Our highlights at bauma 2019

in Munich hall C1, stand 513

AZO, your expert for automatic handling of raw materials in powdered, granular and liquid form, is one of the exhibitors at bauma 2019 in Munich between 8 and 14 April 2019.

Visit us in Hall C1, stand 513, where we will be showing solutions for automatic handling of bulk and medium components as well as for incorporating minor quantities and aggregates in the automated process.
 
While bulk and medium-quantity components in the construction chemicals branch have often already been automated, there is still a need to automate minor and micro quantities. These aggregates, chemical additives and admixtures have a far-reaching effect on the chemical and physical properties of construction materials. A decisive factor in the quality of end products is precise composition of formulations within close tolerances.
 
Appointment
AZO solutions for automating batches and minor quantities give you the following advantages:
  • flexible automation of numerous raw materials and formulations
  • maximum throughput possible while observing the strictest accuracy required in dosing and weighing
  • energy-efficient handling of large quantities of products, e.g. in a tower concept with vertical material flow
  • high-quality products thanks to screening of all raw materials used
  • maximum flexibility when changing over products thanks to easy-to-clean systems with extremely low production downtimes
  • ergonomic workplaces with minimum exposure to dust thanks to closed systems
  • process transparency, production security and documentation of all formulations with an interface to a primary host system
  • comprehensive systems that are easy to maintain and service and ensure high availability with future-proof components, which can be upgraded in future

At our trade fair stand you can find out more about the following key themes:

Until now, minor and micro components had to be weighed manually, thus entailing risks and potential errors. These grow with the number of components and batches, and with the required weighing and metering accuracy. This has an adverse effect on product safety and quality overall.
 
Manual operations may under certain circumstances require a large number of staff and demands a high degree of concentration from them during weighing processes. They are to some extent exposed to relatively high amounts of dust.
 
In order to resolve the problems described above, AZO is expanding its already extensive portfolio for automation of minor and micro quantities with the AZO COMPONENTER® Step. This system makes it possible to weigh minor and micro components automatically with gram accuracy, such as aggregates, colourings, additives. It improves product safety while simultaneously boosting production efficiency by reducing individual manual production steps to a minimum.
 
Fully automated filling and transport within the plant result in high throughput rates while achieving considerable levels of accuracy. Tracking and tracing of all raw materials used guarantee maximum product safety. All process steps and weighing results are reproducible, which ensures consistent, strict adherence to recipes. What is more, the AZO COMPONENTER® Step is extremely flexible when it comes to changing products over thanks to its modular design.
 
AZO COMPONENTER® Step - Automatic weighing of minor and micro components
The system was especially designed to minimize the dust exposure in the production area. This is primarily achieved by having the products filled into receptacles and by using aspiration. The outlay for cleaning can be kept low by using storage and target containers for the specific product groups. If necessary, target containers can be provided with liners.
 
The system comprises two levels. The components are held ready in surge bins on the upper level. Prior to filling, the raw materials can be identified using the barcode and allocated to the correct hoppers. This keeps mix-ups of products to a minimum and ensures that raw materials can be traced back. The surge bins can be filled from sacks or big bags; pneumatic filling is also feasible.
 
Metering and weighing of components into target containers
The target containers are positioned below the dosing points using a pneumatic drive. After the product is dosed with the quantity deter­mined in the recipe, the target container is transported one step forward to the next dosing point. There are separate scales provided for each component. Simultaneous weighing of components results in maximum time gain. Dosing screws combined with vibration bottoms underneath the raw material storage ensure accurate metering of components being handled. A vibrating chute can also be used for metering. Once all components are in the target container in accordance with the recipe, it is unloaded at the end of the metering line and is ready for the next process.

The target containers are tracked using identification technology and are thus monitored throughout the entire weighing and metering process. This means that the position, the weighed components and also the allocation of the target containers to a particular recipe are documented and are reproducible.
 
The operator-guided manual weighing centre ManDos is ideal for micro quantities that cannot be fully automated in a profitable manner owing to their consistency (physical properties) or production need (quantity and frequency). However, it is these micro quantities in particular that have a crucial impact on the recipe, meaning that proper control and documentation are essential during their addition to the manufacturing process.
 
ManDos is ideal for the following situations:
  • Low batch frequency
  • Raw materials that are not suitable for automation
  • Frequent changes of ingredients
  • A large number of components
  • Limited investment resources
  • Requirement for end-to-end documentation
ManDos – operator-guided manual weighing system for micro quantities
Our expertise – benefiting you!
ManDos can be used as a stand-alone system, but can also be expanded to a comprehensive, networked batch production system with host interface. The logical user guidance provides the best support for the operator and minimises wasted batches. The raw material identification using barcode and the documentation of all work steps and weighing results ensures traceability of every batch at any time. The system has its own master data management (order and recipe management as well as item and stores management). ManDos meets all the requirements of Regulation (EC) No. 178/2002, can be validated, and can also be used in explosive atmospheres.
 
ManDos – operator-guided manual weighing system for micro quantities
How does ManDos work?
ManDos is a modular system combining the necessary sub-assemblies, such as scales, surge bins, desks, suction systems, barcode readers and label printers, and the software solution needed for this. The ManDos system provides a standard operating concept for a very wide range of terminals. Icons and graphic elements help guide the user.
 
When an order has been started, the operator is informed as to the component that needs to be weighed. After identifying the raw material using a barcode reader, the operator weighs the required amount in a container. A large weight display and a graphic bar diagram with change of colour make it easier to carry out manual dosing within the required tolerance.
 
All the components are weighed into the container in the same way, one after another. If necessary, a label can be printed to identify the target container. The raw materials used and the entire weighing process are recorded and documented from end to end.
 
AZO cyclone screeners combine operationally safe technology with high performance and easy maintenance and cleaning. The screeners can easily be integrated into existing systems thanks to their compact design. The tried-and-tested, inexpensive cyclone screener type E is available both in painted version and in stainless steel.
 
Typical areas of application include:
  • control screening before and during processing to ensure that no impurities, e.g. bag fibres, lumps and scraps of paper, get into production.
  • control screening together with a metal detector prior to filling and packaging to ensure that no foreign matter remains in the finished product.
  • breaking up agglomerates that can occur in bagged goods or hygroscopic bulk solids. The lumps are carefully broken up without any loss of product.
  • separation of agglomerates following drying processes.
  • screening out and returning fine particles, e.g. following granulation in the pharmaceuticals industry.
  • fractionation of bulk solids in powder form into assorted fractions according to particle size.
Painted cyclone screener type E240 with oversized material bag
AZO cyclone screening with ultrasonic assistance
For certain application areas the use of ultrasonic is useful. Sonic pulsing of the screen mesh can be used or fitted retroactively in the AZO type E, DA, FA and RA cyclone screeners.
 
Key advantages
  • Increase in screening capacity
  • Improvement in selectivity
  • Longer times between cleaning
  • Straightforward retrofitting in existing machines
  • Converter is outside the screener and hence outside the flow of powder.
 
The use of ultrasound causes the stainless steel screen to vibrate at high frequency. These minute vibrations prevent near-size particles from sticking in the mesh of the screen fabric. The screen mesh stays clear for longer, which in turn noticeably improves selectivity. This may result in an increase in screen capacity. The screen basket needs to be removed for cleaning far less often and this significantly increases the useful life of the machine.
 
Cyclone screener with mounted ultrasonic converter
Flexible bulk materials receptacles such as big bags have become firmly established for handling powders in a variety of branches. They have clear advantages over sacks when it comes to transporting and storing bulk materials. They are environmentally friendly, require less operating staff and storage space and reduce costs for transport and processes.
 
AZO big bag discharge stations make it possible to discharge big bags without generating excess dust and to feed products reliably into the closed production plant. To improve efficiency and reduce costs even further, AZO has developed a modular concept for a big bag discharge station. The required components such as frame, support beams, chain hoist, discharging aids, big bag docking system, buffer bin and discharging unit can be chosen from a “construction set”, depending on the requirements. The entire discharge station can be configured to suit needs without outlay for design, which has a very positive effect on the price and delivery time. They are comparable with equipment from series production; however the modular station covers a much broader range of uses than a standard model, which makes it very flexible. Modular technology makes it possible to adapt the stations in use to changing production conditions with minimum outlay.
 
As part of a process for managing complexity, AZO will be optimising further equipment lines and meeting demand from customers for reductions in investment costs and shorter delivery times.
 
 
Modular big bag discharge station – cost-effective and versatile
Apart from customized solutions for automating raw materials and processes, AZO also offers the possibility to support the customer in planning production logistics by conducting concept studies.
 
This service is performed by the engineering & services division (AZO®e&s) as part of the pre-engineering process, tailored to the customer's existing or planned new system. Parallel to the plant design, additional process equipment is harmonized and planned with potential vendors. Apart from systems and process engineering, the logistics, media supply and staff rooms also play an important part. They can, if necessary, also be taken into consideration early on during this phase in order to create an ideal basis for further procedures (architecture, planning of budgets etc).
 
Engineering & Services
Regardless of whether it concerns an existing brownfield plant, where the aim is to refurbish existing buildings and/or equipment in accordance with the latest state-of-the-art technology (retrofit) and include possible expansion, or whether the project is at the greenfield stage where the priority is on dimensioning and ensuring investment for the entire facility. This independent planning service combines systems expertise with process-oriented layout design, thus ensuring a comprehensive engineering phase.
 
Logistics and layout are adapted to suit the (core) process engineering so constraints and bottlenecks can be averted or kept to a minimum. Planning is carried out entirely in-house, this simplifies communication and organisation.
 
Various planning and digitalization tools allow us to additionally support specific planning processes whilst including this service in our portfolio. In addition to the usual 3D design, there is the option of preparing systems and components designed using CAD so that they are available for the virtual environment (VR technology). Models are given a realistic, tangible character. This helps to make things more understandable for people not directly involved in the project and offers the advantage of not having to wait for the unit to be completed. This means, for instance, that operator training courses can be held in advance, saving the customer time and money.

 
AZO Pre-Engineering – Everything from a single source
In particular, VR technology can be integrated into the planning for future equipment. However, then questions are raised; “Is the existing space large enough?”, “Where is the best position” and so on. Limits are often reached in existing plants, especially when making adaptations or expansion. In order to counteract such problems, 3D scanning is becoming increasingly important as an as-built documentation. Here too AZO offers you this service, either as a service provider or by integrating it in ongoing projects. A simple  3D scan which offers a range of potential options for creating added value through the data collected, allowing a digital transformation and so providing the customer with maximum assistance in the planning process.
 
The main output of this technology is a point cloud, which depicts the collected data in the form of thousands of three-dimensional point coordinates. Preparing this file makes it possible to directly plan the current situation. In addition to documentation of the current state of the plant, collision-free planning with 3D CAD is possible. The time saved by control, reference and interface procedures can be invested in more detailed and accurate planning. In addition to the point cloud, a 360° photographic view is an additional benefit resulting from this service. A complete 3D scan avoids incomplete documentation for supposedly unimportant areas and thus also possible additional work for other measures.
 
Generating and analysing data and creating added value will remain the focus of AZO within industry 4.0 and will be pushed further in the future.