At a glance
Unilin Insulation was looking for an improved dosing and conveying system for its polyol reactor. The system had to handle big bags of different sizes, including bags containing a difficult-to-handle raw material, but eventually also recycled materials. Moreover, the customer wanted to dose those products accurately. In addition, Unilin requested that the system operate dust-free, so operators would need less extensive PPE.
In close consultation with the client, Lybover set out to find an effective solution for the big bag unloading stations and for dosing the difficult-to-handle raw material. To this end, a whole series of tests were carried out at partner EMDE’s test centre.
The new plant had to be installed in just two weeks.Thanks to 3D scanning, Lybover accurately fitted all components to the space provided. As the units were largely pre-assembled, the installation of the modules on site took place efficiently and without any major work. Good communication and constructive cooperation ensured that the entire project ran smoothly.
Unilin Insulation installed a polyol reactor at its Desselgem (BE) site a few years ago to produce its own polyol for its insulation materials. Remarkably, this reactor will in future be able to work not only with new raw materials, but also with recycled materials. The existing system caused a lot of dust and did not offer possibilities for accurate dosing. In close consultation with the customer, Lybover found a solution that is suitable for big bags of different sizes, doses accurately, is ready for recycled materials and operates with low dust.
Innovative reactor for circular production
Unilin Insulation produces insulation materials for the construction industry, including the PIR insulation boards found in roofs and walls. One of the elements needed to make such insulation is polyol. A few years ago, Unilin Insulation installed a polyol reactor at its production site in Desselgem. The installation allows the company to produce customised polyols and monitor their quality more closely. Moreover, the reactor is suitable for processing waste products into new raw materials. In this way, Unilin Insulation wants to produce more sustainably and take further steps towards the circular economy.
Need for flexible and ergonomic solution
Operators feed the reactor with powdered raw materials delivered in big bags. Unilin initially used a hopper and a screw conveyor system to feed the material to the reactor. Michaël De Baets, Business Development Manager at Lybover BULK, says: ‘The problem was that a lot of dust was released in the process, so operators needed extensive safety equipment. This made the work in the hot environment of the reactor tough. In addition, there was no system to weigh and dose the raw materials accurately. Unilin was looking for a solution that was safer and more ergonomic for operators. The conveyor system also had to be suitable for both powders and the larger briquettes with recycled material.’
Understanding product and process
Lybover developed a dosing and conveying system that met those requirements. This was preceded by an extensive phase of engineering and testing. ‘We studied the use and type of big bags as well as the bulk behaviour of the raw materials,’ explains Michaël De Baets. ‘After all, we wanted a flexible dosing system that could handle not only different sizes, but also the specific product properties of the difficult-to-handle raw materials.’
At the test centre of partner EMDE Automation, Lybover’s engineers carried out various tests to find a suitable dosing system. ‘In consultation with EMDE as well as the customer’s engineers, who were closely involved in the entire process, we arrived at a suitable solution,’ says Wouter Tjampens, Project Engineer at Lybover.
For the conveyor system, Lybover found a solution in the form of a disc conveyor. It easily transports both powders and larger pieces of recyclate horizontally and vertically.
Engineered solution, installed on time
The installation of the dosing and conveying system took place during a two-week holiday period at Unilin. ‘That tight timing meant that good planning was indispensable. Thanks to a 3D scan of the building and reactor zone, we had accurate measurement data to assemble our units in advance and ensure a seamless connection to the reactor. This way, the installation was efficient and with a minimum of adjustment works near the reactor,’ says Wouter Tjampens. By starting the design from the 3D scan, we were also able to easily take into account the limited space available, as the client wants to install additional installations in the building. ‘This project shows the added value of such ‘engineered solutions’, adds Wouter Tjampens. ‘But it also shows the power of good cooperation. The project manager at the client thought along at every stage about the best solution. He was even involved in the testing. That constructive approach led to a smooth implementation.’
More performing and safer
The dosing and conveying system currently has two big bag unloading stations from EMDE. Expansion with a third unit for adding recycled material is planned. ‘The unloading stations are made to make the work as efficient and safe as possible. They are equipped with a hoist, so operators no longer have to unload the big bags with a forklift. In turn, the flexible seal of the infeed hopper allows them to empty big bags of different sizes without dust nuisance. Moreover, each unit has a dust filter. Furthermore, there are various tools to unload the difficult-to-handle product from the bag. For accurate dosing , the units are each on high-quality weighing cells and have a rotary lock. Thanks to the low-dust installation , operators need less personal protective equipment. This makes their work much more comfortable. It is in every respect a considerable upgrade compared to the original installation,’ says Michaël De Baets.