Some people are rather cautious when it comes to direct contact with cement suppliers. But at Beumer, a manufacturer of machinery and conveyor technology, they are certain that "a lot will change in the coming years." This includes, among other things, the switch from 50-kg to 25-kg bags. And enormous CO2 emissions.

While the current crisis also presents opportunities for system providers regarding digitalization, the use of alternative fuels, and the need for automation, on-site presence remains crucial in an industry where deals are typically sealed not only with a signature but also with a firm handshake, says Sales Director Kay Wieczorek. "The pandemic is drastically changing our travel patterns and, consequently, the way we hold meetings and finalize contracts," he says. Communication is becoming increasingly digital. "This growing digitalization will also gain increasing traction in the rather conservative cement industry," Wieczorek is convinced. Even though many cement plant operators are still reacting cautiously to this development, they recognize the advantages. "While we can't be physically present at our customers' sites right now, we can still support them, for example, with our smart glasses," says the cement expert. What happens, for instance, if a packaging plant in Indonesia or Peru breaks down? Beumer has a strong global presence with numerous branches and representatives worldwide and can dispatch one of its globally based technicians if needed, but this also takes time – if the COVID-19 restrictions even allow it. Alternatively, the systems provider can be reached around the clock via its hotline.

For problems that are not trivial, but sometimes complex and difficult to describe over the phone, a technician can put on the customer's smart glasses and receive all the important information superimposed on the live camera image. The advantage lies both in the customer's orientation and in the service provider's, who can essentially "look over the shoulder" of the service technician. Through the smart glasses, customer support sees the same thing as the customer on site and can directly instruct the correct steps.

With increasing digitalization, more and more sensors are being used to collect and analyze information at critical points. These can include, among other things, non-contact proximity switches that reliably transmit signals without any mechanical contact. High-quality photoelectric barriers ensure signal transmission even under challenging environmental conditions.
"Alternative fuels are another major trend," says Kay Wieczorek. Cement production emits large quantities of carbon dioxide. Depending on the processes used, emissions from cement production range from a relatively enormous 0.6 to 0.99 tons of CO2 per ton of cement. It is estimated that the industry is responsible for about seven to eight percent of global CO2 emissions. One approach to sustainably reducing greenhouse gas emissions and production costs is the increased use of alternative fuels. Instead of coal and gas, for example, liquid materials such as waste oil or solvents are used. The majority of solid alternative fuels consist of municipal and industrial waste such as mixtures of plastics, paper, composite materials, or textiles. “However, we can’t just throw all the household waste into the furnace,” says Wieczorek. “Because different materials have different calorific values.” Whole or shredded used tires, on the other hand, are readily accepted. Their rubber has a comparable calorific value to hard coal, and the iron from the reinforcement can be mineralogically incorporated into the cement. This reduces the need for iron-containing additives.
Beumer, for its part, as a systems provider, develops solutions for the entire material flow chain, from unloading the delivery vehicle to storing, weighing, conveying, and dosing solid alternative fuels. This includes fully automated systems that dose, separate, and convey tires of varying sizes and weights to the inlet of the rotary kiln.

Photos: Beumer
For routes over rough terrain or populated areas, there are trough belt conveyors and the well-known, covered "pipe conveyor".

Another topic, according to Wieczorek, is "something we in Europe have already implemented in some cases for decades": the switch from 50-kg to 25-kg bags. The trigger is new legal requirements for the health and safety of the workers who lift and carry these bags. "For us, this means that we have to gradually convert the equipment in our customers' packaging lines," he explains. But this is probably not bad for business either. "It will be an enormous undertaking, because the packaging lines in the plants will naturally have to fill and package just as much cement as before – and thus handle twice the number of bags in the same amount of time."
Even though the bags are only half the weight, manually loading them onto the truck beds remains backbreaking work. Manual truck loading is not only strenuous, it usually requires two people who take turns with their colleagues for each loading operation due to the heavy physical labor. In addition, there is the high level of dust, which is harmful to health. Manual loading often results in fluctuating loading performance and inconsistent quality of bag stacks. "These problems are eliminated with our autopac," says Wieczorek. "One employee can operate several machines simultaneously." This allows operators to optimize workflows, achieve high loading capacities, and work efficiently from bagging to loading. "We have further developed this machine," reports Wieczorek. "We offer a version that can be adapted to a wide variety of loading platform widths." The autopac has another advantage – no pallets are required. In many countries, there is simply a lack of wood for pallets.

“Significantly fewer cement lines are being built. In 2010, there were around 200 in China, but by 2019, that number had dropped to just 18. This is, of course, partly due to the enormous overcapacity, particularly in China. For a long time, the government promoted large construction projects, resulting in the production of enormous quantities of cement – ​​which were also exported en masse. Those days are now over. Today, for example, cement plant operators are converting three lines into one large one,” Wieczorek observed. But even this requires expertise and technology. Worldwide, “Made in Europe” is still considered a seal of quality, especially for process-critical equipment. Wieczorek added: “I am certain that the willingness to invest will increase again in the foreseeable future.”

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