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Mar 9, 2021 at 6:06 PMThe Rüthen-based HaRo Group installs a freight elevator in the form of a vertical conveyor for BASF Catalysts Germany GmbH at the Nienburg/Weser site. The vertical conveyor promises reliability, automation, and cost savings with a short payback period, distinguishing it from conventional freight elevators.
(Rüthen) Higher, faster, further – automated, efficient, and cost-effective: The demands on internal material flow are constantly increasing, and the requirements for current production processes are growing almost daily. Pallets, mesh boxes, and other unit goods are transported in seconds from left to right and from top to bottom. While this may sound like a typical scenario at first glance, many overlook a crucial detail: In most industrial complexes, there is still a reliance on at least partially manual operations involving forklifts and employees.
Overcoming Two Levels
Freight elevators, pallet trucks, and forklifts may streamline part of the process, but they always require operation by employees. The BASF Catalysts Germany GmbH faced a similar situation at its Nienburg/Weser site when it approached the Rüthen-based HaRo Group with its request: As part of an investment project, the company was looking for a goods lift to transport various raw materials between two levels in the production building.
With more than 117,000 employees worldwide, the BASF Group is one of the leading chemical companies in the areas of Chemicals, Materials, Industrial Solutions, Surface Technologies, Nutrition & Care, and Agricultural Solutions. The company promotes itself with the slogan “Chemistry for a Sustainable Future” and is continuously working to improve its process and energy efficiency. The same applies to one of the nearly 400 global locations in Nienburg, where exhaust catalysts and soot particle filters are produced. “In the production process, various raw materials are used on two levels in the production building, which is why a goods lift is needed,” stated the chemical company’s request.
High Level of Automation
Unlike conventional freight elevators, the HaRo vertical conveyor is characterized by a high level of automation and cost savings: Where freight elevators require an employee at every door to load and unload goods, the vertical conveyor operates fully automated thanks to a control and regulation system specifically developed for this system. This was also a compelling argument for the BASF Group to collaborate with HaRo. In joint cooperation with the future user, the HaRo Group designed a concept that could meet the chemical company’s requirements:
With Euro pallets as the conveyed goods, a maximum load of 3,000 kg, and a cycle performance of around 20 pallets to be transported per hour in three-shift operation, the vertical conveyor for BASF fits perfectly into the core profile of the HaRo Group. However, the new conveyor has one special feature: at the customer’s request, the vertical conveyor is completely clad.
Saves Space and Time
Construction manager Markus Löseke explains the advantages of this variant in this context: “A clad vertical conveyor replaces the protective fences that would otherwise be mounted around the system for safety purposes. This not only saves space but also saves some time during installation. Furthermore, the cladding prevents air exchange and thus drafts in the vertical conveyor.”
The handling of the HaRo vertical conveyor is significantly simpler than that of conventional freight elevators: A flat level allows for easy entry of the conveyed goods. Pressing the “Open Door” button and selecting the destination floor is all it takes to set the elevator car of the vertical conveyor in motion. Swing gates equipped with safety switches ensure maximum protection for involved employees, as the doors can only be opened when the elevator car is at the respective floor and the control releases the locking from the door operator.
“Of course, the system also operates in reverse mode, meaning that transport can occur both from the ground floor to the upper floor and vice versa,” adds Markus Löseke from the HaRo Group.
Vertical Conveyors Save Costs in the Long Run
The HaRo vertical conveyor impresses yet another customer by combining the advantages of a freight elevator with the requirements of modern automation according to Industry 4.0. Although the BASF Group consciously opted for a manual entry of the conveyed goods, the Sauerland-based conveyor technology manufacturer also offers a fully automated alternative in its product portfolio: In combination with other conveyor technology components, such as roller tracks, chain conveyors, or modular belt conveyors, as well as lift and direction change units, the entire production flow can be automated if needed, eliminating tedious walking distances for employees and achieving a noticeable time savings.
“In the long term, investments in vertical conveyors guarantee significant cost savings,” promises Christoph Hackländer, managing director of HaRo, with an eye on a quick payback period.
Additionally, potential production downtimes due to installation times are eliminated, as the HaRo vertical conveyor can usually be integrated into existing production processes without increased effort and can be quickly integrated. For example, many installations of the conveyors are often supported by cranes through the roof skin into already existing shafts.
Photo: © Martin Vogt / Image Caption: In addition to manual loading, a fully automated version of the vertical conveyor is also feasible
