Flexible, efficient and extremely versatile
Beckum, 10. February 2016

BEUMER Group's new Rota-Sorter is a cost-efficient sortation system for various items

BEUMER Group has added the Rota-Sorter to its portfolio, a flexible and efficient sortation system that can handle different types of items such as bags, polypacks or packages. The robust machine is very fast and uses a special discharge technology ensuring the gentle handling of items.

The Rota-Sorter helps users transport light, flat items of 120 x 60 x 5 millimetres up to 1,200 x 800 x 800 millimetres and up to 31.5 kilograms on one line. The system is capable of processing up to 5,000 items per hour. The sinusoidal velocity curve of the discharge mechanism ensures gentle handling of the items, even at high throughput rates, thus considerably reducing damage rates. Its quiet operation is another strong advantage of the system.

The Rota-Sorter's simple structure provides functional reliability. The system consists of only a handful moving parts for example. The discharge system requires no complicated electronics and only few sensors to ensure accurate sortation. The discharge system's robust design and easy accessibility for service technicians helps increase system availability and reduces maintenance costs.

The modular system allows companies to remain very flexible: for example, the discharge systems can be mounted anywhere on the outside of the sorter, can be changeed its positioning afterwards and additional discharge systems can be added. Discharge can be realised on one or on both sides. Instead of operating the system as a single sorter, the capacity can be increased to 15,000 items per hour by operating it independently as a double or triple sorter. Depending on the application, BEUMER Group supplies feeding and discharging lines, scanners, weight and volume measuring, accumulation chutes and conveyors, container tipping devices and comprehensive conveying technology.

Crisplant publishes Whitepaper on IATA Resolution 753
Aarhus, 09. February 2016

Crisplant, - part of the BEUMER Group and a leading global supplier of automated baggage handling systems - has published a Whitepaper which outlines the implications of the International Air Transport Association (IATA) Resolution 753 for airports, airlines and baggage handling companies.

IATA is a trade organisation for around 260 of the world’s airlines whose members account for over 80% of all air traffic. Resolution 753 effectively states that airlines must bear the ultimate responsibility for ensuring that each bag is delivered to the correct passenger. As any baggage handling process also involves airport operators and baggage handling companies, the airlines will need to work closely with these stakeholders to implement any changes which are needed to comply with the Resolution 753 before June 2018.

“This resolution is intended to minimise the number of lost or mis-routed items of baggage,” explains Klaus Schäfer, Managing Director, Crisplant. “So whilst airlines and airports may need to invest in upgrades to their existing baggage handling equipment and controls, this can also be seen as an opportunity for all stakeholders to drive down costs.”

The Whitepaper considers a number of baggage handling technologies, ranging from manual scanning to RFID bag-tags, and suggests what upgrade may be necessary to ensure compliance. It also discusses the challenges and options which stakeholders will need to consider when installing new equipment and controls to deliver the transparency which will be required across different control systems.

Written by Kim Madsen, Senior System Manager, Software at Crisplant, the Whitepaper draws on the company’s 40 years of experience in upgrading and installing new baggage handling systems for airports around the world. The publication will help airline and airport operations executives, airport design consultants and baggage handling executives to combine compliance to the Resolution with significant cost savings and the opportunity to improve passenger satisfaction ratings.

The Whitepaper is available from the BEUMER Group website.

Perfectly integrated into the environment
Beckum, 03. February 2016

Portlandzementwerk Wotan H. Schneider from Üxheim-Ahütte in the Volcanic Eifel has acquired a Pipe Conveyor manufactured by BEUMER Group to transport clinker to its cement mill. The 200-metre-long conveying system is customised to fit perfectly into the local environment. Since the system is completely enclosed, no material can fall on the road or passing vehicles. Additionally, absolutely no dust is released into the air, which greatly benefits the environment, which greatly benefits the environment. Furthermore, the conveyor is economical in operation, energy-efficient and maintenance-friendly.

Around 380 million years ago, huge limestone reserves accumulated in the lime dell of Hillesheim in the Volcanic Eifel region of Germany. Numerous dolomite formations and several basalt and lava cones demonstrate the geological diversity of the area. At the heart of the region lies the small parish of Üxheim-Ahütte. Portlandzementwerk Wotan H. Schneider KG, informally known as Wotan Zement, has had its plant on the outskirts of the village with 180 inhabitants since 1923. The family-owned enterprise has 70 employees and produces nine cement types. According to technical director Gerd Morenhoven, these include Portland cement, Portland limestone cement, Portland pozzolana cement, blast-furnace cement and Portland slag cement.  These are bagged or filled into silo trucks and transported to construction sites, ready-mix plants, concrete component manufacturers and building material traders.

The enterprise mines the necessary raw materials (limestone and marl) in the Üxheim, Nohn, Berndorf and Kerpen quarries that all lie closely together in the lime dell of Hillesheim. For the manufacturing of cement clinker, limestone and marl are crushed and homogenised with additional raw materials. In raw mills, the materials are ground to the necessary grain size and dried. The resulting raw meal is then homogenised and temporarily stored in large silos. To obtain cement clinker, a coarse intermediate product, the raw meal is first transported into the cyclone preheater. There it is preheated and deacidified at temperatures of over 950 degrees Celsius.  The material then moves into the rotary kiln where it is burned at temperatures of around 1,450 degrees Celsius. "Due to increased demand for Portland cement we currently need to buy additional cement clinker. It is delivered in trucks to a specially built clinker receiving station", explains the technical director. The cement manufacturer needed an efficient solution for transporting the arriving material to the processing site. "We were looking for an eco-friendly and low-maintenance solution", specifies Gerd Morenhoven.  The new conveyor had to be optimally adapted to the existing premises; for example, it had to follow the course of the access road and not lose any material during transport, even on uphill and downhill slopes.

Comprehensive expertise, optimum support

For the building material manufacturer, BEUMER Group was their first choice to supply optimal conveying equipment. The provider of conveying solutions has been well-established in the building industry for nearly 80 years. BEUMER has bundled its comprehensive expertise in the industry and established different Centers of Competence to offer optimal support to building material manufacturers by providing single-source solutions. The Pipe Conveyor segment is one of BEUMER's Centers of Competence, which are in charge of worldwide project management and sales. This specific project was carried out in close collaboration between the group companies in Austria and the Czech Republic.

Maximum environmental protection, minimum maintenance

"Together with the management team in Üxheim-Ahütte, we developed a solution that is tailored exactly to match the customer's requirements", says Josef Amon, project manager at BEUMER Group Austria GmbH who was responsible for the project. It became apparent that a Pipe Conveyor was the best solution offering environmental protection and low maintenance. Wotan Zement already has a Pipe Conveyor and the system has stood the test of time. "Its closed design reliably protects the environment from dust and people or vehicles from falling goods", explains Josef Amon. The conveyors also offer many other advantages. They are able to navigate long distances and tight vertical and horizontal curve radii. The ability to negotiate sharp curves means that far fewer transfer towers are needed in comparison with other belt conveyors — or, depending on conveying length and curve radii, even none at all. Thanks to this, the customer can significantly reduce costs and BEUMER can more easily adapt the system to specific requirements.

BEUMER Group supplied and installed a system with a pipe diameter of 200 millimetres and a length of 213 metres. It conveys up to 200 tons of material per hour. Another system advantage is the reduced noise emission of the Pipe Conveyor. Special idlers, low-noise bearings and electric motors work very quietly. "This makes for a more pleasant working environment for our employees. Besides, the people in the vicinity are not disturbed by the noise. It is an important aspect, since the plant is located on the outskirts", notes Gerd Morenhoven.

Smooth performance from start to finish

Besides the supply and installation of the Pipe Conveyor, BEUMER also took care of all the necessary solutions for ensuring flawless operation. Among other things, BEUMER equipped the conveying system with a magnetic separator.

The route of the Pipe Conveyor now runs along the access road, crosses a weigh-bridge, then reaches a two-way chute. There, clinker is either transported to the mill via an existing reversible belt conveyor or taken to the existing clinker store.

Constructive solutions

BEUMER Group was in charge of the entire process. BEUMER Austria took over the project implementation: its employees created the basic design and included all the systems supplied by the customer, delivered the components and commissioned the Pipe Conveyor. BEUMER Czech Republic a.s. took care of the detailed engineering, the steel structure and the installation. "We designed the frames so that they could support the pipeline for pneumatic cement transport supplied by the customer", explains Josef Amon. This pneumatic pipeline was part of another project. The simultaneous use of the Pipe Conveyor frames as a pipeline bridge allowed for substantial cost savings in the other project.  "The challenge was to do without additional supporting structures", says Josef Amon. Furthermore, the engineers integrated the Pipe Conveyor into the existing plant structure. "However, because the system was quite old, there was very little documentation left", he reminisces. That challenge, too, was successfully mastered by BEUMER, as Pipe Conveyors are quite easy to integrate into existing plants.

The complete project implementation lasted around ten months. Since February 2015 the system has been operating successfully. "We are very pleased", says the technical director, Gerd Morenhoven. "The transport from the clinker receiving station to the clinker store or the mill is performed quietly, quickly and without material loss".

Reliable energy supplier
Beckum, 28. January 2016

Cement manufacturing is particularly energy-intensive. In order to reduce the use of expensive primary fuels like coal and oil, cement plant operators focus increasingly on alternative fuels and raw materials (AFR). The use is generally focused on the fuels. Neither the manufacturing process, the end product, nor the emissions may be affected. Therefore, high-caloric wastes that cannot be further recycled, e.g. from plastic and packaging residues, paper, composite material or textiles, have to be treated beforehand to be ready for co-processing.

In order to help customers efficiently convey, store and dose the treated fuels, BEUMER Group has established the new business segment AFR systems.

Germany, October 1973: For political reasons, Arab countries reduced their oil production, which caused oil prices to skyrocket. This was a very precarious situation, because crude oil was an important energy source, also for the cement industry to operate their rotary kilns. With this first oil crisis, plant operators started to shift towards using cost-effective fuels and raw materials.

Besides mineral waste that can be used as alternative raw material, the market primarily employs the use of fuel alternatives, because approximately 30 per cent of production costs are spent on energy. In addition to fluid alternative fuels, such as used oil or solvents, the majority of solid fuels consist of whole or shredded scrap tyres, used wood, or mixtures of plastic, paper, composite materials or textiles. After they have been treated and quality-controlled, they show calorific values similar to lignite. The calorific value of scrap tyres is even comparable to that of hard coal. When producing cement, it is also necessary to ensure that the quality of the ash residues matches the quality of the intermediate product clinker. As all material components are completely incorporated into the clinker and mineralised. Their use makes for an economic production process. In addition, primary raw and fossile fuel resources are conserved and landfill volume is reduced.

Pre-treated alternative fuels are mostly supplied from external vendors, ready for co-processing. BEUMER Group now offers tailor-made AFR systems to lime and cement works for a safe storage and transport of solid alternative fuels. Based on wide-ranging experiences and the customer's requirements, the systems comprise the entire chain, from receiving and unloading the delivery vehicle, up to storing, sampling, conveying, dosing and feeding solid alternative fuels. BEUMER Group, provider of intralogistics, supplies its customers worldwide now with customized systems, from one single source.

Tailored to every application

BEUMER Group's program includes the starter system that is used at the main burner. In the cement and limestone industry, primary fuels are usually ground to grain sizes of less than 100 micrometres and fed via the main burner. At the end of the rotary kiln, the burner heats up to 2000 °C, the temperature that is needed for limestone, sand, clay and ore to react and become clinker as an intermediate product. In order to use solid alternative fuels in the sinter zone burner, they should deliver a calorific value that is at least similar to lignite (approx. 22 ± 2 MJ/kg), have grain sizes of less than 30 millimetres and a levitating burn out.

The kiln-ready material is usually delivered in moving-floor trailers. BEUMER Group provides a docking station that also serves as storage on site. Once the trailer is discharged, it is completely replaced or refilled in the large tent using a wheel loader. The material is metered volumetrically and conveyed to the sinter zone burner. This solution is deliberately designed as a test system. This way, the operator can test their suppliers, the quality of the fuels and their kiln reaction or rather the emission behaviour.

Solution for the calciner

With the second system, the calciner can be fed with more coarse alternative solid fuels, such as chopped, tyre derived fuel or fuels as described above, but in a more coarse state. They are generally less pre-processed, contain more three-dimensional particles and therefore require more time to burn out than the more intensively pre-processed alternative fuels for the main burner comprosing exclusively only two-dimensional particles.

The coarse calciner fuel is delivered in moving-floor trailers or tippers. The alternative fuels are quickly unloaded and stored temporarily in a dust-proof way. Another storage serves as a buffer, which can hold the overall capacity of 900 cubic metres of the preceding bunker. From here, the Pipe Conveyor transports the material to the corresponding height of the calciner in the preheater tower. Here, the alternative fuel is weighed and dosed. During the feed towards the hearth in the calciner, there is often the risk of catching fire due to thermal radiation or pulsations of the calciner. For this reason, the valveless special feed was developed, so the material can be safely fed to the calciner.

In order to ensure safe and automatic fuel supply after successful testing, BEUMER Group provides systems for permanent operation with high thermal substitution rates. The systems consist of the receiving area and a storage system, where the crane system can store material of different quality into different storage zones and boxes. Experiences so far have shown that you always have to calculate with disruptives or quality deficits in the fuel. This is why the entire storage and conveying technology in the hall can be potentially provided with equipment that is able to separate metal, wet and three-dimensional disruptives from the fuel for the main burner and keep disrupting oversized grains from each specific alternative fuel.

Equipped with the necessary sensor technology, the operation runs automatically. The crane can be used independently for homogenisation, in order to minimise quality variations or feed the lines towards the main burner and the calciner.

Pipe Conveyor stands the test

Schwenk Zement AG's production capacity make their plant in Bernburg one of the largest and most efficient cement plants in Germany.

In order to reduce energy costs, the cement plant is increasingly using alternative fuels that are engineered in external pre-processing plants into high-quality fuels with defined specifications.

Until now, the work has been using drag chain conveyors. After almost a decade of use and numerous modifications however, more and more maintenance was required. The fuel quality also improved over time, so that, due to its density of 0.2 t/m3, the existing technology was no longer sufficient to convey the required quantities towards the main burner. This created the need for a reliable, eco-friendly and low-maintenance solution. In addition, the new conveyor needed to be optimally adapted to the curved routing in the plant.

Schwenk Zement KG opted for the BEUMER AFR system with its Pipe Conveyor to feed the main burner with alternative fuels. The system works almost completely automatically, from receiving to the feeding system at the rotary kiln. Cranes pick up the engineered alternative fuels in the storehouse and fill them into the discharge bunkers with their equipment. From there, a chain belt conveyor transports the fuel continuously towards the Pipe Conveyor, which conveys it to the weigh feeders before the main burner.

The curved Pipe Conveyor at the core of the system requires little maintenance and its enclosed design and quiet operation protect against emissions and the wind-blown spillage of the fuel. It is able to connect long distances without interruption and navigate tight curve radii that adapt to the individual conditions of the plant.

BEUMER Group UK to upgrade the International Arrivals Baggage reclaim carousels at Glasgow Airport, Scotland
Aarhus, 05. January 2016

BEUMER Group - a leading global supplier of airport baggage handling systems – has been awarded the contract to design, deliver, install and commission an upgrade to the international arrivals baggage reclaim carousels at Scotland’s Glasgow Airport. The contract, which was awarded to BEUMER Group as the Principal Contractor, forms part of Glasgow Airport’s strategic plan to create a modern, attractive airport and to support future growth in passenger numbers.

The existing carousels in the international arrivals baggage hall were based on obsolete, legacy equipment which was no longer supported by the manufacturer. This scenario compromised both the airport’s ability to maintain the carousels and the overall reliability of the system. BEUMER Group’s three new carousels will deliver higher reliability and throughput in addition to providing passengers with a faster reclaims process. The control software for the BEUMER Group carousels will be fully integrated into Glasgow Airport’s existing control systems.

“BEUMER Group UK was awarded this prestigious project due to our proven ability to upgrade legacy baggage handling systems with minimal disruption to the daily operation of the airport," explains Peter Gilks, BEUMER Group UK Managing Director Airport Division.

BEUMER Group is on track to have the new international arrivals baggage reclaim carousels fully operational by May 2016.

A successful family history
Beckum, 09. December 2015

In 2014, BEUMER Group, based in Beckum, looked back on yet another successful year with a turnover of 680 million Euros. This was possible because BEUMER continued to concentrate on its core business capabilities, to be innovative, and consistently to pursue its strategic policy of globalisation. A considerable portion of the credit for all this must go to the shared values of this family-owned company. They are the basis for the system provider’s successful integration of some 4,100 employees, each of whom comes from different cultures and backgrounds, and of those, in particular, who have joined the group as a result of its corporate acquisitions. This year, BEUMER Group celebrates its 80th anniversary.

With innovative system solutions for intralogistics in conveying and loading technology, palletising and packaging technology as well as sortation and distribution systems, BEUMER has established an excellent position in the world market. These solutions are applied in various industries such as cement, lime and gypsum, agriculture and mining, chemicals, pharmaceuticals, energy, food and beverage and also in airports and logistics centres. "We can only achieve a high level of customer satisfaction and a sustainable, successful market presence when the whole team is involved in the corporate strategy in the long term," explains Dr. Christoph Beumer, Chairman and CEO of BEUMER Group. He has been managing the family business since 2000, now in the third generation. Just how innovative and successful this mid-sized company is, has now been extensively documented in the latest edition of the compendium of German world market leaders "Lexikon der deutschen Weltmarktführer", issued by the business press publisher Deutsche Standards EDITIONEN.

It all started with an idler

On December 9, 1935, the 33-year-old Bernhard Beumer started his first work day as an entrepreneur with four employees. Until then, he had been working for a conveying technology company in Essen. One of his most important seed assets, aside from his courage and determination, was the experience he gained as a repair mechanic for conveying technology, working in the mining industry in the Ruhr area before completing his degree in engineering. Bernhard Beumer had long entertained the idea of being independent and founding his own business. When he learned that a vacant factory building in his hometown of Beckum was up for sale, he seized this opportunity. The classic conveying technology formed the foundation of his business.

The entrepreneur starts from scratch. As a young senior engineer, he knew the business, as well as the customer's needs. Already when founding his new company, he brought with him his first orders from the building materials, cement and mining industries. A considerable step towards the success of BEUMER conveying technology was his development of the idler with labyrinth seal. The founder of the company had this innovation patented and integrated it further into other products. From this idler, he derived the company logo which is still used today: The circle represents the cross section of the idler's tube, the arrow is the idler axle and its direction of running. The company continued to grow, employing about 100 people at the outbreak of the Second World War.

The son as successor

Not only the company founder, but also his eldest son bears the name Bernhard Beumer. It was an obvious choice for the son to follow in his father's footsteps. After completing studies in mechanical engineering, he worked at his father's side for 18 years and took over the company after his father's death in 1981. In the field of conveying technology, he particularly pursued the development of bucket elevators. He quickly realised that a chain as a traction element was too heavy. Its net weight cancels out a major portion of its tractive force. By this time, BEUMER was already an expert in belt conveying technology. This gave Bernhard Beumer the idea of using a belt as the traction element for bucket elevators. He used a belt with steel wires to ensure that the buckets are reliably fixed to the belt. He arranged the steel wires so that there are wire-free zones. Holes can be punched into these zones to fasten the buckets tightly to the belt.

With these bucket elevators, BEUMER created a conveying technology which allows for considerably higher speeds and greater centre distances. BEUMER's current belt bucket elevators allow centre distances of 178 metres or more. By the mid-1980s, the supplier had installed about 100 systems altogether, in 2007 and 2008 there were about 450 installed per year, world-wide. Besides the product development in the field of conveying technology, Bernhard Beumer Jr. also continued the initial development of loading systems and set BEUMER on a decisive path for the globalisation of the group, founding companies in Brazil, the USA and Asia.

On any terrain - curved belt conveyors

In the 1960s, BEUMER laid the foundation for curved belt conveying systems. The first theoretical designs on the market were from the company's Department for Research and Development. Today this group is one of the technological leaders for these systems, either as troughed belt conveyors with open design or as Pipe Conveyors. One particularly impressive reference project is the 12.5 km long troughed belt conveyor in the Chinese province of Sichuan, which was put into operation in 2008 and currently conveys about 2,200 tons of limestone from the quarry to the cement plant. Its routing features several vertical and horizontal curves. The system traverses 1.5 kilometres of water surface and extensive bamboo forests, and can overcome height distances of up to 100 metres. For the same project, BEUMER Group has now been awarded the contract to supply and install another conveyor of similar size, and the customer is already planning a third expansion phase.

No more heavy lifting

In the field of loading technology, Bernhard Beumer Jr. developed new products, such as the three-dimensional loading machine for loading cement bags onto trucks. This relieved the physical burden of the workers. In the 1970s, the engineers further developed this machine until it became completely automated. The stationary palletiser is a result of this development. Today, the BEUMER paletpac stacks paper, PE and PP bags on pallets of different sizes in a flexible, precise and stable way. Depending on the product requirements, it can be equipped with a clamp-type turning device or a twin-belt turning device. The latter allows gentle, fast and precise stacking of bagged bulk material on pallets. The BEUMER stretch hood is a well proven high capacity packaging system that then packages the palletised stacks efficiently and economically. This technology has been optimised further in regards to functioning, economic efficiency and ergonomics and was presented for the first time at the Interpack in May 2014. Since its introduction, BEUMER's customers have responded very positively to this system.

The third generation

Since 2000, Dr.-Ing. Christoph Beumer, the founder's grandson, has been managing the company. "The success is primarily due to the familial spirit. We have consistently held to our motto 'We are looking for the long-term success, and not for the short-term profit'," he says. BEUMER ensures the long-term success of the company through manageable growth, a large range of products and a global market presence. BEUMER machines and systems are in use all around the world. The group consistently pursues its globalisation, by setting up local group companies, and even local production facilities in China and Thailand. The result: the company has exhibited extremely stable organic growth over the last several years. Undeterred by the impending financial and global economic crisis, Beumer took over the Danish sortation technology specialist Crisplant in 2009, followed later by companies in India, the US and Belgium. Hundreds of thousands of suitcases every day pass through BEUMER baggage systems at airports in Frankfurt, London, Beijing, Singapore and other locations world-wide. Thousands of packages traverse conveyor belts supplied by the intralogistics specialist at parcel centres operated by Hermes, GeoPost, UPS and FedEx. With its acquisition of Enexco Technologies in India, a manufacturer of grinding systems and packaging machines for the cement industry, BEUMER has reinforced its presence in vital markets and simultaneously systematically expanded its portfolio, without abandoning its traditional segments. And what about the integration of the very diverse cultures? The CEO views this as a chance to learn from each other. "We want to create a working environment where everyone respects each other's individuality," emphasises Dr. Beumer. And due to the fact that the local employees in the group companies speak the same language as their customers, the customers feel understood. This creates a high level of customer retention.

Becoming a single-source provider

In order to be able to fill bags with bulk materials such as cement, mortar or gypsum and therefore provide entire packaging lines for the building materials industry, the BEUMER fillpac, an innovative filling system was introduced to the market in 2013. Users can flexibly integrate and adapt it to existing packaging lines. At the Achema 2015 trade fair, BEUMER presented itself for the first time to the chemical industry as a single-source provider for filling, palletising and packaging technologies with its latest development of an innovative form fill seal (FFS) system. The BEUMER sealpac responds very flexibly to different bulk density, flow characteristics and grain distribution.

More than just service

BEUMER does not only provide and install machines and systems. With highly capable specialists deployed around the globe, the company also ensures trouble-free operation worldwide. BEUMER Group has established a fourth, independent business unit, in the form of its Customer Support unit. The group thus ensures high levels of availability for its customers' machines and systems. Its specialists take care of the customer, starting with the first project discussion, up until the system is in operation. Customer Support offers various service agreements which are matched individually to the respective needs of the customer, including service intervals and response times as agreed by contract. The agreements can range from maintenance and inspection to a long-term placement of service personnel on site. Within the framework of its wide reaching Customer Support business, BEUMER Group also 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.

"I view the company as a little jewel case," explains Dr. Beumer when speaking of the company history. "When my grandfather founded it, it was no more than a little wooden box. He added some velvet lining to it and then handed it over to the second generation, my father, who added some more and embellished it further." And following this tradition, the jewel box was then handed over to Dr. Christoph Beumer. His belief is that if you receive the little box, your task is to keep it safe, to maintain it, and, if possible, always add a little to it. Under no circumstances may you remove anything or simply live off of it. "The responsibility is always handed over as well," emphasises Dr. Beumer.

A very attractive employer
Beckum, 07. December 2015

Skilled personnel are hard to find, not only in Germany. The reasons for this are rooted, among other things, in demographic development. The job market is becoming more emotion-based. Soft skills such as team play and communication, and values like work-life balance and self-realisation are becoming more and more important. Another decisive factor is the business location: the more rural the area is, the harder it is to attract new employees. Urban areas on the other hand face a different problem: potential employers are more likely to "fight" over the most talented applicants (often called a "war for talents"). Located in the Münsterland, a region that is known for its mechanical engineering industry, BEUMER Group offers exciting perspectives and an attractive work environment, especially for young professionals. This is what BEUMER Group's employer branding campaign is directed at.

What makes for an attractive employer? An attractive salary is no longer enough to hire skilled personnel. Especially young professionals have become more selective. At BEUMER Group, the employee always comes first. "Our goal is not the short term profit, but long term success, and this is only possible with motivated and highly-skilled colleagues", says Dr. Christoph Beumer, Chairman and CEO of BEUMER Group. "We can only achieve customer satisfaction and successfully meet the challenges of our competition, if we integrate the entire team sustainably into our company", he explains. The company has been ranked one of the best employers in Germany, according to an extensive study from FOCUS news magazine. Through the social internet platforms XING and kununu, FOCUS questioned more than 70,000 employees from different hierarchy and age levels. 806 companies with more than 500 employees were evaluated from 22 industries.

"Would you recommend working for your company to your friends and to people you know?", and "How satisfied are you with the managerial skills of your superior?", were two of many questions that the German employees at BEUMER Group answered in the company's favour. The family-run company ranked third place in this category, in comparison with other medium-sized companies with up to 2,000 employees. The intralogistics specialist achieved eighth place in the industry comparison of "machine and plant design" and was 85th amongst all 806 companies.

International leading position helps BEUMER stand apart from the crowd

This ranking can certainly also be attributed to the fact that BEUMER Group holds a leading position in the world market for this industry, and has experienced very high growth rates over the past couple of years. With innovative systems for intralogistics in conveying and loading technology, palletising and packaging technology as well as sortation and distribution systems, the company earned an excellent international reputation. Additionally, BEUMER Group continues to successfully seize globalisation opportunities.

Its headquarters, however, are not in Berlin, Munich or Düsseldorf, but in Beckum. A town with about 37,000 inhabitants, located in the northern part of North Rhine-Westphalia. It has a lot to offer: historic sites in beautiful surroundings, with a wide variety of recreational offerings and sports activities. The rural area, however, is also a challenge, that many middle-sized companies have to face. This is not only the case in Beckum, but at several of its international locations as well, so BEUMER Group is opting for a world-wide employer branding strategy. With this strategy, the company wants to face the challenges that come with demographic change and skills shortage and present itself actively as an attractive employer on the job market. BEUMER Group puts the emphasis on their employees. The campaign goal is to demonstrate what the intralogistics company is all about: their people.

Focus on the employee

BEUMER Group is an internationally successful, family-owned company, where employees play a very crucial role. Through their individual performance, every employee contributes to the overall success of the company. And to achieve this, the employer and employee must focus on the same set of values. This is what characterises the BEUMER Group spirit. But what is important to the employees? Have the demands on employers changed? To find out, the group handed out questionnaires at the different group locations and from the answers derived the core messages for the campaign. In order to bring the attention of young professionals towards BEUMER Group, the initiative will be accompanied by billboards, radio spots and the newly designed career website Employees are giving insights about themselves, the company and the attractive work environment, where the focus is on the employee.

Career goal: qualified employee

BEUMER Group devotes particular attention to the development of its own junior staff. To students who are about to write their bachelor or master thesis, the company offers exciting topics of practical relevance in an international environment, accompanied by the intensive support of experienced colleagues. BEUMER Group offers topics for theses in the fields of automation technology, engineering, sales, and research and development. During their time with the company, the students get to know the business, and BEUMER Group gets to know potential junior employees. Students who already graduated in engineering, economics or computer science can also start their career directly with BEUMER Group.

They also have the chance to participate in an international trainee program. Its goal is to prepare graduates for responsible specialist and leadership positions in the company. They move through a two-year development program in Sales, Engineering, Customer Support or the Commercial department. The first months are started at the group company location where the graduate is hired. In order to broaden their personal and professional horizon they are then sent abroad for several months, followed by a working period in a different department. They then complete an additional phase in another international group location, and finish their program at their home group. The trainees are accompanied by a mentor who provides feedback at regular intervals. The participants take an integral role in important projects. Moreover, BEUMER Group offers the program graduate a permanent contract. Christian Penger passed such a program, and is now the director of Corporate Management: "The program offers college graduates a great start into the professional world, combined with international experience. By working in many different parts of the company, a trainee can quickly set up his own network and get to know the respective contacts in the company. During my period as a graduate, I learned at an early stage that taking over responsibility is more than just a slogan."

Moving parcels as quickly as possible
Beckum, 17. November 2015

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.

A very special compound
Beckum, 12. November 2015

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.

Easily operated

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.

Raise performance, extend with modules
Beckum, 09. November 2015

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

Significantly higher results with less effort
Beckum, 30. October 2015

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 introduces TrayDeck: A unique solution to closing the gaps between trays on high-speed tilt-tray sorters
Beckum, 06. October 2015

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.

Calgary Airport Authority awards Crisplant a contract for a second CrisBag® baggage handling system at Calgary International Airport, Alberta, Canada
Beckum, 06. October 2015

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 introduces TrayDeck: A unique solution to closing the gaps between trays on high-speed tilt-tray sorters
Beckum, 06. October 2015

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 to extend DPD’s parcel handling hub in Athlone, Ireland
Beckum, 29. September 2015

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 presents live demos and new software features at Inter Airport 2015
Beckum, 23. September 2015

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.”

Comprehensive support
Moscow, 07. September 2015

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

BEUMER Group and ALSTEF consortium awarded new baggage handling contract by Aéroports de Paris at Paris Charles de Gaulle Airport
Aarhus, 04. August 2015

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.

Sharing your accountability
Beckum, 24. July 2015

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.

Appropriate concepts

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."

From waste to energy
Beckum, 21. July 2015

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.

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