Nothing Moves Without Us

Transcription

1 GB Nothing Moves Without Us Manufacturer of chains and sprockets for heavy industries 90 YEARS IN MOTION

2 Jan Schmelzer Sales Support Florian Gies Sales We are KettenWulf 04 KettenWulf global 06 Partners to industry 08 KettenWulf conveyor chains 10 KettenWulf roller chains 12 KettenWulf sprockets 14 KettenWulf components and special parts 16 Development, production, installation, after-sales 18 Industry solutions 20 Public transportation 22 Bulk material handling industry 24 Wood industry 26 Paper industry 28 Automotive industry 30 Steel industry 32 Hydropower industry (Dams and Locks) 34 Food industry 36 Insulating material industry 38 Machine and plant engineering 40 Wastewater treatment 42 Our production at a glance 43 Certification 44 Quality in all production processes 46 Eco Evolution Technologies 48 Research and development 52 Quality management

3 Peter Keggenhoff Sprocket Production, Germany Ingo Schulte Plant Sieperting, Germany

4 Julia Wulf General Manager Tobias Wulf General Manager Ansgar Wulf General Manager Günter Wulf President

5 90 YEARS IN MOTION 3 KettenWulf trustworthy and reliable KettenWulf: A name which has been synonymous with superior product quality in the manufacturing of chains and sprockets for over 90 years. A name which also signifies customer focus, reliable product quality, personal service and improved customer profitability. We concentrate our attention on those factors which are relevant for both current and potential customers these factors form the basis of all our activities. Trust in technology: In our world-wide production and quality management, we have always placed great importance on the use of leading-edge technology. Providing the best possible quality to our customers is an integral part of our company s commitment, and we employ state-of-the-art machines, tools and production methods to achieve this goal. Quality by intelligence: Our staff is our capital, representing our company in all phases of our interaction with you, the customer. Our sales engineers are flexible and are always ready to give their very best to meet your needs. We put our creativity and our staff s dedication at your disposal in developing tailor-made solutions for your company. We are only satisfied with our work if you are fully satisfied, too. Clients first: Anyone who has conducted business with our company will know how serious we take this phrase. We do not see your questions and requests as problems, but as a challenge. We are there for you whenever you need us always and at any time. We will convince you of the efficiency and reliability of our products over and over again by meeting your requirements. We consistantly review our range of services and products to ensure that our customers needs are satisfied. Our aim is to always give our best for you. Profitability and result oriented: Each project you work on with us will always be a clear investment in improvement. This gives you security of investment and costs another good reason to place your trust in a business relationship with our company a relationship intended to last. Günter Wulf President

6 4 KettenWulf global The main factory in Kückelheim not only houses the company headquarters, but also the KettenWulf Engineering Centre. Here we provide worldwide support for customers in all technical issues. Kückelheim, with a production area of 30,000 square metres and a staff of roughly 550, is the largest production facility of the worldwide KettenWulf Group. KettenWulf production facility in Sieperting, Germany

7 5 Top left: Our central European storage and sales facility in Ghent, Belgium Top right: Production and sales facility Ferlach, Austria Bottom left: The Chinese production and sales facility in Hangzhou Bottom right: Warehouse and sales facility in Atlanta, USA For over 90 years, KettenWulf, as an expanding global company, has stood for quality, reliability and flexibility. More than 1400 employees develop, produce and market customized solutions in the field of conveying and drive technology at ten locations across Europe, America and Asia. All around the globe, KettenWulf is your strategic partner when it comes to delivering optimal product quality. Be it the Sauerland, Hangzhou, Atlanta or Pune as an international company with worldwide operations, our employees are always at your service to meet your unique business needs and to provide you with industry leading technical support. Trust, loyalty and commitment these values are what KettenWulf stands for. As a medium-sized, family-run company, cultivating a strong, personalized partnership with both our customers and suppliers is our highest priority.

8 6 Partners of the industry KettenWulf as a developer and manufacturer of chains and sprockets provides tailor-made solutions in the conveyor and drive engineering sector. Since the individual requirements of every customer are different, KettenWulf provides customized product solutions for all industries. Our engineers and technicians develop special chain systems, adapted to suit specific environmental conditions. Production and management processes certified in accordance with DIN EN ISO 9001:2008, together with the KettenWulf Competence Center in Kückelheim, ensure that KettenWulf s high-quality standards are adhered to all around the world. Specialist engineers at the Competence Center offer their expert knowledge for our top-class product developments worldwide. Almost every industry benefits from our knowledge. Wherever things need to be moved, conveyor or drive technology is involved. We commit our expertise and 90 years of experience to the development of high-quality products in order to enhance product performance and service life. We are partners to all sectors of the industry. For example: in the steel production. Our conveyor chains move multi-ton steel coils at a temperature of 1,000 C precisely and reliably through the various production stages.

9 7 Conveyor chains Roller chains Sprockets Components

10 8 Low-maintenance and lubrication-free chains provide economical and ecological advantages as well as cost reduction in the service and maintenance sector. This illustration shows an example of lubrication-free technology for the escalator industry. KettenWulf conveyor chains KettenWulf is a leading manufacturer of high-quality conveyor and transport chains. Our chains are used in a broad range of applications in a wide variety of industries from automotive production, bulk material handling conveyors to the wood industry. Since the individual requirements of our customers are different, KettenWulf develops specialised conveyor and transport chains, adapted and optimised to suit your specific requirements.

11 9 Tailor-made precision for all industries KettenWulf develops and manufactures special conveyor and transport chains of all types and sizes, for applications in all industrial sectors. We also manufacture standard chains to DIN, ISO and ANSI specifications. Our product range includes galle chains, drawbench chains, block chains, lantern pinion, lifting chains and hinged gear racks for waterway locks and weirs. Figure 1: Chain for the cement industry 1 2 Figure 2: Conveyor chain for paint shop in automotive production Figure 3: Galle chain for dams and locks 3 4 Figure 4: Double-strand chain for paper roll transport Figure 5: Conveyor chain for roller coaster 5 6 Figure 6: Step chain for escalators Figure 7: Conveyor chain for final assembly in the automotive industry 7 8 Figure 8: Steel mill chain for coil transport

12 10 KettenWulf your partner for high quality roller chains. KettenWulf roller chains From applications in various industrial production plants to the use in agricultural machinery KettenWulf offers the ideal roller chain for your particular requirements. Whether you want to use a chain subjected to continuous stresses or with a high resistibility against temperature changes and corrosion KettenWulf always has the perfect solution. We offer an extensive range of roller chains in all sizes for a wide variety of applications. We offer you roller chains according to DIN and international standards.

13 11 Quality ensuring maximum service life High performance roller chains and bush chains for drive and conveyor systems are available from stock. Every day new solutions are successfully developed for special applications. Figure 1: Hollow-pin chain 1 2 Figure 2: Sharp-top roller chain Figure 3: Leaf chain 3 4 Figure 4: KettenWulf roller chain with straight link plates Figure 5: Polymer block chain 5 6 Figure 6: Roller chain for sensitive product handling Figure 7: X-ring roller chain 7 8 Figure 8: BS-HP hollow-pin chain

14 12 KettenWulf produces sprockets in various dimensions and designs according to customer requirements. KettenWulf sprockets Sprockets are a crucial factor in the efficiency and service life of any chain system. For this reason, we at KettenWulf manufacture our own sprockets, since chain and sprockets from one source ensure maximum operational hours. Besides sprockets in all DIN/ ISO/ ANSI standard pitches and tooth forms, our product range includes tailored solutions with optimum tooth shapes and sprocket sizes. Whether you need sprockets of highgrade material, special heat treatment or inductionhardened teeth KettenWulf always has the right solution for you.

15 13 Optimum tooth designs for all chain types For all chains, KettenWulf also provides the matching sprockets. Besides sprockets with tooth profile acc. to DIN standards, we can also manufacture sprockets with optimized tooth forms and milled surfaces. Sprockets made of high-grade materials, heattreated and with induction hardened teeth are part of our standard production program. Our production range includes all sprocket designs such as sprockets with one-sided hubs and sprockets with two-sided hubs, split-type sprockets with detachable tooth segments or tooth gaps, shear-pin sprockets, pinion sprockets or sprockets with our patented noise dampening system. Figure 1: Sprocket with detachable tooth gaps 1 2 Figure 2: Double sprocket with intermediate gaps Figure 3: Triple sprocket 3 4 Figure 4: Sprocket with intermediate gaps and lightening holes Figure 5: Sprocket with saw toothing 5 6 Figure 6: Pinion sprocket Figure 7: Sprocket with segmented rim 7 8 Figure 8: Sprocket with patented noise dampening system

16 14 Drive shaft for the escalator industry KettenWulf components and special parts As a leader in conveyor and drive technology, KettenWulf has established itself as a supplier of special components. Apart from manufacturing drive and tail shafts, we also mount complete drive shaft systems consisting of axle, sprockets and bearings. These shafts are completely assembled at our factory and delivered to our customers as a ready-to-install package. Special parts such as planetary axles or gear cover are further examples of our vast product range.

17 15 Individual solutions We always stay at the cutting edge of our business. As a result, we take advantage of our vast experience and in-depth expertise that we have gained throughout the years to promote new, promising industries. This enabled us to advance into new markets such as the renewable energy industry. Likewise, we are able to offer our customers this extensive know-how so as to develop a product solution perfectly geared to meet their individual requirements. Figure 1: Completely mounted drive shaft 1 2 Figure 2: Axle for large planetary gears Figure 3: Cover for large planetary gears 3 4 Figure 4: Drive shaft for hydraulic engineering Figure 5: Drive shaft for hydraulic engineering 5 6 Figure 6: Tail shaft for the bulk material handling industry Figure 7: Pinion rack 7 8 Figure 8: Drive shaft for bucket elevator

18 16 Development, Entwicklung, Produktion, production, Montage, installation, After after-sales Sales What we can do to assist you Our work is characterised by expertise, experience, efficiency and a high degree of commitment. Our products ensure your long-term, sustainable success. And for this reason, we offer you the use of our services from the very start, making us a reliable partner for your conveyor and drive engineering needs. KettenWulf combines a whole range of highly-specialised fields of expertise to support your projects. We have efficiently networked individual services to achieve the very best solutions for your products.

19 17 Do you have any questions regarding state-of-the-art conveyor and drive technology and are you looking for a partner with a worldwide organization network to assist and support your projects? Then do not hesitate to contact us we consider technical advice and related services to be an essential part of our work. Our experienced engineers and technical staff are always available to answer your questions.» Development: We develop and design the best possible conveyor and drive engineering solutions corresponding to your needs and requirements.» Production: We use state-of-the-art technology to manufacture special conveyor chains, drive chains and sprockets for you.» Installation: If you wish, our reliable and trustworthy partners can handle your on-site installation work.» After-sales: Upon request, we can inspect and check the condition of your chains and sprockets with respect to their functional capability and remaining service life.

20 18 Industrielle Anwendungen Industry solutions

21 19 Products which move entire industries For decades notable vehicle manufacturers have utilized KettenWulf drive and conveyor systems. OEMs trust KettenWulf, because we understand the needs and requirements of the automotive industry. KettenWulf combines the expertise of each department, from Research & Development, to Production and Assembly, in order to provide the best product tailored to your individual transport and conveying needs. Through our extensive experience and knowledge gathered from working with the automotive industry, we can provide innovative, economical and ecologically responsible chain solutions. Our customers are already benefitting from the use of our low-maintenance and lubrication-free free technologies. Our conveyor chains, roller chains and sprockets are used all over the world. Innovative developments, high-quality materials and manufacturing precision are what make the difference. That is why many well-known manufacturers from all sectors put their trust in KettenWulf s products and services. These include manufacturers of» Public transportation» Bulk material handling industry» Wood industry» Paper industry» Automotive industry» Steel industry» Hydropower industry (dams and locks)» Food industry» Insulating material industry» Machine and plant engineering» Wastewater treatment industry

22 20 Public transportation Without our chains, entering this museum would be a sporting challenge. As a leading global manufacturer of conveyor chains, drive chains and sprockets, KettenWulf has been providing innovative solutions in drive technology for escalators and moving walkways for many decades. Our products improve running smoothness and ride comfort and meet the high safety requirements in passenger transportation. Precision-fit production processes: Regular quality checks and the precision of our production processes substantially reduce wear and increase the service life of our chains. Heavy loads, high conveying heights, long moving walkway lengths and chain lift lengths do not pose a problem.

23 21 Figure 1: Escalator step chain for heavy duty escalators, requiring oil lubrication, with outside mounted ball bearing rollers and internal steel protection rollers 1 4 Figure 2: Escalator step chain for heavy duty escalators, with grease nipples for greasing the chain joints, outside mounted ball bearing rollers and internal steel protection rollers 2 5 Figure 3: Non-back-bending double strand escalator step chain for heavy duty escalators, with axles and fixing components mounted on the axle, on the outside with ball bearing rollers and in the inside with steel protection rollers 3 6 Figure 4: Lub-free escalator step chain with internal ball bearing rollers for commercial escalators and escalators with lower high-rises Figure 5: Lub-free chain with internal ball bearing rollers for moving walkways, shown including paletts Figure 6: Roller coaster chain Escalator As a long-standing partner of leading manufacturers in the escalator industry, KettenWulf generated a high development potential. Solutions and developments in the noise reduction and low-maintenance chain technology fields are just a few examples of what customers in the escalator industry have come to rely on. Thanks to the high demands on safety and quality, it is not only in department stores, underground railways and airports that KettenWulf escalators and moving walkways contribute towards the smooth progress of visitors. Amusement Visitors to amusement parks link rollercoasters with excitement and fun. For KettenWulf, the focus is on the fairground operator`s high safety requirements and on the latest production technologies. When it comes to applications in the amusement industry, in particular, equipment manufacturers always face high market pressure to offer the most spectacular attractions. With KettenWulf at their side, customers have a reliable partner whose know-how in various industries will advance further developments. The care taken in product development, production and quality inspections enable the reliable and maintenance friendly use of the chains and sprockets in rollercoasters and water rides.

24 22 Bulk material handling industry Without our chains, the transportation of bulk material with a temperature of 700 C would be too hot to handle. For almost all transportation processes in the bulk material handling industry KettenWulf develops and produces optimal chain designs. Continuously cooperating with equipment manufacturers around the world, we are able to offer innovative and efficient products of the highest quality. Be it coarse or fine grained bulk materials or goods with corrosive or abrasive characteristics, Ketten- Wulf provides special chains and sprockets for the transport of nearly all bulk materials such as: clinker, gypsum and clay for cement production, granulates in fertiliser production, coal, coarse-grained ore, crushed stone, limestone and slate in the mining industry, biomass, coal, slag and quartzite in power stations, polymers in the production of plastic, wood chips in the wood and paper industry, punching waste or scrap in the automotive and metalworking industry, recycling materials in waste separation facilities. High flow rates of material with temperatures of up to 700 C, centre distances of 250 m, high lifting heights and conveying capacities of over 1000 m³/h are some of the main challenges the bulk material handling industry faces. This is why the transport of bulk materials by special chains ranks among the most efficient transport solutions. KettenWulf offers future-oriented chain technology for many different applications in the bulk material handling industry, e.g.» apron conveyors» hinged conveyors» pan conveyors» trough chain conveyors» scraper reclaimers» bucket elevators KettenWulf meets the special requirements of this industry with chain components made to the strictest tolerances, optimal press fits and fatigue resistant materials with superior surface qualities. Moreover, KettenWulf provides technical on-site support to select the best combination of chains and sprockets based on the specific working conditions of the application.

25 23 Figure 1: Central chain for high performance bucket elevators 1 2 Figure 2: Back locked conveyor chain with bent link plates Bucket elevators The use of KettenWulf bucket elevator chains in mechanical vertical conveying has become an indispensable link between different production steps in various industries. Using high-strength materials and high levels of manufacturing precision, KettenWulf offers individual solutions for high performance bucket elevator chains in double strand and central implementations. High-performance bucket elevator chains are primarily used for vertically conveying bulk material, silo feeding and in clinker milling. KettenWulf bucket elevator chains fulfil the highest technical requirements in terms of wear resistance and dynamic loads, as well as in the conveying of abrasive media. For example, bucket elevators are used in cement works, asphalt works, fertiliser factories or steel mills. Apron and pan conveyors Apron and pan conveyors are designed with a single strand or double strand chain configuration and can have attachments on one or both sides. They can be found in applications such as crushers and bunkers for loading and discharge of materials. In general, both types of chain need to stand up to extreme shock loads and highly abrasive ambient conditions in these fields of application. Conveyor chains with a pitch of 160 mm, 250 mm, 315 mm or bigger and breaking loads of kn offer the possibility of handling a large variety of customer-specific requirements. Given the superior quality standards as well as the high degree of customisation of our products, KettenWulf plays a vital role in creating sustainable competitive advantages for our customers. Figure 3: Drag chain with welded scraper fastening and exterior, maintenance free roller Reclaimer systems The stacking and homogenising of bulk materials, in particular of raw material and coal, is carried out by means of various reclaimer systems. For this application, KettenWulf offers a wide selection of conveyor chains, engineered to meet special on-site conditions like high impact loads, abrasive and corrosive media, heat and dust. 3

26 24 Wood industry Beispielbranche Our chains are used for transporting, not for wood cutting. Leading equipment manufacturers as well as plant operators worldwide put their trust in chain technology made by KettenWulf. In close collaboration with these customers, we develop and manufacture individual and innovative product solutions at the highest quality level. We have invested 90 years of research, production and service in the development of cutting-edge technologies, which results in a broad range of both time proven and technically matured products for the wood handling industry and the OEM market. Always considering the high requirements of the respective operation purpose, our engineers and designers develop optimal solutions for nearly all conveying processes of the wood industry, such as» Log transport» Sawing line and plank transport» Wood chips handling» Wood processing

27 25 Figure 1: Chain for log transport 1 2 Figure 2: Chain for wood chips handling Log transport In the log yard KettenWulf conveyor and drive chains are used in different processes such as the log infeed conveyor, root reducer, trimming station, sorting strand and log turner. The requirements on the chains and sprockets are extremely high and usually as versatile as the various production steps in wood handling. KettenWulf meets these demands by the highest product quality to guarantee an optimal service life and thus optimal plant availability for our customers. Sawing line and plank transport Chains for the sawing line and plank transport are available in many different designs. KettenWulf offers a wide range of conveyor and drive chains adjusted to meet the special requirements of each individual conveying task. Our conveyor chains are used in the sawing line, the canter infeed, plank separation and plank storage as well as palletisation. Wood chips handling Wood chips handling has to be dealt with in many steps of wood processing. For instance, wood chips are left over during root reduction, at the trimming and debarking stations or at the sorting and storage areas. Conveyor chains help to keep these installations clean and therefore contribute to a smooth operating process. Moreover, KettenWulf conveyor chains are also used in the recycling industry, e.g. for the infeed of combustibles. Wood processing KettenWulf also offers special and standard chains for the wood processing industry. Given our in-depth expertise and the many years of experience in this particular industry, we are able to provide solutions geared towards your individual conveying application. It does not matter if you send us a drawing, a sample or even just an idea based on the information provided, our engineers and designers will work out an optimal product solution to meet your specific needs. Our products can be used in nearly all wood-related industries such as» Chipboard industry» Furniture industry» Glulam industry» Paper industry» Planing mills» Wood profiling machines

28 26 Paper industry Around the world, 400 million tons of paper is produced each year. This volume needs to be transported as well. In the paper industry KettenWulf chains are used to transport paper rolls, recycled paper and cellulose as well as to move logs through pulp processing operations. KettenWulf has developed specific non-lubricated chains with screwed-on carrier plates for transporting paper rolls. This innovative technology lowers maintenance and operating costs and leads to substantial savings when the attached carrier plates are re-used.

29 27 Figure 1: Double strand V-shaped slat conveyor chain 1 2 Figure 2: Double strand apron conveyor with top plate Figure 3: Triple strand slat conveyor 3 4 Figure 4: Grinder chain Chains for the paper industry: In the paper industry, conveyor chains are especially used for recovered paper. Grinder chains mechanically defibre tree trunks and slat conveyors are used to transport rolls of paper.

30 28 Automotive industry As a car has not yet been filled up with fuel, we are on hand to help it along. A high level of plant availability and minimal servicing costs are the basic requirements for an optimum production flow in automotive manufacturing. As a specialist in this field, KettenWulf has long been a competent supplier to many well known car manufacturers around the world, as well as for their original equipment manufacturers. As a result of comprehensive consultancy at a technical level and customised engineering, we supply high-quality product solutions which are optimally suited to the different requirements of your respective application. In order to not only satisfy the present, but also the future needs and demands of our customers, we make continuous improvements to our products and invest in the development of future-oriented technologies. For example, you can already benefit from our low-maintenance and/or our lubrication-free chain designs today.

31 29 Figure 1: Conveyor chain for spray booth 1 2 Figure 2: Double-strand conveyor chain with mounted wheel carrier plates Chains for longitudinal conveyors In automotive plants, car bodies go through many different production steps such as spraying and painting, drying or grinding. Most of the time they are transported longitudinally on a skid or support frame which is connected to the chain by means of special carrier plates or attachments. The Ketten- Wulf product portfolio includes» Chains with prism-shaped support» Chains with non-stick coating» Chains with welded carrier plates» Lubrication-free chains» Chains for operating in temperatures of up to 250 C Chains for slat conveyors Slat conveyors are used to transport the car bodies or vehicles on a skid in different process sections. Among others, this applies to:» Grinding (body shop)» Final assembly» Finish and filling» Water test» Conservation It is mainly lubrication-free chain designs that are used here. These offer little maintenance efforts and thus low operating costs. Chains for cross transfer conveyors Cross transfer chains are commonly used in various areas of automotive production to connect different conveyor lines and production steps. The car bodies are drawn off one line to be transferred crossways onto the next conveyor. High reliability is essential to ensure a smooth and fast transition of the car bodies in these applications. The KettenWulf cross transfer chains are designed to meet the individual technical requirements of each conveyor line and make an important contribution to securing the highest operational and occupational safety standards in automotive production. For instance, many of the chains used in these kinds of applications are lubrication-free. Other chains are especially designed to allow forklifts to go over them or to be protected against drippings falling from the car bodies after pre-treatment or similar production steps. In order to improve the working conditions by minimising noise emission at workstations, the sprockets for cross transfer conveyors can also be equipped with a special noise-dampening system according to KettenWulf patent. Chains for submerged body conveying Prior to receiving their final coating, all car bodies need to be cleaned off dirt and debris from previous production processes to obtain a good paint finish. This takes place in the so-called pre-treatment lines where the car bodies circulate through a series of dip tanks. Afterwards, the car bodies move on to the ELPO (electrophoretic priming operation) lines to receive their base coat. In both operations, the bodies are totally submerged to make sure that no part is left untreated. KettenWulf offers product solutions for two types of conveyor systems:» RoDip conveyors» Pendulum conveyors

32 30 Steel and aluminium industry Not everything that is round, is easy to move. For 90 years, the KettenWulf Group has been developing and manufacturing special conveyor chains for the steel, metallurgical and aluminium industries worldwide. Our product range covers conveyor chains for the entire production process from stockyard technology for coal and ores, to applications in powder metal facilities, furnaces, steelworks, casting machines and roller mills up to transport and looping tower chains in hot and cold-rolled areas. High-performance products of premier quality, strict compliance to the most extreme specifications, innovation and a complete focus on our customers demands form the basis of our leading reputation. High demands are made on the chains on account of the very heavy transport weights and extreme environmental influences. We develop the latest in chain technologies in order to satisfy the complex requirement profiles from various areas of steel production and processing. Be it to reduce wear on reclaimer chains in ore and coal mixing beds due to abrasion, to enhance temperature resistance in hot material transport or to obtain highest precision for roller chains used in looping tower applications these challenges represent just a small part of the tasks on which we have worked in the past in order to develop successful product solutions.

33 31 Figure 1: Coil transport chain 1 2 Figure 2: Cold strand chain as start-up chain for continuous casting Pig-iron moulding In ingot casting and continuous casting, chains need to withstand temperatures of up to 1000 C and weights of up to 33 tons. This requires comprehensive know-how, which KettenWulf has not only gained through extensive and close collaboration with world-leading OEMs, but also through the many field operations worldwide that use KettenWulf chain technology. Successful chain technology in pig-iron moulding is based on complex geometries, highly wear resistant chain joints and temperature resistant materials. Pig-iron preparation Low-maintenance reclaimer chains for the handling of coal, iron ore and other additives as well as pan conveyor chains for charge preparation are only two of the many product solutions in which we have proven our superior technical capabilities. Chain designs made by KettenWulf include lifetime lubricated support rollers and innovative sealing systems for chain joints to allow for an extended service life of each conveyor system. Attachments can be designed according to your specific requirements. The use of special materials in combination with the highest manufacturing precision and respective heat treatment of the individual chain components increase the resistance of our chains to high temperatures and wear considerably. Secondary conveying Secondary conveying implies the transportation of either waste products such as metal scrap and slag or products which still need to be further processed, e.g. to add a certain coating. For all these purposes, KettenWulf has developed different chain types with specifically adapted product features. Transport of finished products Be it pipes, sheets sections, wire or coils for the transport of finished products, KettenWulf offers a large variety of products which are particular engineered to operate different weights at different speeds and temperatures. This also includes customised carrier plates or attachments, heavy-duty or low-maintenance rollers.

34 32 Hydropower industry (dams and locks) We are required to illustrate size in every dimension. In the water treatment, KettenWulf products are used in dams and locks. Both in power production by impoundment and in lock systems in inland water navigation or in harbour areas our chain systems ensure trouble-free operation. Due to maintenance-free chains with slide bearings, which do not require relubrication, operating costs can be reduced and strict environmental constraints can be satisfied, too.

35 33 Figure 1: Galle chain with anti-corrosion coating, breaking load: 3300 kn 1 2 Figure 2 : Maintenance-free chain with fixed axles Galle chains In the hydropower industry, galle chains are used on the dams to operate the tainter gates or on the water gates to move the gates of the lock-chambers, allowing vessels to pass through. The majority of time custom installation is required for the project. Our customised products are perfectly engineered to satisfy the technical requirements. The high quality of our chains guarantees a long life and a high level of reliability for your installations. Maintenance-free galle chains Protecting the environment has become an important factor in the design and modernization of installations. Our customers are increasingly using maintenancefree chain technology. KettenWulf is the undisputed leader in this sector and offers two types of chains: chains with fixed pins and chains with floating pins. Both are produced from stainless steel and their link plates are fitted with self-lubricating bushings. These chains do not need to be relubricated and do not require additional maintenance work. Their use allows product service life to be extended and contributes to a reduction of maintenance costs as well as a reduction in pollution caused by lubricants. Figure 3: Galle chain with anti-corrosion coating, breaking load: 3300 kn 3 4 Figure 4 : Maintenance-free chain with floating pin Floating pin chains are equipped with self-lubricating bushings in all link plates (inner and outer).

36 34 Food industry We define the term food chain somewhat differently. KettenWulf offers a large variety of products for the food industry. Our chains are used in the production of baked goods, the processing of fish, meat, vegetable, fruit and sweets, as well as the bottling of beverages. We also have speciality products for the further processing of coffee, tea, and tobacco. In order to meet the hygiene standards of the food industry, we offer particular acid and corrosion resistant products which do not require any relubrication.

37 35 Figure 1: bush conveyor chain with one-sided welded attachment angle 1 Figure 2: bush conveyor chain with one-sided extended pin 2 Figure 3: universal joint chain with outboarded roller and folding carrier 3

38 36 Insulating material industry Offering efficient* technology in the manufacturing of products: We make a good match. Conveyor chains and sprockets are used in the manufacturing of insulating material products in blow chambers, curing ovens and/or drop shafts. Extreme environmental conditions with aggressive and abrasive media, temperatures of up to 300 C and high conveying speeds require special chain designs with optimum manufacturing quality. * With the production of insulating materials, the insulation industry manufactures an important product for improving energy efficiency in the field of construction.

39 37 Figure 1: Support chain for curing oven, pitch 70 mm 1 2 Figure 2: Support chain for curing oven, pitch 80 mm Figure 3: Curing oven chain, pitch 150 mm, breaking load 400 kn 3 4 Figure 4: Curing oven chain, pitch 160 mm, breaking load 440 kn Figure 5: Curing oven chain, pitch 175 mm, breaking load 600 kn 5 6 Figure 6: Spinning-forming chain, pitch 70 mm, breaking load 325 kn Figure 7: Spinning-forming chain (heavy duty version), pitch 70 mm, breaking load 500kN 7 8 Figure 8: Spinning-forming chain, Pitch 152,4 mm, breaking load 400kN

40 38 Machine and plant engineering As constant as the german purity law. In the field of machine and plant engineering, KettenWulf has been successful for many years in various industries and has served many leading OEM s with innovative and high-performance products. The expertise of a strong partner is indispensible. This especially applies to the field of machine and plant engineering which includes the following sectors:» Chemical industry» Glass industry» Industrial oven construction» Warehousing and storage» Mill construction» Wind power industry» Beverage industry These individual fields and industries hold many different challenges for chain technology, e.g. complex and long conveyor design lines, great lifting heights, high temperatures or extremely abrasive and corrosive environments. To meet these difficult requirements, KettenWulf always works in close collaboration with their customers to find the optimum production solution for the respective operation purpose. This includes a wide spectrum of professional consultation and onsite technical support.

41 39 Figure 1: Chain for Chemical industry 1 2 Figure 2: Axles for planetary gear systems on wind turbines Chemical industry In the chemical industry, the chains have to stand up to various stresses and strains. This is why Ketten- Wulf mainly engineers customised product solutions which are perfectly adapted to the ambient conditions prevalent in this industry. Glass industry KettenWulf chains can be found in a large variety of applications in the production, onward processing and recycling of glass. Most typically, slat conveyors are used to transport waste glass, scrap glass, raw glass or aggregates. Mill construction The trough conveyor chains used in this area offer an optimum transport solution for the various products. In addition, they can be adapted to specific customer requirements. For example, if certain hygiene regulations have to be adhered to or if low-maintenance technology is asked for. Industrial oven construction The conveying of materials in high temperature ranges places particular demands on chains. To meet these requirements, we use special materials that guarantee increased temperature resistance and optimised wear resistance. Wind power In the economic development of wind as a renewable energy source we support our customers with the latest drive systems. As an important supplier to the international wind energy industry, we are aware of the great responsibility that this entails. Quality, capacity and a global outlook are key challenges for us. Warehousing and storage Many manufacturers of storage systems have long trusted KettenWulf chain technology. Our chain systems are often used in applications where goods are stored, e.g. in paternoster elevator systems for storing steel sections, pallet stores, carpet roller systems in DIY stores and car tyre dealerships. Due to the different weights that can have an impact on the chain systems, the chains - such as hollow pin chains - are customised to match the respective loads. Beverage industry KettenWulf offers a variety of different chains for the beverage industry, ranging from simple designs to special chains that are adapted to the specific needs of the customer. For instance, our product portfolio includes chains which are reduced in weight or chains made of standard materials, high-strength materials as well as stainless steel materials - in every dimension conceivable and necessary for the customer. Palm oil For several years, KettenWulf has produced chains and sprockets for the palm oil industry with growing success. Mainly, these are 4 and 6 inch chains which are used to either transport palm oil fruit for further processing in the works or for taking the pressed fruits to composting.

42 40 Wastewater treatment industry Technology which enables millennium development goals to be reached: Securing water resources! KettenWulf provides a wide range of chains in the field of wastewater treatment. Using the latest technologies, they ensure a great degree of flexibility in water abstraction and sewage treatment systems. Whether for water purification or water abstraction, each chain is engineered in accordance with the individual needs of the customer as well as the requirements of the specific system. * Millennium goals: Improving the protection of the environment The seventh development goal from the UN millennium declaration. Besides standard materials, KettenWulf also uses high-strength materials (coated or galvanised) and different corrosion-resistant, stainless steel materials for production which underlines yet again our technological leadership as a supplier to this industry. Furthermore, KettenWulf chains and sprockets are used in coarse and fine screens as well as in sieve systems.

43 41 Figure 1: Bush conveyor chain for fine screen systems 1 2 Figure 2: Bush conveyor chain for coarse screen systems Figure 3: Bush conveyor chain for band screen systems 3 4 Figure 4: Bush conveyor chain for scraping systems Figure 5: Zinc-plated bush conveyor chain for band screen systems 5 6 Figure 6: Stainless steel bush conveyor chain for band screen systems Available chain types:» standard material» chains with anti-corrosion coating» zinc-plated chains» stainless steel chains made of V2A» stainless steel chains made of V4A» stainless steel chains made of duplex steel

44 42 Our production at a glance CNC lathes are used to produce parts of our chains with utmost precision. We deliver only the best quality products. To ensure this, we only use the most modern machines and manufacturing methods. Furthermore, our quality management and R&D department are engaged in the constant enhancement of our product quality. To ensure the continuous high quality of our products at all levels, practically all the individual parts of our chain products are made in-house by our own staff. Customer satisfaction and confidence are the corner stones of KettenWulf s policy. To ensure constant high product quality, KettenWulf has obtained certification to prove the compliance of its quality management system with the strict requirements of DIN EN ISO 9001:2008. In order to meet our customers quality demands and ensure long product service life, we have implemented quality management procedures in all production and management processes. From incoming goods inspection to final testing and inspection, we take the utmost care to supply only the very best quality products to our customers.

45 43 Quality certified in accordance with DIN EN ISO 9001:2008 Laser cutting: KettenWulf utilizes laser-cutting technology for the production of link plates, which require extreme precision. It also makes the production of plate components with complex contours possible. Heat treatment: We use two different heat treatment processes for the components of our chains and sprockets case-hardening and induction hardening. With these processes, we create chain links with greater friction resistance. Induction hardened sprockets reduce the wear in the tooth gaps, thus ensuring optimum interaction of chains and sprockets over longer periods.

46 44 Mechanical processing: KettenWulf uses only the latest CNC technology in the mechanical processing sector. This makes it possible not only to turn bushings, pins and rollers, but also mill link plates, sprocket teeth and pitch borings. Variable designs are no problem at all, thus enabling us to meet special customer requirements. To ensure a perfect fit, KettenWulf uses precision grinding machines for all bushes, pins and rollers to achieve very tight tolerances. Welding technology: All welding is carried out by our own welding division. State-of-the-art MIG and MAG processes are used here for production. In order to ensure constant high quality, we use partially automated and fully-automated welding equipment to manufacture our products.

47 45 Quality in all production processes Punching: Modern punching technology allows continuous production of link plates and attachments. At KettenWulf, we produce our own punching tools. Using special production methods we can ensure a very high pitch accuracy of our chains. Shot peening of link plates and attachments ensures further quality improvement. Metal-forming: To bend attachment link plates or attachment angles, the bending zones of the work piece are initially heated up through induction. This prevents bending cracks and considerably increases the service life of the link plates. Final assembly: During the last production step the individual components of the chain are assembled by hydraulically operated presses. After the final inspection, the products are shipped to the customers.

48 46 Technologies Product development in harmony with our environment.

49 47 KettenWulf lives environmental protection It is not just our head office in the rural Sauerland which is our direct connection to nature. Rather, our claim to act sustainably is something which determines our daily work. We represent this basic principle in all our sites worldwide, not only by meeting legal stipulations, but also by pursuing even higher standards which we define ourselves. Environmental resources enter our investment considerations as an important factor. As such, we always make our decisions based on an awareness of a sustainable economy. If nothing else, the results of these actions are reflected in our project developments. For example, we channel our forces into:» Chains designed for achieving a better energy efficiency» Lubrication-free technology saving on resources and maintenance work» Noise absorption systems for the benefit of people and the environment

50 48 Research and development By means of wide ranging test runs on our test beds, the quality products from KettenWulf are constantly checked and developed further in our R&D department.

51 49 Low-maintenance and lubrication-free chain technology Our large and well-equipped testing laboratory carries out the following basic examinations and tests on a regular basis:» Service life testing of chain components» Ability to withstand aggressive media» Roller wear testing» High-temperature testing» Fatigue strength testing of chain components This ensures a good lubrication of the chain joints over a long period of time. Therefore, the service life of the chain increases considerably at a simultaneous reduction of the relubrication intervals and the costs incurred, e.g. costs for the lubricant, its disposal and relubrication costs. Please contact us for further information about possible areas of operation for low-maintenance chain technology. We have developed various sealing systems particularly for chains operating in abrasive or corrosive media. These sealing systems protect the chain joints against any kind of damaging, external influences which can enter the chain joint. Figure 1: Low-maintenance bush conveyor chain with patented gasket seal 1 2 Figure 2: Lubrication-free bush conveyor chain Figure 3: Lubrication-free bush conveyor chain with patented sealing system 3 4 Figure 4: Sandwich sealing system for lubricationfree chain joints

52 50 Sprockets with noise dampening system The noise that occurs while the chain engages into the sprocket is oftentimes disturbing and annoying. To decrease this noise efficiently and to improve the working conditions, KettenWulf has developed different noise dampening systems. These systems see to it that the chain joints are smoothly guided into the tooth gap, which leads to a considerable noise reduction. The selection of the most suitable noise dampening system depends on the respective application. Figure 1 and 2: Sprocket with patented noise dampening system 1 2 Figure 3 and 4: Sprocket with special, round noise dampers 3 4 Figure 5 and 6: Sprocket with special rectangular noise dampers 5 6

53 51 Innovation in chain and sprocket technology Over the past many years, there has been a strong increase in the demand for low-maintenance and lubrication-free chains. More and more customers are choosing chains of this type, mainly out of economic and ecological considerations. The advantages are obvious, as the use of low-maintenance and lubrication-free chains greatly due to maintenance and service costs. Since in most cases, post-installation lubrication is no longer necessary in many applications, the possibility of subsequent lubrication and maintenance faults is thus eliminated. KettenWulf has developed a variety of seals for chains for use in special environmental conditions. These seals prevent the entrance of dirt and fluids, thus ensuring good lubrication of the parts over longer periods. This can not only increase the service life considerably, it also lowers the frequency of relubrication in comparison to earlier designs. KettenWulf also offers special chain designs which need very little, if any, lubrication. Depending on the requirements, either lubrication-free chains with sealed or non-sealed bearing designs are used. Innovations in the conveyor chain sector: Lubrication-free chains with sealed or nonsealed bearing designs. Polygon compensation Polygon wheel Output wheel Conveyor sprocket Using our patented polygon compensation system we offer you the option of reducing the polygon effect caused by the fluctuations of the effective pitch circle diameter. You have the option» to reduce the polygon effect at the same required space for drive and deflection and the same pitch» to use a larger pitch at the same required space for drive and deflection and thereby saving costs» to reduce the required space for drive and deflection by reducing the number of teeth (min. Z=6) Driving wheel Please contact us for further information.

54 52 Quality management The high frequency pulsator measures the fatigue strength of materials, components or chains. From the first inspection of the raw material to the final inspection of the finished product: every production process at KettenWulf is subject to a consistent and thorough quality assurance. We inspect important product properties such as wear behaviour, fatigue strength or breaking load by using state-of-the-art testing equipment and techniques. For instance, fatigue strength is measured by means of a high frequency pulsator; breaking load tests of up to 3000kN, hardness testing to HRC, HV and HB, spectral analysis or charpy impact tests can be carried out. By means of spectral analysis the alloying components of the raw materials are analyzed. Breaking load tests of up to 3000kN can be carried out in our vast testing laboratory.

55 53 3D measuring arm for inspection of components Every company has to continually question itself in order to identify blind spots and discover new paths. In most cases, standing still means going backwards. This is why KettenWulf has established various quality initiatives aiming at a continuous optimisation of our performance. Close cooperation with our customers and also with universities and independent laboratories ensures continuous feedback. We value this mutual exchange of know-how and use it for the continued optimisation of both our products and processes. For example, we have invested in state-of-the-art measuring equipment in order to carry out special tests, primarily on critical components and/or new products which otherwise would not be possible. Thanks to these innovative testing methods, you can always rely on the high quality standards of our products.

56 54 Wang Lan Human Ressources, China For further information please visit our website at or request the following company brochures:» Chains and sprockets for the bulk material handling industry» Chains and sprockets for the automotive industry» Chains and sprockets for the steel and aluminium industries» Chains and sprockets for the wood industry» Chains and sprockets for the dams and locks» KettenWulf conveyor chains and sprockets» KettenWulf roller chains

57 55 Dominik Schmidt Apprentice Tool Mechanic, Germany Gottfried Weigl Production, Austria Melanie Kayser Marketing, Germany We are KettenWulf