All specialists under one roof

Turn-key Plants for the Plastics Processing Industry:Innovative Technology – Economic Handling of Bulk Solids.

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The industry sector of the Zeppelin group is among the leading

manufacturers of plants for the storage, conveying, blending,

and proportioning of high-quality bulk solids. Thanks to our

world-wide activities and locations in all important industrial

centres we can always provide our clients with the latest, most

innovative and secure process technology – to ensure maximum

economic success.

As the direct successor of Earl Ferdinand von Zeppelin who,

more than 100 years ago, turned the human dream of flying into

reality by building his legendary air ships we are used to looking

ahead. Constantly innovating, striving for perfection and maximum

functionality in our products has turned us into the company

that Zeppelin is known as today: the technological leader for

handling high-quality bulk solids.

100 years of meeting your tasks has helped us gain strength – through experience.

On site world-wide – always near our customers. Production plants in Germany, Belgium, Brazil, and China as well as partners and representations all over the world enable Zeppelin to serve our customers with speed, flexibility and the utmost closeness to our customers. More than 200 engineers – including specialists in chemical engineering – guarantee innovative and economic design of plants.

The Zeppelin group

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The industrial Zeppelin group and the number of divisions belong-

ing to it orient themselves strictly to the requirements of their

different groups of clients – all activities have, however, one thing

in common: the economic handling of high-quality bulk solids.

Silo plants for the plastic, food, and chemical industry integrated in

the general logistics concept – starting with consultation and design

up to manufacture, assembly, and after-sales service.

Turn-key plants for the plastics processing and chemical industry

as 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 com-

panies, and forwarders from the world-wide leader in the planning

and construction of logistic centers and manufacturing plants.

Competence in bulk solids handling – you can rely on Zeppelin.

As far as construction of silos is concerned Zeppelin has been the leader in the international market for decades. Thanks to our own modern manu-facturing plant and the international experience of our assembly staff and service engineers we guarantee quality of the highest level.

Pulling all the strings: the central office for the industry sector is located in Friedrichshafen, Germany. Here, in the largest Test Center in the world for pellets and powders tests are carried out on an industrial scale – the results of which are available to the subsidiaries. On this basis our clients are always on the safe side – no matter where their plant is located.

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Zeppelin is the leader in the international market for turn-key

plants designed for the handling of high-quality bulk solids.

Zeppelin’s division for processor plants has specialized in

logistics for bulk plastic materials required by plastics

processors – plants with a supreme performance.

Long-term experience, a reference list showing all important and

renowned enterprises in the plastic sector as well as a variety of

patented processes reveal the success of our technologies.

Zeppelin is the technological leader especially for processing plants

for PVC, compounding plants or among others for plants for the

manufacture of cross-linkable cables (made from crosslinked

polyethylene) by the cable industry. A world-wide network enabling

project management capacities on six continents and production

plants in the most important economic regions ensure both –

continuous personal consultation and local assistance as well as

the reliability of a partner with world-wide activities.

The economical operation of your plant is always the focus of our

actions and designs. An exact quantity and compound of the raw

materials (either pellets, powder, recycled material, or other bulk

solids) must be charged into the production process at the right

moment – having exactly the characteristics required by you.

Our aim: the highest quality of your products – achieved by safe

and reliable plant technology – that’s what Zeppelin’s technology

stands for.

Plants for the plastics processing industry supplied by Zeppelin: Benefit from the trends we are setting.

Turn-key Plants

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Material management

Systems for economical raw material management.

In times of continuously increasing

production outputs, product types and

quality requirements process optimization

can only be reached through logical

general concepts. Zeppelin has developed

such concepts especially for the plastics

processing industry: economic, field-

proven, reliable processing.

Those who want to be successful in the

international markets must take advantage

of any chances, starting at the purchasing

stage. This means that your raw material

may be supplied in different packing types.

You will only have the chance to benefit from

any advantages when purchasing the raw

material if you have sufficient storage

capacities and a system designed with

flexibility in mind.

No matter where you purchase your raw

materials – from the Vendor Management

Inventory (VMI) or on free markets – for pro-

cessing significant quantities of raw material

daily you will require a flexible and reliable

raw material management. From reception

and testing of the goods via bulk material

storage, up to just in time feeding of the

production process from day bins – Zeppelin

will supply material handling systems which

are designed and adjusted to your individual

requirements.

Blower station

In order to take advantage of all the purchasing opportunities that the market offers the raw materials have to be processed quickly – independent of the form of packing in which they are supplied (and of which very different types exist) – requiring sufficient storage capacities.

Reception of the product

Bulk storage bins

Big Bag

Container

Bag emptying station

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Variable feeding: no matter which form of raw material (powder or pellets) will be supplied – our intelligent turn-key systems offer the right solution for any task.

You can always rely on Zeppelin - the technological leader for silo technology. Turn-key silo plants, complete with their accessories, are integrated smoothly into your general logistics concept.

Modern engineering foresees that the raw material will be available as near as possible to the machines. For conveying the product from the external silos to the day bins in the production workshops Zeppelin uses technologies which are both: highly efficient and gentle to the product. Thus, the material which is charged into the day bins is to a large extent free from dust and streamers.

Storage

Conveying system

Day bins in the production area

Complete discharge is ensured by the bag emptying station – available in a dust-free execution or optionally with dust extraction for products which give-off dust.

Transfer station rotary valve

Discharge of road tank cars

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For compounding of plastic materials

the feeding system plays a significant

role due to the variety of raw materials

including some difficult to handle ones.

Here the reliability of a complete system

depends on the quality of its individual

components. Thus, the adaption of the

components to the processes of chemical

engineering and the service quality of the

individual components is of significant

importance for the economic efficiency

of the complete process.

For Zeppelin systems all steps in the pro-

cess have been tuned exactly to each other.

For your economic success the proportioning

systems as well as the extruders are of

prime importance. These must have

maximum precision, high service quality

and reliability for round the clock operation –

like those of Zeppelin.

Material handling for compounding of plastic materials.

Compounding

Zeppelin integrates the most suitable

proportioning system as well as appropriate

conveying systems in your plant for handling

a wide range of raw materials and additives

(e. g. stabilizers, slip additives, softening

agents, colors, filling materials, flame

protection agents, cross-linking agents,

sponging agents, glass or carbon fibers

which are used to increase the stability or

mica to improve the optical impression).

Following compounding the partly sensitive

product must be transported smoothly and

packed carefully. Cleaning and examination

of the manufactured material by metallic

collectors and separators as well as clean-

ing of the pipelines using pig systems for

example are an important addition to the

overall quality assurance program.

Feeding and storage of raw product

Pneumatic conveying and proportioning

Control system

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Special technologies like Pump Flow Conveying ensure the reliable and trouble-free transport of glass fibers (shown left) from the Big Bag or container to the proportioning system. Thanks to the gentle conveying the product can be handled without damage ensuring its optimum process performance. (Right side: product destruction caused by improper conveying.)

Profit from the know-how of the Zeppelin group – across other industrial fields. Being the market leader for raw material handling plants for the rubber and carbon black industry we know difficult pro-ducts very well and have developed special conveying technologies – like Overflow. Gained experience which will also be considered in the design of your plant.

Feeding and proportioning of minerals and glass fibers

Gentle product conveying

Extruder

Cooling

Outward transfer of off-spec material Packing in sacks, Big Bags, Oktabins

Charging of road tank cars

Proportioning and mixing unit for granular products (DMG)

Co-extrusion plant for the manu-facture of industrial films. Here, Zeppelin ensures reliable dosing of the raw material and all necessary additives to be added to the manu-facturing process.

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Plants for the conditioning of PVC.

PVC

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For the treatment of PVC powder the

stability of the complete plant plays a

decisive role. When batch quantities are

processed the proportioning systems must

meet the highest requirements as to pre-

cision and reliability in order to guarantee

consistently high product quality – long

term.

Providing a large variety of raw materials to

the production processes requires a first-

class administration of recipes using a mo-

dern, programmable controller. For frequent

changes of recipes rapid cleaning must be

ensured. According to the recipe, even those

raw materials and additives which make high

demands to bulk solids handling (because

of their characteristics) will be automatically

proportioned to heating/cooling mixer com-

binations.

Speaking of raw material costs: Minimizing waste is one of the conditions for competitive produc-tion. Off-spec materials, unspecified merchandise from spot markets, defective batches, waste from interruptions of production, faulty semi-finished goods, slugs or remainders from punching out are too expensive to be wasted. Therefore, Zeppelin provides special products and processes which assist you in optimizing your production correspondingly.

Example of a plant for the treatment of PVC with two integrated heating-/ cooling mixer combinations and central weighing station for light-weight constituents. Extruders or injection moulding machines are either charged pneumatically or by screws.

Following mixing the finished dryblend is

conveyed to the extruder using buffer silos

for intermediate storage – introducing the

risk of product segregation.

You can rely on the Zeppelin technology

for these tasks as well: Depending on your

application pressure, suction or mechanical

screw conveying will be selected – all being

gentle conveying methods which reduce

the inevitable segregation to a minimum.

Inflatable conveying pipelines, vibrated

rubber or PE pipes and the Overflow by-

pass system ensure safe material handling

even under the most difficult conditions.

If required blending silos which have been

specially designed to overcome segregation

problems can be incorporated.

Silo plant

Suction scale

Heating-/cooling mixer combination

Combined sack/Big Bag station

Weighing station for lightweight constituentsControl System

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Zeppelin offers a large variety of blender types for homogenizing batch variations of PVC dryblends, blending and incorporating rework material, or blending granular compounds to reduce variations caused by production.

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Pellet cooler which has been specially developed for the cable industry (PVC). Thanks to the opti-mum distribution of flow and limited residence times it guarantees optimum cooling efficiency.

Scales for lightweight additives with flexible weighing bin.

Bag emptying system with flexible cone and feed screw for products with poor flow characteristics.

Sack emptying stations / Big Bag stations

Intermediate storage of dryblend

Central aspiration

Transport to the extruder by a suction-type conveyor

Transport to the extruder by screw conveyors

Hopper loader with integrated, fully automatic filter for PVC dryblend.

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Storage silos Conveying system

Day bins in the production facilities

Blower

Reception of product

Bulk storage bins

Big Bag

Container

Bag emptying station

Pump flow station

Discharge of road tank cars

Feeding station Pump-Flow

The Zeppelin Pump Flow Concept®: economic and gentle conveying.

Conveying system

patented concept

Zeppelin presents a patented plant

concept for handling of bulk solids

by the plastics processing industry.

The Pump Flow Concept® combines both:

the flexibility of suction-type conveying

with the efficiency of pressure-type

conveying systems.

Several intake stations can be charged

easily, quickly, and economically by different

feeding stations, thus, reducing peripheral

investments, the complexity of the plant and

the operating expenses. The Pump Flow

Concept® is also appropriate for retrofitting

and ensures highest flexibility at long term.

Best suitable for plants with a total con-

sumption of 1,5 – 8 t/h.

Advantages of the Pump-Flow-Concept®:

· gentle conveying of bulk solids

· dust-free discharge from the

distributing bins

· low headroom

· limited space requirement

· low investment costs

· low wear

· highest flexibility

· simple control systems

· free from leakage air

· universally applicable

· flexible construction

· expandable thanks to modular

construction

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Storage silos Conveying system

Day bins in the production facilities

Blower

Reception of product

Bulk storage bins

Big Bag

Container

Bag emptying station

Pump flow station

Discharge of road tank cars

Feeding station Pump-Flow

Demonstration plant in the Test Center. Right: Feeding of bulk solids from Big Bags, left: Pump Flow feeding station. Maximum conveying distance up to 300 m, optionally dilute phase or dense phase conveying.

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The handling of material for the produc-

tion of cable sheathings using VPE pellets

is one of the most demanding tasks in

bulk solids technology. The requirements

for product purity are especially high.

Experience, know-how and integral

systems which fit seamlessly together

decide on the quality of the final product.

That’s why you should trust in the market

leader – and benefit from the experience

gained in the realization of many other

plants – for your success.

When medium high and high-voltage cables

are insulated even the smallest impurities

can cause significant damage. Therefore,

handling of raw materials in clean-room

conditions is the precondition for a reliable

process.

Material handling for the manufacture of medium high and high-voltage cables.

Special applications

Avoiding peroxide clusters and impurities is

basic for a successful process. Therefore,

we rely exclusively on our own knowledge

for this task – all components have been

exclusively designed by Zeppelin.

For this special application constructions

without any dead zones have been

developed. Smooth pipe connections,

special fittings, and gentle low-velocity

conveying – here every detail is decisive.

Material feeding, Vanbox complete with inliner

Material feeding from holbins under clean-room conditions

From the container unloading station with gentle product conveying, the feeding station, the buffer vessel. the dosing channel, the magnetic separator, the cascade separator up to the buffer vessel for the extruder and the filters – all components are spe-cially designed for this application.

Schematic showing material feeding to a production plant for medium high and high-voltage cables. In order to comply with the particularly high requirements of this process purpose designed equipment with special gaskets as well as polished vessels with treated surfaces are foreseen.

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Cascade separator with integrated metal separator and ionizer. Thanks to the special design fine dust and impurity particles adhering to the pellet surface are separated reliably from the raw material. One of the basic elements for avoid-ing impurities in a reliable way.

Dense phase conveying

Drying

Cascade separator

Cross section of a 110 kV cable. Cable sheathing made from cross-linkable plastic material (VPE). The let-in piece and the external cable sheathing is manufactured by a co-extruder (cross-section in full scale shown left).

Co-extruder Co-extruderMain extruder

Adding of purifying agent

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The variety of applications of material

handling in connection with processing

and conditioning of plastic materials

requires special know-how and unusual

products. Being a system supplier

Zeppelin offers a wide range of accessories

to you in order to ensure the reliable and

trouble-free realization of your processes.

Some examples taken from our program:

The complete program of accessories granting maximum profit to our customers.

Components

The experiences which we gained during

the realization of numerous plants will be

considered directly in the concepts for your

plant. We know your requirements – and

offer innovative solutions for any demands

on an economical, reliable, and safe material

handling.

When discharging some products (e. g. PET, PA, TiO2 and partly also PVC) from silos vibrations or even honking may develop, a noise which can be up to 110 dbA. In order to avoid problems in connection with noise protection regulations or even

The Turbo Pig designed by Zeppelin is used for the perfect dry cleaning of conveying systems for powders and pellets. The modular design of the Turbo Pig allows adjustment to the most different requirements

Product samplers are used for taking samples either continuously or discontinuously in pneumatic conveying pipelines.

with the steel structure Zeppelin foresees patented anti-honking sys-tems on request. By the installation of an anti-honking system (shown bottom right) a so-called shear zone will develop near the silo wall – thus, avoiding honking.

placed by the product or the pipelines. Thus, accidental mixing of product following the change of batches can be prevented.

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The Zeppelin streamer separator has been developed specially for removing long streamers without interruption of conveying. It is appropriate for plants with an output of 3 – 30 t/h. (Right: The rotary cylinder of the streamer separator is shown at the right hand side.)

The weighing scale: optimum suitablility for lightweight consti-tuents. Fast, maintenance-free, easy cleaning. Also appropriate for adhesive products.

Universal vacuum hopper loader for automatic charging of extruders, processing machines, vessels, and storage silos with powders and pellets with an output of 100 kg/h up to 2.000 kg/h. Low-maintenance thanks to large filter surfaces com-plete with jet cleaning. For use as individual unit or in multiple feeding systems.

A particularly clever feature of Zeppelin’s new program of diverter valves: the modular system allows individual adjustment of the diverter valve to your special requirements.

Filter for use with scales or receiving hoppers.

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Test Center

Your investments, both in individual

components and complete systems, must

be profitable, with the right product for

each specific job – readily available and at

a fair price. Being the technological leader

Zeppelin provides a powerful Develop-

ment and Test Center supporting different

technologies for handling bulk solids.

Our Test Center, encompassing the entire

Zeppelin product range, is yet another

factor which we place at your disposal

to contribute to your success. Ensuring

that you obtain sound information on your

product and, therefore, the best possible

component or plant design.

Our Test Center is built on an industrial scale

to meet the wide range of demands of our

customers. For this reason we are geared to

provide tailored answers to your individual

tasks, with trials on an industrial scale and

special configurations that can be quickly

installed.

Leading edge technology is not accidental, but earned.

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Two Test Centers – one specially designed

for pellets as well as the requirements of

the large scale chemical industry and one

for powders and additives (for the rubber

and plastics processing industry) form

the hub of our research and development

activities.

Whether commercial sized installation

or processing plant – whenever possible

we conduct full scale tests to avoid the

uncertainties of scale-up.

The Zeppelin Test Center offers an impres-

sive range of options. As our customer you

naturally expect maximum performance

reliability – Zeppelin provides results with

no “ifs and buts” as a sound basis for invest-

ment decisions.

For this reason the results that Zeppelin

provides leave nothing unexplained.

· competent result analysis by our

specialists

· conclusive test reports and

documentation

· determination of relevant design

parameters

Whether powders or pellets – no questions remain unanswered here.

All specialists under one roof

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The Zeppelin group of companies:All specialists under one roof.

Zeppelin Silos & Systems GmbHLeutholdstr. 108D-88045 FriedrichshafenPhone: (+49) 75 41 20 2-02Fax: (+49) 75 41 20 2-491email: zentral.fn@zeppelin.com

Zeppelin Materials Handling GmbHLeutholdstr. 108D-88045 FriedrichshafenPhone: (+49) 75 41 20 2-02Fax: (+49) 75 41 20 2-581email: info.fn@zeppelin.com

Zeppelin Belgium N.V.Munsterenstraat 93600 Genk, BelgiumPhone: (+32) 89 62 94 00Fax: (+32) 89 61 18 31e-mail: zeppelin.belgium@zeppelin.be

Zeppelin Technolgy Far East Pte, Ltd.#18-06 Odeon Towers331 North Bridge RoadSingapore 188720Phone: (+65) 63 36 33 20Fax: (+65) 63 39 99 29e-mail: buero@zeppelin-zfe.com.sg

Zeppelin Systems USA, Inc.P.O. Box 40501Houston TX 77240-0501, USAPhone: (+1) 71 38 49 56 66Fax: (+1) 71 38 49 56 55e-mail: zeppelin-usa@zeppelin-usa.com

JMB Zeppelin Equipamentos Industriais Ltda.Rua João XXIII, N° 650CEP 09851-630 Jardim NazarethSão Bernardo do Campo, SPSão Paulo, BrazilPhone: (+55) 11 43 93 94 00Fax: (+55) 11 43 92 23 33e-mail: diretoria@jmbzeppelin.com.br

Zeppelin Systems India Pvt Ltd.F411-414, Kailas Industrial ComplexGodrej Park Site Off L.B.S. MargVikhroll (West), Mumbay – 400 079IndiaPhone: (+91) 22 25 18 16 14 Fax: (+91) 22 55 97 49 05e-mail: zeppelin@mtnl.net.in

Zeppelin Solid Technology (Beijing) Co., Ltd.Rm. B816, Huibin Office Bldg.No. 8, Beichendong StreetChaoyang DistrictBeijing 100101ChinaPhone: (+86) 10 84 98 51 56Fax: (+86) 10 84 98 41 16e-mail: office@zeppelin-china.com

Zeppelin Plast Tech S.r.l.Centro Direzionale „Summit“Palazzo „C“/Via Brescia20063 Cernusco sul NaviglioItalyPhone: (+39) 02 92 10 69 05Fax: (+39) 02 92 10 42 19e-mail: info@zeppelin-zi.it

Please visit our internet web site: http://www.zeppelin-industry.com© Zeppelin Silos & Systems GmbH, SD 11/05. Any changes are reserved.

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