The Möllers program for the chemical industry

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metering weighing filling Möllers troughout the world palletizing schrinking stretching conveying loading Maschinenfabrik Möllers GmbH u. Co. P.O.

1 metering weighing filling Möllers troughout the world palletizing schrinking stretching conveying loading Maschinenfabrik Möllers GmbH u. Co. P.O. Box 1764, Beckum/Germany Phone 02521/88-0, Fax 02521/88-100, Mobil phone 0171/ and 0171/ controlling monitoring Möllers North America Inc nd St. S. E., Grand Rapids, Michigan 49512/USA Phone 616/ , Fax 616/ Mobil phone 001/ Greif-Velox Maschinenfabrik GmbH P.O. Box , Lübeck/Germany Phone 0451/5303-0, Fax 0451/ Mobil phone 0172/ Logdos GmbH Hornsteiner Str. 2, Bingen/Sigmaringen/Germany Phone 07571/7475-0, Fax 07571/ Mobil phone 0171/ Librawerk Maschinenfabrik GmbH Vossenkamp 1, Braunschweig/Germany Phone 0531/370980, Fax 0531/ The Möllers program for the chemical industry Möllers (UK) Ltd. 27A Station Road, Cheadle Hulme, Cheadle Cheshire SK8 5AF/UK Phone 161/ , Fax 161/ Möllers INTERTEC , Moscow, Russia, ul. Bolotnaja, dom 12, ofis 343 Phone 095/ , Fax 095/ Möllers France S.a.r.l. 26, rue Saarinen, SILIC 240, Rungis Cédex/France Phone 1/ , Fax 1/ Möllers Praha/CR Nad Rokoskou 14, Praha 8/CR Phone 2/ , Fax 2/ Möllers Office Romania Vicim Trading SRL, 3. Bucharest/Romania 4 Mamulari Street 2nd Entrance, 8th Floor, Flat no. 60 Phone 00401/ , Fax 00401/ Möllers Office Poland Kaizen Ltd., ul. Siedleckiego 13/16, Cracow/Poland, Phone 012/ , Fax 012/ Mobil phone 0048/ kaizen@ceti.com.pl Möllers Brazil Via Anhanguera km 14,5 Vila Mangalot, São Paulo/Brazil Phone 011/ , Fax 011/ edz@autocnet.com.br Möllers Office Singapore Mobil phone 0065/

2 Contents Filling technology 3 Metering and weighing technology 6 Liquid filling 8 PLS palletizing technology 10 PFS palletizing technology 16 Robot technology 17 FSA system for secure transport 18 HSA-HE system for secure transport 20 Palletless despatch units 22 Warehouse technology 24 Large container filling 26 Control technology / visualization 28 No other branch of industry generates such an abundance of bulk materials with such differing filling properties as the chemical industry. The scale of particle sizes alone ranges from powdery materials with particle sizes in the millimetre range to coarse lumps larger than a fist. Even the liquid products with multiple viscocities up to the field of pasty products which often require a very individual filling process. No question, a competent supplier to the chemical industry must be able to offer a wide range of filling, palletizing and film-wrapping machines and understand their correct application. Form-fill-and-seal filling, bag checking, palletizing and shrinkpackaging form the functional sequence of this typical Möllers equipment line

plastic bags from the roll and peak capacities of

3 Filling technology Automatic form-filland-seal filling machines, with their efficient production of plastic bags from the roll and peak capacities of 1800 bags/h, are often used for different chemical products 3

Filling technology The choice of the filling machine is determined not only by the properties of the product but also by the

For granular products we often use automatic open-mouth filling stations or form-fill-and-seal machines which actually produce

For products Four-spout valve-bag VIBROpneumatic packer with empty bag applicator, for outputs of up to 2000 bags/h The VELOVAC

4 Filling technology The choice of the filling machine is determined not only by the properties of the product but also by the nature of the bag and the required throughput capacity. For granular products we often use automatic open-mouth filling stations or form-fill-and-seal machines which actually produce the bag from tubular film during the packing process. For products Four-spout valve-bag VIBROpneumatic packer with empty bag applicator, for outputs of up to 2000 bags/h The VELOVAC packer draws the product into the bag by vacuum and achieves a high degree of compaction of the contents without altering the structure of the product 4 The BVPV VIBRO pneumatic packer is a high performance filling plant for bulk materials from 0 to 15mm in the weight range from 5 to 25 kg

which are difficult to de-aerate we have brought out machines with dip-tube evacuation, and in extreme cases we fill the bag in a vacuum chamber where the

However, the opposite is often the case the de-aerated product tends to jam and form bridges.

The bag valves are completely sealed by the ultrasonic welding equipment at each spout.

5 which are difficult to de-aerate we have brought out machines with dip-tube evacuation, and in extreme cases we fill the bag in a vacuum chamber where the air is extracted from the product through the pores in the bag material. However, the opposite is often the case the de-aerated product tends to jam and form bridges. This situation requires a pneumatic packer which is produced as in-line packer with vibrating pressure vessel or as rotary packer. The bag valves are completely sealed by the ultrasonic welding equipment at each spout. The chemical industry is one of the users of openmouth bags which fills its products into bags made of paper, PE or woven polypropylene tape. The bag closing systems available including stitching, welding and gluing. Multi-spout in-line packers can also be set up for unattended operation with automatic valve bag 5 Downcomer-pipe packer with automatic bag applicator and ultrasonic welding equipment

Metering and weighing technology Metering, weighing and filling, as in these open-mouth bag systems, form a continuous process in modern plants Regardless of whether the metering system is

The best possible operating principle for the metering equipment and precise control of the metering process are basic requirements for highly accurate weighing results.

6 Metering and weighing technology Metering, weighing and filling, as in these open-mouth bag systems, form a continuous process in modern plants Regardless of whether the metering system is used for feeding an operating process or weighing of a batch of material for filling, the properties of the material require the application of different types of metering equipment. The best possible operating principle for the metering equipment and precise control of the metering process are basic requirements for highly accurate weighing results. With their precise mode of operation and high output capacity, for which the Libra DYNAMIC weight bottom-discharge weigher with 1600 dischar- System: Shutter metering For metering granulated and coarse bulk materials 6

ges/h sets an example, gross and net weight weight bottomdischarge weighers

reputation of our weighing technology in many branches of the chemical

The Libra net-weight bottom-discharge weigher has become a symbol of

metering System: Vibrating chute metering For non-free flowing pulverized

7 ges/h sets an example, gross and net weight weight bottomdischarge weighers from the Möllers Group have contributed substantially to the outstanding reputation of our weighing technology in many branches of the chemical industry and have also laid the basis for special innovative solutions. The Libra net-weight bottom-discharge weigher has become a symbol of accuracy and high discharge capacities System: Screw metering System: Belt metering System: Vibrating chute metering For non-free flowing pulverized bulk materials For heavy flowing coarse bulk materials For bulk materials which tend to agglomerate 7

Liquid filling Fully automatic, heavy duty, drum filling and sealing plant with four filling stations as well as automatic, empty drum de-palletizing system, AGV

drums and IBCs The Logdos Liquid Filling product has provided us with a trendsetting development in the field of metering and filling liquid.

8 Liquid filling Fully automatic, heavy duty, drum filling and sealing plant with four filling stations as well as automatic, empty drum de-palletizing system, AGV loading/unloading section, and drum palletizing system Coordinate filling plant with highly accurate filling into single or palletized containers such as tins, hobbocks, drums and IBCs The Logdos Liquid Filling product has provided us with a trendsetting development in the field of metering and filling liquid. The full, market tested, range is distinguished by the high level of automation of the automatic filling machines for drums, tins and buckets with capacities of 1 to 250 l, and of up to 2000 l in the semi-auto- 8

Automatic coordinate drum filling plant for palletized container

filling into containers from 1 to 60 l Automatic, multi-spout tin

We can be your designer, manufacturer and supplier from individual

9 Automatic coordinate drum filling plant for palletized container units Automatic filling system for fully automatic, highly accurate filling into containers from 1 to 60 l Automatic, multi-spout tin filling plant with sealing station matic range. We can be your designer, manufacturer and supplier from individual filling stations to fully automatic, heavy duty plants including the conveying technology. 9

destination. The variety of bag formats are reflected in the Möllers palletizer series for the chemical industry.

10 PLS palletizing technology Chemical products are obtained in a wide variety of packaging, of which bags are one of the most frequent. With their careful as well as accurate palletizing Möllers automatic palletizers guarantee loads which can be stacked one on top of the other and transported safely to their destination. The variety of bag formats are reflected in the Möllers palletizer series for the chemical industry. Changeable stacking patterns, different formats of pallets and other load carriers, the use of load stabilizing agents there is hardly any requirement which cannot be fulfilled with the Möllers machines. The bags from the bag straightening station are all the same even shape when they reach the palletizer 10

11 Lifting, turning, lowering the rotating grid turns the material to be palletized carefully without introducing external forces Palletized loads with good stacking characteristics the layer pressure plate levels the surface of the layer 11

An essential contribution to the excellent results which Möllers automatic palletizers achieve in respect of the accuracy

as bag straightening belts, which can be located before or after the palletizer or form an integral part of it.

The layer slides gently into place the aerated slide plate avoids any deformation of the unstable packaged material Bags are

12 An essential contribution to the excellent results which Möllers automatic palletizers achieve in respect of the accuracy and stability of the stack of palletized product, even with partially filled bags, is provided by auxiliary equipment, such as bag straightening belts, which can be located before or after the palletizer or form an integral part of it. They are the result of years of experience and are available as standard modules in the wide Möllers product range. The layer slides gently into place the aerated slide plate avoids any deformation of the unstable packaged material Bags are turned carefully into the correct position for the stacking pattern, the side-flap bag rotator exerts only minimum mechanical stress on the bags 12

Flat film applicator Cardboard sheet / slip sheet

Pressure flattens the bag stack and ensures rapid

stable transport unit Ink-jet coder/printer

is governed by the nature of the bagged product

The range of adjustments ensures the required

for the situation where the bag format is altered

The auxiliary equipment can also have the function

13 Flat film applicator Cardboard sheet / slip sheet applicator metal detector Bag check weigher Pressure flattens the bag stack and ensures rapid de-aeration of the packaged product, providing a stable transport unit Ink-jet coder/printer labelling unit The choice of auxiliary equipment is governed by the nature of the bagged product and its suitability for palletizing. The range of adjustments ensures the required flexibility of the units, e.g. for the situation where the bag format is altered when the product is changed. The auxiliary equipment can also have the function of protecting the content of the palletized load from external effects, such as moisture; film applicators are one example of this. 13

14 PLS-C 1400 EH SH BH The PLS-C 1-4 series of automatic palletizers has been adapted to the needs of chemical operations with 4 machine sizes for 1400 to 24oo bags/h *). The machines can be provided with different stacking pattern programs which, depending on the bag format, can be changed automatically between stacking patterns 5-er 4-er 4-er 6-er 6-er 7-er 10-er with 3 to 10 bags per layer. Möllers PLS palletizers are clearly laid out and built from easily maintained system modules; all the models are characterized by high operational reliability, low operating noise level PLS-C 1600 and low energy consumption. Special models, like the explosion-proof version, are availiable as options. EH SH BH * ) based on the five-bag stacking pattern 5-er 4-er 4-er 6-er 6-er 7-er 10-er

PLS-C 1800 EH SH BH 5-er 4-er 4-er 6-er 6-er 7-er 10-er 1800 1600 1600

EH/mm 1500 2500 1600 2600 1800 2800 2000 3000 2200 3200 Conveyor height BH

15 PLS-C 1800 EH SH BH 5-er 4-er 4-er 6-er 6-er 7-er 10-er PLS-C 2400 EH SH BH Stack height Speed height SH/mm EH/mm Conveyor height BH = 700 mm 5-er 4-er 4-er 6-er 6-er 7-er 10-er

PFS palletizing technology PFS low-level module automatic palletizers can be configured in different ways from separate modules and are characterized by their great adaptability and

They can be supplied in three sizes which are designed for outputs of between 250 and 1200 bags per hour.

16 PFS palletizing technology PFS low-level module automatic palletizers can be configured in different ways from separate modules and are characterized by their great adaptability and space-saving design Möllers PFS lowlevel module automatic palletizers are assembled individually from single functional modules which can be erected on a hall floor. They can be supplied in three sizes which are designed for outputs of between 250 and 1200 bags per hour. Other specific advantages of the Möllers low-level module palletizer are the low position of the bag inlet and the system for forming the stacking pattern which is at a low height above the floor and is easily monitored. PFS 500 PFS 800 PFS to 800 bags/h 800 to 1200 bags/h 250 to 500 bags/h 16

robot has demonstrated its special uses in the chemical industry for sorting mixed packages onto several pallets, for combining different package formats, and for palletizing package shapes which are

17 Robot technology Bag palletizing position equipped with a ROMEO robot. The pallets are reliably secured for transport in the following automatic stretch hooder As one of the first specialised palletizing, depalletizing, and order-picking robot on the market, the ROMEO robot has demonstrated its special uses in the chemical industry for sorting mixed packages onto several pallets, for combining different package formats, and for palletizing package shapes which are difficult to handle. Another frequent ROMEO application is the depalletizing and emptying of bags in a single working cycle. The ROMEO robot used with the Möllers special bag gripper*) is particularly suitable for palletizing bags, an additional suction system also enables it to handle cardboard sheets or slip sheets *) German Federal Patent No Depending on the configuration of the palletizing line bent-arm robots may be a logical alternative to the ROMEO robot 17

FSA system for secure transport A wide variety of different types of package are optimally secured to the pallet with the shrink hood Hood is formed, drawn into place and

has developed a range of machines for this technology with its unrivalled effectiveness; in addition to reliable functioning it also offers the choice of many options so

EP 0 133 462, Anti-collage-patent No. EP 0116 124, Möllers-Combi-FSA-patent No. EP0 250 647 1. Tubular film is formed and drawn into place, pallet is raised 2.

18 FSA system for secure transport A wide variety of different types of package are optimally secured to the pallet with the shrink hood Hood is formed, drawn into place and shrunk in the same machine: FSA- Combi tubular film wrapping machine with integral electrical safety shrink frame Securing pallets for transport with shrink film Möllers has developed a range of machines for this technology with its unrivalled effectiveness; in addition to reliable functioning it also offers the choice of many options so it is highly adaptable to the requirements of the particular application. 4 main operation steps of the Combi FSA *) Undershrink-patent No. EP , Anti-collage-patent No. EP , Möllers-Combi-FSA-patent No. EP Tubular film is formed and drawn into place, pallet is raised 2. Hood is undershrunk, pallet is lowered, upward shrinkage begins. 3. Contra-Laminar equipment: an air film between the load and hood prevents it from sticking to the packaged material. 4. Shrinking the top of the hood. 18

Wrapping and shrinking machines, separately or in one unit, with electrical or gas heating, are also available options, as is the Contra-Laminar system, which prevents the film from sticking to

The clamping effect produced between the packaged product and the load support by the undershrink equipment results in maximum load stability and strength during transport.

19 Wrapping and shrinking machines, separately or in one unit, with electrical or gas heating, are also available options, as is the Contra-Laminar system, which prevents the film from sticking to PE bags. However, attention is always focused on achieving a secure bond between the stack of palletized material and the pallet. The clamping effect produced between the packaged product and the load support by the undershrink equipment results in maximum load stability and strength during transport. FSA tubular film wrapping machine with downstream gas safety shrink frame High-efficiency palletizing and shrinkpackaging line 1. Empty pallet magazine 2. PLS C-2400 automatic palletizer 3. FSA tubular film wrapping machine 4. Safety shrink frame 5. Pallet delivery conveyors 19

HSA-HE system for secure transport High-Expander systemfunctions By the introduction of the new High-Expander stretch-hooding technology, the pallet load securing with stretch film extends its

The main advantage of the stretch hood over the shrink hood is the lack of any application of heat; the hood is mechanically stretched before it is positioned, and then it tightens around the stacked

20 HSA-HE system for secure transport High-Expander systemfunctions By the introduction of the new High-Expander stretch-hooding technology, the pallet load securing with stretch film extends its position as a reliable, economic Hood is formed from the gusseted tube and accepted on the stretching corners environmentally friendly system. The main advantage of the stretch hood over the shrink hood is the lack of any application of heat; the hood is mechanically stretched before it is positioned, and then it tightens around the stacked load and the pallet. Secure understretching of the pallet is a typical feature of the Möllers HSA automatic stretch hooder which has essential advantages in the form of the automatic contour stretching Stretching corners at their closest setting to take the stretch film with very small cross-section **) system*) and the stretching corners with their concentric travel. The automatic HSA-HE High Expander stretch hooding system uses stretch film with an extensibility of up to 150 %, which due to the very high retractive force increases the securing effect produced on the despatch goods. Even for different pallet dimensions only one single tubular film is needed and the film Hood is stretched to the required dimensions consumption is reduced by 30 to 40 % compared to conventional stretch films. * ) Contour stretching ** ) Patented process for adjusting the reefing fingers for picking up the very narrow tubular film width German patent Pallet is raised for understretching Hood is drawn into position Individually controllable stretching of the film hood with stress-relieved top seam by the diagonal stretching device Pallet is safely understretched 20

important advantages of the stretch hooder system Secure

21 Energy-saving and environmentally friendly, no sticking of the film to PE bags, low film consumption these are important advantages of the stretch hooder system Secure understretch: the stretching corners guide the film under the pallet 21

Palletless despatch units The palletless reverse-hood shrinkwrapped package is everything in one, a storage, handling and despatch unit with ideal properties,... ideal rail load.

package produced by the Möllers reverse-hood shrinkwrapping system is everything in one despatch unit, secure for transport and protec- PKS compact shrinkpackaging line,

22 Palletless despatch units The palletless reverse-hood shrinkwrapped package is everything in one, a storage, handling and despatch unit with ideal properties,... ideal rail load... ideal in a barge ideal for storing ideal double pack for a stacker ideal in ocean-going ships ideal on open vehicles absolutely watertight The palletless shrinkwrapped package produced by the Möllers reverse-hood shrinkwrapping system is everything in one despatch unit, secure for transport and protec- PKS compact shrinkpackaging line, German and foreign patents bag flattening station PFS automatic stacker Combi shrink system with profiling equipment stack turning and flattening station package delivery conveyors 22

ted against weather. Reverse-hood shrinkwrapped packages are highly resistant to transport stresses, even over long distances with multiple handling, and they are absolutely watertight.

23 ted against weather. Reverse-hood shrinkwrapped packages are highly resistant to transport stresses, even over long distances with multiple handling, and they are absolutely watertight. Even sensitive products can be stored in the open, transported on open vehicles, and handled in any weather. In addition there is minimum use of packing materials, maximum environmental friendliness and absolutely no pallet costs a triumph of Möllers packaging technology. The palletless package using the reverse-hood shrinkwrapping system 1. Stacking the load with the smaller base layer on top 2. Drawing the inner hood into position 3. First clamping shrink 4. Profiling the shoulders on the base layer 5. Turning and flattening the package 6. Drawing the reverse hood into position 7. Second clamping shrink 8. Final profiling of the base layer shoulders 9. Palletless package ready for despatch

Warehouse technology Automatic Guided Vehicles AGV provide the Möllers palletizing lines with empty pallets and transfer the stacked pallet loads into the high bay warehouse Separating the

storing them at a specific storage position, providing empty pallets or other load carriers; all these steps described here in simplified form but actually taking place as a complex process are

24 Warehouse technology Automatic Guided Vehicles AGV provide the Möllers palletizing lines with empty pallets and transfer the stacked pallet loads into the high bay warehouse Separating the products flowing in from the filling machines according to type, collecting and palletizing them, coding the palletized loads according to content and destination, preparing them for despatch or storing them at a specific storage position, providing empty pallets or other load carriers; all these steps described here in simplified form but actually taking place as a complex process are component parts of the Möllers pallet logistics. Display of a filling and packaging plant for granules; can be shown on the monitor in selectable steps from the entire plant down to a mechanical detail 24

The planning of the pallet logistics together with the supply and installation of all associated system components from roller track systems and AGV systems (automatic guided vehicles) to high bay

25 The planning of the pallet logistics together with the supply and installation of all associated system components from roller track systems and AGV systems (automatic guided vehicles) to high bay warehouses with all the equipment for storing and removing the palletized loads form an important part of the performance spectrum of the Möllers Group in the context of plant engineering contracts. High bay warehouse being supplied with full pallets by Automatic Guided Vehicles Slip-sheet palletizing and loading technology can be an advantageous alternative to the use of pallets where it is a matter of avoiding loss of space, as in containers, or if bags are to be despatched without any load support 25

The Möllers Group has made a name for itself in this field with innovative system solutions, especially for FIBCs (Big- Bags).

26 Large container filling In addition to bags, large despatch containers are also an important form of packaging for many chemical products. They are used as reusable and one-trip containers and require filling plants adapted to the particular type of container. The Möllers Group has made a name for itself in this field with innovative system solutions, especially for FIBCs (Big- Bags). Filling systems with automatic height adjustment are used for filling four-loop FIBCs of different sizes. Systems which, through selection of the required silo, drive out and dock their filling devices automatically onto the silo outlet have proved successful for filling different materials directly from the storage silos. The BigBag can also be used efficiently Two static BigBag filling stations for 1000 kg fourloop bags The swivable hook device offers optimal handling during suspension of the bags. The blank hose clamp assures dust-free filling 26

Filling equipment with infinitely adjustable height permits rapid adaptation to the size

the Möllers Group offer further options for cost-effective production, metering and

27 Filling equipment with infinitely adjustable height permits rapid adaptation to the size of the FIBC Octabins are one of the designs of rigid container which can be filled efficiently in Möllers plants... and secured safely to the pallet by a stretch film hood for transport as a storage and metering container. The FIBC interchangeable racks and FIBC recirculating homogenizing systems developed by the Möllers Group offer further options for cost-effective production, metering and packaging of mixtures of materials. Other types of large containers, such as Octabins, can also be filled reliably and efficiently in Möllers plants. FIBC filling station with rotating suspension device for four-loop containers 27

Control technology/visualization Plant reliability and plant availability, together with pure functionality, are now the

Maschinenfabrik Möllers has taken this circumstance into account with its family of Producat-Win process control systems

The know-how of the Möllers Group, which has grown over the years with respect to the display and diagnostic

28 Control technology/visualization Plant reliability and plant availability, together with pure functionality, are now the basic requirements for capital equipment. Maschinenfabrik Möllers has taken this circumstance into account with its family of Producat-Win process control systems developed in-house. The know-how of the Möllers Group, which has grown over the years with respect to the display and diagnostic capabilities of Möllers plants, has been implemented in this display system. The basis for this Möllers system, which can be integrated into any plant, was formed by highly qualified software and hardware engineers by exchanging information with commissioning engineers and operators. Process control system 28

Binary input and output signals form the basis for an effective diagnostic system.

control system by associated programmable controllers.

for every plant level down to the component level.

29 Binary input and output signals form the basis for an effective diagnostic system. These check not only the sensors but also the actuators and are made available to the control system by associated programmable controllers. These data are processed appropriately within the display system and are shown clearly for every plant level down to the component level. The use of plant-specific design data ensures that with a standardized operator interface the client can carry out an accurate and individual diagnosis of his machines. 29

In addition to display and diagnostic systems Möllers also offers

This is a data transmission system which can be used throughout

Via a modem link Möllers software engineers can dial into the

With an appropriate software tool it is then possible to carry

30 In addition to display and diagnostic systems Möllers also offers the TeleDiag remote diagnostic system. This is a data transmission system which can be used throughout the world. Via a modem link Möllers software engineers can dial into the control system of a machine. With an appropriate software tool it is then possible to carry out a detailed remote diagnosis from the Möllers control centre in Beckum. This is appropriate both for commissioning and during clientspecific modifications: it saves time and reduces costs. 30

The use of the remote diagnostic system provides the client with a powerful tool which, in

availability locally to a level never reached before.

qualified Möllers technical team is capable of restoring stable plant conditions in the

The company headquarter in Beckum Möllers a name for security and reliability in the

31 The use of the remote diagnostic system provides the client with a powerful tool which, in addition to the display and diagnostic systems, makes it possible to raise the plant availability locally to a level never reached before. With installed video systems any changes are also immediately transparent and the highly qualified Möllers technical team is capable of restoring stable plant conditions in the shortest possible time. The company headquarter in Beckum Möllers a name for security and reliability in the bagging, palletizing and despatch technology. By using consequently the most modern and latest technology, quality of the machineries is improved continuously so that Möllers will also set standards in future. 31

HSA-Vario Automatic Transverse Stretch Hooder

MASCHINENFABRIK MÖLLERS HSA-Vario Automatic Transverse Stretch Hooder NORTH AMERICA Best Quality in Stretch Hood Technology Product Stretch Technology for Greatest Demands Securing pallets with stretch