Turn-key Plants for the Plastics Processing Industry:

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1 All specialists under one roof Turn-key Plants for the Plastics Processing Industry: Innovative Technology Economic Handling of Bulk Solids. Plant Engineering

2 The Zeppelin group 100 years of meeting your tasks has helped us gain strength through experience. The industry sector of the Zeppelin group is among the leading manufacturers of plants for the storage, conveying, blending, and proportioning of high-quality bulk solids. Thanks to our world-wide activities and locations in all important industrial centres we can always provide our clients with the latest, most innovative and secure process technology to ensure maximum economic success. As the direct successor of Earl Ferdinand von Zeppelin who, more than 100 years ago, turned the human dream of flying into reality by building his legendary air ships we are used to looking ahead. Constantly innovating, striving for perfection and maximum functionality in our products has turned us into the company that Zeppelin is known as today: the technological leader for handling high-quality bulk solids. On site world-wide always near our customers. Production plants in Germany, Belgium, Brazil, and China as well as partners and representations all over the world enable Zeppelin to serve our customers with speed, flexibility and the utmost closeness to our customers. More than 200 engineers including specialists in chemical engineering guarantee innovative and economic design of plants. 2

3 As far as construction of silos is concerned Zeppelin has been the leader in the international market for decades. Thanks to our own modern manufacturing plant and the international experience of our assembly staff and service engineers we guarantee quality of the highest level. Competence in bulk solids handling you can rely on Zeppelin. The industrial Zeppelin group and the number of divisions belonging to it orient themselves strictly to the requirements of their different groups of clients all activities have, however, one thing in common: the economic handling of high-quality bulk solids. Silo plants for the plastic, food, and chemical industry integrated in the general logistics concept starting with consultation and design up to manufacture, assembly, and after-sales service. Turn-key plants for the plastics processing and chemical industry as well as for rubber producers and tiremakers. Conveying components for any application: for powders or pellets, for high or low pressures, for products with good or poor flowability, for standard or special applications. Silogistic: turn-key plants for plastics producers, engineering companies, and forwarders from the world-wide leader in the planning and construction of logistic centers and manufacturing plants. Pulling all the strings: the central office for the industry sector is located in Friedrichshafen, Germany. Here, in the largest Test Center in the world for pellets and powders tests are carried out on an industrial scale the results of which are available to the subsidiaries. On this basis our clients are always on the safe side no matter where their plant is located. 3

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5 Turn-key Plants Plants for the plastics processing industry supplied by Zeppelin: Benefit from the trends we are setting. Zeppelin is the leader in the international market for turn-key plants designed for the handling of high-quality bulk solids. Zeppelin s division for processor plants has specialized in logistics for bulk plastic materials required by plastics processors plants with a supreme performance. Long-term experience, a reference list showing all important and renowned enterprises in the plastic sector as well as a variety of patented processes reveal the success of our technologies. Zeppelin is the technological leader especially for processing plants for PVC, compounding plants or among others for plants for the manufacture of cross-linkable cables (made from crosslinked polyethylene) by the cable industry. A world-wide network enabling project management capacities on six continents and production plants in the most important economic regions ensure both continuous personal consultation and local assistance as well as the reliability of a partner with world-wide activities. The economical operation of your plant is always the focus of our actions and designs. An exact quantity and compound of the raw materials (either pellets, powder, recycled material, or other bulk solids) must be charged into the production process at the right moment having exactly the characteristics required by you. Our aim: the highest quality of your products achieved by safe and reliable plant technology that s what Zeppelin s technology stands for. 5

6 Material management Systems for economical raw material management. In order to take advantage of all the purchasing opportunities that the market offers the raw materials have to be processed quickly independent of the form of packing in which they are supplied (and of which very different types exist) requiring sufficient storage capacities. In times of continuously increasing production outputs, product types and quality requirements process optimization can only be reached through logical general concepts. Zeppelin has developed such concepts especially for the plastics processing industry: economic, fieldproven, reliable processing. Those who want to be successful in the international markets must take advantage of any chances, starting at the purchasing stage. This means that your raw material may be supplied in different packing types. You will only have the chance to benefit from any advantages when purchasing the raw material if you have sufficient storage capacities and a system designed with flexibility in mind. Reception of the product Container Bulk storage bins No matter where you purchase your raw materials from the Vendor Management Inventory (VMI) or on free markets for processing significant quantities of raw material daily you will require a flexible and reliable raw material management. From reception and testing of the goods via bulk material storage, up to just in time feeding of the production process from day bins Zeppelin will supply material handling systems which are designed and adjusted to your individual requirements. Bag emptying station Big Bag Blower station 6

7 Modern engineering foresees that the raw material will be available as near as possible to the machines. For conveying the product from the external silos to the day bins in the production workshops Zeppelin uses technologies which are both: highly efficient and gentle to the product. Thus, the material which is charged into the day bins is to a large extent free from dust and streamers. You can always rely on Zeppelin - the technological leader for silo technology. Turn-key silo plants, complete with their accessories, are integrated smoothly into your general logistics concept. Complete discharge is ensured by the bag emptying station available in a dust-free execution or optionally with dust extraction for products which give-off dust. Variable feeding: no matter which form of raw material (powder or pellets) will be supplied our intelligent turn-key systems offer the right solution for any task. Storage Discharge of road tank cars Day bins in the production area Transfer station rotary valve Conveying system 7

8 Compounding Material handling for compounding of plastic materials. For compounding of plastic materials the feeding system plays a significant role due to the variety of raw materials including some difficult to handle ones. Here the reliability of a complete system depends on the quality of its individual components. Thus, the adaption of the components to the processes of chemical engineering and the service quality of the individual components is of significant importance for the economic efficiency of the complete process. For Zeppelin systems all steps in the process have been tuned exactly to each other. For your economic success the proportioning systems as well as the extruders are of prime importance. These must have maximum precision, high service quality and reliability for round the clock operation like those of Zeppelin. Zeppelin integrates the most suitable proportioning system as well as appropriate conveying systems in your plant for handling a wide range of raw materials and additives (e. g. stabilizers, slip additives, softening agents, colors, filling materials, flame protection agents, cross-linking agents, sponging agents, glass or carbon fibers which are used to increase the stability or mica to improve the optical impression). Following compounding the partly sensitive product must be transported smoothly and packed carefully. Cleaning and examination of the manufactured material by metallic collectors and separators as well as cleaning of the pipelines using pig systems for example are an important addition to the overall quality assurance program. Pneumatic conveying and proportioning Control system Feeding and storage of raw product 8

9 Special technologies like Pump Flow Conveying ensure the reliable and trouble-free transport of glass fibers (shown left) from the Big Bag or container to the proportioning system. Thanks to the gentle conveying the product can be handled without damage ensuring its optimum process performance. (Right side: product destruction caused by improper conveying.) Profit from the know-how of the Zeppelin group across other industrial fields. Being the market leader for raw material handling plants for the rubber and carbon black industry we know difficult products very well and have developed special conveying technologies like Overflow. Gained experience which will also be considered in the design of your plant. Co-extrusion plant for the manufacture of industrial films. Here, Zeppelin ensures reliable dosing of the raw material and all necessary additives to be added to the manufacturing process. Proportioning and mixing unit for granular products (DMG) Feeding and proportioning of minerals and glass fibers Gentle product conveying Charging of road tank cars Cooling Extruder Outward transfer of off-spec material Packing in sacks, Big Bags, Oktabins 9

10 PVC Plants for the conditioning of PVC. Speaking of raw material costs: Minimizing waste is one of the conditions for competitive production. Off-spec materials, unspecified merchandise from spot markets, defective batches, waste from interruptions of production, faulty semi-finished goods, slugs or remainders from punching out are too expensive to be wasted. Therefore, Zeppelin provides special products and processes which assist you in optimizing your production correspondingly. For the treatment of PVC powder the stability of the complete plant plays a decisive role. When batch quantities are processed the proportioning systems must meet the highest requirements as to precision and reliability in order to guarantee consistently high product quality long term. Providing a large variety of raw materials to the production processes requires a firstclass administration of recipes using a modern, programmable controller. For frequent changes of recipes rapid cleaning must be ensured. According to the recipe, even those raw materials and additives which make high demands to bulk solids handling (because of their characteristics) will be automatically proportioned to heating/cooling mixer combinations. Following mixing the finished dryblend is conveyed to the extruder using buffer silos for intermediate storage introducing the risk of product segregation. You can rely on the Zeppelin technology for these tasks as well: Depending on your application pressure, suction or mechanical screw conveying will be selected all being gentle conveying methods which reduce the inevitable segregation to a minimum. Inflatable conveying pipelines, vibrated rubber or PE pipes and the Overflow bypass system ensure safe material handling even under the most difficult conditions. If required blending silos which have been specially designed to overcome segregation problems can be incorporated. Silo plant Example of a plant for the treatment of PVC with two integrated heating-/ cooling mixer combinations and central weighing station for lightweight constituents. Extruders or injection moulding machines are either charged pneumatically or by screws. Combined sack/ Big Bag station Suction scale Heating-/cooling mixer combination Control System Weighing station for lightweight constituents 10

11 Zeppelin offers a large variety of blender types for homogenizing batch variations of PVC dryblends, blending and incorporating rework material, or blending granular compounds to reduce variations caused by production. Bag emptying system with flexible cone and feed screw for products with poor flow characteristics. Scales for lightweight additives with flexible weighing bin. Pellet cooler which has been specially developed for the cable industry (PVC). Thanks to the optimum distribution of flow and limited residence times it guarantees optimum cooling efficiency. Hopper loader with integrated, fully automatic filter for PVC dryblend. Intermediate storage of dryblend Transport to the extruder by screw conveyors Sack emptying stations / Big Bag stations Central aspiration Transport to the extruder by a suction-type conveyor 11

12 Conveying system The Zeppelin Pump Flow Concept : economic and gentle conveying. Zeppelin presents a patented plant concept for handling of bulk solids by the plastics processing industry. The Pump Flow Concept combines both: the flexibility of suction-type conveying with the efficiency of pressure-type conveying systems. patented concept Several intake stations can be charged easily, quickly, and economically by different feeding stations, thus, reducing peripheral investments, the complexity of the plant and the operating expenses. The Pump Flow Concept is also appropriate for retrofitting and ensures highest flexibility at long term. Best suitable for plants with a total consumption of 1,5 8 t/h. Reception of product Container Advantages of the Pump-Flow-Concept : gentle conveying of bulk solids dust-free discharge from the distributing bins low headroom limited space requirement low investment costs low wear highest flexibility simple control systems free from leakage air universally applicable flexible construction expandable thanks to modular construction Bulk storage bins Bag emptying station Big Bag Feeding station Pump-Flow 12

13 Demonstration plant in the Test Center. Right: Feeding of bulk solids from Big Bags, left: Pump Flow feeding station. Maximum conveying distance up to 300 m, optionally dilute phase or dense phase conveying. Storage silos Conveying system Pump flow station Discharge of road tank cars Day bins in the production facilities Blower 13

14 Special applications Material handling for the manufacture of medium high and high-voltage cables. The handling of material for the production of cable sheathings using VPE pellets is one of the most demanding tasks in bulk solids technology. The requirements for product purity are especially high. Experience, know-how and integral systems which fit seamlessly together decide on the quality of the final product. That s why you should trust in the market leader and benefit from the experience gained in the realization of many other plants for your success. Avoiding peroxide clusters and impurities is basic for a successful process. Therefore, we rely exclusively on our own knowledge for this task all components have been exclusively designed by Zeppelin. For this special application constructions without any dead zones have been developed. Smooth pipe connections, special fittings, and gentle low-velocity conveying here every detail is decisive. When medium high and high-voltage cables are insulated even the smallest impurities can cause significant damage. Therefore, handling of raw materials in clean-room conditions is the precondition for a reliable process. Material feeding, Vanbox complete with inliner Schematic showing material feeding to a production plant for medium high and high-voltage cables. In order to comply with the particularly high requirements of this process purpose designed equipment with special gaskets as well as polished vessels with treated surfaces are foreseen. From the container unloading station with gentle product conveying, the feeding station, the buffer vessel. the dosing channel, the magnetic separator, the cascade separator up to the buffer vessel for the extruder and the filters all components are specially designed for this application. Material feeding from holbins under clean-room conditions 14

15 Cross section of a 110 kv cable. Cable sheathing made from crosslinkable plastic material (VPE). The let-in piece and the external cable sheathing is manufactured by a co-extruder (cross-section in full scale shown left). Cascade separator with integrated metal separator and ionizer. Thanks to the special design fine dust and impurity particles adhering to the pellet surface are separated reliably from the raw material. One of the basic elements for avoiding impurities in a reliable way. Dense phase conveying Cascade separator Adding of purifying agent Drying Co-extruder Main extruder Co-extruder 15

16 Components The complete program of accessories granting maximum profit to our customers. The variety of applications of material handling in connection with processing and conditioning of plastic materials requires special know-how and unusual products. Being a system supplier Zeppelin offers a wide range of accessories to you in order to ensure the reliable and trouble-free realization of your processes. Some examples taken from our program: The experiences which we gained during the realization of numerous plants will be considered directly in the concepts for your plant. We know your requirements and offer innovative solutions for any demands on an economical, reliable, and safe material handling. Product samplers are used for taking samples either continuously or discontinuously in pneumatic conveying pipelines. When discharging some products (e. g. PET, PA, TiO 2 and partly also PVC) from silos vibrations or even honking may develop, a noise which can be up to 110 dba. In order to avoid problems in connection with noise protection regulations or even with the steel structure Zeppelin foresees patented anti-honking systems on request. By the installation of an anti-honking system (shown bottom right) a so-called shear zone will develop near the silo wall thus, avoiding honking. The Turbo Pig designed by Zeppelin is used for the perfect dry cleaning of conveying systems for powders and pellets. The modular design of the Turbo Pig allows adjustment to the most different requirements placed by the product or the pipelines. Thus, accidental mixing of product following the change of batches can be prevented. 16

17 The Zeppelin streamer separator has been developed specially for removing long streamers without interruption of conveying. It is appropriate for plants with an output of 3 30 t/h. (Right: The rotary cylinder of the streamer separator is shown at the right hand side.) Universal vacuum hopper loader for automatic charging of extruders, processing machines, vessels, and storage silos with powders and pellets with an output of 100 kg/h up to kg/h. Low-maintenance thanks to large filter surfaces complete with jet cleaning. For use as individual unit or in multiple feeding systems. A particularly clever feature of Zeppelin s new program of diverter valves: the modular system allows individual adjustment of the diverter valve to your special requirements. The weighing scale: optimum suitablility for lightweight constituents. Fast, maintenance-free, easy cleaning. Also appropriate for adhesive products. Filter for use with scales or receiving hoppers. 17

18 Test Center Leading edge technology is not accidental, but earned. Your investments, both in individual components and complete systems, must be profitable, with the right product for each specific job readily available and at a fair price. Being the technological leader Zeppelin provides a powerful Development and Test Center supporting different technologies for handling bulk solids. Our Test Center, encompassing the entire Zeppelin product range, is yet another factor which we place at your disposal to contribute to your success. Ensuring that you obtain sound information on your product and, therefore, the best possible component or plant design. Our Test Center is built on an industrial scale to meet the wide range of demands of our customers. For this reason we are geared to provide tailored answers to your individual tasks, with trials on an industrial scale and special configurations that can be quickly installed. 18

19 Whether powders or pellets no questions remain unanswered here. Two Test Centers one specially designed for pellets as well as the requirements of the large scale chemical industry and one for powders and additives (for the rubber and plastics processing industry) form the hub of our research and development activities. Whether commercial sized installation or processing plant whenever possible we conduct full scale tests to avoid the uncertainties of scale-up. The Zeppelin Test Center offers an impressive range of options. As our customer you naturally expect maximum performance reliability Zeppelin provides results with no ifs and buts as a sound basis for investment decisions. For this reason the results that Zeppelin provides leave nothing unexplained. competent result analysis by our specialists conclusive test reports and documentation determination of relevant design parameters 19

20 All specialists under one roof The Zeppelin group of companies: All specialists under one roof. Presented by: Zeppelin Silos & Systems GmbH Leutholdstr. 108 D Friedrichshafen Phone: (+49) Fax: (+49) Zeppelin Materials Handling GmbH Leutholdstr. 108 D Friedrichshafen Phone: (+49) Fax: (+49) Zeppelin Belgium N.V. Munsterenstraat Genk, Belgium Phone: (+32) Fax: (+32) zeppelin.belgium@zeppelin.be Zeppelin Technolgy Far East Pte, Ltd. #18-06 Odeon Towers 331 North Bridge Road Singapore Phone: (+65) Fax: (+65) buero@zeppelin-zfe.com.sg JMB Zeppelin Equipamentos Industriais Ltda. Rua João XXIII, N 650 CEP Jardim Nazareth São Bernardo do Campo, SP São Paulo, Brazil Phone: (+55) Fax: (+55) diretoria@jmbzeppelin.com.br Zeppelin Systems India Pvt Ltd. F , Kailas Industrial Complex Godrej Park Site Off L.B.S. Marg Vikhroll (West), Mumbay India Phone: (+91) Fax: (+91) zeppelin@mtnl.net.in Zeppelin Solid Technology (Beijing) Co., Ltd. Rm. B816, Huibin Office Bldg. No. 8, Beichendong Street Chaoyang District Beijing China Phone: (+86) Fax: (+86) office@zeppelin-china.com Zeppelin Systems USA, Inc. P.O. Box Houston TX , USA Phone: (+1) Fax: (+1) zeppelin-usa@zeppelin-usa.com Zeppelin Plast Tech S.r.l. Centro Direzionale Summit Palazzo C /Via Brescia Cernusco sul Naviglio Italy Phone: (+39) Fax: (+39) info@zeppelin-zi.it Please visit our internet web site: Zeppelin Silos & Systems GmbH, SD 11/05. Any changes are reserved.