components during the development phase." We made it easier and safer for the user to operate this system compared to others. In order to facilitate the work for the maintenance personnel and to ensure high system availability, the new packaging system no longer needs a platform. Maintenance work, such as changing the blades or the sealing bars, is now handled at floor level. The operator opens a drawer, providing free access to blades and sealing bars. Additional benefits include the compact design and the resulting low height and small footprint.
A new film transport system, that is particularly gentle on the material, introduces the previously formed film hood into the system. On its way to the crimping and stretching unit, the sealing seam on the film hood cools down so that it can be crimped without losing time. Energy-consuming cooling units and long cooling times become superfluous. The pallets are packed in a shorter cycle time, which increases the packaging capacity at a lower consumption rate. Economical engines and a lower demand in compressed air optimise the energy balance. "The palletised goods are clearly visible through the smooth surface of the transparent, highly flexible film. Film packaging protects the goods against the environment and humidity. It also substantially improves transport safety", describes David Žargi.
The intralogistics specialist has introduced the BEUMER Group Human Machine Interface (HMI). This newly-developed operator panel with an optimised user interface and graphical navigation for operating the systems offers an even more ergonomic workflow to the user. This easily understandable and intuitive interaction concept helps to define efficient working sequences. The soft-touch panel uses pictograms to guide the user through the machine control menus. The panel also gives the operator access to all required training programs and content. The systems are controlled by a Siemens SIMATIC S7-300.
Alfred Blažina's eyes follow the fork-lift truck that transports a pallet with packed bags to the goods issue area. "We have implemented this project hand in hand with BEUMER. The result is a packaging line that is customised to our specific requirements." The cement manufacturer was convinced of the excellent technical cooperation during the planning and development phase, as well as optimal adaptation of the systems. And because BEUMER provided everything from one single source, Calucem has only one contact for the entire system. This was also very important for Alfred Blažina. Because even these high-quality systems need maintenance and service. If necessary, BEUMER service personnel can visit the plant to check the system and perform any required adjustments....
CeMAT India (Dec. 9 to 11) is the international trade fair for material handling, intralogistics, storage and logistics, taking place once a year in New Delhi. The BEUMER Group will be exhibiting there, and, as a system provider, will be showcasing its innovative sorting and distribution installations.
The demand for sorting and distribution systems is growing in India, particularly in the CEP market. To meet this demand, BEUMER has machines in its portfolio that can be equipped with a variety of modules and functions. BEUMER, and the Danish company Crisplant a/s, another member of the BEUMER Group, are among the world’s leading suppliers of sorting and distribution systems. BEUMER will be showcasing its comprehensive expertise at its stand. This includes fully automatic sorting systems such as the Double-Density Tilt-Tray Sorter and the Crisplant LS-4000 High-Speed Loop Sorter. These machines are used throughout the world in postal and distribution centers. The equipment allows goods to be sorted quickly and carefully. The cross-belt and tilt-tray sorters generate high benefits for the user.
The BEUMER Group has also developed the OptiDrive, an efficient force-locking drive system for the high-performance sorter. It acts in both directions – in acceleration and in braking. In this way the pressing force of the drive wheel is automatically adjusted depending on the necessary drive force. This increases efficiency by up to 85 percent.
Visitors to the trade fair can learn all about BEUMER Customer Support. This includes effective customer care, flexible service agreements, custom modernization, efficient supplies of spare parts and comprehensive training for users – as well as a residential service. The Group is thus committed to its responsibility for smooth operation, on the ground and in the long term.
BEUMER at CeMAT India/WIN India 2015: Hall 14, Stand A09...
Up until recently, employees in logistics centres were required to complete physically demanding work when unloading packages, parcels and shipping units of various sizes from different containers or vessels. This was not only exhausting, but even lead to absence due to injury. With its BEUMER Parcel Picker, BEUMER Group has now brought an innovative solution to the market: This semi-automatic machine enables the efficient unloading of the bulk cargo with no physical effort, and it considerably increases throughput in the logistics centres of postal operators and CEP companies.
Online retailing has especially increased the pressure on postal and CEP companies. They are expected to deliver quickly and without any complications, and, at the same time, pay special attention to the employee's health and provide an ergonomic workplace. Increased throughput also means increased physical strain for the employees in the distribution centres, for example when manually moving heavy packages. Non-ergonomic work processes, such as heavy lifting and frequently bending down, can make tasks more difficult. In order to make work processes more efficient, for both operations and its employees, BEUMER Group has developed the BEUMER Parcel Picker, a semi-automatic device for unloading swap bodies and trailers, in a fast and ergonomic way. It has been developed so that this robust and compact device is very easy and safe to operate. Compared to manual unloading which is most commonly used today, operators can considerably increase their throughput: with an average parcel range and an operator that is familiar with the system, throughput rates of more than 2,500 packages per hour are possible.
A convenient workplace
The BEUMER Parcel Picker consists of a modified stationary telescopic belt conveyor and an unloading unit connected on the face side that is operated by the employee. The unit is pushed by the telescoping belt conveyor. The main component is the package manipulator. The operator uses it to pull the packages from the top onto the conveying technology. The package manipulator's design is particularly light and robust. A special attachment, mounted flexibly at the front end, supports proper package handling and prevents damages. The package manipulator is ergonomically designed and is suspended from its centre of gravity to make it neutral in weight, so that the operator does not have to carry it. The packages do not have to be lifted, which means almost no physical strain for the operator. At the same time, the operator's productivity is increased because the work is less exhausting. The suspension also has a motor-driven height adjustment, so it can be optimally adjusted to the height of the employee.
In order to avoid any risk for the employee during operation, BEUMER Group designed the operator platform in regards to ergonomic, functional and safety aspects. The person operating the system always has ample space between them and the packages. In addition, there are side walls attached to the telescoping belt conveyor which offer more protection against bulky items. The operator is supported by numerous automatic assistance systems. The layout of all control and display elements necessary for operation is clear and easy to reach for the operator.
Keeping everything in check
Via an easy to control operating unit at the operator panel, the employee enters the direction of movement into the system. The actual movement is triggered with a foot-operated button, which ensures safe operation. A camera, mounted to the unloading unit, turns on automatically when driving backwards. The employee can always see all activity on his display, even to their rear, and avoid any obstacles.
The employee moves the unloading unit exactly in front of the swap body or trailer. The integrated laser pointers allow for proper alignment and orientation. As soon as the front part of the BEUMER Parcel Picker is located in the swap body, the control switches into automatic operation. The system is positioned using its lateral distance sensors, until the vertical pick-up conveyors are in front of the first packages. With the package manipulator, the user takes individual package stacks and, with gentle movements, pulls them onto the conveyors of the pick-up unit. Here, they are collected and transferred to the telescopic belt conveyor in a bulk stream. 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.
The BEUMER Parcel Picker is very versatile. It is used as a semiautomatic device for unloading bulk goods from swap bodies. The BEUMER Parcel Picker can also be equipped with a module for automatic unloading of roller containers. In an emergency, this innovative system can also be used manually, i.e. like a traditional telescopic belt conveyor....
BEUMER Group - a leading global supplier of automated baggage handling systems – has developed TrayDeck as an effective solution to tilt-tray sorter stoppages caused by loose items or baggage straps falling from the tray and becoming trapped in the gap between trays. This is a common cause of sorter jams and stoppages which reduce the efficiency and throughput in airport baggage handling systems.
“With TrayDeck both capacity and energy consumption of the sorter remain unaffected whilst the risk of unplanned downtime is minimised,” explains Finn Laugesen, Director, Customer Support, BEUMER Group.
TrayDeck’s movable deck accurately follows the movement of the sorter to eliminate the gap between trays whilst allowing them to remain tilted as they enter a curve. When used in airport baggage handling systems, TrayDeck prevents loose baggage straps from becoming trapped under the tray.
TrayDeck can be used in new installations or as an upgrade to an existing system. Retrofitting TrayDeck onto a legacy tilt-tray sorter is a plug-and-play installation. The installation can be managed by Crisplant’s Customer Support team and carried out by the in-house technical or maintenance teams.
The use of TrayDeck as a retro-fit upgrade has been thoroughly tested in legacy Crisplant tilt-tray installations and is currently being installed on a number of sorters in the Middle East and Americas.
TrayDeck will feature on BEUMER Group Stand No 1050, Hall B5 at Inter Airport Europe, 6 to 9 October in Munich, Germany....
Crisplant – part of the BEUMER Group and a leading global supplier of automated baggage handling systems – has been awarded a contract by The Calgary Airport Authority, operator of Calgary International Airport (YYC), to install a second CrisBag® tote-based baggage sorting system with integrated Standard 3 screening.
Under the new contract, Crisplant will replace the conveyor-based baggage handling system in YYC’s existing terminal building with a CrisBag tote-based baggage sorting system with integrated Standard 3 screening. The contract also includes an extension to the existing system which will allow the CrisBag systems in the existing terminal and the airport’s new International Terminal to be linked, extending the 100% system-wide traceability for each item of baggage to both systems.
Crisplant was initially awarded a contract to install a CrisBag system in the new International Terminal as part of The Calgary Airport Authority’s International Facilities Project (IFP). Since that contract was awarded in 2011, Crisplant has worked extensively with the Authority on the design and installation of the system, which is among the first, and the largest of its type, in Canada.
“The new international terminal at Calgary International Airport will incorporate a number of innovative features to support passenger experience, operational efficiency and sustainability”, says Marco Mejia, Vice-President, Planning and Engineering, Calgary Airport Authority. “We have selected Crisplant’s CrisBag system again to support success on all measures across our full baggage-handling operation.”
The CrisBag system features a unique start/stop technology which allows sensor-controlled modules to power-on and power-off only when the totes are in operation. This, combined with a top speed of 10m/sec, makes CrisBag one of the fastest and most energy-efficient baggage-handling systems in the world.
In the final phase of the project, the CrisBag systems in the existing and international terminals will be linked via an inter-terminal baggage transfer connection. This will create a redundant system allowing both baggage handling systems to be controlled from a single control room. The combined systems will provide Calgary International Airport with optimised manning and back-up security, in addition to offering passengers the flexibility of checking-in at either terminal.
“System security and stability are our highest priorities," explains Klaus Schäfer, Managing Director, Crisplant. “Every detail of this project has been planned meticulously to allow both phases of the project to be completed with no disruption to the normal operation of the airport.”
The CrisBag system will provide an initial operational capacity of 8,000 bags per hour, inbound and outbound, when the new International Terminal at Calgary International Airport opens in Q4 2016. Planned expansion will further increase capacity to enable The Calgary Airport Authority to support anticipated passenger growth.
Work on replacing the conveyor-based baggage handling system in the existing terminal with a CrisBag system is scheduled to begin in Q4 2016 with completion and hand-over planned for 2018....
BEUMER Group - a leading global supplier of automated material handling systems - has developed TrayDeck as an effective solution to tilt-tray sorter stoppages caused by loose items falling from the tray and becoming trapped in the gap between trays. This is a common cause of sorter jams and stoppages which reduce the efficiency and throughput in parcel and post distribution centres.
“With TrayDeck both capacity and energy consumption of the sorter remain unaffected whilst the risk of unplanned downtime is minimised” explains Finn Laugesen, Director, Customer Support, BEUMER Group.
TrayDeck’s movable deck accurately follows the movement of the sorter to eliminate the gap between trays whilst allowing them to remain tilted as they enter a curve.
TrayDeck can be used in new installations or as an upgrade to an existing system. Retrofitting TrayDeck onto a legacy tilt-tray sorter is a plug-and-play installation which can be managed by Crisplant’s Customer Support team and carried out by the in-house technical or maintenance teams.
The use of TrayDeck as a retro-fit upgrade has been thoroughly tested in legacy Crisplant tilt-tray installations and is currently being installed on a number of sorters in the Middle East and the Americas....
BEUMER Group – a leading global supplier of automated material handling systems for conveying, loading, palletising, packaging, sortation and distribution – has been awarded a contract to supply a fully automatic parcel sortation system to DPD Ireland as part of the extension to its sortation hub facility in Athlone.
The hub currently operates two line sorters, both of which feed the same 40 chutes used to sort parcels to its network of 38 depots across Ireland. This facility is to be upgraded with a seven-bay building extension, doubling the size of the current premises.
As part of this project, BEUMER Group will install an energy-efficient Crisplant LS-4000CB cross-belt sorter comprising three induction units and four chutes in the extension. The new installation will link to the system in the original building, where it will service the existing 40 chutes. There will also be a fourth induction unit installed in the original building enabling the existing system to reach the four new chutes in the extension, and to take input from the rework area.
The system is designed to handle more than 8,000 items per hour using the four induction units, and when future handling requirements demand, it can be expanded to a capacity of 15,000 items per hour with a total of eight induction units.
The installation of the sortation system is scheduled for completion on 31 July 2016.
DPD’s Chief Executive Officer, Brendan O’ Neill, comments: “DPD is Ireland’s largest dedicated parcel carrier. Our parcel volumes continue to grow as a result of improved market conditions in Ireland and with the ongoing growth in e-commerce and online shopping, it was essential for us to expand the capacity and efficiency of our Athlone hub in order to maintain and improve the service levels to our customers. The hub’s location, right in the centre of Ireland, together with the new BEUMER sortation system, are the perfect combination.”...
BEUMER Group with Crisplant - a leading global supplier of automated baggage handling systems – will feature live demonstrations of two of its latest innovations in baggage handling efficiency: the CrisStore® rack-based storage system and the semi-automatic Baggage Unloader. The BEUMER Group stand will also feature new software controls for OCR/VCS and baggage handling system visualisation and management which have been added to its Airport Software Suite.
The space-efficient CrisStore® rack-based storage system is designed to enable airports of all sizes to improve the capacity, accuracy and security of Early Baggage Storage (EBS). It features 100% tracking and traceability of baggage in addition to dynamic allocation of luggage between different storage modules. These features enhance security and provide on-demand retrieval of an individual bag, or sorting of multiple bags for batch-loading onto ULDs. These capabilities enable a more flexible check-in process and increase the speed and accuracy of transferring baggage to the make-up area.
The second live demonstration will feature the Baggage Unloader, which is part of BEUMER Group's award-winning range of semi-automatic lifting aids. The Baggage Unloader enables a single operator to slide arrivals baggage from the trolley and onto the reclaims conveyor by using the Baggage Unloader’s extendable ramp. This simple system increases throughput to around 10 seconds per bag in addition to significantly reducing the risk of injury associated with manual handling of in-gauge baggage.
“The innovations introduced by these three products reflect Crisplant’s ‘Made Different’ approach to baggage handling,” explains Klaus Schäfer, Managing Director, Crisplant. “By using every opportunity to increase the efficiency, capacity and manageability of new or upgraded baggage handling systems, airports of all sizes can take cost and time out of the baggage handling process.”...
BEUMER Group is presenting itself at the CeMAT Russia (September 22 to 25 in Moscow) as a single-source provider for conveying and loading technology, palletising and packaging technology, and sortation and distribution systems, and will present information on its innovative solutions. The company is pursuing its objective of providing its customers with sustainable systems and machinery of consistently high quality standards for all needs, from one single source.
In the field of conveying and loading technology, the system supplier will present information on belt conveying systems with horizontal and vertical curves, belt bucket elevators, high-capacity belt bucket elevator type HD for particularly large delivery rates and heights, as well as apron conveyors for clinker, blending beds and circular stockpiles. In addition to supplying complete machines and controls for the plants, BEUMER is also often responsible for the entire end-to-end implementation process. This includes planning the project and designing the entire system, as well as coordinating and supervising the installation and commissioning.
BEUMER Group's strength lies in its ability to efficiently combine individual installations and systems with intelligent automation. The company also delivers everything from one single source, for filling, palletising and packaging technology. The BEUMER fillpac can be flexibly integrated with existing packaging lines. The filling system is equipped with calibration-capable weighing equipment. The weighing electronics ensure that the BEUMER fillpac always achieves precise degrees of filling. Special software supports permanent communication between the balance and the filling spout. Users can thus optimise their packaging lines because there is no longer a need to remove bags with an incorrect weight from the process. BEUMER Group has also developed a new highly efficient form fill seal system (FFS system) for chemical products. It forms a ready-made PE tubular film into a bag and fills it with the customer's technical plastic materials like PE, PP, PA or PS. Reliable, gentle and sustainable filling is also possible for salts, building materials, fertilisers and food products. Like the BEUMER fillpac, this system is also equipped with a weighing unit, which ensures the correct quantity of the material filled.
To be able to stack paper, PE and PP bags on pallets of different sizes in a flexible, precise, stable and even more efficient way, the intralogistics supplier offers the BEUMER paletpac high capacity layer palletiser, which has recently been completely revised for more efficiency. The user benefits from improved accessibility, shorter assembly period, higher flexibility and, as a result, lower costs. The palletiser can be equipped with a twin-belt turning device, so that bagged bulk material can be stacked on pallets in a gentle, fast and precise way. If required, BEUMER Customer support can simply upgrade the systems with this solution.
BEUMER also offers the BEUMER robotpac, a space-saving, fully automatic articulated robot, which is able to perform even complex palletising and depalletising tasks reliably and efficiently. A new machine from the BEUMER stretch hood model range will efficiently package the palletised stacks. The high capacity packaging system was given a complete redesign. Various components have been analysed and optimised by the BEUMER experts during its development.
In Russia, the demand for sortation and distribution systems is also rising, especially in the CEP market. E-commerce plays a significant role here. For this demand, BEUMER has systems in its portfolio that can be equipped with different modules and functions. In addition, BEUMER Group's OptiDrive offers an efficient force-locked drive technology for high-performance sorters. This works in both directions of action – when accelerating and braking. The contact pressure of the drive wheel is automatically set depending on the required driving power. This increases efficiency by 85 percent.
At the trade fair, visitors will also learn everything about BEUMER's customer support. It comprises intensive customer service, flexible service agreements, individual modernisations, efficient spare parts supply, extensive training for the users and a residential service.
BEUMER at the CeMAT Russia 2015: hall 3, booth A377
A consortium of automated baggage handling specialists, BEUMER Group and ALSTEF, has been awarded a contract by the owner and operator of Charles de Gaulle Airport, Aéroports de Paris (ADP), for a baggage handling system to handle check-in bags from the Airport's existing Terminal 2E to Satellite 3 (S3). This satellite provides additional airbridges for large-capacity airliners, including the Airbus A380.
The contract will provide an automated baggage handling system in Satellite 3, which previously used the systems in Terminals 2E and 2F to handle check-in and baggage handling.
The decision to award the contract to the BEUMER Group and Alstef consortium was the result of an analysis of competing tenders based on technical and financial criteria. A key factor in the decision was the robustness of the baggage handling system that will allow ADP to realise operational goals in line with the predicted growth figures.
Both BEUMER Group and ALSTEF share a long history of cooperation and partnership with the airport. BEUMER Group company, Crisplant, has supplied tilt-tray sorting systems to the airport since 1993 whilst ALSTEF’s partnership with Aéroports de Paris at CDG and Orly Airports began in 1997.
The consortium’s new baggage handling system will connect six existing check-in islands to a new Crisplant CrisBag® system, with a capacity of 3200 bags/hour, and to five integrated Standard 3 screening machines. ALSTEF will supply and install 500 metres of conveyors, 12 make-up laterals and 6 make-up carousels.
“From 2018, this new BHS will allow Air France and SkyTeam partners to improve sorting efficiency and reduce the delay for bags checked in at Terminal 2E. The additional equipment to collect and sort connecting baggage will be covered in a new call for tenders in 2016,” explains Nadine Vennat, at Aéroports de Paris.
The combination of high-level controls for the baggage handling system, with SAC and SCADA systems, and the low-level controls, will provide Charles de Gaulle Airport with comprehensive management of the entire baggage handling system process. The high-level controls will also feature a web-based user interface to enable remote control of the baggage handling system from a tablet device. In addition, the integration of RFID scanning of bag tags in the new baggage handling system will ensure that Aéroports de Paris remains at the forefront of airport technology. RFID baggage labels have been shown to minimise the number of mishandled bags and have been trialled by Aéroports de Paris since 2013 with the installation of RFID scanners by Air France and KLM.
“The new system will provide the tracking reliability and system availability needed by one of the world’s largest airports due to the inherent flexibility of the CrisBag system,” explains Klaus Schäfer, Managing Director of Crisplant a/s.
"ALSTEF conveyors have been approved and integrated in Paris CDG airport for many years,” adds Pierre Marol, President and CEO of ALSTEF. “A team of ALSTEF employees has also been working on-site since 2004, which has provided insights into the operational requirements of this major European hub.”
The new system is scheduled to begin operation in the summer of 2018. The Airport’s trust in both consortium partners is reflected in a 40-month maintenance contract under which BEUMER Group and ALSTEF will continue to maintain and optimise the system so that CDG Airport can maintain peak operating efficiency....
Within the framework of its wide reaching Customer Support business, BEUMER Group provides Residential Service. It enables logistics service providers to delegate the responsibility of availability, performance and profitability of filling, palletising and packaging installations to BEUMER specialists. The single-source provider has extensive experience and knowledge of technical and logistics matters in the chemical industry, helping ensure the high efficiency of their machines. In order to provide trouble-free operation, BEUMER employees come to customer sites world-wide, even long-term, if required.
Chemical products are at the beginning of the logistics value chain of many products, in very different sectors. A monitored, error-free and, most of all, appropriate handling of chemical products is therefore extremely important. These products need to be reliably filled and palletised, as well as securely packed in order to be delivered damage-free to the processor. Logistics service providers are now more frequently handing over these tasks to manufacturers, who have to meet very high standards. The materials can have very different characteristics: very high product temperatures, for example, or special flow characteristics leading to a low dimensional stability of the bags. Kornelius Thimm, head of Customer Support for BEUMER Group in Beckum, Germany, and very familiar with this industry, explains: "These products have to be handled safely and gently throughout the entire process chain. Plus: the throughput rates of the installations and systems are continually increasing." 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". BEUMER Group offers comprehensive service in order to make sure that its filling, palletising and packaging systems are always perfectly adapted to their tasks and that all processes run smoothly: about 1,000 Customer Support employees currently back the service providers world-wide.
Thimm explains that Customer Support is a separate department, independent of the BEUMER Group's conveying and loading technology, palletising and packaging technology and sortation and distribution systems. He says: "It's basically a company within the company. We have our own Sales Department and develop our own projects." The goal is to support users for even better results and to respond to their rising requirements. This includes training programmes, which are tailor-made for the customer and their systems, as well as qualified Customer Support technicians who offer around-the-clock telephone support every day of the year, worldwide, and help reduce downtime to a minimum. In case of malfunction, the hotline offers around-the-clock competent telephone support (24/7/365).
Residential Service: We assume responsibility
BEUMER Customer Support offers customised service agreements. "In principle, those agreements are specially designed to meet the individual requirements of our customers", explains Thimm. "The service schedules as well as the response times are agreed upon in the contract." The agreements include, for example, the supply of spare parts, preventive as well as routine maintenance, and the operation of the systems. The head of Customer Support identifies a pronounced trend: More and more manufacturers, especially logistics service providers, wish to concentrate on their own core business and to delegate the responsibility for their systems and machines. Kornelius Thimm promises: "With our Residential Service the user can receive filling, palletising and packaging solutions from one source, at any time. BEUMER employees take on the responsibility for operating times, performance and economic efficiency of the systems. If required, we will appoint a team of specialists which will ensure proper machine operation and availability on site."
BEUMER 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. BEUMER is a global company and capable of meeting this challenge.
Within the scope of the Residential Service, BEUMER employees provide service providers with a steady and sustained improvement of their processes and results. Mr. Thimm explains: "We rely for example on the Six Sigma systematic approach. This statistical method is based on the DMAIC, a process which is clearly structured in define, measure, analyse, improve, and control phases. In the "D" phase, the team defines the examined processes on the basis of data and facts. In the "M" phase, the process performance is measured before being analysed it in the "A" phase. The problems that appeared at the analysis stage will be thoroughly examined and solved during the "I" phase. The "C" phase is the last one. BEUMER employees use it for supervision and control purposes. Thimm says: "This method enables us to improve the quality of our customers' processes. It makes it possible for them to reduce their costs."
A view to tomorrow
BEUMER employees continue to carry out preventive maintenance. Thimm explains: "This way, we can avoid uncontrolled machine breakdowns, which can be very expensive." Maintenance and inspection are executed at regular intervals. This includes preventive maintenance and other measures such as applying a protective coating or installing warning devices. The BEUMER team constantly manages and reviews the quantity and availability of the spare parts on site and, if necessary, adapts accordingly. The activities of the BEUMER team include Facility Management as well. Kornelius Thimm adds: "We develop and realize concepts which enable a long-term and trouble-free operation of the buildings. Our employees check the technical installations and maintain them regularly, at agreed intervals."
Thimm says: "We do not only take care of companies that use our systems." All companies with intralogistics equipment can use the BEUMER customer support and residential service. "Our goal is to continue to improve trouble-free material flow in order to guarantee value-added processes", explains Thimm. "We assume the complete responsibility and ensure this way that the service providers remain competitive in the long run."...
The utility company Linz AG relies on a BEUMER Group Pipe Conveyor to transport household and industrial waste as well as sewage sludge from the treatment plant to its power station. This conveyor is not only highly energy efficient, but due to its closed design, it is also possible to convey waste products through public spaces without affecting the environment. The result is: no material loss, no unpleasant smell, and most importantly no pollution to the environment. The Pipe Conveyor can also be optimally adapted to the routing due to its ability to navigate curves.
Linz AG's waste incineration power plant has been in operation since 2011. It is located in the industrial area of the port of Linz, next to the already existing biomass power plant and the district heating plant on the banks of the Danube. In this plant, the company generates district heat and electrical energy for its networks. The utility company manages the entire waste removal process – from collecting to eco-friendly recycling. "We can guarantee much higher supply security in our district heating network as well as adequate waste disposal", explains Erich Ehrentraut, engineer and Head of Waste Management at Linz Service GmbH.
Generating energy from waste and residual material incineration is particularly efficient. The produced heat can be used to generate energy or for steam turbine processes. Trucks, ships and trains transport about 150,000 tons of household, commercial and industrial waste to the residual material processing plant located on a neighbouring property of the Linz tanker port. Additionally, approximately 50,000 tons of dehydrated sewage sludge are processed in the wastewater treatment plant in the municipality of Asten located 13 km away. The sludge as well as the screenings are transported directly from the Asten plant to the power plant.
The highly efficient residual material processing plant sorts and shreds the waste, separating ferrous and non-ferrous metals and impurities. Finally, particles of 80 millimetres are transported into the fuel bunker with a capacity of 3,000 tons.
Safe transport with the Pipe Conveyor
"The residual material processing plant and the heat and power plant are located several hundred metres away from each other", describes Erich Ehrentraut. To complicate matters further, a public street is crossing the route. "We had to guarantee absolutely safe material transport", he says. No waste, not even the smallest amount, can fall on the ground. Additionally, the odour of the waste could not be a nuisance to the people living in the area. The people in charge of the project at Linz AG evaluated several different solutions for the bulk material transport. They then opted for the BEUMER Group Pipe Conveyor. "The particularly efficient system convinced us", Erich Ehrentraut reports.
Comprehensive expertise, optimum support
BEUMER Group is a globally active system supplier for innovative intralogistic solutions. The group has bundled its comprehensive expertise spanning various industries and established different Centers of Competence in order to offer optimal global support of their single-source solutions. The "Pipe Conveyor" segment is one such Center of Competence. These centers are in charge of worldwide project management and sales. They collect and process the expertise from the individual local group companies and pass it on to the global group experts in each respective field.
"Together with the people in charge of the project, BEUMER developed an ideal solution tailored to the customer's requirements", says Josef Staribacher, Managing Director at BEUMER Group Austria. Pipe Conveyors not only protect the environment from falling items during transport due to their closed design, they are also able to navigate long distances and tight curve radii. Due to this characteristic, considerably less transfer towers are required compared to other belt conveyors. This allows for substantial cost savings for the customer and BEUMER can easily customise the system to the individual routing.
BEUMER supplied and installed a Pipe Conveyor with a centre distance of 475 metres. It conveys up to 40 tons of material per hour. The system is running around the clock, seven days a week. Due to the system design and the required system capacity, the Pipe Conveyor has been designed with a diameter of 300 millimetres. The difference in height between the feeding and discharging point is 24 metres.
Durable and quiet
The conveyor belts that we use are very durable and were specially manufactured for the Pipe Conveyor. Based on many years of experience, BEUMER has developed proprietary calculation programs that help to dimension all relevant parameters such as curve radii, conveying capacity and all other customer requirements. Another advantage of the BEUMER solution is the reduced noise emission that the system provides. This is achieved by using special idlers, low-noise bearings, and the correct conveying speed. "This improves the quality of our employees' day-to-day work environment and ensures the people living near the conveyor line are not disturbed by the noise", says Erich Ehrentraut.
High level of system availability guaranteed
The system has been in operation for four years now and Linz AG is very satisfied with the results and benefits of the BEUMER solution. The utility company is also impressed by the high level of system availability, ensured by BEUMER customer support. "High-quality systems reduce machine malfunctions and breakdown and therefore minimise long downtimes", says Josef Staribacher. "This helps Linz AG to provide guaranteed energy supply, because it allows for continuous firing." But even high-quality systems require maintenance and service. If necessary, BEUMER service personnel come to Linz AG to check the system and perform the required adjustments....
Inter Cars SA, based in Warsaw, Poland, has commissioned the BEUMER Group to equip its new distribution center with conveying and sorting equipment, including a warehouse control system. BEUMER will serve as a systems integrator for the project. Inter Cars is establishing a new intralogistics system in order to meet the growing needs of its customers. The online supplier wants to deliver spare parts for cars even faster than before. The distribution center is scheduled for completion in June 2016.
Following a joint planning phase that ran for more than a year, Inter Cars has commissioned BEUMER to fit out its new main distribution center just outside of Warsaw with a complete conveying, order-picking and sorting system. The system will control all the functions, from goods reception to quality assurance, picking of goods, consignment and shipping. These areas will be connected by a conveyor system that is more than five kilometers long. One outstanding piece of equipment is the BEUMER BS7 Belt Tray Sorter with 361 end points designed for gentle handling of spare parts for cars. After being consolidated for customers, the orders will be distributed to 51 destinations by a sliding shoe sorter in the outgoing goods area. BEUMER will also supply a PLC-based machine control unit and a material flow computer for the whole distribution center. The system receives orders from the warehouse management system, which the customer ordered separately. “Order-picking, packaging and shipping can thus be coordinated, and the user can optimize the throughput, cutting costs,” explains Martin Mossinkoff, globally responsible director of Logistics Systems in the BEUMER Group. “Inter Cars will get the entire system from one source. In this way it will avoid interfaces and will have us as a contact for everything.” Employees from the Polish subsidiary of the BEUMER Group will help set up the system and put it into operation, because for the next five years they will be responsible for maintenance and servicing as part of the Residential Service agreement....
The BEUMER Group, intralogistics specialist and complete provider of filling, palletising and packaging systems, unveiled its refinement of the proven high-capacity packaging system at the "interpack 2014" trade fair in the form of the new BEUMER stretch hood A. Since then the intralogistics provider has received excellent customer feedback regarding the packaging system. The specialists optimised the new BEUMER stretch hood A in respect to function, economy and ergonomics. The easy, intuitive and reliable operation was especially appealing to customers.
"Our new BEUMER stretch hood A makes things really easy for the operator", is how Volker Feldmeyer, Business Development Manager in the BEUMER Group, enthusiastically sums up the product. For him, this is one of the main factors behind the positive feedback since the market launch. The systems went to customers in highly diverse markets. These include the cement, construction and chemicals industry, as well as the consumer goods market and logistics sector. "After closely scrutinising the needs of customers in the market together with Sales, our developers came to the question: How can we develop a packaging system that meets user expectations, while working at the highest level and excelling against the competitor products", explains Feldmeyer. "To this end, we brought not only customers but also packaging and pallet manufacturers on board". The aim for BEUMER involved developing a packaging system that is even more user friendly. That means a specially developed BEUMER Group Human Machine Interface (HMI), a touch panel with optimised user interface and graphic navigation, is used. Video sequences show operators how easily the machine can be handled. This easily understandable and intuitive interaction concept helps them to define much more efficient workflows at the machine.
The BEUMER stretch hood A removes the need for a platform or steps. Any maintenance work that is required can be done from the ground without entering the machine, thereby improving safety and making work easier. And because sustainability is becoming an increasingly important factor for companies - especially due to rising energy and raw material costs - BEUMER has opted for low electricity and compressed air use in the technology's application. "That ensures an effective energy balance", explains Feldmeyer.
BEUMER can cover all performance requirements with the newly developed high-capacity packaging system – users gain a packaging solution tailored to their profile in line with specific needs. The latest development is a high-speed version that can continuously package up to 200 pallets an hour in the transport flow, a major advantage in comparison to many rival systems, which can only achieve this performance when the load units are stationary. Even the packaging of products with varying dimensions does not pose any problem for the new machine: Two film formats arranged over one another serve for packaging different pallet sizes. The new generation BEUMER stretch hood A supersedes all previous construction series with its modular design....
As a single-source provider of filling, palletising and packaging systems, BEUMER Group has recently introduced an innovative form fill seal system (FFS system) to the market. The needs of customers in the chemical industry may vary greatly; bulk density, flow characteristics and grain distribution of chemical products require flexibility in bagging and packaging until they reach the final customer. With the new FFS system, BEUMER emphasises a sustainable mode of operation. High throughput, availability and a compact design are key features of the new system. Reproducible weight accuracy of the bags is ensured. Furthermore, operators can handle the highly energy-efficient system ergonomically.
Chemical and petrochemical products are partly characterised by high product temperatures, may be dimensionally unstable and have special flow characteristics. If these materials are filled into bags, their handling can be extremely difficult. As a partner of chemical companies, BEUMER has extended its range of products with the BEUMER sealpac. This FFS system forms a bag from a prefabricated tubular PE film and fills it with technical plastic materials like PE, PP, PA or PS. Salts, building materials, fertilisers or food products can also be filled into bags reliably, gently and sustainably. This system is equipped with a weighing unit which, on the one hand, ensures that the quantity of material filled is not too high as this would result in high costs for the manufacturer. On the other hand, the bags must not contain too little material since the specified quantity has to correspond to the actual contents. Thus operators always obtain exact filling weights with the new FFS system. Then the system seals the bags with a weight of up to 25 kg. This way users can handle up to 2,600 bags per hour.
Less wear and tear, more clarity
In typical systems available in the market, the bags oscillate from one working post to the next one. The resulting vibrations are transferred to the systems and may lead to wear and tear even after a short period of time. BEUMER guides the bags in a straight movement to the individual working stations. The machine runs much more smoothly and there are nearly no vibrations.
In the BEUMER sealpac the individual working posts for forming, filling and closing are of modular design. This division makes work easier for the service personnel since they can check each unit separately and replace it as required. A unique feature of the BEUMER sealpac is its symmetrical structure, which enables the operator to freely decide from which side the system is operated. Moreover, the extremely compact design of the BEUMER sealpac allows a space-saving and flexible installation.
For this system, BEUMER relies on proven components, which have been consistently enhanced. All components are freely available on the market. This reduces both the capital cost for operators and the delivery periods for spare parts. Thanks to various options like print mark control, automatic exchange of film rolls, detached film releasing unit, free or rail-based manoeuvrability and the possibility of processing pre-stretched film, the system can be adapted individually to customer requirements.
Saving costs across the board
In the chemical industry, systems are often running 24 hours a day, 7 days a week. Any standstill may result in considerable costs. Therefore, BEUMER sets great store by high availability. The sealpac has a robust design, which extends maintenance intervals. Its modular structure enables an easy cleaning. Operators can quickly retrofit the system. Like all BEUMER machines and systems, the sealpac is characterised by its energy-efficient, environmentally friendly and safe mode of operation. The construction series is equipped with an ergonomic control terminal (HMI– Human Machine Interface) including an optimised user interface and navigation. This enables the personnel to operate the system quickly and easily. Users at the system are provided with an easily understandable and intuitive interaction concept, enabling them to define efficient working sequences.
This new system rounds off the product portfolio of the intralogistics supplier along the customers' logistics value chain. Thus, users only have one contact for the entire system, from project planning and project management up to service....
BEUMER Group, a leading global supplier of automated material handling systems, has finished the handover of a complete material handling and sortation system for a new logistics center in Shanghai for JD.com, China's largest e-tailer.
JD.com's industry-leading self-operated logistics network has been central to the company's growth, by enabling timely and reliable fulfillment for customers. Given the underdevelopment of third-party fulfillment services in China in terms of warehousing and logistics facilities, and last-mile delivery services, JD.com made a strategic decision in 2007 to build and operate its own nationwide fulfillment infrastructure. JD.com launched operations for the initial phase of its first highly automated "Asia No.1" warehouse, located in Shanghai in 2014.
The new sortation system comprises seven conveyor lines, which are suspended from the ceiling to free as much floor space as possible in the 100,000m² warehouse. Cartons and plastic bags arrive at warehouse levels 1 and 2, from where they are automatically inducted to the 254m long Crisplant LS-4000CB cross-belt sorter, with destination sorting to 131 chutes. The complete material handling system has a sortation capacity of 13,521 items per hour.
As the largest online direct sales company in China, JD.com accounted for more than 56% of the country's direct B2C e-commerce market in Q1 of 2015. The company fulfilled a total of more than 689 million orders in 2014 from its warehouses to satisfy demand from its over 105 million active customers....
Cement, mortar or gypsum - the bulk density, flow characteristics and grain distribution of these products, which are filled in bags and packed for delivery to the customer, may vary significantly. BEUMER Group, a single-source provider of filling, palletising and packaging systems offers the BEUMER fillpac®, which can be flexibly integrated and adapted with existing packaging lines by the user. Depending on project requirements, BEUMER Group offers varying designs. Specific weighing electronics are utilised to ensure weight accuracy of the bags. Operators can nearly eliminate rejects caused by too high or too low filling weights.
Building materials have their own specific characteristics, such as high product temperatures or different volumes and weights - they may show an unusual flow behaviour and may be dimensionally unstable. As a partner to this industry, BEUMER Group successfully enable material manufacturers to fill bags without any product loss with the BEUMER fillpac®, an efficient filling machine. The systems of this construction series fill reliably, carefully and sustainably while meeting the required throughput.
The BEUMER fillpac® is equipped with a weighing unit, which communicates permanently with the filler neck via a dedicated software. The automatic bag weight control determines the exact filling weight while filling. This way the system always achieves accurate degrees of filling. Thus the packaging line works more efficiently as it is no longer necessary to remove under or overweight bags from the material flow. In addition, the quantity indicated on the bag always corresponds to the real volume.
Air filling machines for pourable and coarse-grained products
Depending on the requirements and on the material characteristics such as bulk density, flow behaviour or grain distribution, BEUMER Group can offer both air and turbine filling machines from the construction series. The air filling machines are suitable for bagging pourable and coarse-grained products with particle sizes up to ten millimetres. The systems use a blower to fluidise the materials in a pressure chamber. The products can then be filled into bags gently and precisely. Depending on the throughput, the user may opt for a rotary or an inline filling machine. The air rotary filling machines have four to twelve filling modules which are arranged in a circular pattern. Depending on the number of filling spouts, the systems reach a maximum capacity of 1,200 to 3,600 bags per hour for 25-kilo bags.
The air inline filling machines are generally equipped with one to four filling modules. Depending on the number of filling spouts positioned next to each other, the system achieves a capacity reaching between 300 and 1,200 25-kg-bags per hour. Regardless of whether the system is arranged in a circular pattern or in a line, capacity and utilisation can be improved by installing an optional automatic bag placer. The filling process is carried out either automatically or at the push of a button. Two configurations are available for removing the bag at the end of the filling process: either manually or automatically with vertical bag discharge on a belt conveyor.
Turbine filling machine for free flowing and fine-grain products
The turbine process is the appropriate solution for companies which predominantly fill free flowing and fine-grained materials, such as cement or gypsum. The turbine filling machines use motor-driven impellers. They can be arranged either horizontally or vertically, ensuring a particularly high filling pressure and thus a very good compaction of the fine-grained materials to be bagged. The result is filled bags which are compact and dimensionally stable so that the user is no longer required to vent them.
With up to 20 filling modules, the BEUMER fillpac® R for example can fill up to 300 tons of fine-grain materials per hour into diverse bag types. The HDPE bag placer, an exclusive offering of BEUMER Group, enables dependable filling of HDPE bags. The filling impeller is characterised by its speed and the maximum material throughput. The bag weight adjustment, which automatically adjusts the weight of the next bag, always ensures precise results. Opening and closing of the vertically mounted filling spout is carried out outside of the dirty area - this way the three-position cylinder which regulates the coarse and fine flow is protected from dust. The cylinder for bag discharging is also located in the dust-free zone above the filling spout. This solution minimises wear and tear on both cylinders and, therefore, ensures longer service life.
BEUMER Group also offers the turbine filling machines with inline design. The filling modules are placed next to each other for ready access, which makes them extremely easy to maintain. The inline filling machines are best suited for production environments with low throughput rates.
The BEUMER construction series is equipped with an ergonomic control terminal. The improved Human Machine Interface concept allows operators to work in a simple and intuitive way. Almost all built-in components of the BEUMER fillpac® are freely available commercially. This reduces delivery times for spare parts and lowers capital costs for the user. Furthermore, the intralogistics supplier has designed the system in a way that individual customer requirements or special operational requests can be implemented flexibly and cost-effectively....
BEUMER Group - a leading global supplier of automated parcel and post sorting systems - will showcase innovative automated sorting technologies at PARCEL-EXPO Asia Pacific 2015. These technologies will include products which have already been installed by BEUMER Group China and Crisplant Singapore to help major companies within the Asia Pacific region to achieve leading-edge speed, capacity and energy-efficiency from the sorting process.
The BEUMER Group will also present papers at PARCEL-EXPO Asia Pacific's two-day conference on business development, productivity and innovation in the Asia-Pacific region:
- 'How automated identification can boost tracking capabilities' Wednesday 13 May, 'Innovation & Trends' moderated by Derek Osborn, CEO, Whatnext4U.
- 'Automating the parcel distribution centre in a world of e-commerce' Thursday 14 May, 'Parcel Hub Development and Logistics' session.
"The sorting technologies being presented at this exhibition combine two of the leading names in automated sorting technologies, BEUMER and Crisplant. The innovations introduced by these BEUMER Group companies are already being used to achieve unprecedented capacity and energy efficiency to companies throughout the Asia Pacific region. These companies include the Singapore post office, SingPost; express parcel courier, SF Express; and two of China's leading online retailers, JD.com and VIPshop," explains Martin Mossinkoff, Managing Director, Logistic Systems, BEUMER Group.
BEUMER Group companies, BEUMER Group China and Crisplant Singapore, will be on Stand No. 4025 at the second PARCEL-EXPO Asia Pacific which will be held in Singapore on 13 - 14 May 2015....
For many companies in the chemical, building material or food industries, the efficient packaging of their palletised goods is a deciding competitive factor. Some of the crucial factors are transport security, anti-theft protection, display characteristics of the packaged goods, as well as weatherproofing for outside storage. Further key factors are process efficiency and cost reduction (energy and material consumption), as well as the system output (the number of pallets that can be packaged during a specific amount of time). All of these factors need to be taken into account in order to determine the perfect packaging technology. Stretch hooding has proven to be particularly efficient in comparison with other techniques.
Palletising and packaging play a particularly important role, in any industry, for delivering your goods in optimum condition to your customers. If the required stability is not provided, goods such as glass, stone or bricks stacked on trucks can detach from the palletised unit and break. This can cause tremendous costs, depending on the product. Materials such as cement, flour or cocoa powder need special protection against atmospheric influences and humidity during transport and storage. To accommodate this, there are different packaging solutions available to the customer. It is important to find the most economical and environmentally sustainable solution. There are currently three different palletising packaging techniques on the market: shrink hooding, stretch wrapping and stretch hooding.
Efficient packaging with shrink film
Film packaging for pallets was developed by a German chemical producer in the mid-1960s, based on using shrink film. The film is produced as a tube using blow head extruders with tubular dies, which are then further processed or slit open to become a flat film. Hot air heats the film during the shrinking process up to the softening point. The film is shrunk to fit perfectly around the palletised goods, which, after cooling down, creates the necessary stability to secure the load. The heat required for the shrinking process is produced by the packaging system either electrically or with gas. If required, the pallet can be packaged leaving its base open for the skids of the fork-lift. This allows high-bay storage. It is also possible to draw the film over the pallet base. The shrinking method is particularly suited for products that are sensitive to elastic packaging stacking, such as glass. The goods are reliably protected against environmental impacts such as snow, rain, UV radiation, dust and insects. However, the shrinking process causes the film to become milky, which makes it difficult to see the packaged goods or imprinted barcodes. Additional disadvantages: polyethylene (PE) bags might weld to the packaging film and the heat effect can be a fire hazard.
Or opt for wrapping instead?
A decade passed before a US-based crude oil refiner and chemical resins supplier discovered the ingredients for a stretchable film, and the stretch wrapping technique was born. This packaging technique is still one of the most popular solutions with many companies, due to the low initial investment costs for the machines compared to shrink or stretch hood systems. The consumption of stretch wrapping film in Europe alone is estimated to be 1.4 million metric tons per year. This technique, however, requires a lot of material which means that the operator has to change the film roll frequently. This makes the technique suitable for low production rates.
The stretch wrapping film's elasticity allows solidifying the palletised goods during packaging. This technique, however, only provides little vertical tension force to the load, which is needed to provide stability for the transportation loads. This technique is not suited for materials with sharp edges, such as stones or bricks. Another disadvantage: additional plastic film is required to protect the goods against environmental impacts and humidity. The film overlay prevents an optimal display of the products and barcodes on the film cannot be read easily. And because the film is wrapped, you cannot print on it. Additionally, the film attracts dirt particles due to its adhesion properties and the products collect dust during longer storage periods. The film also does not offer any protection against theft, as unauthorised persons can remove goods from the pallet without ripping the film. Another problem: projecting film remnants, typical with this packaging technique, can disturb the sensor system of the conveying technology or the rack feeders. This causes repeated error messages. Due to the many setting parameters, the quantity of the film required for the packaging cannot be calculated exactly.
High transport security with stretch hoods
The stretch hood technology is a combination of the film hood and stretch wrapping techniques. BEUMER installed the first stretch hood system in Belgium in 1988. But the largest breakthrough for this pallet packaging technique only came about 15 years ago. The availability of improved raw materials allowed the quality of the film to be considerably increased. Like shrink hooding, the stretch film adapts to any product that is stacked on the pallet. And similar to wrapping, the film is very elastic and therefore solidifies the material via contracting forces. This technique guarantees high load stability. The packaging film does not get glued to the product during the process. It is possible to pack the pallet both for high-bay storage systems and with understretch. The smooth film surface ensures high visibility of the packaged goods, and therefore provides an excellent display of the packed goods at the Point of Sale because barcode labelling is quickly and consistently recognisable. The used film is recyclable. Stretch hooding does not use heat, which reduces the fire hazard considerably, increases operational reliability and therefore minimises insurance rates. Less film and energy are required, which means less damage to the environment. In the majority of industrial and consumer product applications, stretch hooding offers the best possible protection for palletised goods. A sheet placed on the pallet offers additional protection on six sides against external influences with this packaging solution. It allows for a clean and dry outdoor storage, as goods are reliably protected against environmental impacts, humidity, insects and UV rays.
Packaging solutions compared
The BEUMER portfolio includes innovative solutions and systems for all these packaging techniques. But in order to stay competitive in the long run, companies should not only consider the total cost of ownership when making investment decisions. A comprehensive approach is necessary to determine the perfect packaging method. By considering the total value of ownership (TVO), the efficiency of the operating investments can be specified more comprehensively and in more detail. This is why BEUMER Group considers economical, ecological and social aspects when developing their plants and systems. This allows our customers to plan their investments strategically.
Double your throughput with stretch hooding
Besides load securing, another important factor for most companies when choosing the perfect packaging method, is the protection against environmental impacts. This is why the BEUMER experts compared shrink hooding to stretch hooding and found a clear cost advantage for the stretch method. They took a palletised stack of 1,630 millilitres in height for test purposes. Systems that use shrink hooding to package palletised items can process 35 to 70 pallets per hour. With this process, the film strength lies between 120 and 180 micrometres. By using the stretch hooding method, throughput is nearly doubled with 100 to 120 pallets per hour. The film that is used is also thinner, only 70 and 140 micrometres. Less material is required due to the elasticity of the film.
In 2014, the market price for shrink film was at 1.70 EUR per kilogram. The packaging costs for a film hood were approx. 1.02 EUR. The film costs for 300,000 pallets per year were approx. 306,000 EUR. The film used for stretch hooding is currently slightly more expensive with 1.90 EUR per kilogram. To form a film hood, however, you only require materials totalling 57 cents. This leads to a remarkable cost difference of approx. 159,000 EUR for the same amount of pallets per year. The customer can achieve cost savings of approx. 52 percent.
The systems also differ in regards to their energy demands. The gas consumption for shrink hooding is at approx. two kilowatt hours per pallet. The energy required to form a stretch hood costs six cents. For the calculated 300,000 pallets per year, the total cost is 18,000 EUR. Due to the fact that the stretch hood system works without gas and the costs for energy consumption are almost identical for both techniques, the user can save those costs by implementing the stretch hood method.
The maintenance costs for shrink hooding can vary, especially for older machines, between 2,000 and 8,000 EUR per year. We used 4,000 EUR as the basis for our calculation. The calculated average costs for the stretch hooding method are between 1,000 and 3,000 EUR per year. Assuming an average value of 2,000 EUR, the user saves 2,000 EUR per year in maintenance costs. This means significantly lower costs per year when using the stretch hooding technique.
The BEUMER stretch hood® A is the result of the intralogistics specialist from Beckum redesigning its tried-and-trusted packaging system from scratch. During its development, our specialists analysed various components and optimised them in terms of function, arrangement and ergonomics. This includes an intuitive menu system on the machine control via a soft-touch panel, an optimised, ergonomically designed workplace for the operator and material-friendly transporting of the film in the machine thanks to an innovative film transport system. The new system also features improved system performance and requires far less floor space.
Each product has its own handling characteristics, which require a careful analysis by the user. This analysis is necessary to determine the pallet packaging requirements. BEUMER provides the operator with an online configurator to calculate and evaluate the economic efficiency of different packaging techniques, as well as the added value for their company. In addition, BEUMER experts will create a presentation that is individually tailored to the customer's requirements. The customer gets a reliable comparison between the different packaging methods, the individual energy consumption, as well as the maintenance, investment and system costs....