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Zeppelin - Silos and Pneumatic conveyors
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All specialists under one roof
Turn-key Plants for the Plastics Processing Industry:Innovative Technology – Economic Handling of Bulk Solids.
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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.
100 years of meeting your tasks has helped us gain strength – through experience.
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.
The Zeppelin group
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The industrial Zeppelin group and the number of divisions belong-
ing 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 com-
panies, and forwarders from the world-wide leader in the planning
and construction of logistic centers and manufacturing plants.
Competence in bulk solids handling – you can rely on Zeppelin.
As far as construction of silos is concerned Zeppelin has been the leader in the international market for decades. Thanks to our own modern manu-facturing plant and the international experience of our assembly staff and service engineers we guarantee quality of the highest level.
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.
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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.
Plants for the plastics processing industry supplied by Zeppelin: Benefit from the trends we are setting.
Turn-key Plants
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Material management
Systems for economical raw material management.
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, field-
proven, 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.
No matter where you purchase your raw
materials – from the Vendor Management
Inventory (VMI) or on free markets – for pro-
cessing 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.
Blower station
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.
Reception of the product
Bulk storage bins
Big Bag
Container
Bag emptying station
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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.
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.
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.
Storage
Conveying system
Day bins in the production area
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.
Transfer station rotary valve
Discharge of road tank cars
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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 pro-
cess 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.
Material handling for compounding of plastic materials.
Compounding
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 clean-
ing of the pipelines using pig systems for
example are an important addition to the
overall quality assurance program.
Feeding and storage of raw product
Pneumatic conveying and proportioning
Control system
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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 pro-ducts very well and have developed special conveying technologies – like Overflow. Gained experience which will also be considered in the design of your plant.
Feeding and proportioning of minerals and glass fibers
Gentle product conveying
Extruder
Cooling
Outward transfer of off-spec material Packing in sacks, Big Bags, Oktabins
Charging of road tank cars
Proportioning and mixing unit for granular products (DMG)
Co-extrusion plant for the manu-facture of industrial films. Here, Zeppelin ensures reliable dosing of the raw material and all necessary additives to be added to the manu-facturing process.
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Plants for the conditioning of PVC.
PVC
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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 pre-
cision 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 first-
class administration of recipes using a mo-
dern, 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 com-
binations.
Speaking of raw material costs: Minimizing waste is one of the conditions for competitive produc-tion. 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.
Example of a plant for the treatment of PVC with two integrated heating-/ cooling mixer combinations and central weighing station for light-weight constituents. Extruders or injection moulding machines are either charged pneumatically or by screws.
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 by-
pass 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
Suction scale
Heating-/cooling mixer combination
Combined sack/Big Bag station
Weighing station for lightweight constituentsControl System
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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.
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Pellet cooler which has been specially developed for the cable industry (PVC). Thanks to the opti-mum distribution of flow and limited residence times it guarantees optimum cooling efficiency.
Scales for lightweight additives with flexible weighing bin.
Bag emptying system with flexible cone and feed screw for products with poor flow characteristics.
Sack emptying stations / Big Bag stations
Intermediate storage of dryblend
Central aspiration
Transport to the extruder by a suction-type conveyor
Transport to the extruder by screw conveyors
Hopper loader with integrated, fully automatic filter for PVC dryblend.
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Storage silos Conveying system
Day bins in the production facilities
Blower
Reception of product
Bulk storage bins
Big Bag
Container
Bag emptying station
Pump flow station
Discharge of road tank cars
Feeding station Pump-Flow
The Zeppelin Pump Flow Concept®: economic and gentle conveying.
Conveying system
patented concept
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.
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 con-
sumption of 1,5 – 8 t/h.
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
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Storage silos Conveying system
Day bins in the production facilities
Blower
Reception of product
Bulk storage bins
Big Bag
Container
Bag emptying station
Pump flow station
Discharge of road tank cars
Feeding station Pump-Flow
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.
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The handling of material for the produc-
tion 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.
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 handling for the manufacture of medium high and high-voltage cables.
Special applications
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.
Material feeding, Vanbox complete with inliner
Material feeding from holbins under clean-room conditions
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 spe-cially designed for this application.
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.
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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 avoid-ing impurities in a reliable way.
Dense phase conveying
Drying
Cascade separator
Cross section of a 110 kV cable. Cable sheathing made from cross-linkable 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).
Co-extruder Co-extruderMain extruder
Adding of purifying agent
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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 complete program of accessories granting maximum profit to our customers.
Components
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.
When discharging some products (e. g. PET, PA, TiO2 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
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
Product samplers are used for taking samples either continuously or discontinuously in pneumatic conveying pipelines.
with the steel structure Zeppelin foresees patented anti-honking sys-tems 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.
placed by the product or the pipelines. Thus, accidental mixing of product following the change of batches can be prevented.
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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.)
The weighing scale: optimum suitablility for lightweight consti-tuents. Fast, maintenance-free, easy cleaning. Also appropriate for adhesive products.
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 2.000 kg/h. Low-maintenance thanks to large filter surfaces com-plete 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.
Filter for use with scales or receiving hoppers.
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Test Center
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 Develop-
ment 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.
Leading edge technology is not accidental, but earned.
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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 impres-
sive 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 invest-
ment 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
Whether powders or pellets – no questions remain unanswered here.
All specialists under one roof
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The Zeppelin group of companies:All specialists under one roof.
Zeppelin Silos & Systems GmbHLeutholdstr. 108D-88045 FriedrichshafenPhone: (+49) 75 41 20 2-02Fax: (+49) 75 41 20 2-491email: [email protected]
Zeppelin Materials Handling GmbHLeutholdstr. 108D-88045 FriedrichshafenPhone: (+49) 75 41 20 2-02Fax: (+49) 75 41 20 2-581email: [email protected]
Zeppelin Belgium N.V.Munsterenstraat 93600 Genk, BelgiumPhone: (+32) 89 62 94 00Fax: (+32) 89 61 18 31e-mail: [email protected]
Zeppelin Technolgy Far East Pte, Ltd.#18-06 Odeon Towers331 North Bridge RoadSingapore 188720Phone: (+65) 63 36 33 20Fax: (+65) 63 39 99 29e-mail: [email protected]
Zeppelin Systems USA, Inc.P.O. Box 40501Houston TX 77240-0501, USAPhone: (+1) 71 38 49 56 66Fax: (+1) 71 38 49 56 55e-mail: [email protected]
JMB Zeppelin Equipamentos Industriais Ltda.Rua João XXIII, N° 650CEP 09851-630 Jardim NazarethSão Bernardo do Campo, SPSão Paulo, BrazilPhone: (+55) 11 43 93 94 00Fax: (+55) 11 43 92 23 33e-mail: [email protected]
Zeppelin Systems India Pvt Ltd.F411-414, Kailas Industrial ComplexGodrej Park Site Off L.B.S. MargVikhroll (West), Mumbay – 400 079IndiaPhone: (+91) 22 25 18 16 14 Fax: (+91) 22 55 97 49 05e-mail: [email protected]
Zeppelin Solid Technology (Beijing) Co., Ltd.Rm. B816, Huibin Office Bldg.No. 8, Beichendong StreetChaoyang DistrictBeijing 100101ChinaPhone: (+86) 10 84 98 51 56Fax: (+86) 10 84 98 41 16e-mail: [email protected]
Zeppelin Plast Tech S.r.l.Centro Direzionale „Summit“Palazzo „C“/Via Brescia20063 Cernusco sul NaviglioItalyPhone: (+39) 02 92 10 69 05Fax: (+39) 02 92 10 42 19e-mail: [email protected]
Please visit our internet web site: http://www.zeppelin-industry.com© Zeppelin Silos & Systems GmbH, SD 11/05. Any changes are reserved.
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