AN INNOVATIVE MULTI-PURPOSE AUTOMATED BAGHANDLING

Giancarlo Baistrocchi

FLSmidth Ventomatic Spa - Senior Area Sales Manager

The Indian Cement Industry, in order to increase the current efficiency and safety workingconditions of the existing installations and to provide “state of the art” solutions for the newinstallations, needs a significant improvement in terms of automation and mechanization of thepacking, loading and dispatch technology.

FLSmidth Ventomatic® has a complete range of product and solutions for supporting theCustomers, providing equipment, expertise, technical support and proper technical assistance byan extremely qualified technical staff.

Established in 1957, FLSmidth Ventomatic Spa is one of the world’s leading suppliers of completeplants and single machinery for high accuracy and high capacity packaging and dispatching ofpowder and granulated products such as cement, dry mortar, lime, gypsum, tile adhesive, sand,carbonates, talcum and fertilizers.

In July 2009, FLSmidth Group (for strategic expansion of FLSmidth Ventomatic SpA) acquired thevery well known Indian company EEL India Pvt. Limited, today FLSmidth Ventomatic India. TheDirection and Engineering offices are based in Gurgaon, in Bawal the new manufacturing andassembling workshop – a property area ( fenced)of 129.000 sqm. out of which 67.000 sqmcovered area ( no. 3 workshops and facilities).

Cement dispatch as key factor

In a modern Cement factory, the efficiency of a cement dispatch unit is a key factor.The term EFFICIENCY is an aggregation of several factors such as :

- Degree of automation and mechanization of the department, leading to a significantreduction of man power and the increasing of safety working conditions ;

- Increasing and optimization of each individual equipment efficiency and performance interms of actual output, better weigh accuracy, reduced down time for maintenance andamount of spare parts required for maintenance;

- Reduction of dust emission and optimization of the dispatch consumables with particularreference to the bags characteristics;

- Ability to satisfy the market requirements, in terms of sufficient amount of bags to bedelivered/loaded on trucks and/or rail wagons;

- Definition of the most rational packing/dispatch and loading plant configuration andlayout in terms of characteristics, number and size of equipment, flexibility and logistic.

- The characteristics of carriers available (in India. For example trucks have different shapeand dimension, rail wagon dimension and related access doors are fixed and limited)moreover the limits imposed by the Authorities (with particular reference to railtransportation) can’t be neglected.

In the below image Fig-1 there is an overall view of a possible concept of a complete, modern andrational bag dispatch unit

Fig-1: Cement bag dispatch

In order to reach the above mentioned goal there are some pre-conditions to be provided, one of themost important is the optimization of the cement bag characteristics .

Currently , in India, the most diffused and in use cement bag is the traditional HDPE nonlaminated stitched bag because two main reasons:

- A very well established industry for the production of this type of bags which is able tosatisfy the market requirements in terms of quantity and lead time;

- A competitive price (also considering the huge amount of bags supplied), compared toother type of bags such as paper of PP laminated glued valve , but in this moment it isdifficult to understand the realistic gap due to the low request of paper or PP laminatedbags versus the HDPE non laminated bags

The HDPE non laminated stitched bag, in terms of manufacturing sequence, needs a relevantimplication of manual operations during the manufacturing process, consequently themanufacturing accuracy (mainly in terms of dimension tolerances) is not stable and not actuallycontrolled.In case of equipment with high degree of automation the above mentioned factor lead to a verysensitive impact on the performance mainly in terms of efficiency .

The challenge is to find the right compromise and balance between the basic pre-conditions to beprovided for a good performance of complete automatic installation and the implementation ofthe bag quality /characteristics with a sustainable price.

When the possible implementation of the bag quality is under Customer evaluation, becauserequested from the equipment supplier, it is important to make a consideration, quite oftenunderestimated.With the utilization of a bag with better manufacturing characteristics (either paper or laminatedtype ), there is a very significant reduction of dust emission during the filling process and thehandling of full bags, with the following advantages:

- Better weigh accuracy of each individual bag (no cement delivered for free, no illegalunderweight bags );

- Less dust in the environment and consequently safer and healthier working conditions;- Less waste of cement and pollution;- Less costs for periodic cleaning of equipment and working area ;- Less wearing of equipment due to the abrasiveness of the cement dust and consequently

less maintenance costs;- Better presentation of the product (bag) when introduced into the market

From a realistic calculation currently during filling –handling- loading phases, each bag loses anamount of cement between 1 and 2 Kilos.A mid size cement factory easily delivers from 15 to 20 million bags per year which meansfrom 30.000 to 40.000 tons of cement wasted.

In conclusion it must be kept in due consideration that using HDPE non laminated stitched bags,the operative limit of the bag applicator is limited to max 2400 bph while with bags of differentlevel (paper or PP laminated glued valve) the limit is increased to over 5000 bph. The advantageis the possibility to install very high capacity line (i.e. up to 3000 bph with an automatic truckloading lines and over 4000 bph with a palletizing lines) in other words a packing line with 12/16spouts or more can be provided with single discharge line with all related positive implications(less space, less equipment, less operators, less maintenance etc. ).