Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, discusses how packing equipment manufacturers enhance efficiency and sustainability.
When we hear the word ‘sustainability,’ many people jump to a definition that focuses solely on environmental impacts. However, in the truest sense of the word, sustainability encompasses three factors — social, economic and, of course, environmental.
As with all businesses, cement plants have been drawn into the sustainability conversation. As pressure mounts to save resources and reduce carbon footprints and energy consumption, cement plants are developing smart and efficient practices to meet strict environmental standards. To reach sustainability objectives, facilities need to scrutinise the entire plant to identify the most effective solutions. Yet many operations overlook packing and loading lines, writing them off as insignificant to sustainability. However, plants can reduce resource consumption and improve product protection by optimising every system and that includes the packing process.
Some key areas to focus on while optimising a plant for sustainability include choosing the right equipment and components that can be customised to the plant as well as considering machine designs that allow for upgrades and enhancements. These options increase the longevity of the packing line while improving filling accuracy and reducing lost product.
Cleanliness, health and safety
Many producers believe dust is an inevitable byproduct of cement production. This is a myth. It is true that packing powdered material, for example, requires the addition of air to move the material, inevitably creating dust. However, dust suppression technology available today can offer nearly dust-free working conditions. By reducing dust, minimising product loss and promoting the careful use of resources, the employee, the environment and the bottom line all benefit. Maintaining cleanliness also enhances employee health and provides a safer working environment. Reducing dust is just one way to enhance sustainability in a packing plant, though. Adjustments at nearly every stage of the filling process — from feeding and dosing to packing and loading — can have a positive impact.
Feeding and dosing
The first step in the packing process is when material is fed into the packer silo. The material is then moved through a rotary feeder and a dosing system. In this initial step, many machines feature a slide gate dosing unit, which leaves a gap of several millimeters where dust and spillage can escape. To reduce dust production and protect against spillage, operations should consider a fully enclosed, metal shaft-sealed system featuring a rubber interface between the gates. This simple changeout makes the process at least 70 per cent cleaner and up to eight per cent faster compared to traditional slide gate systems. The only dust and spillage that can escape using this system comes from the way the filling spout and the bag valve interact — a challenge that some manufacturers are prepared to address with services such as updated bag sealing technology.
Sealing technology
Advanced sealing technology goes a long way in addressing material loss during bag filling and sealing. Standard rigid filling spouts require the unsealed valve bag to adhere to the tube, leaving room for product to escape. Once packed, unsealed valve bags rely on the inner pressure of the bag to close, which results in the bag being only 70 per cent closed and leaves a 30 per cent opening for spillage.
To solve this challenge, premium manufacturers offer specialized inflatable filling tubes that hermetically seals the gap between the bag and the filling spout during the filling process. This translates to no dust escaping through the valve and, when filling is complete, the bag is removed from the spout and the valve is welded shut by an ultrasonic sealing unit. This creates a cleaner working environment with less product loss, cleanup and energy consumption and better weight accuracy. During palletizing, transportation and storage, these completely sealed bags can make producers stand out with custom designs and a clean packing solution.
FFS technology
Another factor that should be considered for reducing product loss is the type of bag, and its compatibility with the packing equipment. Specialised manufacturers analyse the material being packed and the bags used before making recommendations. These customised recommendations increase the harmony between the bags, packing machines and product. For example, tubular film bags are ideal as a completely sealed, weatherproof and leakproof solution for a wide range of industries, spanning from cement to building and chemical products.
Tubular film is fed into a packing machine where it is cut and sealed, ensuring it is 100 per cent closed. This sealing method creates a permanent, tamper-resistant closure that holds up reliably during transport and storage — a key advantage over other methods that may weaken under shifting conditions. These tubular film bags are also completely emptiable, eliminating product loss for the consumer. Plus, they are recyclable, providing an additional sustainability benefit.
If making the switch to a Form-Fill-Seal (FFS) or tubular film machine, consider the manufacturer and the machine itself. Some FFS machines use vacuum methods to compact material as it’s filled into the bag. On the other hand, some machines are equipped with vibration technology to accomplish this task, which is much more effective and allows for the same amount of product to be packed into a smaller bag, meaning less film used per bag.
Over time, this translates to significant environmental and economic advantages. The fully sealed bags remain clean and uniform, which can draw in more customers. The weatherproof qualities of these bags make handling and storage easier.
Automation at play
Once equipment and bag material choices have been made, it’s time to look at automation, which helps significantly impact efficiency and sustainability. A fully automated packing line allows for more flexible line layouts and negates the inefficiencies caused by human error or manual limitations. Though both may seem like small matters, the effects add up over time. Automation also allows skilled labor to focus on higher-value tasks, improving overall workforce utilisation.
Manual processes, such as bag placement, leave room for lost productivity and errors from tired or distracted workers, who may be late placing a bag on the filling spout or miss a bag entirely. If a bag is not placed at the correct time in the correct way, facilities see major product loss of material per missed bag.
To replace the manual process, a robotic depalletiser can transfer bags — even loose, unstrapped bundles — from the pallet to the automatic bag placer. Automated bag application systems eliminate provide steady packing by ensuring continuous and accurate bag placement. Then, the bag placer securely places the bags onto the filling spout at a rate that matches the packing machine, with an output of up to 6,000 bags per hour with some models. An automated bag application system allows for a consistent, sustained pace for bag placement that is simply impossible to achieve with manual labour.
Some plants are limited by space, making it difficult or seemingly impossible to accommodate the footprint needed for production-boosting automation. This requirement previously inhibited automation, forcing manual placement and increasing safety risks by putting operators near the packing machine. However, innovative new products developed by leading manufacturers provide systems to transfer empty bags from the bag applicator to the packing machine, eliminating the need to place the bulky applicator right next to the packing machine. With the new and innovative systems, bag applicators can be positioned away from the packing machine — even in a different room. Not only does this protect the bag applicator from the immediate surroundings of the packing machine, but it also allows the plant to position it in a way that makes maintenance easier and allows users to completely rethink their empty bag logistics process.
Properly maintained equipment works more efficiently for longer, increasing sustainability and allowing operations to get the most out of their packing line. In addition to these options, palletisers — either robotic or traditional layer palletisers — can be incorporated to completely automate lines from empty to full bag.
Digitalisation and lifetime of equipment
The integration of equipment monitoring technology across all machines is an excellent way to achieve easier equipment optimisation and preventative maintenance tailored to the needs of the plant. Maintenance warnings or optimisation adjustments are displayed on the HMI, which is integrated into the control and weighing units of the machine, allowing service personnel to address concerns before they become critical and preventing unexpected downtime and lost production.
Systems with a centralised digital solution connect multiple machines together to translate data from the machine control and weighing system, making updating the entire packing line easier and resulting in more versatility. These systems require relatively low investments and result in fast return on investment. One of the easiest ways to start a sustainability journey is to invest in digitalisation.
Beyond digitalisation, some manufacturers offer rebuilds and upgrades kits to expand the flexibility, longevity and return on investment of packing lines. These kits also help the plant adapt as changes are made to the composition of materials. Many kits come preconfigured, making connecting them much easier than other upgrade options. As businesses continue to grow, some plants will need to expand, whether that means diversifying into other materials or adding new locations.
ETO approach
While many quality assemble-to-order systems enhance key sustainability metrics, operations that want to take things one step farther often look to packing plants that are truly engineered to order. For facilities seeking even more tailored solutions, engineer-to-order (ETO) systems offer long-term benefits by allowing companies to customise with all the features that continue to save money and boost profitability for years to come. Consider working with a manufacturer that offers a truly consultative approach to determine the best options for not only the packing machine but the entire plant.
All together, these systems make packing powdered material safer, cleaner and more efficient, allowing for greater operational sustainability. Choosing the right technology is an essential step to maximise the sustainability process when it comes to preventing product loss and saving resources like energy.
Diversification and expansion
In the cement industry, circumstances change quickly, and operations need options to meet demand wherever in the world that might be. Look for a manufacturer who offers prefabricated, modular packing systems for quick installation in situations with short timelines between when a purchasing decision needs to be made and entry into a new market. These specialised systems can be disassembled and reassembled in different areas, making it a sustainable option for production facilities.
It has also become increasingly important for operations to look for ways to diversify their product output. One way cement plants can do this is by using cement byproducts to create new materials. For example, instead of burning limestone, plants can use it as a component of fertiliser, which allows for an additional source of revenue in new
markets and effectively reduces the amount of CO2 the plant produces. To accomplish this, consider working with a manufacturer that offers a depth of expertise in a wide range of industries and process engineering capabilities.
Our blue planet
No matter what the future of packing brings, when experienced cement producers and equipment manufacturers partner, it results in more sustainable, efficient plants. The future of sustainability does not just rely solely on reducing power usage, dust suppression or even minimising product loss. Instead, the truly sustainable operations will be those that account for the big-picture view of all factors — from environmental to social and economic.
About the author:
Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, is a mechanical engineer with over 30 years of industry expertise.
