Mehul Doshi, Head of Department — Customer Support and Service, HAVER & BOECKER, shares insights on leveraging diagnostics and optimisation tools to address challenges in automation of bagging, packaging, and palletising processes.
In the fiercely competitive cement industry, optimising bagging, packaging and palletising processes is no longer a luxury but a necessity. Cutting-edge diagnostics and tailored optimisation plans are transforming how plants enhance efficiency, reduce waste, and boost safety — all while advancing sustainability goals. Through a seamless blend of digital monitoring and hands-on audits, manufacturers are now able to identify bottlenecks, minimise product loss and future-proof their operations, shares Mehul Doshi, Head of Department — Customer Support and Service, HAVER & BOECKER, in this exclusive interview.
How do QUAT2RO® and POP enhance efficiency in bagging, packaging, and palletising for the cement industry?
Comprising the diagnostics section of HAVER & BOECKER’s PROcheck lifecycle approach, QUAT2RO® and the Plant Optimisation Plan (POP) help operations increase plant performance, optimise machine conditions, set up and use resources, raise health and safety standards and improve energy efficiency.
As the digital tool of HAVER & BOECKER’s diagnostics approach, QUAT2RO® collects short-term and long-term production data on all connected machines. The data combines performance and maintenance reports into a single dashboard to make monitoring equipment settings simple. QUAT2RO® System Monitoring alerts operators to any discrepancy in the packing or palletising machines to allow faster maintenance and increase efficiency on the packing line. HAVER & BOECKER recommends installing QUAT2RO® on packing lines before engaging in a Plant Optimisation Plan (POP) to collect information on the baseline performance of the line.
POP is the human approach toward diagnostics. For the POP, HAVER & BOECKER engineers visit the customer plant to observe the operation and recommend enhancements classified by level of urgency. The full plant audit considers all areas, from product storage and handling to packing, bag transport, palletising and loading lines, as well as surrounding machines and environmental factors. The engineers send a full report tagged with green, yellow or red to highlight areas for improvement, ensuring that critical updates are prioritised.
HAVER & BOECKER’s Bag Optimisation Plan (BOP) is a very important part of the POP and allows it to go beyond the mechanical equipment and into the important role of consumables. While the goal of the POP is to find the perfect harmony between the bag, the product and the machine, the BOP focuses on all aspects of the bag and includes a bag volume test, bag valve check, visual pallet check and a bag specification check. The HAVER & BOECKER Institute tests and analyses the bag and the product to optimise all three major factors in the packing process — machine, bag and product —resulting in the highest levels of productivity and efficiency.
What common challenges in cement packing plants do your diagnostics tools address, and how are the solutions tailored?
HAVER & BOECKER diagnostics tools primarily focus on production issues, whether that’s tracking equipment efficiency through QUAT2RO® or providing recommendations for optimising existing equipment and processes. One of the biggest challenges plants face is dust escaping as bags are filled. Most packing equipment comes in a one-size-fits-all approach, meaning it’s not optimised for each individual product. If not treated properly, free-flowing powder material like cement will settle on the floor, equipment and operators instead of in the bag. HAVER & BOECKER diagnostics, specifically their POP and BOP, considers the individual properties of the cement being poured and how to direct it into the bag most effectively.
The bags used for packing cement can contribute to the amount of material lost in the packing process. Unsealed valve bags rely on the inner pressure of the bag to close, which results in the bag being only 70 per cent closed, leaving a 30 per cent opening for spillage. An improperly sealed bag results in material loss at a rapid rate while in storage and throughout transport, leading to a total product loss of up to 5 per cent. That’s why HAVER & BOECKER offers SEAL technology. Ultrasonic sealing effectively welds bags shut, resulting in the bag being 100 per cent closed. Unlike adhesive closed bags, this type of seal means bags won’t unstick over time and cause spillage if left in storage. This bag also eliminates product loss during transport.
If a facility is seeing similar product loss in their plant, HAVER & BOECKER will address the type of bag being used and recommend an upgrade to SEAL technology in their optimisation plan. They will also address any dust production issues in the full packing line to optimise production.
How does QUAT2RO® improve process efficiency, and which KPIs are critical?
QUAT2RO® detects issues before they become critical to the packing line. Operators can monitor machines’ production rates in real time to see how their equipment is performing. The results can be used to check production levels and identify solutions to productivity challenges and inefficiencies. This data can show any bottlenecks in the packing line so operators can address the issue immediately.
All data is stored in a single online portal with customisable alert systems and report templates. The portal keeps track of maintenance intervals for all assemblies and components and sends early notifications as a reminder to order wear parts. The system can also be accessed by the HAVER & BOECKER service team, providing cement plants with direct contact with our experts to address any of their concerns.
How do your solutions support sustainability goals like energy efficiency and waste reduction?
Sustainability and energy efficiency are at the heart of what we do. HAVER & BOECKER offers 10 energy saving solutions for packing lines that cover everything from optimising equipment performance to keeping equipment clean and having equipment serviced regularly. Optimising machine performance leads to energy efficiency because any material that escapes the packing process is a loss, which means the rest of the production plant needs to produce more to make up for it. Having a packing line fully optimised is one easy way to ensure energy efficiency and waste reduction.
How does the PROcheck lifecycle approach integrate with existing equipment in cement plants?
One of the many benefits of PROcheck lifestyle approach is that it can be integrated into the cement plant’s processes at any time. The first step to a full PROcheck is the Plant Optimisation Plan where an engineer comes to visit the plant and assess the technology, packing line and product being produced. No matter what technology is currently in use, our engineers provide a full report addressing any concerns and suggesting updates.
What trends in bagging, packaging, and palletising are shaping the cement industry?
Sustainability and automation are prime motivators for the cement industry right now. Whether that’s completely automating processes to increase efficiency or using electric equipment to cut down on carbon emissions, cement producers want to be able to produce better quality cement with more technologically advanced equipment.
The industry has seen a huge push toward automation in many places around the world. However, the main pushback against automation is budget. Budgetary restrictions are universal and often hold cement plants back from taking the plunge. We recognise this need and have started working with The Portland Company to provide Assemble to Order packing equipment with introductory automation that helps plants start their journey with plenty of room to expand into more customised equipment with us later. This ensures that all operations, no matter where in the world they’re located, can get an automated option suited for their unique packing line and access best-in-class service.
How does POP (and BOP) ensure optimal coordination of machines, bags, and products?
A POP includes a full plant audit that considers all areas, from product storage and handling to packing, bag transport, palletising and loading lines as well as surrounding machines and environmental factors. The goal of the report is to give plant managers a thorough, solid idea of how their plant is currently performing and where critical updates need to be made. The full POP, including the BOP, considers machines, bags and products to give an overarching recommendation on how all of them can work together for the best results.
The HAVER & BOECKER Institute completes the BOP, checking the chemical composition of the product, how the machine can aerate the product for maximum efficiency in filling and which bags provide the best protection for that specific product. The goal is to have a cohesive packing line that works together in the most efficient way possible.
What new innovations or upgrades are you introducing to improve packing plant performance?
Our newest products are meant to continually improve the packing line and provide the best support possible throughout the packing process. One major update we’ve introduced is the AMICUS Advanced Robot Family. The AMICUS DEPAL Edition depalletises bags and places them on an automatic bag applicator while the AMICUS PAL Edition palletises bags, boxes, drums and pails for transport. The AMICUS DEPAL replaces a previously manual process and increases safety, which is one of the major benefits of the system. If a facility invests in both an AMICUS PAL and DEPAL, they can create a fully automated packing line from empty to full bag.
Another optimisation HAVER & BOECKER is focused on is the unique ADAMS® Technology. ADAMS® is the system for packing cement into PE bags, offering an unlimited list of advantages. There has been rapid growth in the way ADAMS® is used, including how it has expanded into the cement sector. The FFS film bags used with the ADAMS® ROTO-PACKER protect powder cement from the elements while in transit and in storage. The waterproof, weatherproof bags offer a variety of benefits to all the industries we touch, which is an exciting expansion of our pre-existing line.
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