ELOCOM 2016 PROJECTS

ELOCOM 2016 PROJECTS

The technical study and development of engineering that has been carried out in recent times by ELOCOM for the packaging of powdered products (micronized, hyperventilated, …) and difficult to handle and dosage, has been reflected in a constant way.

The projects carried out and / or delivered during the year 2016 show it.We will next name some of these and other projects with their particularities (products, capacities, applications …), as well as the sectors to which they are destined.

Packaging installations for powdered or granulated products.

ELOCOM 2016 PROJECTSThere have been several bagging lines for 20kg format. In sealed bag (with decompression valve). The novelty in addition to being able to work in FFS bagging systems (CV-4000P series) with these products, is to reduce the volume of the product through a densification system (up to 50%), the formation of a bag adjusted to the volume of the product already densified (bulk density 0.3-0.4kg / lit. to density compacted 0.65-0.75kg.lit) and the development of a decompression valve system that allows the evacuation of air from inside the bag and avoids the entrance of any external agent (hermetic bag).

In addition to reducing costs by suction (2-3,000NL / min to 3-400Nl / min.), it also reduces maintenance, contamination, dirt and product losses.

EP400As far as open mouth packers are concerned, the projects carried out for powdered and granulated products, such as milk powder, sugar, salt and cereals, have not been any less successful.

The different destinations of the applications made have shown us that we are a supplier of guarantees for the different sectors, and of course with presence in all of them.
 The solution that Elocom is providing for powdered products is giving a very good result, and this is perceived in each of the projects that are carried out, since the packaging of these products in open-sack bag is usually a problem for the manufacturers due to the low capacity of production, as for the dirt that is generated or for the conformation of the final bag.

In this sense other important advances have been made for the packaging in Bigbags for these same products and others of difficult behavior. In particular, all models of fillers for different applications have been manufactured and delivered throughout the year.

Automatic BB filler with placement of BBs from coil by robot,Automatic BB filler with placement of BBs from coil by robot, for products for animal feed. This model has a system of unwinding and automatic separation of bigbags from a coil, its opening and positioning in the filling mouth of the filler, its dosage and evacuation by motorized rollers or belt conveyors.

Semiautomatic BB Net Weight FillerSemiautomatic BB Net Weight Filler allows the dosage and weighing of granulated products or medium-good fluidity, such as pvc pellets, fertilizers, seeds and cereals, etc …

The positioning and closing of the mouth of the BB is manual (optionally automatic), all the movements are made from the control panel and its design created to facilitate the operations to the worker as well as their safety.

Semiautomatic BB Weight Filler in INOXSemiautomatic BB Weight Filler in INOX allows the dosage of products of difficult-medium behavior, such as powder products (mining, pharmacy, food, etc …)

 

 

Gross weight manual BB filler.Gross weight manual BB filler.This model is ideal for products with good performance and for installations with low-medium productions. BBs of different sizes can be made, with or without filling mouth, with weighing control system or volumetric.

 

 

 

Palletizing systems.

There have been numerous projects with very different characteristics of palletizing (production, palletizing mosaics, and / or different applications). Within the range of palletizers we can find Palletizers by Layers (Maxipal, Masterpal, Europal) and the range of robots (anthropomorphic robot and gantry).

Maxipal The Maxipal model offers its different versions (Speed and / or complete layer) becoming the most standardized model among the range of our palletizers by low, and offering a very high quality and variety of possibilities in palletizing mosaics.

One of the most important points to take into account in the layered palletization is the conformation of the sacks prior to palletizing. For this we have different confirmation systems depending on the packaged product (powder or granules) and the type of bag.

IMG-20170119-WA0001In this photo we can see the manufacture of several palletizers simultaneously and different features as seen in the first two, corresponding to the models Masterpal 1200 and Europal.

 

The Masterpal 1200 belongs to the Masterpal series where there are models 1000- 1200 and 1500 depending on the speeds to be achieved. In the series Masterpal we always works with the pallet by low, unlike the Europal (to the left of the photo) in which it is a palletizer with pallet by stop. This means that the empty pallet rises to pick up the layer, and so on the rest.

RobotThe facilities of anthropomorphic robots have been a very constant application in recent times, and in general they are about non-easy solution projects with applications for different lines of simultaneous production, application and taking of sheets of cardboard and empty pallets with different measures, Bags with different densities and different product heights, palletizing points and different mosaics, etc … For this, the most advanced technologies for detection and speed of movement, as well as qualities for aggressive, corrosive environments, etc. have been implemented in the lines.

The gantry-type palletizing systemThe gantry-type palletizing system is very convenient and practical for users because of its simplicity, functionality and possibilities that it allows.

This type of palletisation is ideal for low-medium production facilities, with total line automation or even pallet palletizing on the floor with manual placement and removal.

The precision in its movements offers a very good palletizing quality, and the possibilities offered by the PLC allows the user to manipulate and create new programs.

In order to complete the bagging and palletizing lines, it is not possible to avoid overpacking systems, which are no less important for the finishing and complete image of the packaging of the different products. For this, Elocom has two suppliers with high recognition at European and global level in all sectors. For stretch film packaging systems we have TOSA S.R.L. And for coating systems with LACHENMEIER.

TOSA S.R.L          LACHENMEIER

These examples reflect the great success in ELOCOM‘s solutions for these products, bearing in mind that all this has also been carried out with the transfer to the new ELOCOM & PROYMEC Assembly production plant.

The new plant has been prepared to cover more manufacturing processes (assembly train, machining machinery, painting chamber, as well as personnel and other equipment …).

This will allow ELOCOM, among other things, to obtain greater control of the manufacturing process in its phases (design, orders to suppliers, manufacturing and / or assembly, delivery date) optimization of material costs, greater guarantee of materials and Equipment supplied. These and other manufacturing processes make a company a guarantee provider, without forgetting the experience of more than 30 years in the packaging sector.

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Big bag filler presentation (2nd CALL)

Big Bag Filler

The Conference presentation of the new big bag filler, will be held between 18 and 22 April 2016, ELOCOM invited to visit all companies interested in our facilities in Castellon. Big Bag Filler

During a week and accompanied by the staff of ELOCOM, the clients will be able to visit, receive information and to see some plants working with product.

In order of innovation interest, the installations that will be available to visit will be:

Semiautomatic BigBag filler

1-     Semiautomatic BigBag filler with weight loss for micronized products of high level of aeration.

Installation prepared to work with BigBags of up to 1.200 Kg of calcium hydroxide with a production of 25 BB/hour densified from 0,3 to 0,6 gr/cm3.

This installation will be available to see with fluidization charge systems so that it receives the product in the worst possible conditions.

The remaining Big Bags are compact and full until their top part.

Semiautomatic filler

2-     Semiautomatic filler with net weight weigher for granulated products.

Velocity of 60 BB/hour in 1.000 Kg. Automatic system of alimentation of empty pallets and evacuation of full pallets.

 

3-    Semiautomatic weigher of net weight for dust products. Very similar installation to the previous one dealing with the composition and in the velocity but with an alimentation through 2 worm drives (thick and refined).

4-     Semiautomatic filler for BigBags for pharmaceutical ambience.

Gross weight machine (does not need velocity but yes possibility of full cleaning), totally in stainless steel . As option, it also has a thermo sealing system of the mouth in automatic cycle and insufflation of Nitrogen for inert environment.

 manual fillers

5-     Several models of manual fillers of gross weight..

 

 

 

 

Automatic alimentation of BigBag

6-     Automatic alimentation of BigBag to filler. The set starts from BigBags in coil and once they are separated of this last, they are immediately placed thanks to a ROBOT of 6 axes in one or several BigBags.

For this event, confirmation of assistance and arrival hour is required in order to prepare the necessary staff in the needed languages.

The presentation will be held in the new installations of the company of the Group, ELOCOM PROYMEC ASSEMBLY, S.L. in Villareal – CASTELLON (ESPAÑA). In the next reminding of this presentation, the address and the exact dates will be communicated.

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Wood pellet bagging – New installations

Wood pellet bagging

Wood pellet bagging line

Various installations of wood pellet bagging lines have been mounted in the last months of 2015 in the sector of biomass for the wood pellet packing with different applications, capacities and characteristics such as for example Lucena, Maderas Campo or Infinit but also in exportation to Baltic countries and in South America with 3 main bagging installations of which production capacity is very high.

Maderas Campos S.L. is a company dedicated to the wood sector since Don Francisco Campos García founded it in the 70’s in Alcalá la Real (Jaén). During all of these years, he adapted the company to all the new trends and opportunities of the market such as parquet and pallet board manufacturing or wood cutting.

In 2015, renewable energies inspired them and pushed them to create OLOGIMASA, a company specially oriented towards transportation, forest exploitation and biomass. ELOCOM helped in the acquisition of packing machinery for wood pellet.

The new development in the CV-4000 bagging machines to work with paper coil allows the to offer, in a very eco-friendly sector dealing with renewable energies, an ecologic package which is 100% recyclable as paper. In order to accomplish this, CV bagging machines have been adapted with special mechanisms and systems that allow it to handle and manage the paper sheets for it’s unrolling, conformation and sealing.

 

Wood pellet bagging pallet

This ecologic package has had a very good acceptation in the sector and several installations have already been delivered to pack wood pellet with paper coil. Recently, the factory with highest production capacity of wood pellets of South America has been launched. The installation has a complete line of high production with top speeds of 1.650 bags/h. in bagging, double swing dosage and bagging, anthropomorphic robot of multiple take palletizing and stretching film wrapper.

 

Wood pellet palletizing robot
Wood pellet palletizing robot

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ELOCOM PROYMEC ASSEMBLY S.L.

ELOCOM PROYMEC ASSEMBLY S.L.

In its expansion in manufacturing plants, ELOCOM has taken new and strategic steps. In addition to the factories in Burgos in 2000 and ELOCOM ITALIA srl in 2012, this year, ELOCOM PROYMEC ASSEMBLY SL Villarreal (Spain) has been inaugurated.

ELOCOM PROYMEC ASSEMBLY

The project is based on designing and creating teams, dealing with some basic aspects such as quality, safety, reliability, accessibility, convenience and communication, that are always present in ELOCOM supplies.

 

elocom proymec assembly teem

In order to unite all these aspects in any of the equipment (baggers, palletizers, fillers BB`s …) ELOCOM has a group of technics and engineers with extensive knowledge of the latest advances in technology.

 

ELOCOM has an experience of more than 25 years exporting, and is aware of the needs that require some markets. Thanks to this experience and close collaboration with the company Proymec Castellon, SL (Proyectos y Mecanicos Levante, S.L.), the decision of exploiting synergies founding a new plant in which projects are developed together has been taken to provide a comprehensive solution, for storage systems, transportation and handling of solids and for bagged and palletized products.

The company ELOCOM PROYMEC ASSEMBLY, S.L. is already operational, and the production of layer palletizers and BigBag fillers has been brought to it.

With the expansion of the already existing technical office, ELOCOM has a well equipped technical office to develop and adapt the machines to the needs of each client. Currently, the 3D drawing system is used in the entire range of machines of ELOCOM.

 

ELOCOM PROYMEC ASSEMBLY offices

In the plant of Villarreal, many of the tasks that were previously outsourced to external companies (machining, metalwork, painting, etc …) are made in the workshops of 3,000m2; this has improved the reaction time to urgent requests or last minute changes.

Nowadays, the most important new development projects being carried out are:

Big Bag fillers for micronized products at high speeds.

– New layer palletizer to 11 layers / minute at height (new lift).

Robot palletizing bags at high speeds, up to 1,500 bags / hour (with several units and mounted 2,015)

 

ELOCOM PROYMEC ASSEMBLY installations

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Bagging installations from paper reel for wood pellets.

BAGGING INSTALLATIONS FROM PAPER REEL FOR WOOD PELLETS

The first bagging installations line from paper reel for wood pellets in Spain has been recently put in operation.

The advantage of working either with paper or PE reels is positively welcomed in the biomass sector.

The increase of the so-called”ecological package “that allows for 100% paper bag recycling offers a commercial versatility highly appreciated among the customers…

Complete paper line in operation.

Bagging installations from paper reel for wood pellets
Bagging installations from paper reel for wood pellets

Besides the first production line in Ribpellet shown in the video, other customers like Infinit (Barcelona) and Maderas Campo (Jaen) have already confirmed to ELOCOM their purchase of the versatile reel bagger PE/Paper.

The automatic packing innovation is of a very high magnitude because until now these materials were used only in the food sector and in small sizes.

When customizing the materials to different products, the
material is studied to meet different requirements; when it
comes to mining product s, the basic requirement is the high
resistance of the bag. In this case the paper coil packing
includes a larger amount of biopolymers in order to have a
recyclable and biodegradable product . In biomass, the
highest content of paper is essential.

In industries working with micronized powder products, the
great advantage of this packing system is that it prevents the
emission of high amounts of dust occurring in the traditional
valve packing. It also provides bigger savings in aspiration
costs. Furthermore, the high cost of valve bags that in many
cases require an inner polyethylene film, means that
switching to a FFS with paper roll very are quickly profitable.

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Wood pellet installation near Kaliningrad (Russia)

WOOD PELLET INSTALLATION

This October 2015 ELOCOM has put in operation a new bagging & palletizing installation for wood pellets in the outskirts of Kaliningrad (Russia).

WOOD PELLET INSTALLATION

One more installation in pellet Biomass in the Baltic region to add to the existing lines in Lithuania and Latvia, a region with a huge potential in woodland.

The installation running at 900 bags/hour consists on a flat reel bagging machine CV4025 with electronic gravity weigher, Maxipal Speed palletiser and hermetic cycle wrapper with top cover dispenser.

The evolution of the geographical expansion of ELOCOM has
been amazing.

By 2.001 ELOCOM installed the first automatic packing
machine in Spain. It was something new that in no way was
supposed to be a wide market. In the following years,
complete packing lines were installed countrywide in Spain, as
well as in Portugal.
Nowadays, the leading companies in Spain in wood pellet
production lines have automatic ELOCOM packing lines.

ELOCOM has lines installed in different countries of Europe as
Germany, France, Italy, Lithuania,… the reason being above all
due the confidence of large specialized engineering in the
Industry.

The challenges that the ELOCOM Export department is
currently engaged in are clearly targeted.

Several automatic packing facilities installed in the Americas,
which involve the leading companies in the production of
pellet in the USA and in several Latin American countries such
as Brazil or Chile.

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Mortar bagging “WATERPROOF” Installation in Canada.

Mortar bagging

Recently a new plant has been installed for mortar bagging in high speed up to 1.100 bags/hour with sheet reel bagging system and double dosing and weighting system.

The bagging system with relief valve from sheet reel allows bagging micronized products, powder or granulated with different features (hygroscopic, corrosive, abrasive,…) and granulometry; isolating them from every external agent. This allows to stock bags outside without risk to deteriorate.

mortar bagging machine

Besides the type of closing, the bagging includes a product densification device, reducing the product volume and the size of packaging.

The bagging system is completed with a flattener for the bag flattening, to compact and regulate the product along the bag in order to get an optimal stability and image of the full pallet. Palletizing quality directly affects the amount of film used during the wrapping. In the unreeling process (optionally) an embossed device could be installed which improves the stability between bags and layers on the pallet, and reduces the use of stretch film

Some of advantage of this bagging system with relief valve relative to other (valve or open mouth) are, packaging cost saving, packaging tightness, less powder in environment, less leak of product, less pneumatic and electrical consumption, less pollution, simplicity in operation and maintenance of the filler, among others…

The dust emissions from the packing station is minimized
because in the process there’s not any open outlet that could
drop dust. This entails a significant savings in aspiration in
comparison with installations valve and open mouth. The
total consumption of the packing line with aspiration can be
reduced for the same production, 18-19 kW in the case of
valve packers, about 7 KW in the case of the FFS.

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Maxibale bagging installation for Projar.

logo projar

Maxibale bagging installation

PROJAR, a company with over 30 years experience in the supply of products for the hortofruticulture, landscape and an environmental sector is leader in that market with over 17 million euro/year turnover.

With factories in Brasil, Portugal, Sri Lanka and India they supply to more than 15 countries thanks to his export network. The Projar Group offers advanced environmental services such as green roofs or waste water phytodepuration.

Pursuing its development and modernization program, they have recently renewed their confidence in ELOCOM purchasing state of the art machinery for Maxibales in fully automatic cycle.

 

maxibale bagging installation

The company already had an automatic line for bagging and palletizing substrate bags mainly focused on the professional market. This installation conceived for working with technical products such as blonde peat and coir fibre is capable of producing up to 2.500 mm pallets high.

The purpose of the new installation is to reduce to a maximum the transportation costs, taking to the limits the hydraulic pressing of the products.

To accommodate the machine we required over 10 m height. The machine press the product while it is “wrapped” with stretch film. Once the wrapping stage is finished, the load is thermo sealed and properly closed at the top and the bottom parts.

El máximo rendimiento de la instalación y en función del producto a envasar (1 o 2 prensadas) es de 15 a 20 Maxibalas/hora y permite envasados de muy diferente altura.

Con esta instalación PROJAR es capaz de hacer frente a la gran demanda de este tipo de envasado que sus clientes de agricultura y jardinería profesional estaban viendo suministrada desde países del norte de Europa. PROJAR por su gran calidad de materiales y mezclas ofrece una garantía de constancia de producto que difícilmente puede ser garantizada cuando el proveedor se encuentra a distancias que no permiten la supervisión directa.

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Open mouth bagging machine Model: EP500

Open mouth bagging machine

Based on the “low cost” concept the new EP500 Open mouth bagging machine design still guarantees the reliability and automatation of the EP SERIES.

open mouth bagging machine  EP-500 general view

Despite the search for reducing cost and improve competitivity, operational reliability remains intact thanks to:

-Identical filling mouth as the EP-400 and EP-600.

Bags placer with clamps with proven efficiency in higher EP models such as the EP-1500.

Bags translation through straps such as in the EP-400 and EP-600 models.

Therefore it works with powder products and without or without gussets bags without adjustments required.

open mouth bagging machine  EP-500 bag container

Regarding the empty bags storage and selection, the classical system has been included guaranteeing performance with paper, PE and high quality PP bags. The inclusion of a conveyor belt will ensure a multiple stations empty magazine.

The reduction in costs comes basically from the materials used such as motors, gearboxes, pneumatics etc… avoiding first brands compare to the other EP models.

Also, instead of using a control panel with color touch screen and data and digitized drawings, a basic panel for electronic weighing and keypads drive for the bagging machine.

The bagging machine is also available with sewing units from relevant market brands and other units fromless known manufacturers.

open mouth bagging machine  EP-500 sac container

One of the strengths of this machine is the combination of the empty bags positioning arm, filling mouth and full bag translation. Reducing the movements to the straight minimum also reduces the error probability.

At the same time it is an easy machine to use, maintain and regulate, suitable for small businesses that do not have specialized departments in automatic machines.

The potential of the EP-500 in the two existing versions is:

-EP-500 gross weight 350-400 bags/hour (Depending on product and accuracy).

-EP-500 net weight: 550-600 bags/hour.

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ELOCOM MOMTAJES, S.L. – Maintenance Contracts

Elocom Montajes S.L.

Important increase of the” Close maintenance agreement” model among the maintenance options available.

Elocom montajes

Elocom Montajes, S.L. is a company belonging to the Elocom Group with independent management in charge of erection, commissioning, after sale service, technical assistance and spares supply of the ELOCOM installations.

At the present, from the 1.200 ELOCOM bagging installations running worldwide, over 7% of our clients have purchased the option that offers highest standards in security and maintenance efficiency.

ELOCOM MONTAJES, S.L. offers different maintenance contracts adapted to the needs of each individual client. The most requested is probably the purchase of 2 annual revisions where our technicians revise the sensible and worn parts, adjust and replace the damaged parts if required.

Today, the companies are searching for the most suitable maintenance plans that can guarantee the continuous production. The lack of maintenance and adjustments becomes the main spot of breakdowns in the production lines with the consequent economic losses due to the forced activity breaks.

The Analysis of the maintenance contract indicators clearly states that:

The biggest the company, the highest is the tendency to program the maintenance actuation. In Fact, according to the classification of ELOCOM clients, 61% of the maintenance contracts are agreed with the considered” Big Companies”.

In terms of geographical location, a steep increase is noticed in “Export” especially in emergent countries in Latin America and some Asian countries.

As expected, some sectors with Special issues and difficult atmospheres in terms of dust and Corrosivity such as fertilizers and salt have a higher percentage of maintenance contracts.

To conclude, it is important to highlight that the biggest advantage of the ELOCOM Montajes, S.L. maintenance contracts is the fact that the machine performs better and INCREASE CUSTOMERS SATISFACTION.

Si analizamos desde diferentes parámetros, la atribución de contratos nos señala:

–        Cuanto mayor es la empresa, mayor es la tendencia a programar mediante contratos de mantenimiento. De hecho, dentro de la distribución de clientes de Elocom, el 61% de los Contratos de Mantenimiento son pactados con empresas consideradas “Empresa Grande”.

–        Por distribución geográfica, cabe destacar el gran aumento en “Exportación” y en concreto en países emergentes de Latinoamérica y algunos de Asia .

–        Como era de esperar, algunos sectores con especial problemática de mal ambiente de polvo o corrosión, entre los que se destacan fertilizantes y sal, tienen el mayor porcentaje de Contratos de Mantenimiento.

Como punto final, queremos señalar que la mayor ventaja de que se acuerden Contratos de Mantenimiento con ElocomMontajes,S.L. es que al trabajar mejor las máquinas, se consigue un incremento en la SATISFACCION de los CLIENTES.

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