Bulk Grain Technologies

Systems, Equipment and Services

Bulk Grain Technologies:Introduction

Members of the Schenck ProcessGroup, Redler® are leading providersof feeding, automation and bulk solidshandling solutions.

The Schenck Process Group are globalmarket leaders for solutions inmeasuring and process technologies inindustrial weighing, feeding, screeningand automation.

Always close to customers, with anunrivalled global network of operatingcompanies Redler® are yourcompetent global partner for weighing,feeding, screening and automationsolutions throughout the processindustries.

The Schenck Process Group develops,manufactures and markets a full range ofsolutions, products and turnkey systemson the basis of combining processengineering expertise, reliablecomponents and field-proven technology.

Members of the Schenck ProcessGroup are:

Contents

4 Intake: Land & Sea

6 Storage: Silos & Flat Stores

8 Transfer: Conveying & Elevating

9 Process: Weighing & Cleaning

10 Automation: Control & Monitoring

11 Projects: Design & Contract Management

90 years of bulk materials handling expertisemeans Redler® are able to offer innovativeand comprehensive system designs for bulkgrain applications.

Whatever your requirement, wherever it isrequired, Redler® can help.

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Bulk Grain Technologies:Capabilities

Redler® is much more than a bulk materials handling equipment supplier. Their experience and expertise provides a full range of services including -

Single Machines & Machine Systems

Turnkey Plants

Plant Upgrades & Refurbishment

Consultancy & Feasibility Studies

Mechanical & Electrical Design

Contract Management & Installation Services

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Bulk Grain Technologies:Intake

Road & Rail

Redler® supply intake systems to suit different sizesand designs of road vehicles, a range of transfercapacities and methods of operation.

The high capacity unloading systems are suppliedbased on proven equipment designs to ensure highprocess availability.

Below ground or surface mounted (Redler IntraBulk®)options can be offered for truck unloading, eachconforming to the highest standard of safety andenvironmental protection.

The design of transfer equipment and systems toremove foreign matter ensures reliability inoperation.

Additionally, Schenck Process weighing technologycan be incorporated in the intake area to provideadditional functionality.

Land

Intake from road and rail are a vital part of any grain processing facility.

Understanding and controlling the potential risks associated with the intake of material with an unknowncondition is critical to protecting the operation of the whole plant.

Rugged and robust designs are essential and Redler® systems meet this challenge.

Grab Crane Hoppers

Some Portside and inland sites use grab cranes to intake grain and derivatives.

Redler® supply custom designed PortBulk® mobilehoppers, to facilitate high capacity unloadingcomplete with integral weighing where required,while ensuring low dust emissions.

Redler® designs are tailored to suit the crane to beused and the onward transfer - either into trucks or directly to belt or chain conveyors.

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Bulk Grain Technologies:Intake

Sea

Bulk sea freight offers the best method of receiving large volumes of grain, but shipping costs necessitateshigh capacity, high reliability unloading systems.

Working with specialist European Alliance Partners Redler® can offer a variety of unloader / loader designseach with advantages in particular applications.

Mechanical

For the highest capacities, the mechanical ship unloaderoffers low operating costs with high reliability andefficient unloading of the largest vessels.

The unloading leg is based on a high capacity en-masseelevator of the type originated by Redler®.

Pneumatic

Ideal for medium duty capacities and final “clean out” of holds, pneumatic unloaders have lower capital costsand can be installed in a smaller footprint making themappropriate for more congested Port areas and smallervessels.

Screw

An alternative design of unloader uses a vertical auger to lift grain from the hold and is suitable for highcapacity unloading. of grain and derivatives

This type of machine can offer high transfer capacities in a relatively low weight unit, reducing the need for jettymodifications.

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Bulk Grain Technologies:Storage

Concrete Silos

For longer term storage of grain in moreaggressive climatic conditions, concrete silos arepreferable as their inherent temperature stabilityreduces the risk of grain overheating withoutexpensive ventilation.

The design of concrete silos requires specialistcivil engineering knowledge and Redler®

cooperates with partner companies who have an extensive understanding of the necessarydesigns.

Steel Silos

Silos constructed from steel offer a relativelyquick erection time and lower capital cost for a given storage capacity and can be suppliedwith either hopper or more commonly, flatbottom design.

If flat bottomed silos are selected, it is importantto use a sweep discharger that has been correctlysized for the duty and a suitably sized aerationsystem to ensure reliable discharge.

Redler® operate closely with a number ofEuropean Steel Silo manufacturers to design fullyintegrated silo storage systems complete withthe necessary elevators and conveyors forloading, recirculation and reclaim.

Silo Storage

For most grains, vertical silos offer an effective way of storing material until it is required in a downstreamprocess or is due to be transferred elsewhere. Careful consideration of the overall design of a silo complexwill ensure that operations are safe, reliable and allow for simple maintenance.

The correct selection of the silo construction material will reflect the site climate and the intended operationof the facility.

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Bulk Grain Technologies:Storage

Flat Storage

In such cases a flat store served by a RedlerMaxiStore® system offers a particularlyeconomic method of storing materials as thesystem allows high efficiency with fullyautomated loading using significantly more ofthe building volume than typically achieved withtraditional systems.

Photo below illustrates the MaxiStore®

distribution conveyor connected to the reversingshuttle belt ready to fill the storage area.

Flat Storage

A flat warehouse is often the best solution when considering storage to suit -

High volumetric throughputs

Different types and qualities of material that require segregation

Materials with poor or variable handling characteristics that make reclaimfrom a silo difficult (for example meals)

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Bulk Grain Technologies:Transfer and Handling

Bucket Elevators

Redler® supply belt & bucket and chain & bucketelevators in a wide range of capacities in heights inexcess of 75m.

The machines are fitted with safety monitoring and dustexplosion protection features to ensure reliable and safeoperation

Chain Conveyors

Redler® are the originators of the en-masse conveying and elevating system and have unrivalled experience inhandling all types of grains and meals in this type ofcompact, relatively low power, gentle conveyor.

The slow running speed and fully enclosed design offersreduction in material degredation, whilst also offeringsafety and environmental advantages over other conveyortypes.

Redler® have machines operating in thousands of sitesaround the world at capacities up to 2000 tonnes per hour.

Belt Conveyors

For high capacity, long distance, single outlet conveying,correctly configured belt conveyors offer an economicsolution.

Redler® supply belt conveyors to suit capacities up to2000 tonnes per hour and supply these with thenecessary safety and dust control features to ensure safe,hygienic and reliable operation.

En-masse Eleveyors

As an alternative to belt & bucket elevators, Redler® areable to supply Eleveyors based on the same en-masseprinciple used in their chain conveyors.

These allow grain to be moved gently either vertically orboth horizontally and vertically in a single machine whichsignificantly reduces the space required for the transferequipment.

Transfer & Handling

The correct equipment selection both in terms oftype and design is vital to the successful operation of a bulk grain facility.

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Bulk Grain Technologies:Process Systems

Dust Control

It is essential to control the dust present or generated at all stages of a grain handling and processing system.This includes reduction of dust emissions at intakepoints such as road tipping and aspiration of dust onhandling and processing equipment to reduceenvironmental and safety risks.

Redler® have extensive experience in correctly designingand supplying dust extraction, filtration and disposalschemes.

Bulk Outloading

If grain is held in a silo, it will either be transferreddirectly to a process on the same site, or will needto be outloaded to allow transfer to another site.Redler® design and supply tailor made systems forloading of ships, barges, road and rail vehicles athigh capacities.

Weighing

Weighing of grain on intake or outload from a grain silois important for material stock management and anumber of techniques are possible.

The most commonly employed method for intake is thecontinuous bulk scale system which gives reliableaccuracy at high throughputs.

Redler® work with reputable European equipmentmanufacturers to ensure the essential reliability of thiselement of the system.

Cleaning

The condition of grain entering a silo or mill complex is often not known and precautions must be taken toremove all types of foreign matter prior to storage,onward transfer to process or outloading.

Redler® design and supply various configurations ofmagnetic metal removal and grain screening systems tosuit the different physical and operational requirementsof the site.

Process Systems

Most bulk grain handling will require some form of “pre-processing” before it is transferred to adownstream process or off site.

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Bulk Grain Technologies:Automation

Automation

The successful and reliable operation of a bulkgrain facility requires not only good overall designand high quality equipment, but also reliable &flexible system control automation.

System Controls

Redler® supplies control systems using thelatest designs of PLC and SCADA controls,inventory management systems and externalsystem communications.

The Redler® in-house electrical engineeringteam are also able to upgrade control systemson existing plants to bring them into line withlatest designs and link them into new systemswhere required.

Redler® are experienced providers of all types of monitoring & control equipment involved ingrain silo system management, dust explosionprotection / grain storage condition and caneffectively design to meet or exceed the relevantregulations required on any project.

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Bulk Grain Technologies:Design & Contract Management

Project Management Services

Redler® are competent project managers for all levels ofbulk materials handling projects from the installation ofsingle machines to complete storage silo and processingplants.

Redler® contract managers have both bulk materialshandling knowledge and the relevant understanding of the latest project management techniques to ensuresmooth progress of any job.

Design & Procurement

Redler® engineering and procurement departments arespecifically organised to ensure 'right first time' supportfor any grain system project with many years of designexperience and the worldwide buying power to guaranteethe correct equipment is delivered on time, every time.

Site Services

Redler® site engineers are fully experienced in a widerange of bulk materials handling equipment and systems.They are familiar with working at sites across the world,whether they are installing or commissioning newfacilities or servicing existing installations.

They are backed up by the Redler® Customer ServiceTeam who are able to offer comprehensive technicalsupport and source spare parts for any previouslysupplied Redler® machine together with many othersuppliers equipment.

Design & Contract Management

No project will be successful without a professional approach to the detailed work inherent in every phase and anongoing commitment to working closely with the other contractors involved. Many Redler® employees are longserving, bulk materials handling experts who bring that level of professional pride to every job they do.

Publication No. 29/04

Stock Redler LimitedRedler HouseDudbridge, StroudGloucestershire GL5 3EY EnglandT +44 (0) 1453 763 611F +44 (0) 1453 763 582chain@redler.comwww.redler.com

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T +49 61 51-32 10 28F +49 61 51-32 11 72sales@schenckprocess.comwww.schenckprocess.com