Container Filling System
High-speed Container Loading
27.05.2009 | Deskman: Wolfgang Geisler
The German start-up company Siloadmaxx has launched with great success the probably fastest mobile container filling system for bulk material. Their big aim: to make empty container-rides a thing of the past.
With the worldwide patented mobile system “Siloadmaxx”, bulk materials are filled into a standard container directly on the manufacturer’s site. The system is capable of loading up to 25 t in about 25 minutes and has the potential to reach a daily filling capacity of 500 t. But the accelerated loading of 25 t of material is not the major advantage of the system: direct loading of loose materials into containers minimizes transportation routes and packaging costs, and this is why the developers, Thomas Heinzen and Christian Hanses, are convinced about the future potential of their concept: “We shorten commodity flows and will make worldwide transport of empty containers a thing of the past”, says Mr. Heinzen.
Rising energy costs and increasing scarcity of raw materials are only two of the many factors that speak for a success of the system, which presents the possibility of significant cost savings for a great number of industries, including cement, with the range of possible applications growing constantly. Due to the high pressure on bulk material logistics, existing structures, that have often been around for decades, are now started to be rethought and new process links are created. The target is to ensure a sustained development, something that can only be done if unnecessary transportation is minimised and greater capacity utilization of transport media is achieved.
This is where Siloadmaxx comes into play. According to its developers, with the new system every transported container will be filled to its maximum volume respectively weight capacity, dependant on the bulk density of each material. This efficient loading process combined with the advantages of the container transport now enables to enter new markets where the transport of cheap loose goods often failed because of high transport and loading costs or where loose goods could not be loaded for technical, rational and infrastructural reasons. Its mobility and safety mean it can be used in difficult environments such as those found in the emerging and developing markets, where deficits in the infrastructure mean that there are no modern stationary loading systems.
The Conventional Process Chain
The fact that conventional loading methods for filling containers provide substantial and potentially unnecessary costs quickly becomes clear when one considers the many single stages the bulk load has run through from the manufacturer, through further processing and storage before it reaches its final destination. Conventional loading methods, such as belt or screw conveyors, are two of the many partly ineffective and therefore expensive procedures in worldwide transportation. In conventional procedures, the manufacturer fills a silo vehicle with bulk material from a vertical silo. Often that material is then transported to a packaging company, where it is filled into bulk bags or sacks. Once driven by trailer to the port, the material is put into sea containers and is finally ready for shipment.
The diagram in Fig. 1 depicts this process:
- 1. A tip-up silo or silo loader is filled with bulk material from a vertical silo by the manufacturer. The material is transported by road to the packaging company, where
- 2. it is blown into the storage silos.
- 3. The bulk bags or sacks are then filled.
- 4. The packaged material is loaded onto a trailer and transported to the container port, again by road.
- 5. At the port, the bags are unloaded, and
- 6. transferred into sea containers.
- 7. It is then loaded onto the ship. This process takes an average of 2 days until the material is finally ready for shipment. The container usually contains no more than 17 t of material.
This is an established and daily process in the transportation and logistics business. But this process involves large amounts of manpower and time, greatly delaying the whole process and limiting its flexibility, which in turn creates additional costs.
The New Process Chain
The Siloadmaxx process is completely different. A standard container can be filled from a silo vehicle or loader directly at the factory, with the ability to process up to 25 t in just 25 minutes. Conventional loading methods for loose materials, such as belt or screw conveyors, or the intermediate step at the packaging company, are no longer required. No detours – no delays. Optimising the procedures this way helps to save time, transport resources and money.
Fig. 2 shows that by using the Siloadmaxx process, substantial time reductions can be made in comparison with conventional methods. These savings help to reduce operating costs and add value to the process.
1. The silo vehicle is filled from a vertical silo by the manufacturer.
2. In contrast to conventional methods, this can be used directly on site for loading the sea containers. A 20-foot container on a semi-trailer is docked onto the Siloadmaxx. Loose and free-flowing bulk materials can be loaded up to the full 25 t capacity of the container. The material now only has to be transported from the manufacturer to the container port.
3. At the port, the container is taken off the trailer and set down for loading onto the ship.
The Power of Simplicity
The concept of the system is simple: the complete machine has a standardised 20 ft (ISO) size allowing it to be used for fast and economical filling almost everywhere. During operation, the empty container is docked directly onto the back of the Siloadmaxx. Standardised hoses for the material and forced air form the connection between the silo vehicle and the hose unit. The heart of the loader is a telescopic pipe system which can be extended inside the empty container electromechanically. A distributor head sprays the material over the whole width and height of the container to ensure an even filling to the top.
Fig. 4 shows that in order to enable environmentally sound contamination-free loading, the rear part of the loading system has been surrounded by a sealed frame. A special filter unit, designed as a closed system, is being used for bulk goods with intensive formation of dust, such as cement. It ensures the dust to be sucked up out of the filling container and precipitated to be lead back into the material flow via a bypass line.
Logistic Services –not only Loading of Goods
The heart of the whole marketing concept behind Siloadmaxx is a rental system for the machines, which ensures that the machines are provided as needed and keeping costs clear. When an order is placed, the machine is delivered to the customer’s site and, if required, experts can be supplied in order to either instruct the customer or to operate the machine. Materials such as dry bulk liners are also included in the rental service.
With today’s market situation it is clear that it’s not enough to simply build reliable, flexible and efficient machines. This is why the manufactures of the new loading system not only offer the machine, but also a comprehensive service concept. Tailor-made models are individually adjustable for the customers. Following consultation with a member of the Siloadmaxx team, they can decide what services they would like to call on. In close collaboration with partners in logistics and haulage service companies, Siloadmaxx offers the organisation and scheduling of the entire commodity flow as a one-stop shop, providing entire door-to-door solutions.
The Unloading Process
Even the best “In” would be nothing without an “Out”. Therefore, a corresponding concept to unload the material has been developed as well: with integrated twist locks a purpose-made device can be easily attached to the standardised corner castings of each ISO container. A rotary feeder is mounted to the outlet and in combination with a container tipping chassis, thus enables the unloading of a number of materials which may then, for instance, be transferred pneumatically into a stationary silo.
Signs of a Great Future
As Christian Hanses puts it: „We optimise the conventional process chain in order to avoid excess transportation, therefore saving both time and valuable resources. Together with our customers we develop new concepts, which integrate our modern system for the efficient loading and unloading of bulk materials into their existing procedure.”
An increasing number of requests presents the possibility of developing even more options for the configuration of the machines. However, Marc Herzmann is unfazed by the prospect of this increased demand: “We grow to meet such challenges,” he said with great enthusiasm. As technical director of the company, he is responsible for the customising and further development of the first generation of Siloadmaxx machines. He attaches great importance to maintaining its compatibility with a wide spectrum of all kinds of materials. Their various different physical properties constitute the biggest challenge. However, the company is confident to be able to handle every challenge that the customers throw at it.
Silodamaxx GmbH & Co. KG
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