HAVER & BOECKER wins LAFARGE Global Supplier Award 2014
The HAVER ADAMS® technology was the most convincing in the category of sustainability / Award for technology used exclusively by Lafarge Tarmac in the UK
With its ADAMS® technology for filling powder-type products into watertight PE bags, HAVER & BOECKER was able to win in the category of "sustainability". The jury's reasoning: the technology showed "an ability to operate in a sustainable manner, including the deployment of appropriate corrective actions".
"Suppliers play an important role in our operations, delivering value year after year and pushing the boundaries in terms of innovation and cost competitiveness," said Thierry Metro, Senior Vice President Energy & Strategic Sourcing at LAFARGE, while expressing his appreciation for suppliers. He explained the motivation for the award: "We want to recognize and celebrate our work together. The Global Supplier Awards represents a victory for our suppliers, for Lafarge and for our customers."
The now prize-winning HAVER ADAMS® technology for filling powder-type products into watertight PE bags was developed together by both companies in a mutual cooperation project. Lafarge Tarmac had identified a significant customer issue: the wastage of cement from damaged paper packed cement for which PE bags were an excellent solution. The combination of Lafarge Tarmac's customer and solutions led focus with H&B's technical expertise has resulted in PE bags being a very successful innovation in the UK packed cement market. Since 2005 HAVER & BOECKER OHG has equipped six Lafarge Tarmac plants in Great Britain with 12 HAVER ADAMS® filling systems. Lafarge Tarmac is a 50:50 joint venture between Lafarge SA and Anglo American plc. Over the past years the HAVER ADAMS® technology was upgraded so that an increase in speed from 1200 bags per hour to 2000 bags per hour could be reached.
The following chain of argumentation was the basis for the prize: HAVER & BOECKER OHG developed a new filling machine called HAVER ADAMS® technology for PE bags, which was installed in UK. The PE bags used are characterized by their impermeability and resistance to tearing. When compared to paper bags, bag rupture and breakage can be reduced by 80 to 90% during normal handling. In addition it provides:
- Less product loss (during filling and transport)
- Cost savings from transport (reduced volume, no additional protective packaging)
- Fewer customers complaints (better weight accuracy, less bag breakage)
- Better employee health protection (dust free)
- Reduction of CO2 (PE 100% recyclable, less product loss)
Drop tests conducted at the HAVER & BOECKER Research and Development Center have shown that PE bags are 500% more resistant to tearing than paper bags. The number of bags damaged by normal handling over the course of the entire logistics chain is well below one per cent while for paper bags the figure is 5 to 7 per cent. Product loss after filling and during transport is thus prevented.
Compared to paper bags, filling takes place with 50% better weight accuracy. All these characteristics result in reduced product use. Because the production of cement consumes resources and emits CO2, the use of PE bags can be viewed as a significant step in reducing environmental impact.
The emptying of residue is considerably higher with PE bags. While up to 120 grams of product remain in a paper bag, the value for a PE bag is only 20 grams. This means product use is reduced, and this means CO2 savings.
The manufacture of paper bags is energy intensive and requires large quantities of water, which in turn subsequently needs to be treated. PE bags also offer benefits when it comes to disposal: While paper bags are burned or thrown away, and thus burden the environment, PE bags are 100% recyclable. And in the event paper bags should be indeed recycled, the need for energy is ten times greater than what is required for PE bag recycling.
In addition to the advantages of sustainability, the ADAMS technology is convincing in other areas. Because cement is a product that can put health at risk, trigger skin irritation, allergic reactions, or even lung ailments, inhaling it or contact with skin or eyes must be avoided.
So that the surrounding areas can remain free of dust or product residue, the packaging needs to be air-tight. Using PE bags means the packaging is hermetically sealed. Neither the machine operators in the plant nor the workers involved in transport, stocking, or even the end-customer, become subjected to danger when handling the cement. The bags are absolutely air-tight and a contamination of the environment is excluded as long as the bags are not damaged.
The PE bag's impermeability results in extended shelf-life. This makes production more independent of temporal and seasonal fluctuations. The plant can be continuously operated at full capacity with the production flow having less variation. This creates a logistical advantage.
Also because of the PE packaging's impermeability, filled bags even can be stored outdoors without adversely impacting product quality. This kind of stocking is considerably less expensive than stocking in a warehouse. It is possible to stock and display the product outside directly next to complimentary products such as paving stones, which acts to boost sales.
Because of the impermeability and tear-resistance of PE bags, the downstream system components such as the discharge belt, palletiser, etc. are subjected to less contamination and thus less wear and tear. Cleaning costs and maintenance intensity along with the associated necessary downtime are reduced.
As a world premiere, HAVER & BOECKER introduced the ROTO-PACKER® ADAMS® MINI at Powtech 2014 in Nuremberg. It is based on the proven ADAMS® technology and for the first time fills powder products into compact PE bags, reaching speeds of up to 600 bags/hr at steplessly selectable weights from 1 to 10 kg. The technology will be ready for the market by the end of the year. Meanwhile the experts at HAVER's Innovation Management are already concentrating on increasing the speed to 1200 bags/hr.
HAVER & BOECKER warmly invites all interested persons to an introduction of a HAVER & BOECKER ADAMS® system. Please contact Christian Reinke by e-mail: firstname.lastname@example.org.
Haver & Boecker MASCHINENFABRIK
HAVER & BOECKER is a tradition-conscious, family-run, mid-sized company with headquarters in Oelde, Westphalia, Germany. Under the umbrella of HAVER & BOECKER OHG, one finds the Wire Weaving and Machinery Divisions. Together with over 50 subsidiary companies on all five continents, they make up the HAVER Group which has 2870 employees and 150 representatives. In 2013 the HAVER Group posted a sales turnover of 470 million euros.
The Wire Weaving Division produces woven wire mesh and processes it into engineered woven wire products. They are used for screening and filtration by the chemical, plastics, automotive, aviation, aerospace, electronics, foodstuffs and feed industries, as well as for architectural applications and analysis sieves.
The Machinery Division specialises in packing and weighing technology. It develops, produces and markets systems and plants for filling and processing loose, bulk materials of every type. The product range includes packing and loading systems for powder-type and granulated materials, packing machines for filling food and animal feed, as well as filling stations and complete filling lines for liquid and pasty products. The product range is supplemented by screening machines, machines for washing, pelletizing plates, agitators, mixers, palletizing and loading systems, silos, ship loading and unloading equipment.