Longer maintenance intervals, more efficient production and an optimised stack configuration with regard to storage and sales were the main reasons why Schwenk Putztechnik opted for the Beumer Group’s palletising technology. The single-source provider from Beckum supplied three high-capacity layer palletisers type Beumer paletpac. Two others were commissioned recently. All of them are equipped with the newly developed Beumer twin-belt turning device, which enables bags filled with building material to be turned gently and stacks them in the correct position on pallets ensuring their dimensional stability. The twin-belt turning device can be rapidly adapted to various bag sizes.
Dry mortars are prefabricated mixtures composed of mineral binding agents such as cement, limestone and gypsum, as well as sand, rock dust and further additives. On the building site the craftsmen merely have to mix them with water so that they are ready for use. By avoiding possible mixing errors, the producer can ensure a constant high product quality of this building material. Schwenk Putztechnik GmbH & Co. KG, headquartered in Ulm, is one of the leading manufacturers of sustainable and ecological dry mortar. The company has produced its materials for more than 160 years in seven ultra-modern plants. “We place great importance on presenting our products optimally in the building material trade,” said Martin Markus, who manages the Schwenk Putztechnik plants in Eigeltingen and Allmendingen in Baden-Württemberg. With regards to the manufacturing process, the company focuses on trouble-free transport, palletising process and packaging.
The twin-belt turning device: two parallel driven belt conveyors, which are driven with different speeds during the turning process, bring the bags gently into the required position.
Safe handling of bags
“Our previous palletising solution caused considerable problems during the turning of bags,” stated Peter Richter, Deputy Factory Manager in Allmendingen. “Due to jerky movements the bags were deformed and sometimes even torn.” The building material manufacturer was not able to ensure a proper and constant appearance of the palletised bags. Schwenk Putztechnik not only wanted to achieve an improved and steady stacking result, but also wanted to increase the production capacity, reduce dust emissions and prolong maintenance intervals.
While researching a suitable supplier, the building material manufacturer found Beumer Group. This single-source provider from Beckum supplies sustainable systems for filling, palletising and packaging technology from one source. “In cooperation with Schwenk Putztechnik we developed a solution that covers the requirements of both production plants,” Peter Schmidt reported. As Sales Manager he was responsible for the project and has managed the Palletising and Packaging Technology business segment of the Beumer Group since January 2014.
Gentle palletising is ensured
Beumer Group presented the high-capacity layer palletiser Beumer paletpac to the building material manufacturer. This construction series allows for the exact stacking of bags filled with bulk material on pallets layer by layer. Due to the geometric precision during layer and stack formation, stable bag stacks are formed. Beumer supplied a system that can palletise 1800 bags per hour, as well as a system with a capacity of 2500 bags per hour. In both plants the employees can adapt the palletiser quickly and easily to different bag sizes without the use of tools. With a pack height of up to 2400 mm, the Beumer paletpac stacks bags on any commonly used pallet size and in all technically possible packing patterns. A multi-program interface enables the user to set parameters easily and quickly. The new Beumer Group Human Machine Interface (HMI) ensures a user-friendly operation of the system. This control terminal provides the employee with an easily understandable and intuitive interaction, enabling the user to quickly learn how to operate the system and to define efficient working sequences after just a short training and introduction period.
In order to reach a precise packing pattern dependent positioning, the intelligent control of the twin-belt turning device involves the physical properties of the items to be packed.
Stable stack formation
“In order to turn the bags rapidly and gently to the required position ensuring their dimensional stability, the systems are provided with our newly developed twin-belt turning device. In regards to the stackability, this device offers an immense advantage when compared with conventional turning processes,” Peter Schmidt explained. The system component moves the bags without stressing them from a mechanical viewpoint. Instead, two parallel driven belt conveyors are used, which during the turning process are driven with different speeds bringing the bags gently into the desired position. The intelligent control of the twin-belt turning device involves the physical properties of the items to be packed in order to achieve an exact positioning preset by the respective packing pattern. In case of changes in bag sizes, all relevant parameters are registered and controlled via software. For this, the system reverts to an active control loop. The regulation of the drives is carried out by frequency converters, thus developing a gentle, regular rotation and ensuring that the bagged products are not deformed. This results in constant stack results for the whole service life of the system. Ready packed pallets can be stacked on top of each other in a space-saving and safe way.
A further advantage is that time-consuming modifications in case of changed bag sizes are no longer required. “The operator only has to enter the bag length and the bag width. Then the system brings the bag into the corresponding position,” explained Bernhard Temming, Service Manager at Beumer. Thanks to the modular structure, the twin-belt turning device can be quickly and easily retrofitted even in already existing palletising systems.
The Beumer paletpac forms exact, stable and thus space-saving bag stacks.
Quiet and efficient
A further reason for Schwenk Putztechnik to opt for the Beumer systems was their efficient operation. In addition to capital costs, operational costs, spare parts costs and also maintenance costs play an important role. “These are better reduced with the twin-belt turning device than with other turning devices,” said Service Manager Bernhard Temming. “The mere automated product change avoids idle times,” and as the system component abstains from cost-intensive mechanical components, this optimises the maintenance and repair costs in the long-term and reduces the life-cycle costs. “Comparable solutions of competitors for the layer preparation rely on pneumatic elements with correspondingly high operational costs. In our twin-belt turning devices work is done by energy efficient synchronous servomotors,” explained Temming. The relinquishment of mechanical parts also lowers noises during operation.
For this project Beumer’s scope ran from projection up to installation. The experts at Beumer Customer Support take care of the optimisation and maintenance of the systems, and are always available. In case of acute problems, the building material manufacturer can contact the Beumer Hotline around the clock. An online connection with the machine allows for rapid fault analyses. “We are very satisfied with the service. This was a further important aspect which led us to opt for Beumer,” added Martin Markus.
Adapted from a Beumer Group press release by Louise Fordham
Read the article online at: https://www.worldcement.com/europe-cis/28052014/schwenk_putztechnik_opts_for_beumer_group_palletising_technology_44/