Zeppelin Systems GmbH

Graf-Zeppelin-Platz 1 , 88045 Friedrichshafen
Germany

Telephone +49 7541 20202
Fax +49 7541 2021491
zentral.fn@zeppelin.com

Trade fair hall

  • Hall 9 / B41
 Interactive Plan

Hall map

K 2016 hall map (Hall 9): stand B41

Fairground map

K 2016 fairground map: Hall 9

Our range of products

Product categories

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.01  Machines and equipment for preprocessing and recycling
  • 03.01.001  Mixers
  • 03.01.001.01  Mixers, continuous type, for solids

Mixers, continuous type, for solids

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.01  Machines and equipment for preprocessing and recycling
  • 03.01.001  Mixers
  • 03.01.001.03  Mixers, batch type, for solids

Mixers, batch type, for solids

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.01  Machines and equipment for preprocessing and recycling
  • 03.01.004  Screening machines, classifiers, dedusting systems for plastic pellets

Screening machines, classifiers, dedusting systems for plastic pellets

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.01  Machines and equipment for preprocessing and recycling
  • 03.01.009  Compounding lines
  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.01  Machines and equipment for preprocessing and recycling
  • 03.01.010  Recycling plants
  • 03.01.010.05  Recycling plants for rubber waste

Recycling plants for rubber waste

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.02  Machinery and plant for processing
  • 03.02.009  Machines for the tyre industry

Machines for the tyre industry

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.01  Silos
  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.02  Silo discharge devices
  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.03  Driers for bulk materials

Driers for bulk materials

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.04  Conveyors (except factory trucks and carts)
  • 03.07.002.04.01  Pneumatic conveyors
  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.04  Conveyors (except factory trucks and carts)
  • 03.07.002.04.02  Screw conveyors

Screw conveyors

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.05  Dosing and metering equipment
  • 03.07.002.05.01  Volumetric dosing and metering equipment

Volumetric dosing and metering equipment

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.002  Material handling
  • 03.07.002.05  Dosing and metering equipment
  • 03.07.002.05.02  Gravimetric dosing and metering equipment

Gravimetric dosing and metering equipment

Our products

Product category: Compounding lines

Plastics-Processing Plants

Zeppelin is at the cutting edge of plastics processing, specializing in PVC processing plants, compounding plants and the manufacturing of cross linkable polyethylene cables for the cable industry.

We are particularly valued for the perfect integration of our sys- tems and components in the overall process. We provide our customers with customized solutions for their individual requirements for flexible and reliable raw material management. Turn-key silo solutions are seamlessly integrated into the overall logistical concept.

Innovative conveying processes, dosing systems, mixers etc. – Zeppelin always has the right solution for all your plastic pro- cessing requirements. This is where our global network, with project management ca- pacities on six continents and production plants in the most im- portant economic regions, comes into play, always guaranteeing our customers personal advice and on-site support.

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Product category: Compounding lines

Plastics Compounding

Complex tasks require extensive know-how to develop optimum solutions. We are in our element here, such as with the compounding of plastics. Many different and difficult to process raw materials place the highest demands on extruders and dosing systems in particular. 

Absolute precision, high availability, and 24/7 reliability are crucial to the operating success of the entire system. We integrate the appropriate dosing device into the system together with the relevant conveying process for the various raw materials and additives, such as stabilizers, lubricants, plasticizers, pigments, fillers, flame retardants, cross-linking agents, propellants or glass or carbon fibers, for example, to improve the rigidity or mica to improve the appearance. 

We also provide innovative solutions and components for gentle conveying after the compounding as well as for the obligatory cleaning and inspection of finished goods. But that is not all: whether it's semi- or fully-automated packaging systems or complete finished goods logistics through to silo loading facilities – Zeppelin supplies turn-key plants from a single source.

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Product category: Compounding lines

PVC Processing

The stability of the entire system plays a crucial role for the treatment of PVC powder. Dosing systems for a batch process must meet the highest demands in terms of precision and reliability to ensure a consistently high product quality in the long run.

The supply of a wide variety of raw materials requires first-class recipe management via a modern, freely programmable control system. This must also be able to cope with rapid cleaning with frequent recipe changes. The raw materials and additives that place high demands on the bulk material and liquid handling due to their properties are automatically dosed into the heating-cooling mixers depending on the recipe. The finished dry blend is conveyed to the extruder via intermediate silos after this mixing process.

Gentle conveying processes – pressure, suction or mechanical screw conveying is used depending on your application – reduce the resulting separation to a minimum. Inflatable conveying lines, vibrated rubber or PE pipes and the Overflow bypass conveying system ensure the reliable handling of materials even under the most difficult conditions. In addition, blending silos, specifically developed for this task, are even located upstream of the extruder, if required.

Plasticizers and other liquids, temperature-controlled or melted as required, are supplied via liquid dosing systems. Likewise, liquid weighers or volumetric multi-dosing systems are used for closed systems.

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Product category: Compounding lines

Plants for the rubber and tire industry

Zeppelin relies on its own first-class technology for rubber and tire plants. More than 500 systems that have been constructed around the world as well as a list of references with all the major companies from the industry also speak for themselves within this sector.

The operating success of companies in the rubber and tire industry depends on the exact mixing of raw materials and the reliable and high-precision supply and dosing. A decisive factor is the mixing – a task that requires special technologies, know-how and most importantly experience.

Zeppelin supplies complete plants from a single source from the receipt of raw materials and the storage and conveying technology, the weighing and dosing of carbon black, silica, oils as well as other additives and small components through to turn-key mixing rooms.

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Product category: Compounding lines

Plants for Plastics Producers and Forwarders

You want to be able to rely on a strong partner when constructing your plant? Then Zeppelin is your first choice as a general contractor.

You can simply focus on your core expertise and we will take care of all the necessary details. From identifying your needs, a site survey and defining the utilities through to dealing with the authorities or taking the legal requirements into consideration: our package includes a wide range of services.

The concept is always consistent, tailored to your needs and implemented from a single source. Whether it's silo or conveying technology, civil engineering or detailed engineering through to assembly and commissioning on site: we have the know-how, produce the key components ourselves and place great value on high quality and reliability when selecting partners and suppliers.

Zeppelin as a general contractor:

- A complete system tailored precisely to your needs
- Innovative concepts to solve the defined requirements
- Fast system availability through reduced interfaces and optimized processes
- Coordination of all third party suppliers
- No interface-related losses – one point of contact
- Optimized total investment and operating costs

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Product category: Recycling plants for rubber waste

Recycling plants for rubber waste

Around 630,000 tons of used tires are accumulated each year in Germany alone. There are 3.2 million tons within the European Union and even 4.4 million in the USA. In the European Union alone, 4% of these end up in landfill sites and 50% are used as fuel in furnaces within the cement industry – a huge waste of precious raw materials. Still, every car tire contains approx. 2 to 3 kg of carbon black.

Zeppelin is seeking to eliminate this waste and ensure sustainable business activities through recycling. Together with our project partner Pyrolyx AG we have succeeded in recovering oil, gas and high-quality carbon black in particular from tires on an industrial scale.

The quality of the carbon black is a decisive factor for the effectiveness of the process. As a leading manufacturer of systems for the tire industry, we enjoy a high reputation within this field with our process engineering know-how. With our turn-key recycling systems we want to close the recycling loop, conserve resources and play our part in ensuring that energy efficiency and sustainability are not just empty phrases, but instead have an effective impact in reality.

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Product category: Compounding lines

Cable Sheating with VPE granulate

The handling of material for the production of cable sheathings using VPE granulate is one of the most demanding tasks in bulk materials technology. The product purity requirements here are particularly high. Experience, know-how and complete systems, precisely harmonized with one another, determine the quality of the finished product.

Even the slightest contamination can cause major damage when insulating medium- and high-voltage cables. The handling of raw materials under clean room conditions is therefore essential for a reliable process.

Peroxide clusters and contamination are not tolerable. That is why we only rely on our own ability with this challenge: All components in this case originate exclusively from Zeppelin. Designs without any dead space were developed for this special application. Smooth pipe connections, special fittings and gentle low-velocity conveying – here every detail is decisive.

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Product category: Mixers, continuous type, for solids, Mixers, batch type, for solids

HENSCHEL-Mixers®

A variety of different mixing tasks need to be solved in the manufacture of products. Zeppelin has various types of mixers available for this.

HENSCHEL-Mixers® have set standards for more than 60 years and are therefore one of the world's most well-known machines for the plastics industry. In addition to plastics processing, our mixers are also used in the chemical, food, lacquer, paint, pigment and cosmetics industries.

Efficient production lines with high availability and reproducible product quality can only be achieved with optimum systems technology and a process that is designed for the specific requirements of the respective product. Our systems and mixers guarantee this in continuous and batch-based system solutions.

Laboratory Mixer FML
» Universal use for mixing, coating, granulating and heating
» Development of new applications and scale-up to the production machine

High Intensity Mixer FM/MB
» Universal use for mixing, coating, granulating and heating
» Also used for homogenizing and coloring

Universal Cooler Mixer KM
» For cooling processes and homogenizing of bulk materials

Horizontal Mixer HM
» Product cooling and mixing processes with high throughput rates in batch operation

Masterbatch Mixer MB
» Friction mixer with water-cooled mixing tools for temperature-sensitive products

Container Mixer CM
Mixing system for a wide range of applications, with transport containers for optimized handling and minimal cleaning efforts

Continuous Turbo Mixer CTM
» Continuous mixing and coating process with friction at a high throughput

Container Mixer Inliner CMI
» Enhancement of the „Container Mixer“ concept into mixing within an inliner for outstanding mixing qualities and minimized maintenance

Horizontal HCE
» Enhancement of the HM series
» Higher throughput
» Small size design
» Optimized wear protection
» Higher operating safety

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Product category: Silos

Silo types

Bolt-Tec - bolting rather than welding
With our Bolt-Tec silos for volumes up to 1000 m3, we have made top quality even more cost-efficient. The automatic prefabrication of the silo segments allows short delivery times. They can be trans- ported by ship in standard containers at little cost. They can also be transported at a reasonable cost via road with a curtainsider truck. The silos can even be assembled when only little space is provided, e.g. inside buildings. The modular principle allows our customers to assemble their silos themselves.

Panel-Tec - for silos larger than 500 m3
Panel-Tec silo segments are prefabricated in our manufacturing plant as well before they are transported to the site in containers and at little cost. Flange joints make it possible to quickly assemble and bolt together the modules. The silo can therefore be assembled in a short time. After that, the silos are welded automatically on the inside.

Weld-Tec - standard welded silos
Many customers prefer standard welded silos when the distance to the installation site is short or if the silo is relatively small. However, there are great differences in quality in this field. As a leading company in silo construction, Zeppelin guarantees premium long-term quality. If structural or process-related criteria (e.g. for process silos, due to design pressure/temperature, and for blen- ding silos, due to diverse installations) make standard welded fabrication necessary, Weld-Tec is the best choice.

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Product category: Mixers, continuous type, for solids, Silos

Blending Silos

Due to fluctuations in the process or the raw materials, it is not always easy to attain consistently high product quality in producing or recycling plastics. Zeppelin's blending silos make it possible to balance out these fluctuations and achieve considerably better results. Our vast product range covers many bulk materials and the corresponding mixing efficiency requirements, even in the standard version.

The use of Zeppelin blending silos provides many advantages:

Reduced energy consumption
Since they are designed as gravity blenders, no additional power is required.
Saving time
Generally, one cycle is sufficient for the homogenization of the product. For highest requirements, we offer pneumatic recircula- tion systems for several cycles.
Low total investment
Since the silos are highly-efficient, it is often possible to use fewer or smaller blenders.
Neutralization of smell and taste
Every blender can be equipped with aeration and degassing equipment. Cooling, heating, inerting or drying is also possible in our blending silos.

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Product category: Silos

Storage Silos

With our storage silos made of aluminium or stainless steel, we ensure cost-efficient, dependable and gentle storage of your high-quality bulk materials. In order to ensure optimum operation at all times, the correct static and process-related design of the silos is essential.

Our structural engineers consider all the current calculation prin- ciples and country-specific regulations, e.g. wind and earthquake loads. Structural explosion protection by means of explosion pres- sure venting as well as preventative ex-protection by grounding all plant parts and avoiding ignition sources are also part of the portfolio.

With the process-related design of the silos, we avoid bridging and ratholing asymmetrical flow zones, segregation or condensation. In addition, tried and tested anti-honking systems provide for noise-free processes to ensure your operating success.

When bulk materials from new manufacturing processes need to be stored, we identify the flow properties in advance reliably on the basis of shear tests. In many cases, we use our comprehensive range of accessories for our designs. We manufacture or develop these key components ourselves.

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Product category: Silos

Process silos

Reliability in the daily use is of utmost importance in process silos. You can rely on the knowledge of Zeppelin process engineering silo specialists whatever the purpose of your application.

Whether degassing residual monomers, drying, heating or cooling within a silo or purge bin – the bulk material that requires proce- dural handling is in good hands with Zeppelin.

Experts in the field
Silos can only be optimally designed for individual requirements with the necessary experience and a lot of process know-how. You can count on the world leading plant manufacturer’s proficiency and the knowledge acquired through Zeppelin’s bulk material network.

Product degassing
Discharging residual monomers is an important production process step, particularly of LDPE, in order to reach the LEL (lower explosive limit). Whether purge bin or stepped cone silo, the design based on mass flow and no dead zones is the essential factor.

Product heating/cooling
Heating or cooling a product during the process – or in combination with bulk material degassing – are further options to optimize processes.

Product and flow properties
Every bulk material is different – what is important to know is how it reacts. Whether products with good or poor flowability, pellets or powders: we have the ideal solution for every product property.

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Product category: Silos

Silo accessories Zeppelin rotary feeder

Modern concepts provide the raw materi- als as close to the machines as possible. For conveying the product from external si- los to the day bins in the production plant, Zeppelin uses technologies which are both highly efficient and product-gentle.

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Product category: Pneumatic conveyors

The right conveying processes for individual requirements

We analyze the bulk material properties of our customers' products and take the system parameters, the concept of the entire system as well as the investment and operating costs into consideration. From this we develop the optimum system for their individual requirements.

We use different principles (variants) when it comes to conveying systems depending on the customer's specific requirements:

Pneumatic dilute phase conveying (Lean-Tec)
Pneumatic dense phase conveying (Dense-Tec)
Pneumatic bypass conveying (Twin-Tec)
Hydraulic conveying (Hydro-Tec)

Clever combinations are also possible, such as dilute phase conveying over long distances, then sorting and subsequently the use of gentle dense phase conveying. The conveying systems have an efficient modular design and the most economical solution is tailored to your product and your specific requirements. Our conveying systems are synonymous with process reliability, maximum efficiency and product-friendly transport.

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Product category: Pneumatic conveyors

Dense phase conveying

Pneumatic dense phase conveying is normally used for pellets with high quality requirements. This system is recommended especially for products susceptible to abrasion. The dense phase conveying is more complex than the dilute phase conveying, is operated with higher pressures (up to typically 3.5 bar) and it requires more complex components regarding design and layout. However, the dense phase conveying is often the more economic solution for short conveying distances.

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Product category: Pneumatic conveyors

Dilute phase conveying (Lean Tec)

The pneumatic dilute phase conveying process is mainly character- ized by the system’s high flexibility e.g. in case of varying conveying quantities. This type of conveying system is very simple compared to other conveying processes and can be used for short or long conveying distances. The necessary components are simple and require low maintenance. A further advantage of dilute phase conveying is a reduction in total investment costs: lower pipe forces mean less costly pipe supports.

Velocity (typical): 15 – 35 m/s
Air to solids ratio (typical): < 20 kg/kg

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Product category: Pneumatic conveyors

Bypass-Systems

The innovative Intraflow system is a bypass system which prevents the clogging of pipes by dissolving the plugs as they form. Air is injected through a small pipe installed in the conveying piping to ensure continuous, gentle transport of the product and operational reliability. This bypass system is mainly used for bulk materials with good fluidization characteristics, especially PTA/CTA.

Velocity (typical): depending on the selected conveying system
Air to solids ratio (typical): < 50 kg/kg
 

Twin-Tec Overflow und Airfloat: specially designed for powders
Two special bypass systems (Overflow and Airfloat) allow the use of the gentle dense phase conveying even for powders. Secondary air is injected through valves into the conveying pipes at exactly defined intervals. This process ensures trouble-free dense phase conveying, a method which is preferably used for granulated carbon black or silica due to the low rate of particle destruction.

Velocity (typical): 3 – 10 m/s
Air to solids ratio (typical): < 80 kg/kg

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Product category: Pneumatic conveyors

Hydraulic conveying – Hydro-Tec

For hydraulic conveying, water is used as conveying medium instead of gas. This conveying method is especially advantageous in case of long conveying distances or extremely high purity demands and the complex system has a lower energy consumption for conveying. Furthermore, smaller pipe diameters can be used even for high con- veying capacities resulting in minimal pipe forces and noise emissions.

Velocity (typical): 1.5 – 3 m/s
Solid concentration: < 40%

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Product category: Screening machines, classifiers, dedusting systems for plastic pellets

Elutriators

The diversity of plastics with most varied characteristics has exploded due to the ever-increasing market requirements. The proper selection of suitable product cleaning systems is therefore a decisive factor for the success of plastics producers and proces- sors as they handle large quantities daily. Whether PE, PP, glass fiber reinforced pellets or particularly soft plastics such as LDPE with EVA – for every specific conveying task there’s a perfectly matching solution.

Zeppelin elutriators are used for cleaning plastic pellets and separating dust particles such as streamers and angel hair. This cleaning method ensures the highest possible product quality before packing or loading. Zeppelin offers a range of separators designed to provide optimal solutions for your applications.

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Product category: Screening machines, classifiers, dedusting systems for plastic pellets

Sifter

The rotary sifter RS is used in the food, chemical, plastics processing and pharmaceutical industries as pre-sifter before silos or in bag filling stations, after-sifter under containers and for in-line sifter for pressure-tight operations (up to 0.8 bar excess and 0.5 bar (g) vacuum pressure) in pneumatic conveying systems.

Coarse materials can be easily removed; the sifter drum of poly- ester or stainless steel is exchangeable. Our rotary sieves serve to sift out foreign matters and impurities, as well as protect the downstream processing machinery.

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Product category: Screening machines, classifiers, dedusting systems for plastic pellets

Dedusting systems

Zeppelin’s successful and proven technology has been used in the plastics industry for many years. The applications range from polymers and soft elastomers to technical plastics. Zeppelin’s full range of components for product cleaning covers the most varied requirements and provides you with the basis for your plant’s corresponding system module in order to achieve maximum product quality. Zeppelin offers pellet

cleaning systems, drum screen systems, cyclone separators, filters and samplers.

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Product category: Silos

Silo accessories - filters

To promote quality and to achieve added value are basic require- ments for our systems. We develop and produce ourselves all components that are essential to a cost-effective complete system in order to always meet these requirements. Nobody pays more attention to the important details than the one who conceived the entire system. Tried and tested, state-of-the-art technology, smoothly integrated in your overall concept – this is what you can expect from the Zeppelin components.

Jet venting filter
Fully automatic operating jet venting filter for the continuous filtering of pneumatic conveying air from continuously operating hoppers and silos. High degree of dust and powdery products separation from the exhaust air or process gases at constant filter resistance in nearly all technical applications.

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Product category: Silos

Zeppelin vacuum hopper loader

All-purpose device for automatic feeding of pelletized, powdered, and granulated products to silos, hoppers, processing machines and extruders. Low maintenance required thanks to the large filter area with automatic jet cleaning.

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Product category: Silo discharge devices

Silo discharge devices

To promote quality and to achieve added value are basic require- ments for our systems. We develop and produce ourselves all components that are essential to a cost-effective complete system in order to always meet these requirements. Nobody pays more attention to the important details than the one who conceived the entire system. Tried and tested, state-of-the-art technology, smoothly integrated in your overall concept – this is what you can expect from the Zeppelin components.

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Product category: Silo discharge devices

Vibratory cone/bottom

Vibratory cones/bottoms are used for the activation of the product flow of non-fluidizable bulk material or of those with poor flowabilty. The unbalanced motor is vertically mounted to the discharge bed creating horizontal circular vibrations that are carried into the product column. This causes the product to flow through the ringshape between the discharge bed and support cone to the discharge opening.

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Product category: Silo discharge devices

Zeppelin Fluidizing discharge cone

Discharge device for less free flowing bulk solids via fluidising combined with mechanical movement. Enables complete discharging. Suitable for powdery products. With additional equipment (i.e. fluidisation hoses, pads) usable for large silos. Adaptable to thevarious requirements by selecting the corresponding accessories. Temperature range: -10°C to +80°C.

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Company news

Date

Topic

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Oct 17, 2016

More than just smart:

Zeppelin is setting trends in the digitalization of plants and components in the plastics industry

Zeppelin Systems is moving a step closer to plant component digitalization with its Smart Components App. For Dietmar Dieing, responsible for this new development at Zeppelin, "Digitalization and Industry 4.0 are hot discussion topics these days. What is mostly important for the customer is that he gets real added value from these concepts. Our new Smart Components App greatly facilitates the users' daily work."

The new app actively supports maintenance and service technicians by automatically identifying the components and providing specific information to mobile devices. "Very few users are able to say offhand when a rotary feeder was installed, let alone give details on performance data or previous maintenance work. Although there are identification plates, they don't necessarily provide all the required and accurate information and rough environmental conditions have probably made them illegible," Dieing explains. The Smart Components App, on the other hand, provides precise information on specifications, spare parts lists, commissioning instructions, operation, maintenance and service intervals. Furthermore, customers can chat in real time with an expert through this app. The chat service also enables the transfer of pictures and videos so that Zeppelin experts from around the world can provide the best assistance.

Using the app is a child's play: once the app is running on a smartphone, tablet or laptop, all Zeppelin components in proximity will appear on the display. Even in a large plant, the user can quickly locate the component in case location information has not been properly documented. The user is then guided intuitively through the menu. The biggest advantage over identification plates is that the information can not only be read, but it can also be edited and more can be added. "Digital checklists and maintenance protocols can be created using this app and maintenance dates can be scheduled. This enables transparent paperless documentation for the components' entire life-cycle," Dieing points out.

The app is not only usable for new products. As of the second quarter of 2017, all Zeppelin components will be equipped with this feature. Older components such as rotary feeders in difficult environments can also be retrofitted easily. Zeppelin customers will be able to enjoy all benefits of this application as it is free of charge, apart from service costs.

At this year's K trade fair, the plant engineering specialist from Friedrichshafen, Germany, will demonstrate how the app works and what the benefits for the users in the plastics industry are. The app, which will be presented in hall 9, booth B41 in Düsseldorf, is only the first step toward digitalization in the plastics industry. New ideas relating to Industry 4.0 will be introduced as early as 2017. "This includes the fully automatic integration in control
systems," Dieing concludes.

About the Zeppelin Group

The Zeppelin Group operates 190 sites around the world. In the 2015 fiscal year, its 7,800 employees generated sales of over 2.3 billion euros. Group-wide collaboration in the Zeppelin group revolves around a management holding company and six strategic business units: Construction Equipment EU (sales and servicing of construction machines), Construction Equipment CIS (sales and servicing of construction and agricultural machines), Rental (rental and project solutions for the construction and industry sectors), Power Systems (drive, propulsion, traction, and energy systems) and Plant Engineering (engineering and plant engineering) as well as Digital Services and Solutions (new digital business models). Zeppelin GmbH is the Group holding company. It is legally domiciled in Friedrichshafen and has its head office in Garching near Munich, Germany.
For more information, please visit www.zeppelin.com.

About Zeppelin Plant Engineering

The strategic business unit (SBU) Zeppelin Plant Engineering is specialized in developing, manufacturing and building components and systems for handling (storing, conveying, mixing, dosing and weighing) high-quality bulk material. They are used worldwide by customers in industries such as plastics producers and processors, rubber and tire, chemical and food. Zeppelin supports its customers in everything from project planning, engineering, production, on-site assembly and commissioning to customer service.

Detailed information available at www.zeppelin-systems.com.

Zeppelin Systems GmbH
Graf-Zeppelin-Platz 1
88045 Friedrichshafen
Germany
Press office
Jessica Büttner
Head of Marketing Communications
Tel.: +49 6074 691-2370
E-Mail: jessica.buettner@zeppelin.com

www.zeppelin-systems.com

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Oct 17, 2016

Plant perfection achieved more efficiently

Zeppelin Systems ensures seamless integration of all elements of the compounding process

The increasing use of plastics in car manufacturing and the electronics industry has led to a higher demand for customized compounds and subsequently for efficiently operating plants. Although the extruder remains the core component in these plants, other modules such as material handling, electric controls and the steel structure also account for a substantial share of the total investment costs, not to mention building technology, dimensioning and provision of energy and auxiliary materials. Furthermore, support when designing the individual process steps can be an integral part of the plant's success. Hubert Stojanovic, Head of Sales, Engineering Plastics, at Zeppelin Systems, describes the situation of many plastic compounds producers: "Producers of technical compounds generally distinguish themselves through their process know-how, but don't always want or are not able to deal with the fine-tuning of the parameters, detail planning and project management when building their plant."
Zeppelin Systems has been handling these tasks for many years now. The company headquartered in Friedrichshafen, Germany, not only supports its customers in selecting the optimal machines and components, it also takes over tasks such as installation planning, document compilation and supervision of schedules. In other words, Zeppelin Systems takes charge of the entire project coordination. "We provide our customers with unbiased advice – just like an architect would do when selecting his building stones," Sascha Schmid, Sales Manager, Engineering Plastics at Zeppelin Systems explains. "The producer can therefore concentrate on his value-adding process and be sure that his project will run smoothly and optimally."

Zeppelin Systems monitored and coordinated the integration of systems – provided by the customer – for weighing/dosing, extruding, granulating, controlling as well as packing and bagging at a well-known compounder. In the final expansion stage, the plant will produce approx. 140,000 tons of compounds yearly. Zeppelin not only supplied the material handling and the Bolt-Tec design storage silos, but also ensured that the entire plant runs efficiently despite the highly abrasive compounds with fiberglass. "Hard to handle bulk materials require extensive know-how in terms of wear protection as this has to be taken into account throughout the entire plant," Hubert Stojanovic adds. "This enabled us to optimally design the
overall process."

Project completion was successful in part thanks to decades of experience in collaborating with all major suppliers. "For many, material handling only holds a secondary role, but it is present in all main interfaces throughout the process, e.g. for material supply in the extruder or at the packing station," Sascha Schmid explains. "Over the years, we have acquired deep understanding of the processes. As a result, our role has evolved from plant designer to architect."

Zeppelin Systems' new role as architect and its advantages for compound producers will be presented at this year's K in Düsseldorf, Germany, in hall 9, booth B41.

About the Zeppelin Group

The Zeppelin Group operates 190 sites around the world. In the 2015 fiscal year, its 7,800 employees generated sales of over 2.3 billion euros. Group-wide collaboration in the Zeppelin group revolves around a management holding company and six strategic business units: Construction Equipment EU (sales and servicing of construction machines), Construction Equipment CIS (sales and servicing of construction and agricultural machines), Rental (rental and project solutions for the construction and industry sectors), Power Systems (drive, propulsion, traction, and energy systems) and Plant Engineering (engineering and plant engineering) as well as Digital Services and Solutions (new digital business models). Zeppelin GmbH is the Group holding company. It is legally domiciled in Friedrichshafen and has its head office in Garching near Munich, Germany.
For more information, please visit www.zeppelin.com.

About Zeppelin Plant Engineering

The strategic business unit (SBU) Zeppelin Plant Engineering is specialized in developing, manufacturing and building components and systems for handling (storing, conveying, mixing, dosing and weighing) high-quality bulk material. They are used worldwide by customers in industries such as plastics producers and processors, rubber and tire, chemical and food. Zeppelin supports its customers in everything from project planning, engineering, production, on-site assembly and commissioning to customer service.

Detailed information available at www.zeppelin-systems.com.

Zeppelin Systems GmbH
Graf-Zeppelin-Platz 1
88045 Friedrichshafen
Germany
Press office
Jessica Büttner
Head of Marketing Communications
Tel.: +49 6074 691-2370
E-Mail: jessica.buettner@zeppelin.com

www.zeppelin-systems.com

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Oct 17, 2016

Planning balance

Zeppelin Systems takes the lead in international large-scale plant construction in the field of plastics production

International large-scale projects for plastics production plants are extremely complex. These plants, which total investment costs can very well reach hundreds of millions, are generally supervised by engineering, procurement and construction (EPC) companies as well as by the process licensors. Innovative plant engineering companies assume an increasingly important role in the process design of such plants.

Unlike many plant engineering companies, Zeppelin Systems goes beyond just simply meeting the specifications of the EPC companies. "In the end, it's the plant operator who is left with the results. A process that has not been optimally planned will affect the operator's daily business. Adjustments are hardly possible to make afterwards due to the size of the plant," Michael Pfrieger, Business Unit Manager Polyolefin Plants at Zeppelin Systems, explains. The company based in Friedrichshafen, Germany, is therefore taking a different approach and doesn't shy away from suggesting alternative plant designs to the given specifications. The company benefits from decades of international experience in manufacturing plants for plastics producers. "We know which technology is state-of-the-art and this is why we were often able to help the end customer lower his investment and operation costs," Pfrieger says and adds two examples to illustrate his point:

Example: Production of polypropylene pellets

Although removing monomers from plastics is a common process, there is still room for optimization. The EPC specification was to remove the monomers right after the production process and then to store the powder in a storage silo. This closed loop process design, however, required silos capable of withstanding a very high pressure, which naturally leads to very high costs. The extrusion process in which more monomers are formed was placed after storage. Zeppelin therefore suggested that degassing be placed at the end of the extrusion process. After going through underwater pelletizing, the pellets are now heated, degassed and cooled again in a process integrated in the conveying system before they are transported to the mixing silo. The plastics producer not only benefitted from lower investment costs (expensive pressurized silos no longer necessary), but also from an improvement in the quality of the end product. "We were only able to suggest these plant modifications because we have field experience in the matter. We also simulated the process in our Technology Center and were able to confirm that it does work," Pfrieger explains.

Example: Production of PE and PP pellets

Another example comes from storage. In the original EPC specifications, four bagging silos with four separator systems were foreseen. For the EPC companies, this was a reasonable approach as simple device multiplication reduced some planning costs for them. However, there was only one production line in the plant, which meant only one separator could be used. Zeppelin suggested using one central separator system that feeds gravimetrically into the four bagging silos. Although the steel structure was slightly more expensive, it allowed considerable savings by reducing the amount of separator systems from four to only one. "This is an excellent example how to reduce investment and operating cost without
compromising on flexibility," Pfrieger emphasizes.

Zeppelin Systems always has the total system and the target technology in mind when planning a plant and decides for the optimal solution for process and operator rather than just executing specifications. "We strive for a balance between proven systems and individual solutions," Pfrieger explains the strategy. "Like an architect we decide for the best fitting subsystem or process for the plant."

Zeppelin Systems, the plant engineering specialist from Friedrichshafen, Germany, will demonstrate how to realize large plants for plastics at this year's K, hall 9, booth B41 in Düsseldorf, Germany.

About the Zeppelin Group

The Zeppelin Group operates 190 sites around the world. In the 2015 fiscal year, its 7,800 employees generated sales of over 2.3 billion euros. Group-wide collaboration in the Zeppelin group revolves around a management holding company and six strategic business units: Construction Equipment EU (sales and servicing of construction machines), Construction Equipment CIS (sales and servicing of construction and agricultural machines), Rental (rental and project solutions for the construction and industry sectors), Power Systems (drive, propulsion, traction, and energy systems) and Plant Engineering (engineering and plant engineering) as well as Digital Services and Solutions (new digital business models). Zeppelin GmbH is the Group holding company. It is legally domiciled in Friedrichshafen and has its head office in Garching near Munich, Germany.
For more information, please visit www.zeppelin.com.

About Zeppelin Plant Engineering

The strategic business unit (SBU) Zeppelin Plant Engineering is specialized in developing, manufacturing and building components and systems for handling (storing, conveying, mixing, dosing and weighing) high-quality bulk material. They are used worldwide by customers in industries such as plastics producers and processors, rubber and tire, chemical and food. Zeppelin supports its customers in everything from project planning, engineering, production, on-site assembly and commissioning to customer service.

Detailed information available at www.zeppelin-systems.com.

Zeppelin Systems GmbH
Graf-Zeppelin-Platz 1
88045 Friedrichshafen
Germany
Press office
Jessica Büttner
Head of Marketing Communications
Tel.: +49 6074 691-2370
E-Mail: jessica.buettner@zeppelin.com

www.zeppelin-systems.com

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Oct 17, 2016

Early planning substantially reduces investment costs

Zeppelin Systems presents innovative approaches to planning plants for technical plastics

The market for technical plastics grows by approx. 4% yearly, and so do the requirements for the production processes. Every slight adjustment to the process not only has an impact on the quality of the end product, but also on the efficiency of the production process and of the internal material flow.

New approaches are therefore required for planning plants for technical plastics. "The sooner we are involved in the planning process, the more efficiently the plant will operate afterwards," Hans Schneider, Head of Corporate Development at Zeppelin Systems, explains. In order to achieve this, Zeppelin Systems, as plant architect, has to manage in detail all processes in the production of technical plastics and act as system integrator. "As architects, we provide our customers with unbiased and manufacturer-independent advice to find the best possible solution. This may lead to a completely revised plant design, but one that would reduce the investment and operating costs substantially."

There are numerous key elements in the production process of technical plastics: the selection of the appropriate dosing and discharge modules for non-free flowing products, gas recirculation systems for product handling under inert gas atmosphere, dust explosion protection or the entire silo logistics including pneumatic conveying, product homogenization and dedusting.

The following are examples of simplifications in the production of polyamide.

Example 1:
Polyamides are very hygroscopic and generally require the addition of nitrogen after the granulation and drying processes in order to prevent moisture absorption. Nitrogen, however, is very expensive, so the systems have to be designed as very complex gas recirculation systems. The necessary nitrogen recirculation reduces the system's flexibility and requires additional piping. Aspects such as higher instrumentation requirements, nitrogen supply and discharge, and newly designed vessels for higher pressure, but also safety issues have to be taken into account. The plant's leak tightness is particularly important and additional protection systems for the operators, such as gas detectors in the plant, have to be foreseen. Zeppelin Systems therefore convinced a polyamide producer of a fundamental change in plant technology. After drying, the polyamide will be pneumatically conveyed in an open system with special dried air rather than in a nitrogen gas recirculation system, reducing complexity and investment costs significantly. Protective systems are no longer necessary, instrumentation and silo design have been simplified and cheaper compressors can be used.
For the operator, the biggest advantage is that the plant design has been greatly simplified, enabling a more flexible production.

Example 2:
The polyamide pellets were to be uniformly coated with a small amount of flow additives in a large-scale mixer in a single process step after granulation. The original process was designed as batch operation. Instead, a continuous coating process with addition and filtering of flow additives was developed with the customer, tested in the Technology Center and finally implemented. The shift from batch to continuous process not only saved money, it also created free space in the production area. "At the beginning of the project, the task was to optimize the mixer. The idea of rearranging the entire process would have never come to the customer's mind," Schneider adds. Now, there is not only considerably more space in the
production area, the new coating process is only a fraction of the cost of the originally planned mixer

All these measures, whether for new plants or for optimizing existing ones, have one thing in common: Zeppelin was involved at a very early stage of the planning process and was therefore able to pave the way for massive changes in the plant design. Other examples of how the plant operator can benefit from innovative planning processes can be seen at this year's K in Düsseldorf, Germany. Zeppelin will present itself in its new role as architect and its new approaches to efficient plant planning in hall 9, booth B41.

About the Zeppelin Group

The Zeppelin Group operates 190 sites around the world. In the 2015 fiscal year, its 7,800 employees generated sales of over 2.3 billion euros. Group-wide collaboration in the Zeppelin group revolves around a management holding company and six strategic business units: Construction Equipment EU (sales and servicing of construction machines), Construction Equipment CIS (sales and servicing of construction and agricultural machines), Rental (rental and project solutions for the construction and industry sectors), Power Systems (drive, propulsion, traction, and energy systems) and Plant Engineering (engineering and plant engineering) as well as Digital Services and Solutions (new digital business models). Zeppelin GmbH is the Group holding company. It is legally domiciled in Friedrichshafen and has its head office in Garching near Munich, Germany.
For more information, please visit www.zeppelin.com.

About Zeppelin Plant Engineering

The strategic business unit (SBU) Zeppelin Plant Engineering is specialized in developing, manufacturing and building components and systems for handling (storing, conveying, mixing, dosing and weighing) high-quality bulk material. They are used worldwide by customers in industries such as plastics producers and processors, rubber and tire, chemical and food. Zeppelin supports its customers in everything from project planning, engineering, production, on-site assembly and commissioning to customer service.

Detailed information available at www.zeppelin-systems.com.

Zeppelin Systems GmbH
Graf-Zeppelin-Platz 1
88045 Friedrichshafen
Germany
Press office
Jessica Büttner
Head of Marketing Communications
Tel.: +49 6074 691-2370
E-Mail: jessica.buettner@zeppelin.com

www.zeppelin-systems.com

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Oct 17, 2016

The new approach to plant planning. Faster and more efficient to market

Nowadays, billion-euro investment decisions in the plastics production and processing industry are taken in a very short time. According to Rochus Hofmann, Managing Director of Zeppelin Systems, the time between an investment decision and commissioning is less than half of what it was a few years ago. These challenges can only be met with better and faster planning.

The plant engineering specialist from Friedrichshafen will demonstrate its new approach to planning and designing plants for the plastics industry at the K 2016. Zeppelin Systems is a plant architect with extensive knowledge of all processes and acts as systems integrator. This allows a significant reduction in the time to market period. "We are now thinking like architects in order to implement our customers' ideas into a working concept," Hofmann describes. "We impartially advise our customer on the best possible solution. The customer then decides what he wants and we make sure all elements fit together perfectly." For the customer this is a double win: he can select from a larger variety of products and the overall process will be optimized.

While a traditional machine construction company focuses on the machine, a plant engineering company's planning will keep the total plant in mind. To do so, Zeppelin Systems makes use of various modern planning tools. One of them is the Zeppelin Value Engineering concept which enables extensive discussions and the optimization of the plant concept in digital form at a very early stage. This leads to better concept solutions such as optimized piping, improved room layout or perfect positioning of all components, and shorter distances. An innovative planning software supports this process. "We use the same tools as international contractors, planning every plant using 3D technology," Hofmann explains. This experience is also useful for revamping. With the help of a 3D laser scanner, an accurate model of an existing plant can be created. This is always helpful in cases where building alterations have not been recorded over time, data formats are not convertible or when the drawings do not correspond to reality. Informed decisions can then be taken regarding the components that will remain in the old plant or be relocated and those that will be disassembled during modernization. Rebuilding a plant can therefore be planned accurately and performed with little production downtime and a high level of security. Zeppelin Systems supports plants for the production and processing of plastics from the first planning steps to realization, covering the complete lifecycle including modernization.

In the future, focus will be set on innovatively developing the planning process, for example by further improving digitalization – not only when planning, but also with the use of components which can communicate in a digital network. Therefore, Zeppelin focuses its
component development on this new product segment named "smart components" and will also present new ideas regarding Industry 4.0 at the K 2016, hall 9, booth B41 in Düsseldorf.

About the Zeppelin Group

The Zeppelin Group operates 190 sites around the world. In the 2015 fiscal year, its 7,800 employees generated sales of over 2.3 billion euros. Group-wide collaboration in the Zeppelin group revolves around a management holding company and six strategic business units: Construction Equipment EU (sales and servicing of construction machines), Construction Equipment CIS (sales and servicing of construction and agricultural machines), Rental (rental and project solutions for the construction and industry sectors), Power Systems (drive, propulsion, traction, and energy systems) and Plant Engineering (engineering and plant engineering) as well as Digital Services and Solutions (new digital business models). Zeppelin GmbH is the Group holding company. It is legally domiciled in Friedrichshafen and has its head office in Garching near Munich, Germany.
For more information, please visit www.zeppelin.com.

About Zeppelin Plant Engineering

The strategic business unit (SBU) Zeppelin Plant Engineering is specialized in developing, manufacturing and building components and systems for handling (storing, conveying, mixing, dosing and weighing) high-quality bulk material. They are used worldwide by customers in industries such as plastics producers and processors, rubber and tire, chemical and food. Zeppelin supports its customers in everything from project planning, engineering, production, on-site assembly and commissioning to customer service.

Detailed information available at www.zeppelin-systems.com.

Zeppelin Systems GmbH
Graf-Zeppelin-Platz 1
88045 Friedrichshafen
Germany
Press office
Jessica Büttner
Head of Marketing Communications
Tel.: +49 6074 691-2370
E-Mail: jessica.buettner@zeppelin.com

www.zeppelin-systems.com

More Less

About us

Company details

The Strategic Business Unit (SGE) Zeppelin plant engineering with its 1.300 employees at 20 locations world-wide is specialized in the development, the production and the construction of components and systems for the handling (storage, conveying, mixing, metering and scaling) of high quality bulk materials. In this area Zeppelin Systems supports its customers from the project development phase via engineering, production, job site installation, commissioning to the customer service. The customers of the SGE plant engineering belong to the chemical industry, plastic producers and processors, the rubber and tyre industry as well as the food industry.

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Company data

Sales volume

> 100 Mill. US $

Export content

max. 75%

Number of employees

> 500

Foundation

1952

Area of business

Machinery and equipment for the plastics and rubber industries

Target groups
  • Plastic product manufacturing
  • Chemical industry
  • Rubber manufacturing / processing