Silo Plants for the Plastics Processing Industry - Zeppelin Systems ...

Zeppelin has been the leader in theinternational market of silo constructionfor decades. Thanks to our own modernmanufacturing and the internationalexperience of our assembly staff andservice engineers we guarantee qualityof the highest level.Competence in bulk solids handling –you can rely on ZeppelinThe industrial Zeppelin Group and its various divisions are focusedon the requirements of their customer groups. All activities have,however, one thing in common: the economic handling of premiumbulk solids.Silo plants for the plastic, food, and chemical industries integratedin one logistics concept: from consultation and design to manufacture,assembly and after-sales service.Turn-key plants for the plastics processing and chemical industryas well as for rubber producers and tiremakers.Conveying components for any application: for powders or pellets,for high or low pressures, for products with good or poor flowability,for standard or special applications.Silogistic: turn-key plants for plastics producers, engineering companiesand forwarders. Zeppelin is the world-wide leader in the planningand construction of logistic centers and manufacturing plants.Pulling all the strings: the centraloffice for the industry sector islocated in Friedrichshafen, Germany.Here, in the world‘s largest TechnologyCenter for pellets and powders,tests are carried out on an industrialscale. The test results are availableto all subsidiaries, therefore allowingour clients to always be on thesafe side – no matter where theirplant is located.3

Production programA full range of productsfor every applicationAll Zeppelin welders are TÜVcertifiedto ensure the unconditionalquality standards required in ourdemanding business and whichform the basis of our renown longtermZeppelin quality.Aluminium storage silosThe solution for most fields of applicationrequiring economical, safe, and reliablestorage of high-quality bulk solids (pellets,powders, etc.)····available in shell diameters from 2,400 to4,200 mm standardized for your bulk solidswith long or short silo skirt, pipe feetor bracketsfor silo anchoring on concrete foundationor steel structurespecial accessories available on requestSmall aluminium or stainless steel binsFor use as temporary or daily silo.Stainless steel silosThe optimum solution for extreme requirements:minimum wear and maximum productpurity.Multi-chamber silosThe ingenious alternative for limited spaceconditions – suitable for a wide range of products,small batch quantities or separation ofbatches.Explosion-proof silos for explosivebulk materialsWith explosion-proof design accordingto VDI 3673 / VDI 2263 and equipped withrupture disks for maximum explosionprotection.4

Predefined standardor customized productThe Zeppelin silo model range for plasticsprocessors consists of two basic productionseries.Our model range of predefined silos forstandard applications is tailored to eachcustomer group‘s requirements (e.g. batchsilos for automotive industry suppliers, silosfor PET, silos for plastic pellets for the productionof plastic film).Because of this acquired knowledge, wecan provide you quickly and at a competitiveprice with a fully equipped turn-key standardsilo which can be integrated easily andsmoothly into your process.For more demanding tasks we rely onindividual solutions. Benefit from our experienceand competent advice. We designyour silo in perfect accordance with yourrequirements, thus ensuring maximum performancereliability and highest functionalityin the daily use.By taking advantage of the know-how ofthe international silo technology leader, youwill benefit from a first-class product and alladvantages of the Zeppelin network – fromconsultation via design to production andassembly on site.STARTPelletsDo you use pellets or powder?PowderWill separation of batches be required?NoWhich type of powder is used?YesWhich type of pellets do you use?TiO2 PVC Chalk Lime Foodstuffs OthersPE PP PET PC PMMA Industrial plastics OthersFlourOthersAny special requirements regarding product purity?YesNoDo you want to blend your product?Will you use the silo in the building trade?YesNoIs the powder explosive?NoYesFor which market do you produce your products?TreadsPipes/CablesArticles ofdaily useToysHouseholdarticlesNoYesDo you want to blend your powder?NoYesSilo used forseparation ofbatchesMulti-purposesiloSilo forstoring PETproductsSilo designedfor high-purityapplicationsBlendingsiloSilo designedfor the buildingtradePowdersiloBlendingsiloSilo designedfor explosivebulk materials5

Know-howWith Zeppelin, premiumbulk solids are in safe handsThe success of companies which process high-quality polymersfluctuates with the quality level of raw material handling.Those seeking profitable solutions put their trust in Zeppelinand in the experience of an internationally successful industrialgroup. As system supplier, Zeppelin provides turn-key silo plantsin particular for the plastics processing industry. Services includeconsultation and engineering, manufacture and commissioning.Research and DevelopmentKnowing everything there is to know about bulk solids is the keyto today and tomorrow‘s success. Therefore, Zeppelin ownsone of the world‘s largest bulk solids library and the TechnologyCenter where tests are carried out on a 1:1 scale. With Zeppelin,your company‘s future is assured:··research on flow properties, product ageing,contamination, and wear protectionoptimization of silo filling and dischargewater accumulation and condensation, degassing behaviorexplosion protectionConsultingWe think in the long term – and advise you accordingly. After all,your plant performance has a direct influence on your productivity.Besides all the process engineering details, our silo plant conceptsalso allow for future developments, preparing you optimally for themarkets of tomorrow:·advice on new products with different flow propertiesmodification and optimization of existing plantsdevelopment of conceptsadvice on profitabilitylogistic consulting6

ServicesZeppelin’s know-howto your advantage!The quality of our systems is the basis for your productivity.That’s why Zeppelin offers not only silo plants, but also competentsupport, first-class service and an impressive service package –not to mention our top-quality products. This means lastingquality from a good source – and hence an excellent return onyour investment.Service programA global company should naturally score particularly high in termsof customer service. We promise all-round, long-term customersatisfaction – right from the start. Zeppelin quality also stands for:·optimization or adaptation even after several yearsmodification / repair of silosrelocation of individual silos or complete plantsspare parts serviceServiceClose contact with the customer means you can expect highquality on the service side, too. The concept is simple: you leave theentire project in our hands and therefore free up your time for moreimportant business!··installation servicefull project management – beginning with the architect viathe foundation constructor to the official authoritiessupply of structural design calculations (verifiable or verified)instruction and training of your personnelmaintenance service7

Transport and assemblyManufacturing and transport methodsZeppelin emboxable silos – the ingeniousalternative for reducing freight chargesPrefabricated silos for assembly on siteIn order to reduce freight charges, silos areemboxed in each other. This method requireshighest precision but also offers the customersignificant volume, thus cost, reductions:saving up to 45% of the normally requiredshipping volume for two emboxable silos andas much as 80% for six silos!Emboxable silos are manufactured with a slightdifference in diameter and equipped with aflange connection at the transition between thecylinder and the hopper. Cylinders, hoppers,and possibly the skirts of a silo group can, thus,be emboxed in each other for transportation.Saving costs for long-distance transportationwhile maintaining the Zeppelin quality. Silosegments are prefabricated according to themodular design, transported at reasonablefreight charges to the site where they arewelded according to the renowned Zeppelinquality. Problems which may be caused e.g.by bad weather conditions, an especiallytight schedule or impaired access to theconstruction site can, thus, be avoided.Emboxable silos (photo on the left):Transport at low prices – easy andrapid assembly of silos on site.9

Blending and homogenization silosThe Zeppelin blender model range: innovativetechnology ensuring highest product qualityAs demand for high-quality plastic pelletsis increasing, blending and homogenizationare becoming more and more important.Zeppelin has developed various blenderdesigns to prevent quality variations(e.g. during the production of Masterbatchor recycling of plastic materials) and thereforebe able to offer an economical and reliablesolution for virtually any application.Zeppelin aluminium or stainless steel blenderscan be integrated into your process easily.You can really rely on Zeppelin as technologyand market leader to guarantee maximumprocess reliability, optimum blending results,and first-class consulting services right fromthe beginning.Reduced expenditure of time –accelerated overall processesZeppelin blenders often only require a singlemixing cycle to obtain the blending qualitydesired. Recirculations, by using an externalconveying system, can normally be avoided.Lower investment –optimum blending qualityThanks to innovative concepts and morethan 20 years of experience as technologicalleader in the construction of blending silos,Zeppelin‘s high-quality blending is ensured.It is therefore not uncommon that less orsmaller blenders than in conventionalsystems are needed.Advantages of the Zeppelin blending andhomogenization silos at a glance:Reduced energy input –lower operating expensesIntelligent blender design and optimumdimensioning help minimizing the energyconsumption of the blenders integrated inyour production process.10

Multi-Flow ®Multi-Pipe ®Centro-Blend ®The blenders are dimensioned in theZeppelin Technology Center accordingto the customer’s requirements.Applications:For bulk solids having easy topoor flowability (e.g. powders,pellets, dryblends, compoundsor recycling materials).Description of apparatus:The blending hopper generatesvarious flow velocities of thebulk solids in the hopper andcylindrical blender section. Thedifferent residence times providethe blending effect. Multi-FlowBlending Hoppers can be weldedinto silos during fabrication orflange connected or welded ontoexisting silos.Applications:The universal blender for all freeflowing powders and pellets.Several blending pipes ensure aneffective blending.Description of apparatus:Bulk solids enter the blendingpipes at various intakes and flowto the central hopper outlet.Different residence times supportthe blending.Applications:Equipped with a large centralblending pipe for poor flowabilitymaterials such as powders,pellets and recycling materials,dryblends and compounds.Description of apparatus:Bulk solids are simultaneouslywithdrawn through intakes at variouslevels in the silo and directedto the central blending pipe.The number and size of the intakeopenings are selected accordingto the blender geometry and flowproperties of the bulk solids.11

Quality standardsoOptimum product qualityThe silo interior is free of edges andcorners thanks to low-scratch manufacturingwork of our certified welders.oOptimum design – also in accordancewith your specificationsoDetailed drawings and static calculationsrequired for the building permit,drafts in the planning phase, assistanceduring the project realization – supportingthe architect, the foundationconstructor or the local authorities.13oFree on-site delivery – completelyassembled67o Assembly serviceoInstruction and trainingof your personneloSmooth integration of the silo plantinto your material flow conceptAnti-slip coatingAnti-slip coating or checkeredplates offer additional safety foryour personnelo Electrical system: All electricalconnections are in the junction box inthe silo skirt 3o Silo binvent filters (for powders)High-quality filters 4 to fit your productspecifications, designed to fill tanktrucks (appropriate for the final sloshingof product), complete with pneumaticcleaning, compressed air supply tank,and brand filter elements.2Typical silofor pelletso Safety pressure relief valve accordingto BGV C 12 5o Aluminium or stainless steel silos2oStandard silos are available involumes of up to 350 m³. Otherdimensions available upon request.Filling pipe elbowWe recommend filling pipe elbowsmade of stainless steel, a particularlyhigh strength materialo For any bulk densityoSilo anchoring on concretefoundation or steel structureo Mass flow if required9oWith explosion protection inaccordance with VDI 3673 / VDI 2263if necessary1112oSafety device againstfaults during filling319Daily bins12

oInerting or blanketing for bulksolids to reduce the moisture contentor prevent water condensationo Outlet flange1complete withemergency slide valve54oSilo measuring technologyWith the reliable measuring technologyfrom leading manufacturers(completely cabled in the junctionbox located in the silo skirt) youwill always have a good overview.The device includes minimumPressure relief safety valve67and maximum level indicators 6(alarm in option), continuousfilling level measurement 7 , siloweighing systems9 , controlcabinets8and silo controlsystems. For visualization of thesilo filling levels, a silo managementsystem, which transfers the data tointernal and external systems 10 ,can also be used.o Illumination of the silo skirt 11o Lockable door in the silo skirt12o Safe access equipment 13Typical silofor powdersRoof edge railing, ladder and connectingwalkways in accordancewith the regulations for the preventionof accidents and maintenanceplatform or anti-slip coating.o Product discharge 14Silo binvent filterOn request, Zeppelin can alsodesign your silo for mass flow toconstantly discharge the bulk solids(first-in / first-out principle).17o Vibrating bottom / auxiliarydischarge equipment 15For bulk materials with poorflowability111514o Filling of silosCoupling 16 for the filling pipe 17 ,low-wear filling pipe DN 100 madefrom aluminium or stainlesssteel, operating panel 18 atEmergency slide valvethe filling pipe, pinch valve 19 .18oFoundation ringFor safe anchoring. Standardfoundation rings are galvanizedand delivered in advance.31916817500 kg 17500 kgFull Full10EmptyEmptyQuit9Suction box13

Manufacturing competenceZeppelin long-term qualitymeans money well spentSmart investors opt for quality right from the start –because investments have to pay off in the long runIn other words: the better the system design, the moreprofessional the logistics service, and the higher thefabrication quality, the more profitable the silo system –and the higher your profits! In short: the sooner youget in touch with Zeppelin, the better!Patented technology, e.g. specialcone forming machines meansa competitive advantage for usand first-class products for you.Innovative welding techniques(such as simultaneous double-sidedwelding) speed up the fabricationof your product and guarantee aminimum of weld seams in lastingZeppelin quality.Zeppelin uses only high-caliberprofessionals for its production, too.Our TÜV-certified welders undergoextensive in-house training in theinterests of long-term product quality.This means an optimum surfacefinish of your silo for optimum flowproperties and maximum strength.Water jet cutting machine:Fast, precise, powerful. The waterjet cuts aluminium plates of up to200 mm and steel plates of up to150 mm with a pump pressure of4100 bar.14

Quality managementWith Zeppelin yourcompany’s future is assuredQuality management at Zeppelin is everythingyou would expect from such a firstclasssupplier. Not only does the customerbenefit from it, but the entire industry aswell: for example, it was our engineers whoassisted the TÜV authorities in defining theDIN calculation regulations.As an internationally active andsuccessful industrial group, Zeppelinhas all important and relevantlicenses for welding andmanufacturing techniques.All quality tests (whether destructiveor non-destructive) are carriedout in the Zeppelin laboratories.Vertical assembly of Zeppelin silos:a further guarantee for extremeprecision and hence maximum stability.In the long term, this meanssatisfied and successful customers.15

All specialists under one roofwww.lake-of-consens.comThe Zeppelin Group of companies:All specialists under one roofPresented by:Please visit our web site:http://www.zeppelin-industry.com© Zeppelin Silos & Systems GmbH,SD 08/08. Subject to modificationswithout notice.Zeppelin Silos & Systems GmbHLeutholdstr. 10888045 FriedrichshafenGermanyE-mail: zentral.fn@zeppelin.comZeppelin Belgium N.V.Munsterenstraat 93600 GenkBelgiumE-mail: zeppelin.belgium@zeppelin.beZeppelin Technology Far East Pte, Ltd.237 Alexandra Road#03-03/04/05 The AlexcierSingapore 159929SingaporeE-mail: angie@zeppelin.sgZeppelin Systems USA, Inc.11050 West Little YorkBuilding DHouston, TX 77041USAE-mail: zeppelin-usa@zeppelin-usa.comJMB Zeppelin EquipamentosIndustriais Ltda.Rua João XXIII, N° 650Bairro CooperativaCEP 09851-707São Bernardo do CampoSão PauloBrazilE-mail: info@jmbz.com.brZeppelin Systems India Pvt. Ltd.F411-414, Kailas Industrial ComplexGodrej Park Site, Off L.B.S. MargVikhroll (West), Mumbay – 400 079IndiaE-mail: info@zeppelin-india.comZeppelin Solid Technology(Beijing) Co. Ltd.111#, Parkview CenterNo. 5, Fangyuan West RoadChaoyang DistrictBeijing 10016ChinaE-mail: office@zeppelin-china.comZeppelin Plast Tech S.r.l.Centro Direzionale „Summit“Palazzo „C“/Via Brescia, 2620063 Cernusco sul Naviglio (MI)ItalyE-mail: info@zeppelin-zi.comZeppelin Systems Ltd.Multiflex 5, Core 27Little Oak DriveSherwood Business ParkAnnesleyNottingham NG15 0EBUnited KingdomE-mail: info@zeppelin-uk.comZeppelin RepresentativeOffice MoscowLeninskij Prospekt 95 A, Room 464119313 MoscowRussiaE-mail: marcus.reichmann@zeppelin.comZeppelin Gulf Company Ltd.Dammam-Jubail HighwayJuaymahP.O. Box 9998, Dammam 31423Kingdom of Saudi ArabiaE-mail: zeppelingulf@zeppelin-gulf.comZeppelin ZTRSilo Imalat ve Sistemleri San. Tic. Ltd. Sti.F. Kerim Gökay Cad.Ortabahar Sok. No. 6/3234732 Göztepe - IstanbulTurkeyE-mail: mehmet.tuerker@zeppelin-tr.com