Handling of bulk materials in compounding industries

Handling of bulk materials in compounding industries Dr. Semen Chlesberg Senior Manager Sales Interplastica 2013, Moscow Corporate Presentation 201...
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Handling of bulk materials in compounding industries

Dr. Semen Chlesberg Senior Manager Sales

Interplastica 2013, Moscow

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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ZEPPELIN – more than 100 years of inspiration

INNOVATION

TRADITION

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Milestones of the company‘s history

New group structure under the holding ZEPPELIN GmbH

1994 1991ff.

... ..

Zeppelin obtains exclusive Caterpillar dealership in Germany, separation in trade and industry divisions

1954 1950

.. 1937 ...

Luftschiffbau Zeppelin GmbH and Zeppelin-Foundation

1909ff. 1908 1900

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Trade:more exclusive CAT dealerships in other countries, internationalization with companies worldwide and extension of the product range

Foundation of Metallwerk Friedrichshafen GmbH, later Zeppelin-Metallwerke GmbH LZ 129 catastrophe of Lakehurst, Termination of commercial flights Foundation of companies ZF, MTU, Dornier First flight of airship LZ1; until 1937 construction of 119 airships

Majority of shares JV Saudi Arabia

2011

JV China (Shanghai) Reimelt Henschel

2010

Alpha Projects (India)

2009

JV Saudi Arabia

2008

FAT Filtertechnik Chronos Richardson (UK) mht Ludwigsburg Fördertechnik Freital

2007

..

2005 2004 2003 2002 2001

Motan Materials Handling China Polymer Alliance (JSW + Haver & Boecker)

.. .. .

Singapore, Brazil, USA

Corporate Presentation 2012 | © Zeppelin Systems GmbH

AVT Anlagen-und Verfahrenstechnik

1990

...

India Belgium, Italy

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HWZ ABS Zeppelin SkySails Zeppelin Power Systems Zeppelin International MVS Zeppelin MaK Deutschland Hyster fork lifters

ZEPPELIN TRADE

ZEPPELIN PLANT ENGINEERING

Milestones of the company‘s history

ZEPPELIN group – Development of sales

[in Mio. €] 3,000

2,447

1,197

1,410

International Sales 50%

616 345

25%

188

9%

34 1950

1955

1960

1965

1970

Corporate Presentation 2012 | © Zeppelin Systems GmbH

1975

1980

1985

5

1990

1995

2000

2005

2010

2015

Rating of the Group

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Zeppelin Group – Overview Strategic Business Units

CONSTRUCTION CONSTR. + AGRO POWER EQUIPMENT EU EQUIPMENT CIS SYSTEMS

RENTAL

PLANT ENGINEERING

Focus on Sales & Service of Construction Equipment within EU

Focus on Sales & Service of Construction Equipment outside EU

Focus on Rental in all regions

»Compact machines »Core machines »Large machines »Used machines »Product support »Hydraulic service »Paving »Lift trucks »Agriculture

»Mining, Quarry (Large) »Oil & Gas »Paving »General construction »Agriculture »Forestry

Focus on high quality industrial solids handling and liquids processing plants world-wide

Corporate Presentation 2012 | © Zeppelin Systems GmbH

Focus on Power Systems in all regions

»Industrial / Energy »Marine/ Ships/ Petroleum

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»Construction machines »Construction equipment »Lift trucks »Vehicles »Containers »Construction /Traffic guidance systems

»Plants for plastics producing, plastics processing, rubber and food industries »Silos and blenders »Filters »Mixers »Compounders »Components

A product or a complex plant designed by Zeppelin will always be one thing – engineered for Your success

POLYMER PLANTS

PLASTICS PROCESSING & RUBBER PLANTS

SILOS & FILTERS & COMPONENTS

REIMELT FOOD TECHNOLOGY

HENSCHEL MIXING TECHNOLOGY

LIQUIDS PROCESSING

ACTIVITIES:

Project Development • Engineering • Procurement • Production Site assembly • Startup • After Sales Service

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Zeppelin Systems at a glance Locations worldwide: 20 Sales: 234 Mio. EUR in 2011 Employees/ Trainees worldwide: 1.092/ 50 Engineers worldwide: over 400 specialists Shop floor area worldwide: ca. 60.000 m2 Silos built per year: ca. 650 in 2011 Engineering hours worldwide: more than 750.000 h per year

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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We are on site world-wide – always near our customers SALES PROJECT DEVEL.

» » » » » » » » » » » » » » » »

Friedrichshafen/Germany Ludwigsburg/Germany Freital/Germany Rödermark/Germany Kassel/Germany Genk/Belgium Milan/Italy Lyon/France Nottingham/UK Sao Paulo/Brazil Houston & Tampa/USA Beijing & Shanghai/ China Baroda/India Seoul/Korea Jubail/Saudi Arabia Singapore

Corporate Presentation 2012 | © Zeppelin Systems GmbH

ENGINEERING

PRODUCTION

STARTUP

SERVICE

X

X

X

X

X X X X X X X X X X X X X X X X

X X X X X X X X X X

X X X

X X X

X X X

X X X X X

X

X X

X 10

X

X X X X X X X X X X X X X X

Our scope of supply alongside the value chain of our customers PRODUCER

FORWARDER

Conveying, Storage

Blending, Dedusting

Cooling, Degassing, Drying Corporate Presentation 2011 2012 | © Zeppelin Systems GmbH

COMPOUNDER/ PROCESSOR

Storage, Conveying

Packing, Loading, Distribution 11

Dosing, Weighing, Processing, Mixing

Zeppelin plant engineering – business fields Polymer Plants Plants for plastics producers and forwarders

Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Reimelt Food Technology Plants for the food, confectionery and bakery industry

Henschel Mixing Technology Mixers, extruders and compounders

Liquids Processing Plants for the beverages and pharmaceuticals industry

Silos & Filters Silo technology and filters

Components Diverter valves, rotary feeders, separators …

Quality-Service Aviation, automotive, mechanical engineering

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Make big plans! Perfection down to the smallest detail Polymer Plants

Silogistic: Plants for Polymer Producers and Forwarders

Plants for plastics producers and forwarders

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Turn-key plants for processors – from one single source Turn-key systems supplied by the technology leader Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

» Consulting and FEED Study Concepts » Material Intake and Storage Systems » Weighing, Dosing and Mixing Technology

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» Automation and Material Management » Startup and After Sales Service » Bulk solids, Liquids and Small Chemicals Handling

Save return on invest with up to date concepts and high reliability equipment Systems for compounding and PVC processing Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

» » » » » » »

PVC & Stabilisers Carbon Black & Rubber Additives & Chemicals Plastics & Compounds Powders & Liquids Colors & Fillers And many more…

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Feed your process with the best concepts Bulk Solids, Liquids and Chemicals Handling Systems for Rubber Plants, Additives and Chemicals Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

» Various Conveying Technologies and Concepts » Small Chemicals and Minor Ingredients Handling » Liquid Processes » Rework and Plant Aspiration Concepts

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Competence Fields of Zeppelin Processor Market Rubber Compound Tire

technical Rubber

¾ technical rubber goods ¾ tires ¾ cables

PVC Compound Profile non Profile

¾ pipes ¾ profiles ¾ films & sheets ¾ cables

Polymers & Compound Compound

Processors

¾ engineered plastics ¾ tailor-made products ¾ pipes/profiles/ films/fibres ¾ cables

Additives & Chemicals Chemicals

Additives

Colours & Pigments Pigments

Paints

¾ fillers

¾ pencil

¾ functional additives

¾ pigment & colour concentrates

¾ raw material

¾ powder coating & bonding

¾ ceramics ¾ dust ¾ biomass

¾ toner fillers

Bulk Products handled in the Processor Market Rubber Compound Tire

technical Rubber

PVC Compound Profile non Profile

¾ Carbon Black

¾ PVC

¾ Silica

¾ TiO2, Calk

¾ Oil

¾ Oil

¾ small chemicals

¾ Stabiliser

¾ minor ingredients ¾ Modifier ¾ Additives

Polymers & Compound Compound

Processors

¾ Pellets such as, PE, PP, PC, PET, PA ¾ engineered plastics ¾ Fillers ¾ Glass fiber ¾ Various Additives

Additives & Chemicals Chemicals

Additives

Colours & Pigments Pigments

Paints

¾ Calc, Silica

¾ Pigments

¾ PTA

¾ Colours

¾ CB, TiO2

¾ Carbon Black Pigment

¾ Super Absorber ¾ Aerosil, Talkum ¾ Melamine

¾ Cellulose, Starch….

Main Markets Processing Industry Rubber Compounding

Rubber & Tire, Tire manufacturing, technical Rubber ¾ Technical rubber ¾ Tires ¾ Cables

Main Markets Processing Industry PVC Compounding

PVC Processing and Handling ¾ Pipes ¾ Profiles ¾ Foils ¾ Cables

Main Markets Processing Industry Polyolefine Compounding

Plastic Processors, Extrusion Processes, Engineered Plastics ¾ Pre-fabricated Products ¾ Finished Products ¾ Pipes / Profiles / Foils ¾ Cables

Main Markets Processing Industry Chemicals & Additives Handling

Powder, Mass-produced Goods, Fillers, Chemicals ¾ Fillers ¾ Pre-fabricated Goods ¾ Raw Materials

Systems for Plastic Processors

Summary Systems for the Rubber and Tire Industry

Raw Material Management with System

Summary Compounding System

Summary PVC System for the manufacturing of Plastic Window Profiles or Pipes

Summary VPE System for the manufacturing of medium-high and high voltage cables

Summary Pump-Flow - cost-efficient and product saving bulk material transport, e. g. for glass fibres

Intelligent solutions for complex tasks Mixer solutions for colors, paints, pigments, chemicals and fluids

Henschel Mixing Technology Mixers, extruders and compounders

Corporate Presentation 2012 | © Zeppelin Systems GmbH

» Rigid and soft PVC » Masterbatch and pigment preparation » WPC and natural raw material Compounds » Rubber powder » Chemicals, Stabilizers, Additives

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» Toners, Pencil lead » PTFE-Compounds » Coating of minerals and powders » Blending » Mixing of Food components » Homogenizing » Continuous mixing

Intelligent solutions for complex tasks Manufacturing of Compounders RHC + Single Screw Extruders ESE » Screw diameters 25 to 120 mm » L/D 8 to 64 » Output 5 – 5,000 kg/hour Henschel Mixing Technology Mixers, extruders and compounders

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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» Highly filled Polyolefine Compounds » Soft and rigid PVC » Glass-Fibres-filled Compounds PA, PA6, PA 6.6, PA 6.10, PA 11, PA 12 » Technical Compounds: ABS, PS, PBT, PC, PMMA, PEEK, etc. » Wood and Natural Fibre Compounds » Black, white and colour Masterbatches

There is accounting for taste - but not for technology Technologies

Applications » Fresh bakery products » Durable bakery products » Fat fried bakery products Reimelt Food Technology Plants for the food, confectionery and bakery industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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» » » »

Bulk solids handling Liquids Fermentation Continuous dough kneading (Codos) » Fat frying equipment

There is accounting for taste – but not for technology Applications

Reimelt Food Technology

» » » »

Technologies

Sweets Sugar Cereals Confectionaries

Plants for the food, confectionery and bakery industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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» » » » »

Bulk solids handling Liquids Fat treatment Sugar powder conditioning Sugar handling & dissolving

There is accounting for taste – but not for technology Technologies

Applications

Reimelt Food Technology Plants for the food, confectionery and bakery industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

» » » » »

Convenience mixes Baking mixes Spices Baby food Milk powder & drinks

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» Reci-Pure® concept » Ingredients mixing » Backtracing of charges

We bring solids and liquids together Applications

Systems for » » » » » »

Storage Conveying Dissolving Decolorization UHT treatment Cleaning in place

» » » » » »

Water Soft drinks Fruit juices Smoothies Wellness drinks Alcoholic drinks

Liquids Processing Plants for the beverage industry

Engineering – Solutions for the Beverage Industry

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Competence in automation engineering for Plastics Processors and Food Technology

Fabrication management level

Intelligent overall concepts from machine control to MES system with ERP connection (e.g. SAP)

(Enterprise Resource Planning)

Application of the latest WEB technologies

Process management level

Integration into existing IT landscapes

(Manufacturing Execution System)

Process control level

Everything from a single source for more than 40 years

Production level

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Tailor-made silos and blenders Silo manufacturing and transport methods

For every customer requirement the suitable solution

Silos & Filters Silo technology and filters

BOLT-TEC Site assembly by bolting

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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WELD-TEC Shop-welded silos

PANEL-TEC Site assembly by welding

Summary Components

Suction -/ Scales

Diverter valve WKP

Scales for small components

Pneumatic dosing valve

Scales for multiple liquid products

Container filling station

Loss-in-weight batch For feeding and dosing poor flowing material scale for poorlyflowing products

Components for bag handling

Dosing screws

Summary Components

Rotary valve APN

Liquid scale

Rotary valve MDS

Overflow pipe

Diverter valve NG-V

Diverter valve ZWS

Rotary valve DS 5

Diverter valve TWR

Fibre separator BNC

Summary Components for Plastic Processing Handling

Air Quantity Unit

Diverter valve

Rotary valve

Sampler

Conveying Pipes & Silo / Storage Hopper

Anti-Honking Systems for Silos

General vacuum hopper loader

Filter / -systems

Summary Components for Plastic Processing Handling

Dosing & Mixing unit (DMG)

Scale Systems

Overflow valve

PVC cylinder dryer

Technical Centre for Conveying Tests

Research and development for your success in the world’s biggest technology center Zeppelin Test Centers in Friedrichshafen, Rödermark, Kassel » Trials in industrial scale » Development of new products

» FRIEDRICHSHAFEN: Plastics and chemicals

» KASSEL: Mixing and compounding

» RÖDERMARK: Food products Construction in 2011

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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» Validation of plant design » Analysis of bulk solids

Quality-Service with high-level equipment and knowledge Our full service package at a glance » X-radiation laboratory for x-ray examination (picture left) » Material testing » 3D measuring » Test fluid calibration » Ultrasonic testing » Welding and acid cleaning of aviation components

Quality-Service Aviation, Automotive, Mechan. Engineering

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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» Crack testing of motor blocks (picture right) » Quality and Eco-management, consulting and training » DIN EN ISO 9001, ISO/TS 16949, DIN EN 3834, DIN EN 15085, DIN EN 9100, AQAP 2110, DIN EN ISO 14001, IRIS,…

A glance at some of our TOP references Polymer Plants Plants for plastics producers and forwarders

Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Reimelt Food Technology Plants for the food, confectionery and bakery industry

Henschel Mixing Technology Mixers, extruders and compounders

Liquids Processing Plants for the beverages and pharmaceuticals industry

Silos & Filters Silo technology and filters

Components Diverter valves, rotary feeders, separators …

Service Assembly, maintenance and spare parts

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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References Polymer Plants Plants for plastics producers and forwarders

Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Reimelt Food Technology Plants for the food, confectionery and bakery industry

Henschel Mixing Technology Mixers, extruders and compounders

Liquids Processing Plants for the beverages and pharmaceuticals industry

Silos & Filters Silo technology and filters

Components Diverter valves, rotary feeders, separators …

Service Assembly, maintenance and spare parts

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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Biotest, Merck, Roche, ebewe, Krones

At Zeppelin tradition meets future – a great chance for committed young people

INDUSTRIAL EDUCATION:

DHBW-STUDY:

Anlagenmechaniker, nach Abschluss Einsatz als Facharbeiter in der Produktion und auf unseren Baustellen weltweit

Studiengang Wirtschaftsingenieur mit Fachrichtungen Technisches Management (MB) Studiengang Maschinenbau: Konstruktion mit Informationsmanagement oder Produktion und Management

Corporate Presentation 2012 | © Zeppelin Systems GmbH

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THANK YOU FOR YOUR ATTENTION ! Corporate Presentation 2012 | © Zeppelin Systems GmbH

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