BHT: Jan 2011

BULK HANDLING TODAY January 2011

January 2011
Featured on the cover:
Rema Tip Top SA

Contents
Tel: (011) 813 2222 Cover Story Trucking & Transport
www.rema-tiptop.com 5 Controlled Asset Management 27 Just One Hand
Procurement Safety Equipment

7 Active Buying 31 Controlling Safety Costs
Lifting Equipment 34 Market Forum

8 How it Shouldn’t be Done
11 Making Lifting Safer Endorsing Bodies
• CMA (Conveyor Manufacturers
Logistics Association)
13 It’s Not All About Price
• LEEASA (Lifting Equipment Engineering
Association of South Africa)
Harbours
15 Container Terminal Leads in • RFA (Road Freight Association)
Productivity
• SAIMechE (SA Institution of Mechanical
Beltcon Engineering)
17 Constant Speed Versus Variable Speed
• SAIMH (SA Institute of Materials Handling)
Copyright Operation for Belt Conveyor Systems
All rights reserved. No editorial
matter published in “Bulk Han-
dling Today” may be reproduced
in any form or language without
written permission of the publish-
ers. While every effort is made to
ensure accurate reproduction, the
editor, authors, publishers and
their employees or agents shall
not be responsible or in any way
liable for any errors, omissions or
inaccuracies in the publication,
whether arising from negligence or
otherwise or for any consequences
arising therefrom. The inclusion
or exclusion of any product does
not mean that the publisher or
editorial board advocates or rejects
its use either generally or in any
particular field or fields.
The monthly circulation

is 4 016 Proprietor and Publisher: Advertising Sales:
PROMECH PUBLISHING Surita Marx
Tel: (011) 781-1401 DTP: Zinobia Docrat and
Fax: (011) 781-1403 Sean Bacher
E-mail:
Our e-mail address is bulkhandling@promech.co.za Printed by:
bulkhandling@promech.co.za Website: www.promech.co.za Typo Colour Printing
Managing Editor: Tel: (011) 402-3468
Visit our website on www.promech.co.za
Susan Custers

CONVEYOR MANUFACTURERS ASSOCIATION
From the Chairman’s Desk A brand new year awaits, with information that has been collected now has to be
all the attendant resolutions and funnelled down into a Conveyor Manual that the
hopes for the next twelve months industry can relate to and use on a daily basis.
neatly mapped out in our minds.
Despite reminders, Belt Reco and
A
t the CMA, various milestones Siemens (Flender) had to be expelled
continue to be worked for and due to unpaid subscriptions
this year, instead of waiting until
a task has been completed, Also within the technical remit comes the pub-
I would like to extend my thanks to lication of new and revised national standards.
everyone contributing in the working SABS will shortly be publishing a brand new
groups involved for the hard work that SANS 968 (solid woven belting), which to the
has already gone into these activities. best of our knowledge is a world first. Also long
First and foremost is the CMA Hand- awaited is the publication of SANS 1313 parts
book Project, where the mountain of 1 to 3 (idlers) which is in the final stages of red
tape before being released to the
public.
CMA Members List as at January 2011 Safety is never far from anyone’s
All members subscribe to the CMA Code of Ethics mind in the mining industry, there-
ABB Industry Martin Engineering fore a second and follow-up Safety
Afripp Projects Melco Conveyor Equipment Symposium is planned to be held in
Actom Moret Mining the next couple of months. The first
Atlanta Manufacturing MS Conveyor Pulleys SA Safety Symposium yielded very valid
Bateman Engineered Technologies Nepean Conveyors data and there are some suggestions
for modification of the legislation
Bauer OE Bearings
being discussed, making the follow
BMG Oriental Rubber Industries SA
up Symposium an essential item on
Bearings International Osborn Engineered Products
everyone’s calendar.
Bonfiglioli Power Transmissions PH Projects Holdings
Bosworth Read Swatman & Voigt On the downside, it is very sad to
report that this year we have had
Brelko Conveyor Products Rema Tip Top South Africa
to do something that has not been
CKIT Conveyor Engineers Renold Crofts
done for a very long time. Despite
Continental Crushing & Conveying Roymec reminders, two of our members did
Conveyor Watch RSV ENCO Consulting not pay the annual subscription, so
CMG Electric Motors South Africa Rula Bulk Materials Handling after a period of suspension, regretfully
CPM Engineering Sandvik Materials Handling SA had to be expelled from membership.
CPI Technologies Schaeffler South Africa The companies are Belt Reco and
CT Systems Secrivest Siemens (Flender).
David Brown Gear Industries Beltcon 16 is due to be held on 3
SENET
Delras Engineering and 4 August this year, again at
SET Agencies
DRA Mineral Projects Birchwood Conference Centre on the
SEW Eurodrive
Dunlop Belting Products East Rand. For information on what
Shaft Engineering
Dymot Engineering Company promises to be an outstanding bulk
Shaw Almex Africa
ELB Engineering Services handling conference please visit the
SKF South Africa website www.beltcon.org.za.
Facet Engineering
Fenner Conveyor Belting (South Africa) ThyssenKrupp Materials Handling
Lastly but certainly not least, thanks
Flexible Steel Lacing SA Transmission Components
go to my fellow Directors, who not
Hägglunds Drives South Africa Transvaal Rubber Company only contribute to various working
Hansen Transmissions SA Unitek Engineers groups, assist with events, but also
Hosch - Fördertechnik (SA) Veyance Technologies Africa have to do many duties as a Direc-
Lesa Mining Equipment and Conveyor Voith Turbo tor of the CMA. I wish you all a very
Belt Zest Electric Motors successful, prosperous and happy
M & J Engineering new year!
Simon Curry
Chairman

COVER STORY
Controlled Asset
Management
Just over a year ago, Rema Tip Top South Africa embarked on rolling out
a business plan whereby the company’s services were extended to
become more of a partnership with the client, in other words much more
than merely providing a service. This business principle is based on a
TCO (total cost of ownership) model dealing with the complete life cycle
management of certain aspects of a client’s business.
T
his initiative, welcomed by industry, quickly
led to the model being implemented in
Dries van Coller
practice at a couple of mining sites. These
partnerships not only open up better com-
Conveyor mechanicals are sourced from a number
munication channels between the two parties,
of strategic equipment partners which allows us
but also provide an opportunity for on-the-ground
to offer a full service. In terms of maintenance,
experience of working together to the benefit of
however, we service all the equipment around the
all concerned.
conveyor systems ourselves. The savings we’ve
Embracing complete life cycle management achieved to date are beyond our wildest expectations
and participating clients are more than satisfied
Business model with the results.”
“Bulk Handling Today” speaks to Dries van Coller The core of this business model revolves around
head of marketing, about the evolution of the TCO asset management, not only Rema Tip Top’s own
concept that has now been extended to include a assets, but also those at the client’s facilities. “We
TMS (Total Maintenance and Service) plan. “Where are out to improve utilisation and performance,
companies historically ran on a reactive or run-to- reduce costs, extend asset life and improve return
failure service model, we are now, with the TMS on investment as well as return on assets,” says
model, embracing complete life cycle management Dries. “We recognise that the wide impact and
and costing, planned maintenance and best practices interdependencies between operations, design,
to focus on proactive maintenance instead. asset performance, personnel productivity and life
cycle costs add up to much more than maintenance
Huge success
management.
When Rema Tip Top initiated the TCO concept in
South Africa, it was a fairly new development in Sharing goals
the conveyor industry but it soon became clear “The bulk materials handling and processing indus-
that the local industry was more than ready for it. try in South Africa is a highly competitive one and
“Over the past eighteen months, our service model real innovative solutions that actually save money
has been implemented at a local coal mine and it’s at the end of the day are bound to draw attention.
been a huge success,” says Dries. “At the recent Electra Mining show we indentified a
“We physically established a presence on site and more sophisticated client base with a definite need
our personnel took over full control of the conveyor for our products and services. The huge number
operations in terms of maintenance, repairs and of enquiries we had from our clients was a clear
continuous improvements. Our staff have become indication that our concept has been accepted by
part and parcel of the mine’s daily activities on a both local and African markets,” adds Dries.
full-time basis looking after all conveyor opera- “As we are intimately involved in the client’s busi-
tions. ness, we’re not only dealing with client’s assets,
but we’re also affected by failures that are disrup-
Joint forces
tive and very costly. At the same time, we have
“Since forming the alliance with Dunlop, the full
to adhere to stringent occupational health, safety
service offering now emanates from one company,”
and environmental regulations.
explains Dries “We now supply the belting, maintain
and install it together with our wide range of con- Software
veyor products that make up a conveyor system.” “The main objective of implementing an enterprise

COVER STORY
asset management system is to strike an optimal “To do this we chose a software solution that can
balance between maximising overall asset productivity be described as much more than a CMMS (com-
and minimising TCO while maintaining a maximum puterised maintenance management software)
return on investment,” explains Dries. package which usually only captures standard
transaction maintenance metrics. Our asset perfor-
mance management solution enables us to create
a more comprehensive view by also capturing and
consolidating metrics from a variety of operational
and financial areas. The result is improved visibility
into not only past and present performances, but
also into the future.”
The TMS model can be tailored to any

of the various service applications
Tangible numbers
The TMS model can be tailored to any of the vari-
ous service applications, be it corrosion protection,
wear protection, conveyor maintenance, conveyor
servicing or a combination of these. “We follow
the same business model and simply adapt it to
each client’s specific requirements,” says Dries.
“However, the unique programme is very flexible,
so we can tweak it to make each installation site
specific, even within the same company.
With most of the growing pains now ironed out
in terms of the practicalities of implementing this
model in the real world, Dries is confident that an
above average saving coupled with maximum avail-
ability and reliability is not unrealistic. “We now
have tangible results that can be compared with the
past history of operations in our pilot projects,” he
adds in conclusion. “Besides the highly favourable
savings we’re achieving, we’re also busy creating
an industry standard, not so much for ourselves,
but for the industry as a whole.”
Dries van Coller, Rema Tip Top South Africa, Tel: (011)
813 2222. Email: marketing@rematiptop.co.za

PROCUREMENT
Active Buying
I see one of the greatest problems of the corporate world as being their buying systems. I call it “passive
buying”. Procurement is centralised in a department in which the staff have no specialised knowledge of the
products.
T
he technical them I reject their conditions of purchase,
guy, who and if they want to buy from me they
needs a must pay upfront. This really cast a cat
product, among the pigeons. Five months later
requisitions it. I was paid upfront and I supplied the
It goes out on goods. The suppliers who push their
tender and gets products are the ones who have little
bought from to offer. The suppliers who do not
the cheapest push are the ones whose products
supplier or are bought on their own virtue.
the one who So how should purchasing be done?
manages to Whoever needs the product should
buck the take full responsibility for it and buy
system. The it. If it works, he or she should get the
product pur- credit and if not he must suffer the
chased may blame. Under these circumstances,
have little in corruption cannot thrive.
common with the
requisitioned item. We A neat tip
all know that money Open tenders are good, pro-
changes hands under the vided all suppliers get the
table, but the responsi- enquiries. It is a pity that
bility for purchasing is customers don’t send en-
so diffuse that nobody quiries to all the suppliers.
can be pinpointed as “Active buying” is where
guilty. the customer goes out and
looks for the appropriate
Just give your card to the guy product. Unfortunately this
who needs the product and tell only happens in small and
him he must choose an agent medium-size companies.
himself to represent you Here’s a neat tip; if you want to sell anything to the
mines, just give your card to the guy who needs
the product and tell him since the mine does not
This caused great consternation. If I don’t supply it, where will have an account with you, he must choose an agent
they get it? I said I was sure they could get it for a quarter of the himself to represent you.
price in India; all they have to do is look for it. Look for it? What a
concept! They have never looked for anything before. All they do is Watch the miner smile! Your business is in the bag,
wait for people to come and beg them to buy their products. and at your price too!
Tel: (011) 412-3261, Fax: (011) 692-1232, Email: keram@
global.co.za, Website: www.keramicalia.com
Double the price
I have a large corporate company that has been
buying a small item off me for many years. I don’t Book Now for March 2011
really want the business, I don’t even manufacture • Conveying
the product, I just outsource it. Then one day I had • Weighing
to tender for this business. I sighed, doubled the • Harbours, ports & railways
price and tendered. Mine was the only tender. Then • Trucking
they lost my tender. I said “that’s fine; I don’t want Contact Surita Marx Tel: (011) 781-1401,
the business anyway.” Fax: (011) 781-1403 or
Now I suddenly had this huge corporation begging E-mail: bulkhandling@promech.co.za to
me to sell them a product. I was most amused. I told confirm your space

LIFTING EQUIPMENT
How it Shouldn’t It’s not every day that
be Done even a journalist such as

myself can spot a fault so
blatant, it sends cold
shivers down your spine.
The case in question is
a hydraulic truck loader
fitted onto the back of a
brick delivery truck.
in general. He has 38
year’s experience in
this specialised field
and hardly every shies
away from a repair job,
but with this crane he
just shakes his head
and says, “No thanks,
just go and buy a new
one.
Fatigue
“To start with, the crane
wasn’t mounted prop-
erly onto the chassis in
the first place,” he says
as we walk around the
truck to point out the
faults. “There is no fish-
plate onto the chassis
of the truck to reinforce
How a crane should not be fixed
T
he structure of this crane
has been patched up and
welded so many times it’s
difficult to make out the
original structure, never mind
trying to work out why it’s peril-
ously angled as if it might come
off the chassis any minute. “Bulk
It’s difficult to make out the original

structure
Handling Today” came across this

crane when visiting A 2 Z Lifting
Equipment in Meyerton to talk to
owner Wally Clarke about servic- Wally Clarke of A2Z Lifting Equipment points to the hydraulic system on
ing hydraulic lifting equipment a truck

LIFTING EQUIPMENT
the chassis so it can bear the weight

of the crane, never mind the loads the
crane has to handle. Also, there should
have been a boxed steel reinforcement
between the two fishplates, but there
is absolutely nothing even remotely
like that on this rig.”
The result is that not only did the chassis
start bending after a while, but cracks
systematically developed, evident in
long thick welds where someone tried
to reinforce the steel plates. What’s
more, the stresses also transferred to
the structural plates of the crane itself
as things eventually got so bent out of
shape because the crane lacked stable
support. “Hydraulically this crane still
works just fine, but in order to under-
take safe lifting you’d have to rebuild
the entire crane structure including
The doomed crane that Wally wouldn’t touch
the rear part of the truck’s chassis,”
says Wally. “Apart from the fact that
it would cost the equivalent of a new
crane to repair, I just couldn’t do it; my
good reputation is at stake.”
Life-long experience
On meeting Wally, he is clearly a truly
hands-on man. It doesn’t take long to
realise that when he says it can or can’t
be done, it’s a fact. “As a young ap-
prentice I started with hydraulic cranes
and I’ve been involved all my life,” he
says with a broad smile. “When we
refurbish or rebuild a hydraulic crane
we do it properly, and it leaves our
workshop, pretty much brand new. Too
many people take shortcuts nowadays
to make more money, but it’s just not
worth it.”
As an example Wally tells the story
of how he recently had to refurbish
a hydraulic lifting system built by a
reputable manufacturer down at the
coast. “A client brought me a car car- A crane being refurbished
rier he’d recently purchased,” he says.
“It didn’t take long to find excessive pitting on the with control valves or hold valves and I’ll always
shafts and, when we stripped the cylinder, we recommend fitting a new unit,” he says. “It’s an
found it had damaged seals and was leaking. We intricate system where very fine cracks can develop
sent the shaft for testing and found that the chrom- that you can’t see and when you then refit an old
ing on it was shallow and far below the required one, even if everything else is new, you’re bound
thickness causing the shaft to rust very easily, in to find it starts leaking soon after.
turn damaging the seals. This is what happens if
you take shortcuts to save money and therefore Many people take shortcuts nowadays to make more
we only buy hydraulics shafts and cylinder tubing money
from reputable suppliers who have SABS ratings
on their stock.” “We often get people who say they’ve reconditioned
the control valve system, but in my book that’s just
Control valves not possible,” Wally adds. “Apart from microscopic
Another area where people often require Wally’s cracks, the ports do wear which is not something
experience is with old control valve units. “Over the that can be re-bored or fixed. The only way you
years I’ve learnt that you just don’t take chances can detect wear in a control valve unit is to put the

LIFTING EQUIPMENT
l Customers, Suppliers and

r loya
We wish all ou el a Prosperous 2011
Personn crane under load. When testing all the functions you’ll pick
up that the crane doesn’t hold the load and slowly drops,
or another rod starts creeping slowly by itself, a sign that
Here to Stay
the control valve is leaking through to another port.
“The problem is this tendency only shows up when the oil
has warmed up and therefore the chances are you won’t
always detect it in the workshop. Once out in the field, the
MS Conveyor Pulleys SA (Pty) Ltd is as strong as crane starts acting up,” Wally adds. “It’s just not worth the
trouble and expense, so we always recommend installing
ever despite the loss of Max Schenck who was in the
a new unit.”
Pulleys industry for over 25 years and was well known
as the LEGEND OF PULLEYS.
His son Morné, a mechanical engineer in training and
stalwart of the business, has taken over the reins hav-
ing been well-coached by Max in the in’s and out’s of
the business, which includes the unique design and
manufacturing philosophy of the pulleys .
Morné is well-placed to run the technical and manufac-
turing side of MS Conveyor Pulleys SA (Pty) Ltd
with the able assistance of Magda Schenck the wife of
the late Max Schenck who has been intimately involved
in the financial and management side of the business
from inception.
MS Conveyor Pulleys SA (Pty) Ltd offers a mod- Walter, Wally’s son, is a skilled artisan who builds mechanical
ern, well established factory run by experienced and pick ups single handedly
dedicated employees.
Brick grabs
Wally’s son, Walter, is learning the tricks of the trade from
his father and is a partner in the business. That’s if he’s
not busy with his own sideline of making the brick grabs
they now also manufacture. “We have our own design with
several variations for fitting to a hydraulic crane,” explains
Wally as we end our tour of the facility at the area where
his son is crouched over an intricate weld on the frame of
a mechanical grab. Walter explains, “Apart from standard
grabs we customise to specific requirements. This one, for
example, can also be picked up by a forklift truck.”
A 2 Z Lifting Equipment, Wally Clarke, Tel: (016) 362-3882, Email:
wally@a2zhydraulics.co.za, Website: www.a2zliftingequipment.
co.za
Forthcoming Features 2011

April 2011
• Power Transmission
• Lifting equipment
• Earthmoving & Plant Hire
• Construction
May 2011
• Conveying
• Crushers, screens, chutes and liners
• Project Management
Tel: (011) 894-4900 • Trucking
Email: quotes@mscpsa.co.za Contact Surita Marx Tel: (011) 781-1401,
for all your pulley requirements Fax: (011) 781-1403 or
E-mail: bulkhandling@promech.co.za to
www.mscpsa.co.za confirm your space
10 BULK HANDLING TODAY January 2011

LIFTING EQUIPMENT
Making Lifting Safer

Lifting stuff can be very dangerous, especially if it’s heavy
control of all types of machinery is “Bexl Control
machinery or products lifted with overhead cranes, mobile or Systems” based in Benoni. To learn more, “Bulk
tower cranes. A golden rule in terms of safety is to keep people Handling Today” speaks to Paul Barcelos (Managing
away from an overhead load. In the case of the operator, he Member) and Fanie du Toit (Manager).
should be within a safe working distance from the load
“Today the control of cranes and machines by radio
depending on the process so that if something does go wrong,
control is a standard application in many produc-
then the operator is still safe in the event that a load does drop.
tion and logistics operations,” says Fanie. “It has
been proven to save time, reduce operating risks
and increase efficiency because it allows operators
a perfect view of the payload and they can often
even lend a hand in placing the load in position
accurately.”
Radio control
“In some cases for example, where two people where
required to carry out a task such as an operator
and a slinger on tower cranes,” adds Paul. “The
operator now doubles up as a slinger because he
operates the crane from the ground with a remote
wireless controller. Besides saving on extra labour,
the operator can see down shafts or over buildings
(depending where he is operating from) that could
block his view if he were sitting in a control cabin
affixed to the crane.”
Bexl is the South African partner of HBC radiomatic
in Germany. HBC radiomatic have been manufac-
turing wireless control systems for over 60 years.
Many systems are specified by several OEMs. Other
Paul Barcelos (left) and Fanie du Toit of Bexl Control Systems
machinery, operated remotely by radio control, in-
cludes continuous underground mining machines,
O
earthmoving equipment, drilling machines and
ne way to achieve this is to control the even mobile concrete mixers and boom concrete
crane operation remotely, either with pouring machinery.
a long cable, or even better, by radio
control, giving the operator total freedom
to observe the operation at all angles from a safe Reduced the risk of anything falling on
distance. A company specialising in the remote the operator
Seeing around corners

“Whether controlling industrial or construction
cranes, mobile hydraulic applications, winches
or cranes, we have standard solutions for most of
the variants,” says Fanie. “However, customising
a control solution for specific out-of-the-ordinary
applications is regularly done. In such cases we
either adapt one of our standard controllers, or we
even design a whole new controller which HBC
radiomatic Germany builds for us to the unique
specifications. The possibilities are unlimited,
thanks to the enormous number of features that
can be combined in countless ways.”
Just such a challenge arose recently when Bexl
received a request to assist in making the loading
Functionality on a control unit ranges from simple operations to complex
functions in different types of machines
area of mining trucks safer because a Hazard and
BULK HANDLING TODAY January 2011 11

LIFTING EQUIPMENT
which will immediately

activate the parking brakes
before cutting the engine.
Other safety features include
a sensing system which will
trigger a quick automatic
shut down if the unit gets
knocked very hard (Shock
off), or it can sense a roll-
ing motion (roll-detect) as
when the operator trips and
falls, rolling on the ground.
The zero-g sensor will also
shut down everything when
it senses the unit falling
or being thrown about in
the air.” HBC radiomatic
has added safety features,
such as AFS (Automatic
Frequency Selection) or
AFM (Automatic Frequency
Management).
An assortment of of control units supplied by Bexl
Operability (HAZOP) study by the mining house

had shown that the operators were working in a
high risk unstable environment. “They wanted to
move the loader operator away from the loading
area without having to install a system which would
cost as much as a truck does,” explains Paul. “We
designed a wireless control system where the re-
mote control unit has a colour LCD screen and a
camera which allows the operator to clearly see the
loading area behind the truck two hundred metres
away. This solution completely reduced the risk of
anything falling on the operator who normally has
to be right in the loading area in order to operate
Different protocals are easily managed by simply slot-
the machine.”
ting different electronic cards into position
Reduce operating risks and increase efficiency
ICASA Approval
Safety features Like any other radio device, the radio module used in
Designing and building a remote control isn’t just the wireless remote control unit for machine control
a matter of extending the operational control of a is governed by ICASA (Independent Communica-
machine from afar, it’s also governed by several tions Authority of South Africa) and has to fall in
safety features which usually distinguish a good prescribed and approved frequencies. “We often
remote control system from a bad one. “First and see end-users who’ve made the mistake of buying
foremost the operator should be able to isolate the radio controllers that are not ICASA approved,”
machine instantly when something goes wrong,” says Paul in a conclusive remark. Section 35 (1)
explains Fanie. “The unit should also isolate and of the Electronics Communication Act, 2005 (Act
switch off automatically if certain parameters are No 36 of 2005), the applicable radio regulations
exceeded or something critical in the operation which currently remain in force in terms of sec-
starts malfunctioning. tion 95 (2)
“This could be something like the interference of Ensure that when you are buying a Radio Remote
strong outside radio signals, for example, which Control unit that it is ICASA approved and see the
would prompt the remote unit to automatically put seller’s Radio Equipment Type Approval number
an operation on hold in a safe mode,” adds Fanie. issued by ICASA.”
“Or, if there is a mechanical malfunction on a remote Bexl Control Systems, Fanie du Toit or Paul Barcelos
controlled excavator, like a fire for example, the Tel: (011) 421-0004/0025, Email: paul@bexl.co.za or
operator must have one single emergency button fanie@bexl.co.za

LOGISTICS
It’s Not All

The answer is no
We have asked ourselves: “Is there value in being
the cheapest transport contractor?” says André
Jansen van Vuuren of Cargo Carriers. Our
answer is no and we drive the added-
About Price
value proposition much harder than
cutting costs for our customers. By
adding value, we reduce cost. The
result is that our customers stay with
us for very long periods, primarily
because they appreciate the value and
The first man to set foot on the Moon, Neil
benefits that we invariably bring to their
Armstrong, was asked what he had feared
businesses.
most before getting into the Apollo 11 space
capsule. It was not the fact that he was “Such value derives from
sitting atop one million litres of highly flam- backward integration
mable rocket fuel; nor was it because he within our customers’
was going where no man had supply chains and Cargo
Carriers’ commitment to
been before.
delivering a very high
service level at all
times, without fail!
“In support of this we
H
have implemented a
is biggest fear? That branch best practice
the two million system within all our
separate compo- contracts that focuses
nents installed in on each customer and
the Apollo 11 space craft were the specific needs of
manufactured by the lowest that customer.”
bidder! Armstrong obviously
Non negotiable
had gathered previous ex-
The results, when
perience of lowest cost not
compared with inter-
equating to best value!
national standards,
Hardest hit show significant im-
Today, more than 40 years provements. The com-
later, mankind continues to parison against the total
regularly encounter and debate acceptable levels of service and
the topic of lowest cost and value complaints in, for example,
for money so neatly highlighted by the chemical industry, shows
Neil Armstrong’s simple retort. The improvement by leaps and
current international downturn and bounds.
credit crunch is prompting new “Exceptional service levels,
pre-occupation with low cost, and however, come at a cost and
manufacturers and suppliers have we regard this cost as a non-
become more cost conscious at all negotiable issue. Our focus on
levels within their organisations. improving and increasing our
There is an impact on the logistics levels of service has differenti-
industry. Logistics, sitting at the ated us from our competitors and
end of the supply chain, is invari- this, together with our innovative
ably hardest hit when it comes to approach to the supply chain of
cost cutting, despite the fact that each customer, is the foundation
logistics in many cases contributes stone of our competitive edge,”
less than 10% of the total cost in André adds.
the manufacturing and supply
Resources
chain. Come what may,
Cargo Carriers subscribes to the
its status as a cost
POOGI (process of on going improve-
focus point seems
ment) approach as detailed within
permanent.
the concepts of the Theory of
André Jansen van Vuuren, Divisional Director: Marketing Constraints (TOC) published

LOGISTICS
by Eli Goldratt, a renowned Deep knowledge

Israeli physicist and business The Cargo Carriers group has traditionally operated
guru who also developed, in clearly defined vertical markets, namely steel,
among others, the concept of chemicals, powders, fuel and sugar.
OPT (Optimised Production
“We have industry experts with deep knowledge
Technology) and Critical
of these verticals so that we can walk the talk and
Chain Project Manage-
clearly understand the needs of our customers and
ment, which emphasise
the constraints within their supply chains.”
the resources required to
properly plan and manage This focused approach based upon expert knowledge
projects. has led to Cargo Carriers being widely accepted
as a logistics leader in the industries within which
The way South African com-
we operate.
mercial and industrial enter-
prises do business changes on
a daily basis, and even more so
in the current challenging economic
times.
Company experiences the real costs of low-cost logistics

when the wheels fall off
“With POOGI and TOC woven into our business

culture and methodology, we understand this and
embrace the challenges associated with change,
at the same time being committed to continuously
extract value for our customers and shareholders,”
says André
“The wheels fall off”

Low cost logistics services and solutions simply
cannot deliver the required depth of experience and
industry expertise. They invariably require short
cuts that result in unforeseen costs being incurred
elsewhere through late, lost or incorrect delivery,
inadequate storage, vehicle accidents, damaged
loads and product loss and liability.
The real value of expert logistics services and solu-
tions usually becomes apparent only as a company
experiences the real costs of low-cost logistics
when “the wheels fall off”. Major contracts can be
compromised or cancelled and essential product
may not reach its destination on time, invoking
heavy financial penalties. There are many other
variables that can go wrong if a low cost approach
is adopted. Simply stated, low cost is often very
high cost.
Cargo Carriers, Andre Jansen van Vuuren, Tel: (011) Tel:
(011) 485-8700, Fax: (011) 485-8781, www.cargocarri-
ers.co.za

HARBOURS
Container Terminal Leads

in Productivity
Better planning and streamlining of operations has given Cape ship-to-shore (STS) cranes and rubber tyred gantry
Town’s container terminal the lead in productivity among the (RTG) cranes. Decreased stack congestion in the
five container facilities operated by Transnet Port Terminals terminal has encouraged a smoother operational flow.
(TPT) in South Africa Velile says, “We have managed to strike a balance
in the availability of resources to meet operational
V
demand and have also systematically improved
elile Dube, the new Regional Terminal productivity in our RTG crane operations.”
Executive for TPT’s Western Province
operations, attributed the improved per- New cranes
formance in July to a reduction in force The new STS cranes give the terminal a competi-
majeure disruptions caused by inclement weather, tive edge because they are faster than the older
as well as improved employee skills as opera- cranes and boast twin lifting capability, where two
six metre containers are handled simultaneously.
Truck turnaround time was 26 minutes on average This minimises the crane cycle time and increases
against a target of 30 minutes maximum the cycle frequency. Also contributing to improved
productivity in July was Ship Working Hours (SWH),
tors become more proficient in handling the new which were maintained at an average of 41 moves
equipment procured as part of the terminal’s five on all vessels. Ship Working Hours is the number
year capacity creation project. of containers moved by the cranes working on a
vessel in one hour.
The equipment includes new Super Post Panamax
Better housekeeping
Truck turnaround time was 26 minutes on average
against a target of 30 minutes maximum, while stack
occupancy was an average of 46% against a ceiling
figure of 65%. Further plans to improve landside
operations are advanced and even greater produc-
tivity is expected.
Greater emphasis
has been placed
on housekeeping
compliance, which
ensures conducive
landside opera-
tions.
The terminal’s ongo-
ing refurbishment
has extended the
quay wall by 10 me-
tres and increased
the draft by 15.5 metres on the high productivity
Berth 601 and the first 40m of Berth 602.
Equipped with four of the latest Super Post Panamax
ship-to-shore cranes, the terminal is now able to
service 305 metre vessels along Berth 601 and
the first 40 metres of Berth 602. In addition, the
increased berth and increased height capacity of
the cranes allow for the efficient handling of Super
Panamax vessels.
Cape Town’s container terminal leads in productivity amongst Transnet Port terminals, Ayanda Mantshongo, Cell: 083 301
the five container facilities operated by Transnet Port Ter-
2975, Email: Ayanda.Mantshongo@transnet.net
minals (TPT) in South Africa

BELTCON
Constant Speed Versus

Variable Speed Operation
Variable speed control for the coal handling conveyors intended for the new Medupi power station have been
evaluated in comparison to constant speed operation.
T
his evaluation is based on the assumption ponent selection from the perspective of the end
that ISO 5048 applies to the design of the user. In the case of the Eskom plants the design
conveyor belts operating over the required capacity is based on the full load condition of the
capacity range for both variable speed con- boiler units including backlog recovery capability
trol as well as for variable loading of the conveyor or capacity loss recovery ability as well as the
(constant speed). impact on the system availability and the coal
The artificial friction factor ‘ƒ’ used by ISO 5048 has quality variation.
been calculated according to the procedure explained The normal operating capacity of the system is
by the author Ishwar G. Mulani in his publication at as low capacity as can be expected. The fo-
titled ‘Engineering Science and Application Design cus is thus on high availability and reliability of
for Belt Conveyors’ for the specific belt speed and the system to ensure that production and plant
load conditions evaluated. This procedure enables performance targets can be achieved within the
the estimation of the individual friction components operational realities.
that make up the artificial friction factor ‘ƒ’ i.e. The following aspects are considered:
bearing rotational, belt indentation, belt bending
and the material flexure friction components. • The belt artificial friction coefficient focusing on
the belt indentation resistance at idlers as the
The conveyors are designed for the maximum main part of the resistance to motion.
required capacity but operate normally at a • The load versus life implication on rotating
relatively much lower capacity. The reason for components like idlers and pulleys.
this capacity range is as a result of ranging coal
qualities, boiler unit load factor and demand • The relative wear implication at load points,
side implications. From the evaluation of this skirting zones, tilted idlers and belt cleaners.
specific application for the specific capacity • The energy consumption for the operation of
range, it is shown that the variable speed con- the conveyor.
trol option is favoured in terms of lower energy Other technical areas that are discussed include:
consumption, less wear at loading areas and
the expected improved operating behaviour • The operation of the gearboxes under reduced
as a result of better belt alignment due to the speed conditions.
optimum loading ratio. • The design challenge regarding transfer stations
in the case of variable speed drives.
Introduction
Eskom has opted for variable speed control on • The efficiency and reliability of the electrical
the belt conveyor systems for the proposed new variable speed drive system.
capacity expansion program on fossil fired Power Motion resistance components of belt
Generating Stations. conveyors
There are different opinions in industry regarding The energy consumption of a belt conveyor sys-
the potential advantages and disadvantages when tem is determined by the resistance to motion of
comparing variable speed control to constant speed the belt system along the carry and return sides
operation of belt conveyor systems. This paper of the belt. The total resistance to motion is the
presents the evaluation process regarding the op- algebraic summation of all the resistances. The
tions of variable speed control in comparison to resistance forces can broadly be classified into 3
constant speed operation of belt conveyors from a categories.
technical point of view. • Slope or gravity resistance
The evaluation is for a specific application: trans- The relative height change from the feed
porting coal in the electrical Power Generating point to the discharge will generate gravity
Industry for the specific capacity range and com- resistance by lifting or lowering of the mate-

BELTCON
rotational, sliding and internal

resistances as a result of the
belt/material interaction.
Many components (idlers and
pulleys) rotate along the con-
veyor length; frictional rotational
resistance is generated by these
components.
Sliding friction is introduced at
belt cleaners, skirting, tilted idlers
etc. as result of belt or material
sliding motion.
The belt sags between idler sets
and rises up on approaching
idlers, the trough shape also
opens out in between idler sets
and closes on approaching idlers.
This motion also applies to the
material load stream and is ex-
Figure 1: Belt indentation resistance at the idler roll pressed by the material flexure
resistance.
rial that is conveyed. This resistance can The belts flexure resistance
therefore be power requiring or regenerative originates from the motion interface at idler
in terms of its resistance component. sets expressed as belt bending resistance with
the belt sagging motion in between idler sets.
• Load point material acceleration resistance The deformation or denting of the belt contact
The material velocity component onto zone at each idler roll results in belt indentation
the receiving belt is usually different to rolling resistance as result of the time related
the belt speed. This results in an inertial visco-elastic properties of the rubber cover of
resistance at the load point. the belt (Figure 1). In many long conveyors the
energy consumption is mainly contributed by
• Frictional resistance
the work done to overcome indentation rolling
This resistance component includes resistance.
Figure 2: Schematic of the mass model for a conveyor belt

BELTCON
Main resistance to the three different values of mass. In ISO 5048

This is the most significant resistance on the this is calculated as a single entity to avoid complex-
belt conveyor. The main resistance is dominant ity. This common equivalent artificial / fictitious
for long horizontal conveyors and in the case of resistance coefficient ‘f’ applies to the total moving
inclined conveyors the slope resistance may be mass force to calculate the main resistance FH on
the dominant component. The main resistance is basis of Coulomb’s law of friction.
encountered as result of the resistance to motion The main resistance
while transporting material on the belt supported
on the idlers. This resistance includes the follow-
ing friction components:
The total belt resistance according to ISO
• Idler roll rotational friction 5048 ‘FU’
• Material flexure resistance as result of belt
sag, and The total resistance of the conveyor belt
includes in addition to the Main or Primary
• Belt flexure resistance comprising of the belt
resistance (FH) also the Secondary resistances
bending resistance due to belt sag and the
(FN), the Slope resistance (FSt) and the Special
belt indentation resistance due to belt cover
resistances (FS).
deformation at the idler roll contact zone.
These three friction components are the basis for The Secondary resistances (FN) are friction and
the artificial coefficient of friction ‘ƒ’ as used in inertia based and occur at specific parts of the
the ISO 5048 conveyor design standard. belt conveyor.
The artificial friction coefficient ‘ƒ’ The Secondary resistances include:
As discussed, the artificial coefficient applies to • Material acceleration resistance at the load
the combination of the following resistances that point,
opposes belt motion:
• Material sliding resistance along the chute at
• Idler rotational resistance, the load point,
• Material flexure resistance, and • Belt cleaner resistance, and
• Belt flexure resistance that includes belt in- • Wrap and bearing resistances at the pulleys.
dentation at idlers and belt bending as result
The Secondary resistances are independent of the
of sag.
length of the conveyor and are constant.
These resistances are directly related to
the following motion masses expressed
per metre of conveyor length:
• Idler rotating mass,
• Belt mass, and
• Material mass.
The motion masses have a cumulative
relation to the frictional resistances.
The idler bearing supports the mass of
the rotational parts, the belt mass and
the material supported on the belt as
illustrated in Figure 2. The idler rotat-
ing resistance is therefore proportional
to the sum total of the three masses
mentioned.
The belt flexure is affected by the belt’s
own weight and the material weight
supported on the belt. Belt flexure
resistance is therefore proportional to
the weight of the belt and the material
on the belt.
The material flexure resistance in turn is
only affected by the material self-weight,
as it is on top of the moving masses.
With this in mind there could be three
different friction coefficients applicable Figure 3: Illustration of the friction force applicable tp an idler roll

BELTCON
Figure 4: Comparison of the artificial friction factor for variable and constant speed
operation

BELTCON
The significance of the Secondary resistances • Belt cleaner resistance,

relative to the primary motion resistance declines • Belt turn-over resistance,
in the case of longer belts. A general assumption
is therefore permissible; the total sum of the Sec- • Discharge plough resistance, and
ondary resistances is therefore being accounted • Tripper resistance.
for by means of a length based coefficient C in
Slope resistance (FSt) is the resistance introduced
ISO 5048.
as result of the lifting or lowering of material on
Special resistances (FS) do not occur on all belt sloped conveyors.
conveyors. These are resistances as result of:
• Idler tilt relative to the belt, The total belt resistance
• Sliding friction at chute skirting if present over FU = FH + FN + FSt + FS
part or the full length,
Figure 5: Comparison of the energy requirement for variable and constant speed operation

BELTCON
Calculation of the artificial friction Conclusion on the results of the artificial

coefficient ‘f’ For Varying Material Load friction factor calculation
Conditions Or Varying Belt Speed From the results on the calculation of the artificial
friction coefficient as represented in Figure 4, it is
evident that the constant speed operation results
Idler rotational friction factor
in a lower friction value at the reduced capacity
The rotating portion of an idler is normally sup-
range of operation for the conveyors evaluated.
ported on ball bearings. Seals protect the bearings
The friction coefficient is therefore greater in the
and the space within the seals and bearings are
case of the variable speed drive as result of the
filled with grease for lubrication as well as added
larger material load stream.
sealing effect.
The potential benefit in this case for constant
The idler while rotating encounters resistance
speed operation has to be considered on the basis
from:
of the combined implication of friction and speed
• Bearing friction resistance, that constitutes the energy consumption. The
• Misalignment of idlers relative to the belt line, contributor that affects the greatest impact to this
and relationship will be the governing entity in terms
of friction factor versus speed in determining the
• Resistance as result of the grease that is in contact
energy requirement.
with stationary and moving components.
The Rotational resistance due to the bearing fric- Comparison of the energy consumption
tional resistance as illustrated in Figure 3 is as a between constant speed and variable
result of the radial load ‘R’ onto the bearing and speed operation
the bearing friction coefficient μ. The radial load The required driving force on the driving pulleys
is proportional to the loading at the idler as result of the conveyors and the operating power require-
of the belt and material on the belt. ments for the capacity range is calculated on the
basis of ISO 5048 by utilising the artificial friction
The force required to overcome idler bearing re-
coefficient values calculated above. The maximum
sistance ‘F1’ is therefore F1= (µ·R)·d / D with d=
operational belt sag tension is limited to a maximum
bearing bore diameter and D= idler roll diameter.
value of 1% for the static operating condition in
The typical value for the coefficient of friction
terms of pre-tensioning.
μ=0.0015 for ball bearings in the 6200 / 6300
series range.
With reference to the graphs as illustrated in
Thus F1=0.0015 (d / D) R. Figures 4 and 5 the results of the power re-
quirement for the conveyors shows an opposite
In the case of misaligned idler rolls, the equiva-
trend with reference to the artificial friction
lent sliding friction coefficient=(μ0)(off-set
coefficient. In this case the variable speed
gradient)=(μ0)(sinØ). The value for μ0 is in
option requires less driving power than the
the range of 0.3 to 0.4 for a rubber belt onto
constant speed for the lower capacity range.
a steel idler roll. The equivalent sliding friction
The effect of the speed reduction in the case of
coefficient as result of idler misalignment at an
the variable speed option compared to reduced
assumed rate of 3 mm for 1000 mm length of
friction in the case of constant speed operation
idler base yields a value of 0.4x3/1000=0.0012.
has an overriding impact on the power require-
It is assumed that idler frames will be installed
ment and the variable speed option presents
within this offset gradient range.
a distinct advantage in this regard.
The typical values for seal resistance range from
1 N to 4 N per roll and can be obtained from the Conveyor component evaluation
idler manufacturers. As discussed, the proposed conveyors operate
For the purpose of evaluation the load onto the idler normally under reduced capacity, however, the
rolls are considered on basis of the load condition. design is based on the maximum capacity required
The mentioned parameters were assumed to be to maintain boiler load under the most unfavour-
constant for the evaluations. able conditions.
Mine to Stockyard to Terrace Silo’s

In the evaluation of variable speed versus fixed
Conveying Link speed technology, the maximum design parameters
Stockyard Terrace silo’s to Mill bins
Line per unit of the conveyor remain a common requirement.
Line configuration Single line Dul line
(6 lines) This implies that the component selection is for
Maximum design the same peak load condition and belt strength,
4000 3200 1150
capacity TPH pulley shaft sizing, idler maximum static load basis
Average capacity etc. is identical.
(most likely coal 2409 1205 402
quality) TPH
Table 1: Capasity Sizing of Conveyors

BELTCON
It was therefore decided to compare the drive op- dling plant include the combination of overland
tions in terms of the relative benefit expressed as conveyors that link the supply mine to the coal
a benefit factor relative to the peak load criteria in stockyard located in close proximity to the Power
terms of life for the rotating components like pulleys Station as well as the linkage conveyors from the
and idlers. This benefit is calculated on basis of stockyard to the station terrace storage and finally
the reduced dynamic load condition that applies the terrace conveyors that includes the incline
either in terms of reduced loading for fixed speed conveyors into the boiler house as well as the over
operation or the benefit as result of the reduced mill bin distribution conveyors.
speed in the case of variable speed. As far as the capacity sizing of these conveyors is
To enable this comparison it was decided to express concerned the following table applies:
the overall impact of the operating capacity range The intended operation of the system is based on
on the basis of the equivalent load for the combined utilising all conveyors under normal operation.
impact of operational time spent at maximum design In cases of redundant conveyors, for availability
capacity versus normal operational capacity. The reasons both conveyors will operate under shared
procedure as defined in publications like the NSK load conditions rather than running only one of the
Bearing Manual express the equivalent condition dual conveyors with the second on stand-by. In the
in terms of rotational speed as follows: event of failure of a conveyor, the capacity shortfall
nm = (n1t1 + n2t2 + ………+ nntn) / (t1 + t2 + will be compensated for by running the other
………+ tn)
Discussion on variable speed electric
As far as abrasion or sliding wear impact is con- drives versus the high speed fluid cou-
cerned at loading points or any other sliding wear
plings for constant speed.
interfaces like belt cleaners, it was decided to base
The need for controlling the dynamic behaviour
the design evaluation between variable speed and
of a conveyor belt system via the drive is to affect
fixed speed operation on the principle of the relative
the following:
wear number as defined by the author Prof A.W
Roberts in the publication titled ‘Relative Wear’. • Smooth starting,
The following equation for determining the relative • Energy saving,
wear number applies: • Increased plant life, and
Nwr =δw / (ρ.g.B).(vs / vo). Tan Ф • Process control requirements.
Where: Nwr = relative wear number Direct on-line starting of electric motors can cause
the following problems:
δw = Normal pressure at the boundary
• Slipping of belts at the drive pulley,
ρ = Material density
• High wear and tear on couplings, gearboxes,
B = Chute width
bearings and other mechanical components,
vs = Entry velocity
• High inrush (starting) current,
vo = Material velocity relative to the boundary
• Equipment damage when starting against
Ф = Friction angle between material and bound- rotating machinery,
ary
• Torque spikes in Star-Delta and Soft-Start
Design evaluation of the conveyors systems, and
The conveyors evaluated for the Medupi coal han- • Safety issues
Figure 6: The components of a frequency variable speed drive

BELTCON
The basic drive technology of the modern frequency • VSD can supply a 150% overload condition,
converter electric variable speed drive has a few
• VSD can give operators sufficient warning
basic components (Refer to Figure 6):
before tripping,
• Rectifier,
• No oil spills – environmental impact,
• Fixed DC link voltage, and
• Load sharing in multi drive motor system ap-
• An inverter that controls output voltage and plications
frequency
• Energy savings
• The inverter section is a number of electronic
‘switches’ - Power factor (0.96 for VSD compared to
• This is used to convert the DC link energy, by 0.85 for constant speed),
a series of pulses - Speed control is based on demand, and
- Load dependant control.
The conventional technology to control the
starting characteristic in the case of a constant • Load dependent belt speed adjustment,
speed conveyor is a Fluid Coupling (FC). In the - Soft starting,
case of variable speed drive control an Electrical
Variable Speed Drive (VSD) is used. - No in-rush current or high starting currents
(Transformers and switchgear do not need to be
In the case of the Fluid Coupling the following oversized),
features can be mentioned: - No limit on the number of starts per hour
• Soft and shockless starting of machines and (electronic starting),
conveyor drives, - Adjustable starting and stopping ramp times,
• Acceleration of very large masses without the - Load sharing control is independent of capacity
necessity to use oversized motors, loading on the belt, and
• Load relieved and faster motor start since cou- - Regenerative ability for a controlled ramp
pling torque grows proportional to the second down.
power of motor speed. Negligible heating-up
of motor, as the high starting current is only The main reasons for considering a variable speed
drawn for a short time, drive option are:
• Starting of heavily loaded machines by • No high motor starting current,
induction motors also with flat motor char- • Synchronising (load sharing) is much easier with
acteristic (voltage drop, high voltage motors) VSD’S, the control adjustment is immediate,
by utilizing the motor pull-out torque,
• Controlled start up times on conveyors is pos-
• Limitation of torque when starting conveyor sible on basis of the actual load condition,
belts,
• On regenerative conveyors runaway can be
• Load compensation in multi-motor drives as controlled by means of the VSD,
result of the ability to slip and varying the oil
filling level; successive starting of motors by • No belt slip problems at drives
reducing starting torque and avoiding simul- • Reduced maintenance cost,
taneous starting current peaks,
• Energy savings,
• Little slip of couplings at nominal static load
condition, • Reduced risk to the performance in terms of
human influence by applying incorrect main-
• Easy adjustment of transmittable torque by tenance interventions, and it is possible to
varying the fluid level, manage the natural frequency range by means
• In case of overload, protection of the fluid of ‘skipping’ thereof in the case of the VSD.
filling is possible by means of electronic or Conclusion
mechanical thermal control devices, and This paper presents the engineering process followed
• Water as operating medium is possible in a in deciding the type of conveyor drive technology
special coupling design. for application to the coal plant conveyors for the
new Eskom Medupi Power Station.
An Electric Variable Speed Drive has the following
key features: The conclusion is that the variable speed drive
(VSD) presents a distinct benefit in terms of energy
• Automatically adjustable torque limitations, savings and reduced risk with reference to incor-
• Load variations automatically compensated rect maintenance interventions that result in plant
for (no need to adjust oil levels), unavailability.

BELTCON
The calculated energy cost saving for the

conveyors (excluding all coal stockyard Malpractice
machines) evaluated in the case of In support of an article by Peter Turchetti of Elephant Lifting as it appeared
Medupi for a projected life of 50 years in the October issue. It can be confirmed by many technicians and LMIs,
equates to R21million in the case of as Peter mentions that people get killed by lifting equipment, for example
the variable speed option in NPV terms by standing underneath objects being lifted or transported.
base dated April 2009. This bad habit of rig-
The finding of this study is applicable gers and/or machinery
to this specific application. These operators persists as
conveyors evaluated are designed for they fail to point out
the maximum load condition as far as bad practices.
component sizing is concerned, although Operators and/or rig-
the normal operation of the plant occurs gers registered, or un-
at reduced capacity throughput. The registered, should be
VSD has fewer moving parts or wear- totally in charge of the
ing parts and the reliability is therefore lifting operation. The
enhanced. unfortunate situation is
This paper has been condensed due to space that the lifting industry
constraints. The authors are A.P.Wiid, is characterised by in-
F.Sithole, M Bagus & T.H.Khosa. This pa- competent persons, often without the knowledge of management in all
per was first presented at Beltcon 15 held in categories of lifting equipment training.
Johannesburg on September 2 and 3, 2009
and copyright is vested with the IMHC. Training facilities need to concentrate on the correct use of safety equip-
Enquiries can be made through the website; ment and we need more articles like these to make industry aware of
www.beltcon.org.za such malpractices.
Thank you
Roman Vogt, Reg.Techni.Eng, Reg. LMI

TRUCKING & TRANSPORT
Just One Hand

Moving heavy rolls of paper, railway wagons, and even parked aircrafts by hand may sound like magic, but it’s
humanly possible! The unassuming “Easy Roller” works just as its name implies. With this device, up to 100
tons can be easily manoeuvre without exerting great effort. The secret lies within the device’s utilisation of
the wheeled object’s net mass to its own advantage.
absolutely no risk of an explosion while operating

the air motor.
Controlled motion
In a straightforward, yet ingenious manner, the
“Easy Roller” acquires its power from the net mass
of the wheeled equipment, and in doing so, moves
forward. The transport device is positioned in front
of the equipment, for example a heavy roll of cable.
It operates on two rubber rollers, over which the
drive roller is positioned. The front castor is pressed
against the drive roller by springs. The rear sec-
tion is initially comprised of free space. When the
employee presses the manoeuvring valve handle,
the air motor starts, thereby enabling the drive
roller’s chain-controlled backward motion.
What happens? The drive roller transfers the move-
ment to the front castor and the “Easy Roller” moves
in the direction of the cable drum. Simultaneously,
the device is pressed down in order to initiate
contact between the drive roller and rear castor,
thereby transferring the torque for the forward ro-
tation. If the contact pressure of the rubber drive
roller which continuously grinds with increasing
momentum against the object, is strong enough,
the torque will be transferred to the cable roll. The
heavy cable roll moves and the object acquires a
rolling motion.
Compact powerhouse
The air vane motor powering the drive roller is a
small, compact powerhouse, which was developed
and designed for this sole purpose by Deprag Schulz
in Germany. Project manager Dagmar Dübbelde as-
serts, “The air vane motor described here features a
W
capacity of 1.2 kW. With a length of 218 mm and
ithout having to climb into the driver’s
a diameter of 100 mm, it only weighs 9.1 kg. It is
cab or even turn on the engine, the
right rotating, has an idle speed of 100 rotations
mechatronics engineer can effortlessly
per minute and a nominal torque of 500 Nm. “
manoeuvre the articulated lorry over
the repair pit. It’s not even necessary to know how What makes air vane motors the best option for
to drive one! In one hand, the engineer holds the powering the “Easy Roller”? There are many ad-
handle of the “Easy Roller”. vantages in using air motors. Most importantly
perhaps is their large power density. Depending
There is absolutely no risk of an explosion while on the model, they only require one-fifth of the
operating the air motor electric motor’s net mass or one third of the overall
size. At various speeds, the performance delivered
The air motor, which powers the transport system,
by the air motor, is almost constant. Thus, it can
is hardly audible. Moreover, it does not produce any
be optimally operated over a wide range of vary-
exhaust fumes, thus proving to be environmentally
ing loads.
sound. Aside from the usual odour associated with
motor oils, employees in the workshop will not The engine power is continuously controlled by
be exposed to harmful emissions. Finally, there is throttling the air volume. The motor will never be

overloaded. It withstands ad-

ditional strains until brought
to a standstill and runs effort-
lessly afterwards. This process
can be carried out as many
times as required.
Kinetic Energy
Air motors have a wide ap-
plication spectrum due to the
diverse number of models, the
simple, yet frequently tried
and tested design, the low
net-weight, the vast speed
range, and the explosion
Flexibility is essential when it comes to

full order books in this sector
safety feature,. Air vane motors operate according compressed air expands, the pressure energy sub-
to one basic principle. The air pressure, which is sequently transforms into kinetic energy, thereby
generated by a compressor and circulated by an air producing the rotary motion.
hose, moves the revolving rotor, which is encased Air vane motors are resistant to heat and due to
in an eccentric cylinder. their mode of operation, they are well suited for
Vanes, which are found in its slots, are pressed use in critical environments. Through the decom-
outwards against the cylinder wall by the rising pression of the air, the air motor cools down and
centrifugal force. This leads to the formation of therefore overheating would be impossible. Thus,
chambers for the expanding air pressure. As the pressurised air is in itself an uncomplicated source

of energy: there is no threat of danger associated

with electrical connections of any kind.
Well suited
A wide variety of “Easy Roller” models are avail-
able from the transport equipment manufacturer,
which are uniquely tailored for each specific use.
Wheeled transport equipment with driving rollers,
for example, are well suited for paper rolls in the
paper and printing industry. With regards to moving
vehicles, devices with grooved drive rollers ensure
better rotation power. The transport device intended
for aircraft and heavy vehicles is particularly ef-
ficient. For shunting railway wagons, the roller can
be used in conjunction with a rail system in order
to enable more mobility in the “Easy Roller’s” work
area. For transferring under floor rollers or cars,
the transport system is equipped with a thrust bar,
which enables forward movement or when neces-
sary, movement in both directions. produce and maintain. Both of these factors do not
The “Easy Roller” is also capable of manoeuvring apply to the “Easy Roller”. With the utilisation of
within industrial production plants. Flexibility is our transport device, labours costs decrease and
essential when it comes to full order books in this productivity increases.”
sector. Once an order is complete, the parts of Over 50 countries
the production system are quickly and efficiently For the past several years, the firm has been
replaced. The powerful conveyor system, which involved in the development of transport devices.
is operated by only one person, assumes this After their establishment at the beginning of 2009,
task. With a torque of up to 1700 kp and a speed they began preparing to sell internationally. Cur-
of 25 metres per minute, the “Easy Roller” can rently, there are five standard devices available for
move the equipment to any number of places in rolling, sliding, and manoeuvring. Other transport
the production hall. devices will be available in their standard program
Productivity increase in the coming months.
The consistent variable speed control of the trans- The development and construction of high-quality
port device makes precise, controlled manoeuvring air motors is one of the main areas of expertise
a piece of cake. Andreas Hufmann MD of Easy of Deprag, a company with 600 employees and
Roller gmbH adds, “Moving objects with the help business operations in over 50 countries. The re-
of “Easy Roller” increases safety for employees nowned specialist firm for air motors, automation,
and decreases the chance of industrial accidents screwdriving technology, and air pressure tools,
due to improper manoeuvring.” not only operates as a full-service provider for the
The company also offers inexpensive alternatives to utilisation of air motors, but also for complete drive
permanently mounted automatic conveyor systems. solutions.
Andreas explains, “Automatic conveyor systems Dagmar Dübbelde, Deprag Schulz, Email: d.duebbelde@
take up a great deal of space and are expensive to deprag.de, Web: www.deprag.com

SAFETY EQUIPMENT
Controlling Safety Costs

Personal protective equipment (PPE) is much more than bright pink gloves, shiny lime green vests and
equally lustrous hard hats. PPE should in fact conform to specified safety standards and serves to protect
workers as much as protecting their employers against liabilities.
H
owever, it is still only a handful of them will have a PPE policy in
an area hugely ne- place,” says Isak. “In essence a PPE policy links
glected in South the standards, not the brand, of PPE to the type
African industry of application.
purely because companies
tend to buy inferior products Penny-wise, pound-foolish
that don’t provide proper pro- “In the case of a welder, for example, international
tection. Often, it’s a case of standards require a specific profile detailing the
‘penny-wise, pound-foolish’ as type of head protection, eye protection, hearing
companies continue to replace protection, body protection and so on that a welder
inferior product frequently should wear for optimum protection,” explains Isak.
rather than buying in quality “Typically a proper PPE policy is modeled around
product from the get-go. “Bulk the profile for each specific job, making it easy for
Handling Today” speaks to a company to control the total cost of ownership of
Isak Marais, managing direc- safety equipment. Too often, however, companies
tor of Bramhope Investments, tend to buy low cost PPE and don’t realise they’re
a consultancy, importer and running the huge risk of being held liable for in-
wholesaler of PPE into South juries, even years later, as we’ve seen in several
Africa. cases in South Africa.”
Isak Marais
Understanding TCO
PPE policy According to Isak, companies would benefit from
“Many companies, especially reputable big or- understanding the total cost of ownership of PPE
ganisations, have an occupational health and to safeguard staff and to appreciate the money
safety policy, an environmental health and safety saving opportunities. “PPE is a subcomponent of
policy and a HR policy in place, but you’ll find that the maintenance, repair and operational (MRO)

SAFETY EQUIPMENT
expenditure of any large organisation,” he explains. The cost of PPE procurement in organisations varies
“MRO expenditure is typically about 8% of a large from 6% to 15%, depending on the frequency of
organisation’s total procurement expenditure while procurement and the size of the organisation and
PPE represents 1% of total procurement expendi- its processes. “Some of these relate to searching,
ture, but this 1% could be substantially higher than bargaining, contracting and enforcing costs or
some of the other MRO sub-categories. management costs,” says Isak. “We will, for our
“To understand these effects better, you have to example, take 10% as the average.”
first examine the components or elements of PPE’s Holding cost
total cost of ownership consisting of the cost of “If the organisation stocks and controls the inven-
the PPE line item, procurement costs associated tory, the percentage allocated will be around 2%
with the item, the holding cost, the total medical per month,” Isak continues. “This all depends on
cost of injured people, the cost of downtime and the weighted average cost of capital (WACC) and
the legal costs,” Isak explains. the amount of safety stock carried. We will assume
that stock is held for two months, which would
Running the huge risk of being held liable for injuries take the cost to 6%. Where organisations have
outsourced Vendor Inventory Management (VMI),
these costs are excluded.”
Line item cost
“If we take the cost of a line item and equate it to “In 95% of all cases where we’ve carried out a
100%, then in general terms this will be the cost PPE audit, medical costs do not form part of the
of the item that is measured and controlled,” he outlay associated with PPE. Determining this cost
says. “Providing that the correct item is selected also depends on the level of injury,” says Isak. “As
for the application, the other elements will have an example, the treatment of an eye injury can cost
a lower cost associated with them. However, we anything from R15 000 to R100 000. Applying a
have found that in most cases the focus has been cost level of 500% is, in my experience, conservative.
solely on the lowest possible cost for the item, Incidentally, certified spectacles can be purchased
without taking standards or the item’s application from as little as R15. However, although many such
into full consideration,” he adds. examples exist, what is imperative is that the use

SAFETY EQUIPMENT
of PPE be managed and controlled. ing PPE that is fit for purpose and managed and
controlled through various policies and procedures.
Cost of downtime The most effective way to contain this outlay is to
“Although downtime is one of the cost components
ensure that PPE is certified and that a proper PPE
that the correct or incorrect application of PPE can
policy with worker profiling is in place.
influence significantly, measurement is complex
and so it is undertaken by very few organisations.
However, measurement is made simpler if the or-
Ensure that PPE is certified and that a proper PPE
ganisation integrates its HR, OHS, EMS and PPE policy with worker profiling is in place
policies into the organisation’s accounting system.
To aid our comparison with TCO of PPE, we will “We offer global procurement through an efficient
use a fictitious cost of 40%’” Isak elaborates. supply chain and a monitoring system that ensures
efficiency in the demand chain by examining TCO
“But we expect this cost centre to increase as person-
of PPE, rather than just the line item costing,”
nel become aware of their rights in the workplace
Isak says in conclusion. “As mentioned, although
and health and safety legislation becomes more
a typical organisation’s procurement expenditure
encompassing,” explains Isak. “This escalation
on PPE is less than 1% , such a small amount
is mainly driven by increasing legal action being
leads organisations to focus on item/line cost rather
taken by workers, unions and workers rights groups.
than total cost of PPE which makes PPE procure-
Past cases associated with asbestoses have been
ment difficult to control and manage, leading to
noted and current cases associated with respiratory
wastage.”
problems are currently making headlines. I predict
that this will increase in the years to come. Ow- Bramhope Investments, Isak Marais, Tel: 086 000 2726
ing to the current lack of figures available we will Email: isak@bramhope.co.za
assume a cost of 130%.
The result
Engineer Placements
“If we combine all these figures, the TCO of PPE will
be 786%,” Isak explains to summarise the calcula-
tion. “This expense will vary from organisation to www.engineerplacements.com
organisation and depends largely on their purchas-

Market Forum
Stacker reclaimer upgraded Progress evident
Owing to the enormity of the task and Xstrata’s need for Despite strike-related challenges early last year, Transnet
precision organisation, many of the individual projects at its Port Terminals (TPT) Richards Bay approached 2010 with
Atcom East Upgrade Project have been undertaken under solid plans for improved efficiency across its business func-
severe time pressure. The upgrade by Bateman Engineered tions.
Technologies (BET) spares and services division of the circular Guided by Transnet’s Quantum Leap strategy, which empha-
reclaimer was no different. sises improved customer service, productivity, efficiency and
Originally designed and installed 20 years ago to handle volume growth, TPT’s Richards Bay Terminal had to embark
1200tph, the bucket capacity of the reclaimer had been on robust action to address its challenges such as frequent
undermined over the years due to changes in the harrow equipment breakdowns, snapping conveyor belts, train de-
angle. railments, delayed refurbishment projects and environmental
management issues.
Progress is evident. More than
70% of the terminal’s 40-plus
km conveyor belt network is
brand new, new engineers have
been appointed to beef up the
terminal’s maintenance capacity
and improve the reliability of
equipment.
The company has also adopted
a strict approach by issuing
non-conformances to service
providers who fail to deliver on
agreed timelines.
Plenty of focus and effort has
been invested into environmental
management and the terminal
recently cleared all audit find-
ings and will soon acknowledge
its OHSAS 18001 status from
the South African Bureau of
Standards (SABS).
Richards Bay Transnet Port ter-
minals, Sne Makhanya, Tel: 083
Six cranes in use while replacing the harrow, during the final phase of the Atcom stacker reclaimer 344 9918, Email: Sne.Makhanya@
project transnet.net
Paul Davies, BET manager of spares and aftermarket ser-

vices says that the capacity of this type of reclaimer is very
sensitive to the material angle of repose and even relatively
small changes in the harrow angle will have a significant
influence.
Reducing dust while increasing productivity
In light of this, upgrades to the harrow, long-travel drive units, The Port of Seward has completed a conveyor system upgrade
including all componentry, scraper chains, centre, top and for its coal handling operations that has raised throughput by
bottom chain guides, drive sprocket assembly, take-up shaft an estimated 20%, allowing Alaska’s largest coal producer to
assembly, take-up frame structure, rail and reclaimer wheel better compete for international customers. By installing the
and long-travel drive bogies were all upgraded. new Evo Conveyor Load Zone from Martin Engineering, the
New centre guide rollers as well as a newly designed outboard terminal has increased the average load rate for the entire
roller chain and scraper buckets were also supplied. BET ship loading process from 700 mt/h to 858 mt/h.
also installed an entirely new electrical system. The terminal has progressed from an absolute maximum of
Paul says that the order was received in January of last year 18,000 mt/d with dry coal and optimal loading conditions
and that the upgrade construction started on 23rd August to more than 20,000 mt/d on average.
2010. “During this period, not only did we have to complete In the past, a major obstacle to expansion was the port
the upgrade but we also had to complete the designs and facility’s aging infrastructure, which had seen few improve-
fabricate all the components,” he concludes. ments prior to 1999. Upgrades began that year when Alaska
Bateman Engineered Technologies, Paul Davies, Tel: 011 201 2416, Railroad purchased the terminal, but despite best efforts, by
Email: paul.davies@bateman-bet.com 2008 the facility had become a logistical bottleneck and a

Market Forum
With the new conveyor Load Zone from Martin Engineering, the terminal has increased the average load rate for the entire ship-
loading process from 700 mt/h to 858 mt/h
source of occasional dust complaints.

The need to increase throughput at Seward while
protecting the region’s air quality led Usibelli Coal
Mines and its affiliate, Aurora Energy Services to
Martin Engineering’s Inertial Flow Transfer Technology,
the entire chute custom-engineered and modeled in
3-D to provide the optimum design for the material
and flow rate needed. The “hood” controls the flow of
material from the discharging conveyor, maintaining
a coherent material stream and minimising induced
air. A smooth loading chute (“spoon”) places the
stream of coal onto the ship loader’s boom conveyor
at the proper speed and angle with minimal impact,
reducing material degradation, belt abrasion and the
expulsion of airborne dust.
Martin Engineering USA, Email: info@martin-eng.com, Web:
www.martin-eng.com
Making history
From the invention of the world’s first manual chain
hoist in America in 1877 to the lifting of extremely
expensive advanced aviation equipment into the control
towers at the new King Shaka International Airport in Durban Soccer World Cup, the Columbus McKinnon Corporation
… from the supply of urgently needed equipment after the (CMCO) is well positioned to help engineer history.
Haiti earthquake to the provision of tailor made solutions for Both the South African subsidiary (formerly known as Yale
construction of the multi-billion rand stadiums for the 2010 Industrial Products) and its multinational parent are world

Market Forum
renowned for the design and manufacture of a comprehen- Fuel depot goes solar
sive range of lifting, pulling and jacking products as well as Cargo Carriers has for the first time developed a depot that
materials handling systems. Worldwide, the company is all runs completely off solar power.
about precision engineering, superior quality and safety and
Self-sufficient and energy-efficient, the environmentally
all products are ISO 9001 certified.
friendly depot in Evander has already proved a success. Six
The most crucial thing of all, however, is the fact that CMCO months ago the solar-powered depot was pivotal to Cargo
focuses not only on the supply, servicing and installation of Carriers being awarded the Sasol Synfuels contract and a
its products and systems, but also on providing an all round, number of Sasol projects are now being lined up to take
total service solution that meets each of its customer’s advantage of the green depot.
technical needs.
The contract involves the transportation of pitch coke from
Columbus McKinnon Corporation, Graham Campbell, Tel: (031) 700 the Sasol Synfuels Secunda plant to various Sasol clients
4388, E-mail: sales@cmcosa.co.za, www.yale.co.za around South Africa. A high purity carbon residue that is
derived from coal tar pitch, pitch coke is used in metal-
lurgical refinement and the manufacture of anodes and
cathodes. Sasol Synfuels is one of the key suppliers of this
product in Africa.
When the Evander hub was being constructed in 2009 the
surrounding area’s electricity supply was already overloaded
and therefore unavailable. The decision to go solar was simple
Power-shift option added but radical. The depot is considered a giant leap forward
Caterpillar is providing increased customer choice and im- in the logistics industry and is quickly becoming a key dif-
proved operator comfort, with the option of a power-shift ferentiator in tender processes for Cargo Carriers.
transmission for its popular 428E and 434E mechanical “Our environmental efforts have been boosted by the bench-
backhoe loaders. The standard manual shift transmission marking of our fuel, electricity and water usage.” says Cargo
will remain available for those customers who prefer it, while Carriers CEO, Murray Bolton. “These processes are very
the power-shift box, already proven on higher specification E important in our efforts to one day become carbon neutral.
Series Caterpillar models, promises reduced operator effort We hope that this depot draws attention as we believe it
and increased machine productivity. adds great value to the supply chain.”
Caterpillar’s power-shift backhoe loader transmission pro- Cargo Carriers, Tel: (011) 485 8700, www.cargocarriers.co.za
vides four gear selection positions on the control lever. The
transmission features hydraulic clutch pack modulation, to
ensure that drive is taken up smoothly and this improves
the ride for the operator on all types of terrain and reduces
fatigue during travel between job sites.
The popular 428E also benefits from a robust
loader arm redesign that boosts durability
and reliability in the toughest operat-
ing conditions. Front end breakout
has also been increased and this,
in combination with the smoother
gear changing of the power-shift
transmission, results in improved
productivity and lower operator
effort.
Caterpillar SARL, Mia Karls-
son, Email: karlsson_mia@
cat.com

Market Forum
Tight as a drum wired and ready to plug in and run, the system accommodates
A new Tip-Tite drum dump feeder from Flexicon seals drums drums from 114 to 208 litres, and is offered in carbon steel
against a discharge cone, tips the drum and feeds bulk material with durable industrial finishes, with material contact surfaces
into downstream equipment, dust-free at controlled rates. of stainless steel, or in all-stainless steel finished to food,
dairy, pharmaceutical or industrial standards.
The drum platform is raised by a single hydraulic cylinder,
Flexicon Africa, Tel: 041 453
1871, sales@flexicon.co.za,
www.flexicon.co.za
New mobile range

unveiled
Metso Mobile’s comprehen-
sive Lokotrack crushing and
screening series has now
been expanded following the
recent introduction of three
additional models built to
meet the high tonnage de-
mands and different customer
application challenges of the
local market.
Sold and supported by south-
ern African Caterpillar dealer,
Barloworld Equipment, the
new models, which comprise
creating a dust-tight seal between the rim of a drum and the the Lokotrack ST3.5 and ST272 mobile screening units,
underside of the discharge cone. A second hydraulic cylin- and the Lokotrack LT110C mobile primary crusher, are all
der tips the platform-hood assembly and drum, stopping at produced at Metso’s manufacturing facility in Tampare,
dump angles of up to 90 degrees with a motion-dampening Finland. (Metso is a global supplier of a range of solutions
feature. Material flowing through the discharge cone charges for the mining, construction and general industry.)
the intake adapter of a cantilevered flexible screw conveyor
Designed for primary crushing, Metso’s new Lokotrack
that feeds downstream equipment volumetrically.
LT110C is built around the world famous Nordberg C110
Available in stationary and mobile configurations, the drum jaw crusher, which has a feed opening of 1100 x 850mm.
dump feeder is offered with cantilevered flexible screw Power is supplied via a 310 kW Cat C13 diesel engine and
conveyors in cus-
tom lengths oriented
horizontally, or at
an incline, for the
purpose of elevating,
as well as metering,
the material.
Gentle rolling action
of the flexible screw
conveyor in an en-
closed tube reduces
agglomerates dis-
charged from drums,
improving feed rate
accuracy.
Pre-engineered, pre-

Market Forum
the machine has an overall operating weight of 58 tonnes.
The new Lokotrack ST272 is driven by a Cat 4.4 engine, Subscription
boasts an overall weight of 34 tonnes and is built around a Please fax us if you wish to subscribe to “Bulk Handling Today”
heavy-duty two-deck two-bearing screen design. The screen at R375,00 (incl postage, excl VAT) per year; R945,00 per year
box dimensions are 4 866m x 1524m with a screening area for Africa/Overseas (incl postage). We will post you an invoice
per deck of 6,6m2. on receipt of your fax.
Joining the ST272 in southern Africa is the Lokotrack ST3.5 PROMECH PUBLISHING Fax No: (011) 781-1403
mobile screen. It joins the larger ST3.8 model introduced to
Email: editorial@promech.co.za
South Africa earlier last year. Purpose-built for cost-effec-
tive operation and powered by a 75 kW Cat 4.4 engine, the
Lokotrack ST3.5 is equipped with an aggressive 3 580mm From:.........................................................................................
x 1 500mm screen box. The unit has four identical meshes,
which can be swopped around as needed to minimise the (insert your name)
longer-term wear impact.
Barloworld Equipment, Alastair Currie, Tel: (011) 929-0000, E-mail: Title: ..........................................................................................
acurrie@barloworld-equipment.com
Company: .................................................................................
Address: ..................................................................................
....................................................................................................
Moving the earth
HPE Africa’s dedication and commitment to customer service ......................................................................Code: ..................
and after-sales support has led top excavation company, Tlhago
Boswa Earthmoving, to select the company’s exclusive range
Telephone: (.......) ....................................................................
of Hyundai construction equipment.
Tlhago Boswa recently purchased a Hyundai HL770 wheel Fax: (.......) ................................................................................
loader from HPE Africa in November to complement its existing
range of Hyundai HL780 and HL760 wheel loaders, which
Email: .......................................................................................
were purchased from HPE Africa earlier last year.
Index to Advertisers
Afzelia 26
Anchor Industries 25
AST Pyroscan Inside Front Cover
Barloworld/Metso Outside Back Cover
Conexpo Inside Back Cover
Engineer Placements 33
The company also purchased two Hyundai R305LC-7 excava- ILS 16
tors – with a powerful operating weight of 29,4 tons and a
bucket capacity of 2 m3- from HPE Africa in July and October Linde 29
respectively and Tlhago Boswa Director, Alan McGill notes
that to date, Tlhago Boswa has not experienced any technical LMI Academy 6
problems with the Hyundai equipment. MS Conveyor Pulleys 10
“Tlhago Boswa operates in a very demanding and unforgiving
environment, and averages about 500-hours per month on SAID 32
the equipment, so it has to be durable. Hyundai has a good
Scania 28
reputation in the industry and, coupled with the good service
from HPE Africa, I can see a positive future between the two Rema Tip Top/Dunlop Outside Front Cover, 14
companies,” he concludes.
HPE Africa, Kirsty Denholm, Tel: (011) 397 4670, Email: kirsty@ Toyota 30
hpeafrica.co.za, Web: www.hpeafrica.co.za

REBUILD
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Be there to experience the latest innovations and enjoy the attractions
of Las Vegas!
March 22–26 Go to www.conexpoconagg.com/intl for details on how to register.

LaS VEGaS, USa
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is co-located with:

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lowest sustainable cost per ton
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Symbiotic.
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Chemistry.
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professional process advice

Coming soon, to a
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40uncompromising customer
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BULK HANDLING TODAY January 2011 

 BULK HANDLING TODAY January 2011

Featured on the cover:

Rema Tip Top SA

Procurement Safety Equipment

Lifting Equipment 34 Market Forum

The monthly circulation

BULK HANDLING TODAY January 2011 

 BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011 

The TMS model can be tailored to any

 BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011 

How it Shouldn’t It’s not every day that

be Done even a journalist such as

It’s difficult to make out the original

Handling Today” came across this

 BULK HANDLING TODAY January 2011

the chassis so it can bear the weight

BULK HANDLING TODAY January 2011 

l Customers, Suppliers and

Forthcoming Features 2011

10 BULK HANDLING TODAY January 2011

Making Lifting Safer

Seeing around corners

BULK HANDLING TODAY January 2011 11

which will immediately

An assortment of of control units supplied by Bexl

Operability (HAZOP) study by the mining house

12 BULK HANDLING TODAY January 2011

It’s Not All

BULK HANDLING TODAY January 2011 13

by Eli Goldratt, a renowned Deep knowledge

Company experiences the real costs of low-cost logistics

“With POOGI and TOC woven into our business

“The wheels fall off”

14 BULK HANDLING TODAY January 2011

Container Terminal Leads

BULK HANDLING TODAY January 2011 15

Constant Speed Versus

BULK HANDLING TODAY January 2011 17

rotational, sliding and internal

Figure 2: Schematic of the mass model for a conveyor belt

18 BULK HANDLING TODAY January 2011

Main resistance to the three different values of mass. In ISO 5048

BULK HANDLING TODAY January 2011 19

20 BULK HANDLING TODAY January 2011

The significance of the Secondary resistances • Belt cleaner resistance,

BULK HANDLING TODAY January 2011 21

Calculation of the artificial friction Conclusion on the results of the artificial

Mine to Stockyard to Terrace Silo’s

22 BULK HANDLING TODAY January 2011

Figure 6: The components of a frequency variable speed drive

BULK HANDLING TODAY January 2011 23

24 BULK HANDLING TODAY January 2011

The calculated energy cost saving for the

BULK HANDLING TODAY January 2011 25

Just One Hand

absolutely no risk of an explosion while operating

BULK HANDLING TODAY January 2011 27

overloaded. It withstands ad-

Flexibility is essential when it comes to

28 BULK HANDLING TODAY January 2011

of energy: there is no threat of danger associated

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011

BULK HANDLING TODAY January 2011