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
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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
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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
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1975
1980
1985
5
1990
1995
2000
2005
2010
2015
Rating of the Group
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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
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We are on site world-wide – always near our customers SALES PROJECT DEVEL.
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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
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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
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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
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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
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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
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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
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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
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THANK YOU FOR YOUR ATTENTION ! Corporate Presentation 2012 | © Zeppelin Systems GmbH
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