cpp – Process technology for the chemical industry 03.2019

03-2019 

16 COVER 

WEB-BASED PROCESS 

CONTROL SYSTEM 

12 NETWORK MONITORING 

REAL-TIME DETECTION OF 

THREATS 

24 SPECIAL 

K 2019 PREVIEW 

44 CLOUD SOLUTION 

DIGITAL TRANSPARENCY 

ON COMPRESSED AIR 

TREATMENT 

PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY 

WWW.CPP-NET.COM

NEXT GENERATION 

CAPSULE FILLING 

TECHNOLOGY 

+ Best in batch-to-batch 

+ Flexible set-up 

+ TRI.EASY design 

+ Intuitive use 

www.fette-compacting.com

cpp 

EDITORIAL 

THIS PUMP 

WON‘T 

QUIT! 

PC 3001 VARIO select 

Chemistry Vacuum Pump 

K 2019 again fully 

booked 

Only a few days left until K 2019, the leading international trade 

fair for the plastics and rubber industry, opens its doors at the 

Dusseldorf Exhibition Centre. With over 3000 exhibitors from more 

than 60 countries, it will once again be fully booked this year, 

occupying a net exhibition space of around 175,000 m² from 16 to 

23 October. More than 200,000 trade visitors from all over the 

world are expected to travel to the Rhine metropolis. 

The 21st K remains the performance barometer for the industry as a 

whole and a global marketplace for innovation. For eight days, the 

who’s who of the entire plastics and rubber world will meet there 

to discuss current trends, introduce new products and solutions, 

and set the course for the future. K 2019 not only emphasises its 

special status due to the great popularity of the global industry but 

also addresses current challenges. In particular, the event will focus 

on “Plastics for Sustainable Development & Circular Economy”. 

If you are already preparing your visit to K 2019 in October, you 

will find a comprehensive trade fair special starting on page 24 of 

this issue. The special begins with an interesting article about the 

Contraplex wide-chamber mill from Hosokawa Alpine, which has 

been adapted to the specific requirements of 3D printing. 

As early as April this year, Siemens presented the Simatic PCS neo 

process control system based entirely on web technologies at the 

Hannover Messe, which on the one hand builds on existing knowhow 

and protects investments already made but on the other treads 

completely new paths. You can discover what these are in our cover 

story on page 16. 

 

 

 

 

 

www.thebettervacuum.com 

Günter Eckhardt, Editor-in-Chief 

cpp 03-2019 3

cpp CONTENTS 03-2019 

16 Cover The Simatic 

PCS neo process control 

system from Siemens is 

based entirely on web 

technologies but can use 

the hardware already 

installed. 

22 The Contraplex CW 

250 II wide-chamber 

mill features optimised 

grinding tools and temperature 

control, reducing 

liquid nitrogen and 

energy consumption. 

38 A dashboard enables 

users of Wolftechnik's intelligent 

filter controller 

to manage the entire filtration 

process via a single 

interface, where parameters 

can be configured 

and monitored and data 

backed up and restored. 

INSTRUMENTATION, CONTROL, AUTOMATION 

8 Surge protection system for signal circuits 

Fuse terminal blocks can be expanded with fuse 

carriers 

10 Profinet integration in process automation 

IP 67 I/O module with Profinet S2 system redundancy 

12 Real-time detection of threats 

Network monitoring with anomaly detection 

14 Access for authorised persons only 

Safety and security in one operating mode selection and 

access permission system 

16 COVER Replace the software, keep the hardware 

Web-based process control system uses existing 

hardware base 

21 Safe control of separation processes 

Radiometric system for multiphase level measurement 

SPECIAL K 

24 Wide-chamber mill for 3D printing 

Cryogenic size reduction of fine polymer powders 

26 Transforming a dusty process into a clean one 

Customised solution for clean air in plastics 

production 

29 PRODUCTS 

32 The right vacuum cleaner for each material 

Cleanliness and health protection in the plastics 

industry 

34 How to configure your heating and cooling system 

Energy-efficient temperature control of stirrer tanks 

36 All process steps in one machine 

Optimal powder dispersion 

PROCESS ENGINEERING 

38 Networked filter technology for the future 

Smart controller paves the way for Filtration 4.0 

PLANTS, APPARATUS, COMPONENTS 

40 Tailored to the application 

Roots pumps for vacuum distillation 

42 In the age of Industry 4.0 

Compressed air management: service tool and app for 

compressors 

44 Digital transparency on compressed air treatment 

Cloud solution captures and visualises compressor and 

compressed air system data 

47 Drum emptying system with follower plate 

Gentle pumping of pastes and non-flowable substances 

48 Cloud services for digital twins 

Keep your process plant up to date at all times 

50 Grab sampling systems for accurate lab analyses 

Collecting representative samples 

4 cpp 03-2019

40 Oktaline roots 

pumping stations have 

proven to be an advantageous 

solution to realise 

the exact pressure in 

vacuum destillation 

plants. 

50 Grab sampling systems 

provide an effective 

way to safely collect 

samples from a pipeline, 

tank or process vessel to 

be transported to a lab 

for offline analysis. 

PACKAGING TECHNOLOGY 

56 Position indicator for supervised format change 

Process reliability in track and trace systems 

58 Bagging carbon black efficiently 

Dust-free thanks to state-of-the-art vacuum technology 

COLUMNS 

3 Editorial 

4 Contents 

6 News 

22 PRODUCTS 

53 PRODUCTS 

60 Contact the Editors 

60 Imprint 

60 List of Advertisers 

WWW.CPP-NET.COM 

More news, facts, products and 

solutions for the process technology 

in the chemical industry can be found 

on our internet page! 

www.cpp-net.com 



NEWS 

Russian chemical complex 

HONEYWELL SELECTED AS AUTOMATION CONTRACTOR 

Picture: Honeywell 

Honeywell was selected as main automation 

contractor for one of the largest PJSC Metafrax 

chemical complexes in Russia 

Casale SA has selected Honeywell Process 

Solutions to be the main automation contractor 

for a more than 950 million euros 

ammonia, urea and melamine production 

facility being built for PJSC Metafrax, one of 

Russia’s largest chemical companies. The 

plant, located in Gubakha, Russia, is scheduled 

for completion in 2021 and will be 

one of the largest production facilities of its 

type in Russia. The complex is designed for 

a maximum annual production of up to 

575 000 t of urea, 308 000 t of ammonia 

and 40 000 t of melamine. Honeywell will 

work with Casale to deliver a range of 

modular process equipment, control, safety 

and information solutions and competency 

management systems including: Experion 

Process Knowledge System with nine Experion 

Orion workstations, Safety Manager, 

Uniformance Process History Database for 

the collection, storage and analysis of process 

data, Field Device Manager for simplification 

of maintenance tasks and complete 

device configuration, Unisim Operator 

Training Simulator for skills training specific 

to melamine production, and Honeywell 

UOP Pressure Swing Adsorption (PSA) 

unit for hydrogen recovery and purification. 

Picture: Evonik 

Construction of a new natural-gas power plant in Marl 

EVONIK WILL END COAL-FIRED POWER GENERATION 

Evonik is to install a new advanced high-efficiency 

gas and steam turbine power plant 

at Marl Chemical Park 

Finnish manufacturer of high-performance butterfly valves 

ARI-ARMATUREN GROUP AQCUIRED HÖGFORS 

ARI-Armaturen Group has acquired all outstanding 

shares of the Finnish butterfly 

manufacturer Högfors Oy. Högfors develops 

and manufactures a wide range of manual 

and automated butterfly valves and also provides 

ball valves both for a vast variety of 

applications in the power and process industry. 

Since its establishment in 1927 Högfors 

has become a trusted partner with a strong 

market position. Högfors will complement 

Evonik is to install a new advanced high-efficiency 

gas and steam turbine power plant 

at Marl Chemical Park. The specialty chemicals 

group is thus, after more than 80 years, 

ending hard-coal based power and steam 

generation in Marl, which will reduce its 

CO 2 emissions by up to 1 million t/a. Direct 

greenhouse gas emissions of its plants 

worldwide will then be reduced annually by 

almost one fifth. Evonik and its partner 

Siemens signed agreements for the construction 

of the two-block power plant on 

August 30th. Construction is slated to start 

before the end of this year. The high-efficiency 

and very flexible plant, producing 

power and steam in a cogeneration process, 

is expected to come on stream in 2022. Its 

total system efficiency will exceed 90 %. 

The project cost is in the three-digit million-euro 

range. Siemens Gas and Power is 

the main contractor and, jointly with its internal 

partner Siemens Financial Services, is 

responsible for the planning and construction 

of the entire power plant, including a 

new central control station building. Evonik 

will operate the plant in conjunction with 

the existing natural gas power plants. 

With the new power plant Evonik is securing 

cost-efficient and sustainable energy for 

its Marl Chemical Park, Evonik’s largest production 

site, over the long term. Apart from 

power, steam generation is also important 

for production in the Chemical Park. The 

plant has a power output of 180 MW and 

can produce up to 440 t/h of steam. 

ARI’s wide product program of industrial 

valves, especially in the area of metal-seated 

high-performance butterfly valves. At the 

same time, Högfors will benefit from synergies 

in sales, production, sourcing and engineering. 

“We are very excited about this 

great new opportunity to be able to expand 

our value preposition to our customers 

worldwide,” notes Mr. Dietmar Roehrmann, 

Head of Global Sales and Marketing of ARI.” 

Anniversary in the Allgäu region 

PUMPENFABRIK WANGEN 

TURNS 50 

Pumpenfabrik Wangen GmbH celebrates its 

50th anniversary. Founded in September 

1969 as a small trade operation, in 2019 

Pumpenfabrik Wangen GmbH is now a 

globally operating company with its headquarters, 

development and production site 

in Wangen in the Allgäu region of Germany. 

Wangen pumps and pump components 

enjoy regional, national and international 

repute and are used on every continent 

across the globe. ”We can look back with 

satisfaction at our growth over the first 50 

years. Pumpenfabrik Wangen has continually 

grown from being a niche provider in the 

agricultural sector to becoming a global 

supplier of progressing cavity pumps and 

twin screw pumps for a wide range of different 

segments. Our engineering services 

combined with a desire for quality and serious 

commitment throughout all departments 

and by all employees have enabled 

our growth and form the basis for future 

success on the global market and in the 

most diverse market segments,” explains the 

company’s management. With a current 

workforce of 240, expert and extremely 

committed sales partners and a broad-based 

range of pumps for sectors, including agriculture, 

biogas, sewage treatment and environmental 

technology, food, chemicals and 

pharmaceuticals, the company is looking 

optimistically towards the future in 2019. 


GLASS FILTERS 

High quality material for demanding 

tasks: VitraPOR® glassfilter apparatuses 

made from pure borosilicate glass 3.3 

fulfill many requirements in chemical 

and pharmaceutical labs as well as for 

industrial, biological and environmental 

technology applications. 

Properties such as heat resistance to 

over 500 °C and resistance to most 

acids, alkalis and solvents make our 

VitraPOR® glassfilters, which conform to 

international standards, suitable for use 

in many chemical, pharmaceutical and 

technical procedures. 

Custom VitraPOR® sintered elements 

according to your specifications are 

characterized by their neutral properties 

and open-pore structure. They are 

suitable for even the most unusual 

applications. 

VitraPOR® glassfilter apparatuses can 

be supplied in different pore size classes, 

from smaller than 1 micron to over 500 

micron and as custom-made solutions in 

many shapes and sizes. 

ROBU Glasfilter-Geräte GmbH 

Schützenstrasse 13 

57644 Hattert 

Germany 

Made in Germany 

www.robuglas.com 




Pictures: Phoenix Contact 

The Termitrab complete surge protection system for signal circuits is now also available 

with a directly attachable fuse carrier 

Fuse terminal blocks can be expanded with fuse carriers 

Surge protection system 

for signal circuits 

More and more companies demand space-saving components for the cableconnection 

cabinets of their widely branched measurement and control systems, 

which can often be found in process technology. With the Termitrab complete 

product range, Phoenix Contact offers an extremely compact solution for the 

connection and distribution level, which now also offers a fine fuse function. 

More and more companies demand 

space-saving components for the cable-connection 

cabinets of their widely branched 

measurement and control systems, which 

can often be found in process technology. 

With the Termitrab complete product range, 

Phoenix Contact offers an extremely compact 

solution for the connection and distribution 

level, which now also offers a fine 

fuse function. 

On the distribution level of control cabinets 

in process technology, requirements that 

actually are contradictory collide. On the 

one hand, easy access and high maintenance 

convenience are required. On the other 

hand, costs are to be cut – by a compact, 

space-saving design. This space-saving 

design is also based on the large number 

of signals in the system. 

Phoenix Contact designed the Termitrab 

complete system to, among other things, 

resolve this contradiction in an innovative 

manner. The narrow components are origi - 

nally surge protection components for 

signals in the low-voltage range. They are 

designed as multi-level terminal blocks and 

offer two connection levels in through 

wiring. A third connection level can be used 

for a joint reference line or cable shielding. 

The components of the Termitrab complete 


Installation in the past (left): fuse terminal block, surge 

protective module and knife disconnect terminal block 

required a lot of space 

Installation today (right): Termitrab complete – as a system 

combination of fine fuse, surge protection and knife 

disconnect terminal block – makes the installation 

significantly more compact 

New block of the Termitrab complete system: the fuse 

holder for cartridge fuses with 5 x 20 mm 

product range also offer two additional, 

optional functions: knife disconnection and 

modular design. The integrated knife disconnection 

for the two signal wires enables 

the user to disconnect signals from the field 

cables during start-up or maintenance work. 

This way, measurements or test on the field 

side can be implemented easily without 

having to loosen the cables from their 

termination points. 

Thanks to their two-part design, modular, 

pluggable protective devices also facilitate 

replacing overload voltage-limited components. 

This way, recurrent tests according to 

IEC 62305-3 can be carried out without affecting 

the running application. For this, the 

Termitrab complete plug is plugged into the 

Checkmaster 2 test device – and the function 

test is run. The system determines the 

current technical parameters in detail and 

compares them to the set points taking into 

account the permissible tolerance. Each 

single test is saved. The data of all tests can 

then be exported via a USB port to be processed. 

This way, test reports are created 

with low effort. 

Modular fuse carrier 

These functions have been extended – by 

the functions of a modular fuse carrier. 

Now, even more space can be saved during 

installation because the fuse carrier directly 

attaches to the surge protective terminal 

block as a “mounted module”. Installations 

for which a combination of fine fuse, surge 

protection and knife disconnection is desired, 

used to consist of fuse terminal 

blocks, surge protection modules and knife 

disconnect terminal blocks connected in 

series, which had to be connected among 

one another using cables. The new, modular 

system now unites all properties in one extendable 

terminal block. This combination 

not only saves two thirds of the space the 

individual terminal blocks would require, 

but also a substantial part of the wiring. 

Selective overcurrent protection 

Fine fuses are used, e. g., for systems in 

which the signal circuit is connected to a 

24 V(DC) power supply. This can be a connected 

actuator circuit in which a control 

valve is addressed. Such a design is also used 

for a power supply to sensors in the field. 

Usually, a circuit breaker with correspondingly 

high current switching capacity is 

installed directly downstream of the power 

supply system. In this main trunk, values of 

10 or 20 A are typical. To selectively provide 

the individual signal circuit branches with 

overcurrent protection elements, tuned fine 

fuses can be used. The nominal value of 

these fuses is correspondingly lower and 

depends on the operating currents of the 

field devices. In the event of a short circuit 

in a field cable, or an error in a device, the 

fuse in the branch will trip. All other signal 

circuits connected to the same main trunk 

remain unaffected by this error. 

The fine fuse also offers protection for the 

surge protective module itself. The rated 

current identified for the component must 

not be exceeded. Fine fuses for circuits with 

less power typically have a nominal current 

of some 100 mA. For comparison, the rated 

current of most 24 V components from the 

Termitrab complete series is 600 mA – 

which means that it is more than sufficient 

to cover numerous applications. The High 

Current (HC) variants in the Termitrab complete 

range even permit a current of up to 

6 A. This value is also the maximum permissible 

current for the fuse holder. Therefore, 

there is also a harmonised and suitable so - 

lution for actuator circuits with higher 

nominal or starting currents. 

Termitrab complete offers yet another advantage: 

the clever design of the fuse holder 

even enables the user to add a fuse holder to 

all terminal levels at the Termitrab complete 

housing that feature screw-connection technology. 

This way, several channels that are 

switched via the Termitrab complete module 

can be secured. 


Online search: cpp0319phoenix 

AUTHOR: 

THORSTEN HEIL 

Product Manager Business 

Unit Trabtech, 

Phoenix Contact 




IP 67 I/O module with Profinet S2 system redundancy 

Profinet integration in 

process automation 

Profinet is increasingly becoming more attractive to the process automation 

industry. However, there are special requirements that controllers and field 

devices have to meet. Turck‘s forward-looking contribution to Profinet 

integration is a comprehensive functional extension of fieldbus products to 

support S2 system redundancy. 

Protecting plants in the chemical and 

pharmaceutical industry from downtime 

involves considerable effort. Compared to 

factory automation, where the focus is on 

higher unit quantities and shorter cycle 

times, the interruption of a continuous 

production process can lead to enormous 

financial losses. Furthermore, the handling 

of hazardous liquid or gaseous substances 

involves the observance of strict safety precautions 

– particularly in areas provided 

with explosion protection. As a preventative 

measure, companies therefore firstly invest 

in the safeguarding of potential ignition 

sources and secondly in a high availability 

system architecture. Controllers and I/O 

modules in the field are normally provided 

with redundancy in order to ensure safe 

plant operation. If one device or connection 

fails, the otherwise inactive backup solution 

is activated. Planners implement these complex 

or limited redundant systems in accordance 

with the relevant requirements – 

both on the physical device level as well as 

in the underlying programming logic. 

Picture: buhanovskiy – Fotolia.com 

Plants in the chemical and pharmaceutical industries can be more reliably protected 

against failures with I/O systems in Profinet S2 system redundancy 

S2 system redundancy preferred 

In the Profinet context, a new standard was 

created for this with system redundancy. The 

terminology used here is based on a gradation 

that reflects the degree of fail safety 

that an automation system is to provide. No 

redundancy is implemented (S1) if a controller 

and field device only communicate via 

a single connection. However, if a Profinet 

device supports communication relations to 

the primary controller as well as its backup 

via this single connection, this is classified as 

S2. In the event that the main controller fails, 


a bumpless switching to its physical twin is 

performed. For this, the I/O system and I/O 

module in the field must maintain this logical 

dual connection to two entirely spatially 

separated controllers. These S2 solutions 

meet the requirements of many applications 

and are preferred in practical applications. 

The alternative term “simple system redundancy” 

should not obscure this fact. 

Very high and maximum availability can 

only be achieved with R1 or R2 system 

redundancy. This involves the additional 

implementation of a redundant communication 

interface on a field device, and is 

often used in conjunction with remote I/O. 

R2 with its four-way connection represents 

the highest level of complexity. Here, each 

of the two communication interfaces of a 

device can establish communication relations 

– to the main controller and to its 

redundant copy. This crosswise protection 

from failures is used extremely rarely. 

Redundancy principles: S1 is a simple connection, i.e. no redundancy. If a Profinet device communicates 

with the primary controller and its back-up via this connection, this is classified as S2. Very high 

and maximum availability is only offered by R1 or R2 system redundancy, which also require dual 

systems on the field side. 

Picture: Turck 

High availability to the field 

Siemens initiated the Profinet implementation 

of the redundancy profile and designed 

its controller systems to support redundant 

infrastructures. Profinet devices 

had previously not provided support for S2 

system redundancy. Turck is now responding 

to this demand with an extensive expansion 

of functions. 

The TBEN-L5–8IOL will be the first IO-Link 

master module that supports S2 system redundancy 

and offers protection to IP 67 and 

IP 69K, thanks to its fully potted electronic 

unit. This combination of Industrial Ethernet 

and IO-Link offers digitalisation right 

through to the last meter. Furthermore, 

Turck‘s I/O modules come with an additional 

TCP/IP interface for read access to device 

data, so that all digital treasures can be 

gathered. Condition monitoring, asset management 

and predictive maintenance can 

thus be implemented without any limits. 

Turck is also offering SIDI (Simple IO-Link 

Device Integration), probably the most userfriendly 

way of integrating IO-Link into 

Profinet projects. IO-Link masters with SIDI 

give IO-Link devices the identity of a genuine 

Profinet module with their own GSDML 

entry. The function considerably simplifies 

the engineering of IO-Link devices in projects 

with Profinet controllers, since it 

allows access to all parameters and device 

properties from the engineering system 

without the need for additional software. 

Use in practice 

The first TBEN-L5–8IOL modules will soon 

be deployed in the USA in the plant of a 

The TBEN-L5–8IOL IP67 block module is Turck‘s first IO-Link master module to support S2 system 

redundancy 

biopharmaceutical manufacturer, which will 

manage its production with Profinet system 

redundancy and IO-Link in the future. High 

availability is essential for the handling of 

mostly sensitive and cost-intensive products. 

An integrator in the pigging technology 

sector found the additional profile support 

for IP 67 devices equally important. The 

company serves customers in the chemical, 

pharmaceutical and mineral oil sector. The 

high protection class of the TBEN field devices 

now simplifies the planning of systems 

in these sectors. Decentralized and 

modular network architectures can be designed 

so that the space required in the control 

cabinet is substantially reduced. 

The IO-Link master is at the beginning of 

the major product upgrade to S2 system redundancy. 

Over the year, Turck will provide 

other multiprotocol devices with the additional 

function, and block modules of the 

TBEN series will follow, as well as the IO 

systems for the control cabinet of the 

FEN20, BL20 and excom series. The changeover 

to Profinet with a wide range of signal 

types, both for the Ex and the non-Ex area, 

can thus be completed without any obstacles. 


Online search: cpp0319turck 

AUTHOR: 

AUREL BUDA 

Director Product Management 

Factory Automation Systems, 

Turck 

Picture: Turck 




Picture: Skitterphoto – Pixabay 

Network monitoring significantly increases security of Industrial Control Systems 

Network monitoring with anomaly detection 

Real-time detection 

of threats 

Whether spillover effects from ransomware or targeted attacks: the less pleasing 

effects of digitisation on industrial processes can also be felt in the chemical 

industry. Network monitoring with anomaly detection supports those responsible 

in IT and OT in ensuring availability and security of the industrial control system 

and its connected plants. 

It may not always be a targeted attack. Since 

the pharmaceutical giant Merck became the 

victim of the Ransomware Notpetya in 

2017, it is clear to chemical and pharmaceutical 

companies how vulnerable the security 

and availability of their industrial 

control system (ICS) and automation system 

are. Merck had to fight with several weeks 

of production downtime and even had to 

borrow drugs from U.S. authorities. The 

incident cost the Group $375 million. Unlike 

Bayer or the Tasnee oil refinery operating 

in Saudi Arabia, Merck was not even actively 

attacked. Their losses were purely collateral 

damage. The shutdowns in production 

were caused by spillover effects. The 

malware had leapt from the office IT to the 

production line via the necessary ICS connections. 

The ICS is a blind spot 

With this incident, the open flanks of digitisation 

became apparent: higher system 

complexity, opening of the ICS to the internet 

as well as the (so far more poorly than 

properly functioning) marriage of a security-oriented 

office IT and an unsecured, 

availability-oriented production IT. In the 

end, Merck was lucky. Neither were customers 

endangered by changes in recipes, nor 

were employees injured. Especially in the 

chemical industry, there is a thin line between 

cyber security and occupational 

safety. Even the theft of sensitive data did 

not occur to the best of our knowledge. The 

vulnerability of the process industry is due 

to various reasons, which can also be applied 

to other branches of industry as well 

as critical infrastructure. In his book “Industrial 

IT Security“ (Vogel, 2019), ICS security 

expert Sebastian Rohr describes the three 

core problems with the production IT: 

• lack of awareness by employees 

• insufficient documentation of assets and 

applications 

• no monitoring of infrastructure and assets 

(components, systems, applications, data) 

While the first point can be solved through 

training, points 2 and 3 deal with organisational 

and technical challenges. In terms of 

documentation (or asset inventory), Rohr 

soberingly states: “In contrast to the detailed 

documentation of the mechanical and 

safety-critical components of a plant, which 

is constantly improved by quality management, 

the information regarding the IT systems, 

operating systems, applications, tools 

and databases or directories used or in- 


stalled is often inadequate, at best poor, or 

sometimes simply not available at all.” 

This also complicates the management, diagnosis 

and troubleshooting of assets. The 

minimum requirement would be the identification 

and visualisation of assets and its 

connections to each other or to communication 

partners outside the System under 

Consideration (SuC). Additionally, there is 

information on firmware version, configuration, 

protocols, IP addresses, ports and 

communication patterns. After Rhebo Industry 

4.0 Stability and Security Audits at industrial 

and critical infrastructure companies, 

those responsible usually react with 

surprise as to which devices and applications 

are hidden in the ICS and with 

whom they communicate. 

The audits use industrial network monitoring 

with integrated anomaly detection to 

record and subsequently analyse all communication 

processes within the ICS. This 

not only documents the communication 

that runs through routers and firewalls stationed 

at the ICS perimeters. The communication 

between components within the ICS 

is also recorded. Thus those responsible for 

the ICS gain detailed visibility of all assets, 

their properties and behaviour for the first 

time. Frequently, insecure ports, protocols 

and Internet connections are found. Similarly, 

almost all evaluated communication 

data contains unknown devices as well as 

vulnerable firmware versions. 

Ostrichism doesn`t solve the challenge 

Though, monitoring isn‘t completely new 

for production lines in the chemical industry. 

At the very least, this applies to the performance, 

use and wear parameters of the 

plants. This is essential for both process control 

and evolving predictive maintenance. 

The monitoring of the ICS, on the other 

hand, is lacking. Sebastian Rohr emphasizes: 

“This monitoring and evaluation offers considerable 

added value, since the analysis of 

network traffic or load parameters of the 

ICS components enables conclusions to be 

drawn about previously undiscovered attacks 

or manipulation attempts.“ 

The German Federal Office for Information 

Security (BSI) recently recommended integrating 

network monitoring with anomaly 

detection as standard in the production IT. 

This system continuously monitors every 

communication in the ICS and reports any 

irregularities in the expected communication 

pattern during normal operation. 

Our experience from monitoring projects 

has taught us that security is the key, but 

never the whole picture. In addition to new 

Picture: Rhebo 

Picture: Rhebo 

Industrial network monitoring with anomaly detection monitors all connections within an ICS and 

provides information about their properties and communication 

Deviations from the target communication pattern are detected, reported and fully stored for forensic 

analysis by real-time network monitoring 

network nodes, changes in communication 

patterns (e.g. changes in protocols and command 

structure due to malware, attacks or 

manipulation) and unprotected password 

transmission, technical error states must 

also be taken into account. In production 

lines with real-time processes, transmission 

errors, extended round trip times and capacity 

overloads of individual components 

can lead to process interruptions or quality 

issues. The evaluation of the data from our 

network monitoring with anomaly detection 

proves that technical error states are 

very common. The same applies to insecure 

protocols, vulnerable ports and communication 

that does not belong to the production 

process. In order to guarantee cyber security, 

product quality and occupational 

safety, the consistent visibility and continuous 

monitoring of the ICS should therefore 

be among the core tasks of those responsible 

for security as well as plant availability. 

A network monitoring system with realtime 

reporting of threats as well as real-time 

visualisation of the active assets provides all 

functionalities for this purpose. 

www.prozesstechnik-online.de 

Suchwort: cpp0319rhebo 

AUTHOR: 

THOMAS FRIEDEL 

Sales Manager, 

Rhebo 




Safety and security in one operating mode selection and access permission system 

Access for authorised 

persons only 

Complex plant and machinery in particular requires different access permissions and 

operating modes in order to guarantee functionally safe operation. It’s not just a 

case of protecting the human from the machine; the machine must also be protected 

against manipulation by the human. Intelligent operating mode selection and access 

permission systems carry out these tasks without being too complex to handle. 

Staff who are not trained to use certain 

plant and machinery should not even have 

access to danger zones around these machines. 

Only authorised, trained personnel 

should be allowed access – and even then 

only for selected operating modes such as 

automatic, manual intervention in restricted 

conditions or service mode. Simple machine 

operation provides additional support when 

it comes to avoiding misuse and accidents. 

Permission-based access 

Various C standards specify that different 

machine operating modes must also incorporate 

corresponding safety functions. For 

example, EN ISO 16090-1 stipulates at least 

two of these operating modes as mandatory 

for machining centres and special-purpose 

machinery, in order to guarantee functional 

safety. It must be ensured that only one 

operating mode at a time is selected and active 

and that the selected mode is clearly displayed. 

The machine owner decides which 

staff are authorised to use which operating 

mode. Safety functions can then be modified, 

too. For instance, a machine in “setup” 

mode can be operated at a safe, reduced 

speed even if a safety gate is open. In addition 

to functionally safe operating mode 

selection, it is also important to control access 

permissions in order to protect plant 

and machinery from unauthorised access – 

in other words, to guarantee security at machine 

level. The system identifies staff who 

are permitted to access the plant or machine 

because of their job or qualifications. Depending 

on the size of the company, it may 

also be sensible to implement group-based 

permission management. In this case, the 

various enables are assigned not to individuals 

but to whole groups with identical 

access rights. At the same time, access rights 

for a machine type in company-wide use, 

for example, can be stored and assigned 

centrally. This simplifies the allocation and 

administration of access permissions, particularly 

for companies with multiple sites. 

No possibility of manipulation 

When granting access permissions, it is also 

necessary to consider the issue of manipulation 

protection for plant and machinery. 

An operating mode selection and access permission 

system such as the modular PITmode 

fusion offers this dual functionality. 

PITmode fusion consists of the PITreader 

unit with RFID technology, an integrated 

web server and a safe evaluation unit (SEU). 

Each machine operator has an RFID transponder 

key with their own individual access 

permissions. The key is read and taught in 

the PITreader unit. To increase manipulation 

protection, the RFID keys can be coded 

using PITreaders containing company-specific 

programming, i.e. the keys are given a 

password-protected, private signature which 

is encrypted using AES (Advanced Encryption 

Standard). Any keys that are not coded 

with this signature will be denied access. 

Pictures: Pilz 

The modular operating mode selection and access permission system 

PITmode fusion from Pilz combines safety and security in one system 

Sensitive data in good hands 

Data is transferred securely between the 

PITreader and the RFID key using the 

13.56 MHz RFID technology familiar from 


The compact all-in-one device PITmode from Pilz includes the pushbuttons 

for operating mode selection and the SEU 

contactless payments, amongst other things. 

Each key is uniquely coded and has a 64-bit 

security ID. This individual ID lets users assign 

the RFID key to their operating mode 

selection and access permission system. The 

keys can be stored ready for use but not 

coded until they are actually needed. As soon 

as the RFID key configuration is complete 

and no further changes are permitted, the 

key can be locked for editing. Group-based 

permission management can also be realised 

using the RFID keys and PITreader. A group 

area of 32 groups, each with 0 to 64 permission 

levels, is pre-installed on each RFID 

transponder key. In future, it will also be 

possible to design complex, hierarchical permission 

matrices in a free user area. PITmode 

fusion can be used to implement a wide 

range of functions beyond access permission 

and operating mode selection. This could be 

a simple enable, which replaces a key switch 

on the control console, or possibly access 

permission for machine subfunctions. 

Simple handling – clear control 

The aim should be a user-friendly operating 

concept that keeps user handling and operability 

simple despite the wide range of 

functions. This will also help to avoid faults 

and manipulation. That’s why an operator 

panel should be clear and intuitive and not 

contain too many different components. A 

modular operating mode selection and access 

permission system such as PITmode 

fusion can be individually integrated into 

the design of an existing operator panel due 

to its modular structure. Existing pushbuttons 

can likewise be retained, improving usability. 

A multicoloured LED ring on the PITreader 

visualises the user information in 

colour, for example with a “green light” if 

permission is granted. An intelligent operating 

mode selection and access permission 

system enables several mechanical keys to 

be combined within one transponder key, 

so that users do not have to manage different 

keys or access cards. 

Sophisticated operating mode selection and 

access permission management guarantees 

more efficient production processes in plant 

and machinery where it is necessary to 

switch between different control sequences 

and operating modes. To avoid manipulation 

and misuse, it should provide clarity and be 

simple to operate. Modular operating mode 

selection and access permission systems 

such as PITmode fusion unite safety and security 

in one system, ensuring more efficient 

processes and less downtime. 


Online search: cpp0319pilz 

AUTHOR: 

CHRISTOPH BAU- 

MEISTER 

Product Manager Operating 

and Monitoring and Tools, 

Pilz 




Pictures: Siemens 

Web-based process control system uses existing hardware base 

REPLACE THE SOFTWARE, 

KEEP THE HARDWARE 

In the process industry, investment protection and long plant lifecycles 

of up to 40 years play an important role in any innovation. 

The Siemens engineers’ goal when developing the new Simatic 

PCS neo process control system, which is based entirely on web 

technologies, was to harmonise these three aspects. 


Uncluttered engineering interface: All documents released to the project 

engineer can be displayed and processed in a single view. Efficient generation 

of executable automation programmes using a CFC (Continuous 

Function Chart) or ... 

... SFC (Sequential Function Chart) for sequential controls – both based 

on IEC 61131. 

How do you tackle innovation? Do you choose an incremental approach 

or a more disruptive one? Siemens opted for the golden 

mean: on the one hand, the new Simatic PCS neo control system 

has something groundbreaking about it. The system software is 

based exclusively on web technologies and has a consistently object-oriented 

data model. It is no longer necessary to install software 

on specific workstations for administration, engineering and 

plant operation. Thanks to HTML 5, it is now possible to have secure 

access to the system and operate it efficiently just using a 

browser. The user interface is also completely new: it combines 

adaptable, up-to-date technologies with the capabilities, tasks and 

goals of its users. User Experience (UX) Design has embedded user 

experience in the design process for the operator interface. 

On the other hand, the new system also uses the same application 

architecture and hardware portfolio as the established Simatic PCS 7 

process control system, which has proven itself for over 20 years. 

Simatic PCS neo thus continues the Siemens tradition while taking 

two important customer requirements into consideration: the desire 

to protect existing expertise and make a future-proof investment. 

Clearly structured from top to bottom 

However, the Simatic PCS neo process control system also breaks 

with tradition. The system is based on HTML 5 and operated entirely 

using a current web browser. Classic, single-user PCs with an 

installed operator interface or engineering system are a thing of the 

past. Every office computer which meets the security specifications 

and has the relevant certificates can now become an engineering or 

operator station. All the required applications are installed on a central 

server, where all data is managed and saved. The browsers on 

the terminal devices, which can also be smartphones or tablets, retrieve 

data from this central point or send queries back to the 

server, for example operator interventions or changes to setpoints. 

To create an intuitive working environment, Siemens simplified the 

operating philosophy across all applications and implemented a 

‘one workbench’ concept for all applications and tasks. In other 

words, authorised users can toggle between an engineering view 

and a control and monitoring (operational) view with a single 

click. Direct access to operating elements, control sequences, alarms 

or interlocks is therefore possible at any time from a single point of 

entry. Wherever operator interventions are required, clearly structured 

tasks and dialogues guide the user to their goal. 

Licence and user management integrated 

Administration is likewise integrated into this concept, of course. 

Licence and user management is controlled here, as is the administration 

of all software and security-related procedures. Since the 

applications are executed via the browser, cumbersome local installations 

such as on-site updates are made increasingly redundant: 

the latest version of the application appears every time the client 

restarts. 

Interdisciplinary collaboration redefined 

Interdisciplinary collaboration among new project teams assembled 

from all parts of the world is already a reality in many places today 

– and the trend is steadily increasing. Simatic PCS neo confronts this 

challenge with functions which take global collaboration to a new 

level. In engineering, for instance, consistently object-oriented data 

management with centralised data storage ensures that everyone in- 




Online view of parameters: the current target system values are displayed 

after connecting to a controller. This allows the parametric values of a 

function block in the controller, for example from a control, to be 

checked and optimised. 

Increased engineering efficiency: all process objects can be placed on the 

screen intuitively from the technological hierarchy using drag and drop. 

volved in a project can access up-to-the-minute data whenever they 

need it. At the same time, people contribute knowledge from their 

own working environment to the centrally managed project. Owing 

to the clear session concept with automatic consistency checks, the 

data is always coherent, even during parallel working in multiple 

sessions, so that engineering and operational processes can be developed 

concurrently. At the same time, hardware-independent project 

engineering provides an extremely high degree of flexibility. 

The following example demonstrates what this means in practice: 

imagine how much coordination effort is saved if an on-site team 

in the field has access during commissioning to all project data on 

mobile devices and makes changes to the central project in real 

time. Simultaneously with this, employees can toggle between 

engineering and monitoring & control views with a single click 

during the loop check – all on the same device. 

IT security as an integral component 

A browser-based control system? This obviously raises the question 

of cyber security measures. Strict adherence to the “security by design” 

principle was therefore a primary concern with this new development. 

Extremely high security standards were applied to the 

hardware and software design from the outset, e.g. all known secu - 

rity mechanisms are taken into consideration when transferring 

data. In addition to functional tests, the engineers and software developers 

also continuously checked the security measures already 

implemented. The development process was carried out in accordance 

with IEC 62443, the international series of standards for “Industrial 

communication networks – Network and system security”. 

These defined, secure coding standards provided coders, architects 

and designers with guidelines for producing secure source codes. 

Modern encryption processes 

The implemented security functions take effect during subsequent 

use. It goes without saying that modern encryption processes are 

employed to enable secure communication between the web server 

and the web browser (client). Access to the system is only possible 

following authentication and authorisation and all communications 

are based on certificates. Users, computers or devices must identify 

themselves using a digital certificate before they are granted access 

to an application. The new control system also fits into the defencein-depth 

concept which Siemens has been applying and driving forward 

for years now based on the recommendations in IEC 62443. 

Defence in depth combines plant and network security with system 

integrity elements to form a comprehensive protection concept. 

This extensive portfolio of secure network components from 

Siemens is naturally compatible with the new control system. 

Summary 

The Simatic PCS neo process control system provides several farreaching 

innovations. Extensive conformity to international stand - 

ards – from Industrial Ethernet and Control Module Types (CMT) to 

Advanced Encryption Standard (AES) – simultaneously ensures that 

the system is future-proofed for long-term use. The underlying 

hardware structure protects customer investments and know-how. 

The modern Simatic ET 200SP HA I/O system and the intelligent 

Simatic Compact Field Unit (CFU) can be used by either Simatic 

PCS 7 or Simatic PCS neo. This prudent and sustainable approach 

allows individual digitalisation strategies to be implemented very 

flexibly step by step. 


Online search: cpp0319siemens 

AUTHOR: 

MANUEL KELDENICH 

Marketing Manager Simatic PCS neo, 

Siemens 




Radiometric system for multiphase level measurement 

Safe control of separation 

processes 

Processes which take place in aggressive atmospheres, at high pressure or extreme 

temperatures require technology that can withstand these conditions while delivering 

accurate results. Radiometric measuring systems convince with their non-contact, 

reliable and robust operation. The measurement of interfaces under extreme conditions 

is therefore an ideal application for systems such as Berthold’s Emulsionsens. 

The measurement of several phases, socalled 

multiphase levels, poses some challenges 

for the manufacturers of process 

measuring instruments. In addition to the 

often indistinct interfaces, these include the 

(sometimes only slightly) different phase 

densities. Multiphase level measurements 

are used wherever a live image of the highly 

complex separation process in a vessel is 

required in order to adapt certain process 

parameters. Separators, storage tanks, desalters 

and hydrocrackers are typical applications. 

It is clear from these diverse uses 

that multiphase level measurements are frequently 

employed in processes operating 

under extreme conditions, so that radiometric 

measurements are indispensable. The 

measuring principle is based on the attenuation 

of radiation when penetrating materials. 

This is virtually independent of other 

process conditions such as vessel size, buildups 

or internals. 

The Emulsionsens system gives users an 

opportunity to get a glimpse inside the process 

vessel and monitor the interfaces 

formed therein. The multiphase level 

measurement system consists of a combination 

of high-sensitivity scintillation detectors 

and low-activity gamma sources located 

along the desired measurement range. Based 

on the radiometry principle and suitable 

calibration, each detector delivers an individual 

local density value, which can be forwarded 

to the customer’s process control 

system by means of a Hart signal and used to 

create a density profile for the entire measuring 

range. The figure shows the measuring 

principle of Emulsionsens for a desalter and 

the resulting density profile. By mounting 

the detectors on the outer wall of the vessel, 

they are easily accessible and adjustable. 

Picture: Berthold Technologies 

Emulsionsens, shown here for a desalter and the resulting interface density profile 

One-time calibration of the system as part of 

initial commissioning is sufficient, in other 

words no recalibration is required. Since no 

mechanically moving parts are installed and 

the sensors are not in contact with the material 

to be measured, radiometric systems 

are wear-resistant and maintenance-free. Due 

to the curved dip tube which is used to position 

the encapsulated sources, the length of 

the measurement path is almost identical regardless 

of the position (


PRODUCTS 

Ultra-rapid mill with effective air cooling 

Picture: Retsch 

The ultra centrifugal mill ZM 

300 is Retsch’s flagship for 

high-speed size reduction. 

Thanks to the 1500 W powerdrive 

with enhanced performance 

the ZM 300 provides a 

maximum speed of 

23,000 min -1 , resulting in improved 

sample throughput 

throughout the whole speed 

range and higher final fineness. 

The active air cooling of the 

grinding chamber significantly 

reduces heat build-up during 

grinding, even at maximum 

speed. 

The ZM 300 is easily and conveniently 

operated via a 4.3" 

touch display, e. g. for storing 

grinding programs. A QR code 

in the display leads the user to 

the Myretsch web portal which 

provides a wealth of productand 

application-related in- 

formation. The ZM 300 is one of 

the first mills to be controlled 

via the optional app which 

allows for creating own application 

routines, accesses the application 

database and facilitates 

direct contact to the service 

team. 


Online search: cpp0319retsch 

Filters instead of fouling 

Flow measurement 

with added value 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GEORG SCHÜNEMANN GMBH 

Buntentorsdeich 1 - 28201 Bremen - Germany 

Phone: +49 (0) 421 55 909 0 - Fax: +49 (0) 421 55 909 40 

info@sab-bremen.de - www.sab-bremen.de 

The flow meter type 8098, part 

of the Flowave product family, 

has been further developed. In 

addition to precise flow 

measurement, it now provides 

additional information: for 

example, the integrated detection 

of gas bubbles allows rapid 

response in the event of process 

faults. The density factor enables 

quick detection of fluid changeovers. 

In addition, viscosity 

compensation enables precise 

measurements even with highly 

viscous liquids. Besides Bürkert’s 

own BÜS, the standard protocols 

Canopen and Industrial 

Ethernet (Profinet, Ethernet/IP, 

Modbus TCP) are supported for 

digital communication. The 

flowmeter operates according to 

the Surface Acoustic Waves 

(SAW) method, which uses surface 

waves for measurement. 

With this process, there are no 

installed fittings or constructions. 

In addition, there is no 

contact between the sensor elements 

and the medium, thus 

making the process ideal for hygienic 

applications. 


Online search: cpp0319bürkert 

Picture: Bürkert 


Picture: GEA 

Ceramic catalyst filter system 

GEA has developed high-temperature 

filters with ceramic elements 

that enable the removal 

of NO x , dioxins, mercury, and 

VOC through an integrated catalyst 

matrix. Biscat ceramic catalyst 

filters are chemically inert 

and corrosion-resistant. This 

means that for many applications 

only one single system 

is required instead of three. 

Particle separation takes place 

with the aid of filter elements 

made of mineral fibres, the socalled 

ceramic candle. These 

candles are very flexible to use 

even with regard to modifications 

of operating parameters, 

especially at high gas temperatures. 

No cooling of flue gases is 

required and no thermal heat 

energy is wasted. Filter elements 

are cleaned from separated dust 

online during operation by 

means of separate, compressed 

air jet pulses. The single or 

multi-sectional housings allow a 

maximum filter length of 6 m. 

This means that even large gas 

volume flows can be cleaned. 

The design of the system allows 

maintenance of the individual 

elements during operation. 

By injecting lime-based 

reagents, inorganic pollutants 

such as HF, HCl, SOx can also be 

absorbed. GEA has further developed 

the ceramic filter elements 

and enriched them with 

a catalyst. In addition to particles 

and acid gases, nitrogen 

oxides can thus be efficiently 

separated after prior injection of 

ammonia. This replaces the conventional 

selective catalytic reactor 

(SCR). 


Online search: cpp0319gea 

Every child 

is one of a kind and unique. Each child needs 

individual support according to their needs. 

Please help us by donating. Thank you! 

Tel.: 0800/50 30 300 (free of charge) 

IBAN DE22 4306 0967 2222 2000 00 

BIC GENO DE M1 GLS 

www.sos-kinderdoerfer.de 

2016/1 

Electropneumatic positioner 

The Samson positioners from 

the Series 3730 – Trovis 3730–1 

and Trovis 3730 3 for 4 to 

20 mA applications now combine 

the latest technological developments 

with the proven device 

base known from the Type 

3730–1 and Type 3730–3 predecessor 

models. Both positioners 

are particularly rugged 

thanks to their no-wear, noncontact 

travel sensing system. 

Two inductive limit contacts are 

available to reliably indicate 

both valve end positions. 

At the same time, the positioners’ 

air consumption has 

been reduced considerably by 

upgrading the pneumatics 

block. Operation continues to 

rely on the rotary pushbutton 

taken over from the successful 

Series 3730. Trovis 3730–3 

communicates over the Hart 7 

Picture: Samson 

protocol and comes with the 

Expertplus valve diagnostics 

with optimised features. To facilitate 

operation, the positioners 

are fitted with a plaintext 

display that indicates the 

condensed state according to 

Namur, measured values, startup 

settings as well as messages 

in English or German. Trovis 

3730–3 is additionally ready for 

interconnection with SAM 

Chemicals, the cloud-based 

business application for the process 

industry. 


Online search: cpp0319samson 

COG MAKES ITS MARK: 

Resistant from one 

extreme to the other. 

 

 

cpp 03-2019 

www.COG.de/en 

23


SPECIAL K 

Cryogenic size reduction of fine polymer powders 

Wide-chamber mill 

for 3D printing 

The Contraplex wide-chamber mill from Hosokawa Alpine has been adapted to the 

specific requirements of 3D printing. The CW 250 II features optimised grinding 

tools and temperature control, reducing liquid nitrogen and energy consumption. 

Tumbler screening machines or air classifiers are used for the required particle size 

distribution. 

Pictures: Hosokawa Alpine 

Many industrial sectors are focusing increasingly 

on additive manufacturing of 

components made of metal or polymers. Selective 

laser sintering (SLS) constitutes an 

important process for 3D printing of 

polymers. Fine polymer powders are sintered 

in a powder bed by means of laser to 

form three-dimensional objects. This printing 

process, however, calls for polymer 

powders with a particle size of around 

d 90 = 100 μm. Cryogenic comminution is 

one method applied for the production of 

such fine powders. In this case, polymer 

granules are embrittled by means of liquid 

nitrogen (LN 2 ) and then ground in a pin 

mill. The specific consumption of liquid nitrogen 

is a major cost factor. Hosokawa Alpine 

offers solutions to reduce this. Assuming 

an efficient classifier and mill exist in 

circuit, the product specifications can also 

be guaranteed and the operating costs minimised. 

Cryogenic size reduction 

The feed material must first of all be embrittled 

to enable cryogenic comminution. 

To this end, it is cooled in a screw cooler 

charged with LN 2 to a temperature of 

around -190 °C. The residence time in the 

screw cooler is selected such that the granules 

adopt this temperature right into their 

core. In order to make as efficient use of the 

liquid nitrogen as possible, LN 2 is constantly 

introduced into the granule bed along the 

entire conveying line. After being embrittled, 

the feed material is comminuted in 

The Contraplex CW 250 II wide-chamber mill features optimised grinding tools and temperature control, 

reducing liquid nitrogen and energy consumption 

a pin mill. The Hosokawa Alpine Contraplex 

wide-chamber mill CW 250 II is ideal for 

this task. The CW-II product line has been 

given a substantial redesign to make it fit 

for the demands posed by cryogenic size reduction 

of difficult feed materials. Two 

contra-rotating pin discs rotate in the mill at 

speeds of up to 120 m/s each at their outer 

periphery, allowing relative speeds of up to 

240 m/s to be realised. To compensate for 

the energy input caused by comminution, 

liquid nitrogen can be injected into the inlet 

area of the mill for further cooling. 

Optimised screw geometry 

As a result of the LN 2 injected, the mill outlet 

temperature can be regulated to a constant 

target temperature. This is important to 

ensure that the temperature of the feed material 

in the grinding zone is always significantly 

less than its glass transition temperature. 

Over and above this, it serves to prevent 

product deposits. Depending on the 

type of polymer, the standard temperature 

setting is between -20 and -50 °C. In the 

case of PA-6, it has been established that an 

increase in the mill outlet temperature from 

the standard -40 to -10 °C suffices to prevent 

the particles from starting to melt in 

the mill. The resultant lower LN 2 consumption 

naturally has a positive effect on the 

operating costs. 

With regard to the specific operating costs, 

cryogenic grinding is at its most efficient 

when the mill is charged with a maximum 

feed rate until the rated output of the mill 

drive is reached. Homogenisation of the 

product discharged from the screw cooler 

helps to avoid performance and/or current 

peaks. The feed material dosing can be 


Influence of the number of pins on fines and fines throughput 

adapted for higher throughputs without 

running the risk of high feed rate fluctuations, 

which would lead to undesirable 

current peaks and in the worst case bring 

production to a halt. Research projects 

aimed at optimising the product discharge 

by means of design measures on the screw 

cooler were carried out with the aid of DEM 

simulations and subsequently tested successfully 

at the testing centre. The greatest 

effect with respect to homogenisation was 

achieved by modifying the screw geometry 

at the outlet of the screw cooler. 

Adaptation to the pin discs 

Further optimisation of the operating costs 

is possible by aligning cryogenic grinding 

with the screening or classifying step, insofar 

as the target fineness cannot be achieved 

without downstream classifying. During 

grinding, the highest possible throughput 

of finely ground product – for example, less 

than 100 μm – should be generated and 

presented to the classifier. In principle, this 

enables a higher yield of end product. To 

this end, the design of the pin discs can be 

adapted accordingly and the mill operated 

at full load. Amongst other things, these 

modifications can include changes to the 

number and dimensions of the impact pins. 

By reducing the number of pins, the noload 

power decreases and the feed material 

can be charged to the mill at a higher rate. 

The lower stressing frequency leads to a 

somewhat coarser particle size in comparison. 

In spite of this, a higher throughput of 

fines smaller than 100 μm is nevertheless 

possible. Compared to just cryogenic grinding 

with the CW 250 II, the specific operating 

costs are moreover lower if the feed 

rates are higher. 

Intelligent system concept 

It is often only possible to produce polymer 

DEM simulation of the product outlet of the vortex screw cooler 

powders with the target specification d 90 = 

100 μm by means of a downstream classifying 

step using a screen or air classifier – or 

both processes in circuit with automatic return 

of the coarse material. Assuming an intelligent 

system concept for a circuit process, 

the liquid nitrogen that evaporates 

during cryogenic size reduction is perfect 

for direct use as circuit gas for the classifying 

step. This does away with the need for 

gaseous nitrogen, which would otherwise 

be required for the inert mode of operation. 

Routed in circuit, the nitrogen gas is free 

from moisture which could condense on 

the particle surface. This ensures that no additional 

conditioning of the gas is necessary 

for classifying. Agglomeration is prevented 

in this way. 

At a constant sharpness of cut of the classifier, 

the throughput of the end product is 

higher the finer the material. As a result of 

the improved fines yield, a correspondingly 

small amount of coarse material needs to be 

returned to the grinding process. The lesser 

amount of circuit material therefore has a 

positive effect on the total operating costs of 

the grinding and classifying circuit. Tests 

have shown that there is an optimum fineness 

at which the specific operating costs 

for the manufacture of polymer powders 

with a d 90 of 100 μm are at a minimum. For 

the tested PA-6, this results in an optimum 

operating point for the CW 250 II at which 

the generated fines portion


SPECIAL K 

Pictures: Keller Lufttechnik 

Aurora Kunststoffe currently operates five extruders that produce over 50 tons of recompounds daily. They expect demand to rise in 

the future, especially if there is a legally mandated recycling quota. 

Customised solution for clean air in plastics production 

Transforming a dusty 

process into a clean one 

Aurora, a manufacturer of plastic composites, transforms a dusty process into a 

clean one: production manager Alexander Schweinle selected Cleacom from Keller 

Lufttechnik – a customised solution for clean air in plastics production. 

Plastic is truly ubiquitous: depending on 

its formulation, the indestructible material 

takes on numerous properties and is utilised, 

for example, for office chairs, car door 

panels, cable ducts or foil tunnels. It has become 

indispensable in our daily lives. Today, 

however, the use of this neutral material has 

acquired a bad reputation. It has become 

synonymous with environmental disgrace. 

The industry requires new sustainability 

concepts. Aurora Kunststoffe GmbH from 

Neuenstein in north-eastern Baden-Württemberg 

has found a solution: The company 

repurposes recycled plastic granulate into 

quality new products. “The production of 

plastic parts results in about five per cent rejects. 

We purchase this industrial waste and 

transform it into a new, high-quality raw 

material,“ says Alexander Schweinle, production 

manager at Aurora Kunststoffe. 

Specialised knowledge required 

The Aurora experts first examine their raw 

material using spectral analysis in the laboratory, 

in order to precisely ascertain its 

composition. Then they grind the plastic 

parts into small pieces. Some of the ground 

material is re-sold directly, but the bulk is 

processed into first-class composite following 

the addition of molten additives in a 

new extrusion process, from which new 

materials can be produced. “We have the 

expertise and experience to master this process,“ 

reports Alexander Schweinle. “In our 

laboratory, new recycled plastic formulations 

are constantly being developed for a 

wide variety of applications. We test them 

directly with our own injection moulding 

machine.“ 

Increased production 

Alexander Schweinle is proud of his highly 

modernised compounding plant. “Our old 

building burned down in 2017, so we built 

a modernised, larger plant,“ says the production 

manager. “In February 2019, five 

extruders were put into operation instead of 

three. Completely expanded, the plant ac- 


The powdered raw material is processed with the addition of additives in a new extrusion 

process into a quality recompound from which new products can be manufactured 

commodates seven lines. We currently produce 

over 50 tons of compounds per day.“ 

Aurora expects demand to rise in the future. 

“I am certain that eventually there will be a 

legally mandated recycling quota,“ says 

Schweinle. 

Investment in clean air 

With the new factory, Aurora also invested 

in high-tech machinery. “Anyone familiar 

with the recycling of thermoplastics knows 

that it is a challenging and dusty business,“ 

says Schweinle. Visitors would be all the 

more surprised when they viewed the production 

at Aurora, where Keller Lufttechnik 

extraction systems ensure clean air. The 

plant looks splendid. “Anyone who demands 

a clean operation in our industry 

should consider Cleacom from Keller Lufttechnik,“ 

concludes Alexander Schweinle, 

who conducted extensive market research 

prior to his investment. Cleacom stands for 

Clean Compounding. Keller Lufttechnik developed 

this separation concept specifically 

for plastics manufacturers. It combines dry 

separation, which is used for weighing and 

mixing raw materials, with a wet separation 

system for the extrusion process. 

Dry separator for dosing scales 

In association with the production manager 

at Aurora, Thomas Nägele, project manager 

at Keller Lufttechnik, adapted the Cleacom 

technology to the specific requirements at 

Aurora. He says: “Where aggregates are 

weighed and added at the dosing scales, 

dust particles are created, some of which 

are highly reactive and explosive. We have 

equipped our Vario dry separator, to which 

all five lines are connected, with the constructive 

explosion protection ‚ProVent‘, a 

system for flameless pressure relief inside 

buildings.” The extraction system is already 

designed for any future expansion. Following 

demand, an integrated frequency inverter 

will automatically adjust the performance 

of the dust extractor, thereby reducing 

power consumption. If further dosing 

stations are added, the experts will merely 

supplement some collection units. 

Once the filter elements in the central system 

are contaminated with dust and a certain 

differential pressure is reached, a compressed 

air pulse ensures automatic cleaning. 

A filter change is only due after 15,000 

to 20,000 operating hours. “If necessary, we 

merely change the big bags which collect 

the dust,“ says Alexander Schweinle. Keller 

technicians inspect the system once a year. 

Wet separator for clean air 

The more challenging task is assumed by 

the VDN-TA wet separator, which ensures 

breathable air at the extruders. The ex- 



SPECIAL K 

Alexander Schweinle, production manager at Aurora Kunststoffe: “Visitors 

may be pleasantly surprised if they view the production at Aurora, where 

Keller Lufttechnik extraction systems ensure clean air.“ 

At the extruders, adhesive gases escape as well as dust. This challenging 

air cleaning task is solved with the VDN-TA wet separator, which improves 

air quality at the extruders and inside the plant. 

truders produce a homogeneous, molten 

plastic mass from the previously prepared 

formulation at high temperatures, which 

they press through fine openings. Long 

continuous plastic strands are formed, 

which are cooled with water and then 

broken into pellets. The material is dispersed 

using rotating screws before the 

finished granulate falls into a collection 

hopper. At the extruders, adhesive fumes as 

well as dust can escape. These emissions 

cannot be addressed by solely using dry 

separation. Alexander Schweinle confirms 

this: “The result of the dry separation in 

the old production facility was disastrous. 

The adhesive dusts coated each column of 

the separator, as well as in the extruder and 

inside the plant. Dust reformed soon after 

cleaning,“ he remembers. As a result of the 

wet separation process, the laborious 

cleaning task no longer plays a role today, 

and Aurora employees can devote more 

time to their core business and to quality 

control. 

Water mist absorbs adhesive dust 

“In order to keep the ductwork clean, we 

saturate the adhesive particles with water 

as soon as they enter the ductwork system. 

We use the Venturi principle to create a 

fairly even mist,“ says Thomas Nägele. 

When the contaminated air finally enters 

the separator, it is doused there by another 

Venturi nozzle. Using centrifugal force, the 

system then separates the fine water mist 

loaded with foreign substances from the 

air stream. In large plants such as Aurora’s, 

the water then flows into a huge holding 

tank where the impurities will settle. A 

sludge scraper clarifies the water, which 

can then be reused. 

“Keller Lufttechnik referred us to its 

partner Hebro Chemie for the correct 

handling of the waste water. The company 

advised us on measures to prevent the 

growth of microorganisms and reliably 

bind the impurities. This makes the water 

that we recycle very clean,“ says Alexander 

Schweinle. “What remains is about one 

bulk container of sludge per month, which 

we hand over to a specialised waste disposal 

company. 

Customised solutions 

The reason that the new Aurora production 

plant is so clean is due to the beneficial cooperation 

between Aurora and Keller Lufttechnik. 

“We co-designed the system and 

determined customised solutions for some 

special challenges,“ confirms Alexander 

Schweinle. For example, there was a seal on 

the extruder, located on the coupling between 

the blower and the material feed 

screw. “Although we tightened the seal 

regularly, fine powder always escaped. Previously, 

our employees would address the 

problem directly. Additionally, the powdery 

residue caked onto the warm surface of the 

extruder,“ explains the plastics expert. 

“Now we’ve installed a collection system at 

this point that immediately removes the 

dust and works perfectly.” 

Everything is operating smoothly 

Aurora operates six days a week, in three 

shifts intervals. To ensure that production 

does not experience a shutdown, the company 

relies on a functioning extraction system. 

“We conscientiously maintain the separators,“ 

says Alexander Schweinle. Saturday 

is designated for cleaning so that the process 

resumes smoothly again on Monday. 

The fan of the wet separator is equipped 

with a vibration sensor. This signals when 

the blower is not operating smoothly and if 

the fan impeller may either have to be 

cleaned or replaced soon. “Aurora thereby 

has adequate lead time to plan a shutdown 

for the exchange of spare parts that is compatible 

with the production schedule,“ explains 

Thomas Nägele. 

Alexander Schweinle is very satisfied with 

his decision to install Cleacom. “We primarily 

did this for our employees,“ he says. 

„However, I now see how the clean production 

at Aurora Kunststoffe also benefits our 

reputation with customers, suppliers and 

the general public.“ 


Online search: cpp0319keller 

Hall 11, Booth B31 

AUTHOR: 

MICHAEL HACK 

Marketing department 

Keller Lufttechnik 


Organic TPE based on sugar cane 

With Septon Bio, Kuraray is expanding its product range 

of TPE materials with a variant based on natural, renewable 

raw materials. The hydrogenated styrene farnesene 

block copolymer (HSFC) is particularly easy to process 

thanks to its very good flow ability and adhesion. It does 

not require any additional plasticisers and has a broader 

damping range than conventional hydrogenated styrene 

block copolymers (HSBC). Septon BIO series materials 

are based on beta-farnesene, a renewable monomer derived 

from sugar cane. In fermentation processes, proprietary 

yeast strains convert the sugar into beta-farnesene. 

The TPE raw materials are ideal for applications in adhesives, 

sealants, gels, films, and soft compounds and are 

used with their unique grip performance in the manufacture 

of handles, for example for sports equipment. 


Online search: cpp0319kuraray 

Hall 7a, Booth D6 

Picture: Kuraray 

High-performance additive for TPUs 

Picture: Wacker Chemie AG 

Wacker Chemie's new silicone 

additive for thermoplastic polyurethanes 

(TPU), named Genioplast 

Pellet 345, lowers the 

hardness of TPUs, while boosting 

their elasticity and enhancing 

their properties. The surfaces 

of molded parts modified with 

the additive are pleasantly soft 

to the touch and more resistant 

to scratches, abrasion and contamination. 

The new additive is 

readily incorporated into 

thermoplastic polyurethanes and 

has fewer undesirable secondary 

effects than conventional silicone 

products. 

Genioplast Pellet 345 can also 

be used for modifying other 

thermoplastic elastomers as 

well, for example the product, 

can markedly boost the properties 

of thermoplastic polyamide 

and copolyester elastomers. 

Genioplast Pellet 345 is a silicone 

copolymer and is processed 

like a thermoplastic. Organic 

polymer segments contained 

within Genioplast Pellet 

345 make it so compatible with 

thermoplastic polyurethanes 

that it disperses very finely and 

homogeneously throughout the 

polyurethane matrix. The copolymer 

becomes physically 

bound to the matrix and is 

therefore unable to migrate. In 

Europe, Genioplast Pellet 345 is 

authorised for food-contact applications. 


Online search: cpp0319wacker 

Hall 16, Booth F71 

See us in Dusseldorf: 

MESSE K 

Hall 10, Stand H 08 

October 16 – 23, 2019 

PROCESS 

TECHNOLOGY 

PELLETING FOR 

ECONOMIC 

COMPACTING 

AND SHAPING 

We constantly encounter bulk 

products and powdery materials in 

everyday life. They come in various 

particle sizes – from lumpy to powdery. 

Bulk products are processed in many 

industries, for example in the chemical 

and pharmaceutical industry. 

AMANDUS KAHL GmbH & Co. KG 

Dieselstrasse 5–9 · 21465 Reinbek 

Hamburg, Germany 

+49 (0) 40 72 77 10 

info@akahl.de · akahl.de 



SPECIAL K 

Perfomance-enhancing additives for PA 

At K 2019, Brüggemann presents 

its latest developments in 

performance-enhancing additives 

for both virgin polyamides 

and polyamide recyclates. The 

product variants range from efficiency-increasing 

flow enhancers 

for shorter cycle times 

and thinner wall thicknesses, 

through heat stabilisers for 

medium to very high temperatures, 

to reactive additives for 

the production of recyclates 

which match the quality of virgin 

materials. 

Bruggolen TP-P1810 for 

example allows a significant improvement 

in flow properties of 

polyphthalamides (PPA, such as 

PA6T, PA6T/6I, PA6T/6.6 etc.) 

while retaining overall mechanical 

property characteristics. 

Compounders and injection 

molders can thus significantly 

widen the processing window 

and combine high cost efficiency 

with application-specific optimisation. 

For example, it is 

possible with Bruggolen 

TP-P1810 to reliably produce 

and easily process compounds 

with very high fiber contents 

(e.g. 60 %). Producers and processors 

of the corresponding 

compounds will benefit from 

much shorter cycle times. Furthermore, 

both flow enhancers 

allow the production of large or 

complex parts with long flow 

paths and/or low wall thicknesses. 

With the heat stabiliser Bruggolen 

TP-H1805, Brüggemann 

offers the opportunity to stabilise 

fiber-reinforced aliphatic 

polyamides for long-term use at 

temperatures up to 200 °C for 

PA 6 or up to 230 °C for PA 6.6. 

This enables compounders to 

tailor-make products for applications 

in borderline areas that 

were until now the preserve of 

polyphthalamides or other 

high-performance polymers 

such as PPS. Injection-molded 

parts produced with this additive 

– for example air ducts and 

Picture: Brüggemann 

pipes in the engine compartment 

– offer excellent heat resistance 

over the entire required 

temperature range. Separate activation 

is not needed. 


Online search: 

cpp0319brueggemann 

Hall 8a, Booth D08 

Mixer for natural fibre compounds 

Vibratory feeders with automatic refill 

Picture: MTI Mischtechnik 

MTI Mischtechnik will be showing 

a heating/cooling mixer 

combination designed for processing 

natural fibre compounds 

(NFC). The mixing plant has 

been optimised for the production 

of Resysta material and the 

MTI Flex-line M 1000 / K 3300 

has a heating mixer volume of 

1101 l and a cooling mixer volume 

of 3308 l. A Vent tec 2.0 aspiration 

system ensures the dehumidification 

of the mixture. 

The Resysta material consists of 

about 60 % rice husks, rock salts 

and mineral oil. It can be processed 

like wood and thus opens 

up a wide range of applications. 


Online search: cpp0319mti 


Coperion K-Tron will display the 

redesigned K3 vibratory feeder 

in action as part of a recirculating 

system – with automatic refill 

provided by a P-Series vacuum 

receiver and a compact vacuum 

pump. K3 vibratory feeders 

are suitable for feeding recycled 

material or flakes as well as for 

the addition of glass fiber in 

compounding processes. They 

are practically maintenance-free, 

since there is no wear on the 

mechanical parts. P-Series vacuum 

receivers can be used to 

convey a wide range of bulk ma- 

terials. They are constructed of 

stainless steel and features include 

steep cone angles to ensure 

excellent discharge and band 

clamps for quick disassembly. 


Online search: cpp0319coperion 


Picture: Coperion 

New at the K 2019 fair, 

WITTE gear pumps in AT design. 

 

 

 

Hall 10, Booth E40 

Our competence for your success. 

Advanced Technology! The next evolutionary step for polymer pumps. 

 

 

 

 

 

 

 

 

 

30 cpp 03-2019 

Brian 

Industrial mechanic in the 

WITTE assembly workshop since 2006 

WITTE PUMPS & TECHNOLOGY GmbH 

Lise-Meitner-Allee 20 

25436 Tornesch 

Tel. 04120 70 65 9 -0 

www.witte-pumps.com 

sales@witte-pumps.de

Directly on the motor mounted servo pump 

Picture: Baumüller 

Baumüller's servo pump combines 

the advantages of hydraulic 

power transmission with 

the benefits of electric servo 

drive technology. The intelligent 

control of the drive and the low 

energy consumption of the components, 

especially in the partial 

load range, results in a highly 

energy-efficient and yet economical 

solution. And the latest 

enhancement of the servo pump 

solution offers further advantages. 

For example, the servo 

pump is mounted directly on 

the motor with an internal toothing, 

which has a shorter installation 

length and therefore a 

smaller machine installation 

area. Furthermore, direct mounting 

means that several mechanical 

parts are no longer required. 

Another advantage is the intelligent 

use of hydraulic oil as a 

lubricant for the gear tooth 

system. In both the motor and 

the constant pump, existing 

connections allow the hydraulic 

oil to be returned to the circulation 

system, thus allowing the 

leakage flow of the pump to be 

used for the permanent lubrication 

of the gear tooth system. 

There is no need for a grease 

lubrication of the internal 

toothing, which is required 

every 3000 operating hours on 

average. The machine can operate 

without interruption, thus 

increasing productivity. 

The motor can be installed horizontally 

or vertically, depending 

on the application. 



cpp0319baumueller 

Hall 11, Booth A41 

Infrared drum dryer for PET recycling 

Kreyenborg’s infrared rotary 

drum IR-Clean has been developed 

for the treatment of PET 

recycling material. Its tailormade 

geometry, the targeted 

process control and a special 

control unit make the IR-Clean 

especially suitable for drying 

and decontaminating PET recycling 

material. This has been confirmed 

by the American FDA 

Authority and by several challenge 

tests, which have proven 

conformity with the criteria of 

the European EFSA. After the 

drying and decontamination 

process the PET recycling ma- 

terial can be used for packaging 

that comes directly in contact 

with the foodstuff. Consequently, 

the IR-Clean itself, 

which works without any specific 

additional equipment and 

in a very energy-efficient 

manner, but also the material 

cycle it closes and which preserves 

resources without any loss 

in quality, both represent a 

sustainable solution. 



cpp0319kreyenborg 

Hall 9, Booth A55 

Picture: Kreyenborg 



SPECIAL K 

Cleanliness and health protection in the plastics industry 

The right vacuum cleaner 

for each material 

The global plastics industry is one of the main customers for Ruwac vacuum cleaners 

and extraction systems. There, where powders and granulates are processed on a 

large scale, powerful industrial vacuum cleaners are particularly important, as the 

examples described here show. 

The plastics industry has many applications 

for mobile industrial vacuum cleaners 

and stationary dedusting systems – from 

the dust created during production through 

granules of raw material to the powdery additives 

used for processing. The market is 

large enough to be worthwhile for manufacturers 

like Ruwac to specifically target it 

when developing new product series. 

The DA 5112 and DA 5152 mobile vacuum 

cleaners, which will be presented at K 2019, 

are two good examples here. They are 

specially designed for vacuuming large 

quantities of solid material, for instance 

when loading and storing plastic granules. 

This type of application requires a powerful 

drive. To meet this requirement, the vacuum 

cleaners are equipped with a side-channel 

compressor, which simultaneously contributes 

to their compactness. The motor has 

an output of 11 or 15 kW. 

Easy emptying, improved control 

Since the bin must be emptied quite frequently 

when vacuuming large quantities of 

material, the Ruwac designers made it very 

simple to remove. All the operator needs to 

do is press a lever. The bin, which is 

equipped with a tilting device, is then low - 

ered to floor level. It can be moved on its 

own casters and transported quickly and 

easily with the aid of forklift pockets. 

Not only the 150 litre bin and the drive but 

also the filter unit (a dust class M filter bag) 

has a large capacity to suit the target application 

for the vacuum cleaners. Cleaning 

can be carried out either manually or by 

Airshock. Due to its modular design, the industrial 

vacuum cleaner can easily accommodate 

an added residual dust filter for dust 

class H. Another feature of the two new 

models is the improved control system, 

Pictures: Ruwac 

In the plastics industry, there are many possible applications for industrial 

vacuum cleaners – here, a hazardous dust extractor for cleaning a system 

for the production of additives 

During filling, the granulate is collected and vacuumed off before it 

reaches the floor. It can then be reinserted in the transport chain 


machines and systems are rinsed with water 

to ensure no contamination occurs between 

individual pellets before packing. The plastic 

pellets thus collect in the pre-separator and 

the water in the vacuum cleaner itself. The 

pellets are then recycled and the water is 

disposed of in the company’s own wastewater 

treatment plant. 

A BRAND OF ITW ORBITAL CUTTING & WELDING 

The DA 5112 and 5152 type vacuum 

cleaners have been developed for 

vacuuming large quantities of material 

which monitors both the motor’s direction 

of rotation and its temperature and enables 

the vacuum cleaner to be switched on remotely 

(for example, when a production 

system is switched on). 

PC granules in a clean environment 

Depending on the conditions surrounding 

the application, there are other vacuum 

cleaner models which can also be used to 

vacuum granules. In the case of filling and 

silo logistics, when the systems are rinsed 

with water, an extractor for metal chips 

(used here for another purpose) can be the 

optimum solution. One example of this is 

the application at Chemion, a logistics service 

provider handling Makrolon polycarbonate 

manufactured by Covestro at Uer - 

dingen Chemical Park. 

Chemion operates a logistics centre with 

nearly 80 shipping and mixing silos for storing, 

filling and packing around 250,000 t of 

Makrolon per year. When handling these 

quantities, some pellets inevitably fall onto 

the floor. Since the pellets are small, hard and 

round, employees can slip on them, which is 

why they must be removed immediately. 

Ruwac SPS 35 and SPS 250 chip extractors – 

which were originally developed for a completely 

different purpose, namely vacuuming 

and extracting chips in the metalworking 

industry – are used here. 

Separation of liquids and solids 

A typical feature of this type of vacuum 

cleaner is the two-stage operation: the chips 

are extracted from the liquid part (normally 

cooling lubricants) and retained in a preseparator. 

This is also an advantage when 

vacuuming Makrolon pellets, because the 

Back into the transport chain 

A Ruwac DS 2520 L-B1 vacuum cleaner 

with pre-separator is used in another Chemion 

shop at Uerdingen Chemical Park. It is 

installed on a line for filling 900 kg sacks. If 

pellets fall onto the floor next to the container, 

they are collected in a tray underneath 

the machine and vacuumed away. The 

pellets are first of all fed into a customised 

pre-separator designed by Ruwac. They can 

then be filled into a big bag via a rotary 

valve. Clean Makrolon pellets that have not 

yet touched the ground are now returned 

directly to the transport chain, leading to an 

increased material yield. The vacuum cleaner 

hence contributes to the efficiency of the 

plastics logistics while the SPS chip extractors 

improve work safety and cleanliness. 

Use case: Additive manufacturing 

As many ingredients of plastics, compounds 

and masterbatches are obtained from organic, 

powdery materials, hazardous dust 

extraction systems are a common feature in 

the plastics industry. Other vacuum and 

extraction systems are required to manufacture 

and process CFRP or GFRP components 

such as rotor blades for wind turbines. The 

focus is on extracting dust and fibres which 

are hazardous to health – a field in which 

Ruwac has extensive experience and many 

reference installations. The same applies to 

additive manufacturing, a relatively new 

branch of plastics processing. Dedusting 

plays an important role here – also for occupational 

safety reasons – and Ruwac will 

be presenting suitable industrial vacuum 

cleaners and dedusting systems at K 2019. 


Online search: cpp0319ruwac 

Hall 11, Booth G3 

AUTHOR: 

GERALD SCHEFFELS 

Technology journalist 

ORBIMAT 

INTELLIGENT 

WELDING POWER 

SUPPLIES 

RPG 

TUBE SQUARING 

MACHINES 

GF/RA 

ORBITAL CUTTING & 

BEVELING MACHINES 

Visit us: 

BASEL | 24. - 27.09.2019 

Platform for Chemistry, 

Pharmacy and Biotechnology 

STAND D122 

HALL 1.1 

ORBITALUM TOOLS GMBH 

78224 Singen, Germany 

Tel. +49 (0) 77 31 792-0 

tools@orbitalum.com cpp 03-2019 33 

www.orbitalum.com


SPECIAL K 

Energy-efficient temperature control of stirrer tanks 

How to configure your 

heating and cooling system 

In the pharmaceutical and chemical industry, the use of stirrer tanks is routine. The 

reliable temperature control of the tank, however, poses several challenges for 

operators. This article explains what you need to know about configuring a 

temperature control system and how to make it energy-efficient. 

When it comes to the temperature control 

of stirrer tanks, indirect heating and 

cooling has become prevalent in the industry: 

this means a liquid heat carrier circulates 

between the product and consumer. 

The typical temperature control system consists 

of a circulation pump, heater, cooler, 

freezer, expansion vessel, temperature controller 

and consumer. Such a temperature 

control system, however, has complex 

requirements. To ensure the consistent 

quality of the products, local overheating or 

undercooling must be prevented. Thermally 

induced tensions can also have negative effects 

on the stirrer tank, which can be prevented 

by configuring temperature differences 

via the temperature control system. 

In terms of reproducibility, one of the most 

important requirements is the precise adjustability 

of the temperatures. This often 

requires an accuracy of 0.5 K or better. This 

temperature control is only possible with an 

integrated heat carrier for heating, cooling 

and freezing (monofluid system). 

Energy-efficient configuration 

Available primary energies like steam, cooling 

water or brine need to be harnessed and 

effectively integrated in such a system. The 

compound connection of the heat flow 

yields energy savings. Fast switching from 

heating to cooling is another basic prerequisite 

for temperature control systems in 

chemical reaction technology. When doing 

so, it is particularly important that the system 

is able to pass seamlessly through the 

entire necessary temperature range. A closed 

temperature control system also prevents 

corrosion and expensive downtime for 

maintenance or repair. The heat carrier 

liquid serves as an effective separating agent 

between the product and the environment, 

as the product cannot get into the primary 

systems, such as steam and cooling water, in 

the event of a rupture. Often, thermal oils 

are used as a heat carrier. The benefit: They 

can be operated within a broad temperature 

range almost unpressurized. All these 

requirements are fulfilled by a fluid circuit 

connected to primary energy sources, 

which is easily regulated as a closed temperature 

control system. In addition, the installed 

measuring technology allows precise 

balancing of the stirrer tank and primary 

energies. This enables extremely energy-efficient 

operation. 

For an energy-efficient configuration, it is 

important that the temperature control system 

and the stirrer tank are optimally compatible. 

This can be ensured by determining 

the heating and cooling curves of the stirrer 

tank. 

Pictures: Lauda 

Temperature control systems, like this one from Lauda, are suitable for use in pharmaceutical 

and chemical batch processes. Equipped with three heat exchangers, it is able to 

heat, cool or freeze a 16,000 l reactor. 

Selecting the heat carrier 

Selecting the optimum heat carrier is another 

important part of the configuration 

process. Often, it makes sense to compare 

different heat carriers within the complete 

temperature range. As shown by the two 

cooling curves, there can be considerable 

differences: Both thermal oils are approved 

for -20 °C. In the first case, a product temperature 

of 20 °C is reached after only three 

hours, while in the second case, it takes six 

hours. It is therefore extremely important to 


ENERGY-EFFICIENT: 

SECONDARY CIRCUIT UNITS 

Lauda secondary circuit units reliably 

control temperatures up to 400 °C and 

can be connected to in-house primary 

energies 

Cooling curves of an enameled 6,300 l 

double-jacket stirrer tank with two different 

thermal oils as a cooling medium. The 

graphic shows how important it is to 

choose the right heat carrier. 

Both thermal oils are approved for -20 °C. 

Nevertheless, the second medium takes 

twice as long to reach the required temperature. 

Systems that use primary energy 

are best suited to the temperature 

control of stirrer tanks. 

Heating and cooling systems 

from the TR series in the secondary 

circuit unit range consist 

of either one or multiple heat 

exchanger modules. They feature 

a direct media coupling or 

electric heater module. The additional 

letters, such as HKT, indicate 

the number of heating or 

cooling modules, as well as 

temperature control functions. 

These systems produce a temperature-controlled 

liquid flow 

and are designed as a compact, 

fully insulated, ready-to-connect 

system with control cabinet, 

completely pre-tested at the factory. 

The Lauda systems control 

temperatures from -150 to 

+400 °C and use water/glycol, 

thermal oil or special fluids as a 

heat carrier. Suitable primary 

energies are electrical energy, 

steam, hot oil, hot water, air, 

cooling water, cold oil or nitrogen, 

and energy is transferred 

indirectly via heat exchangers or 

electric heaters or a direct coupling. 

Every system is designed 

and constructed precisely to 

user requirements: processoriented, 

tailor-made and highprecision, 

while fulfilling the 

strictest safety standards. 

optimise the heat transfer. On the jacket 

side, there are several ways of going about 

this. For example, a heat carrier should be 

selected with optimal material properties 

for the process. The use of flow nozzles supports 

the heat transfer, as do welded halfpipes 

or the installation of spiral baffle 

plates on the double-jacket. The heating and 

cooling capacities determined from the 

heating and cooling curves serve as the 

basis for the configuration of the temperature 

control system. Three-way control 

valves provide high accuracy of control, 

easily getting to grips with even the tricky 

partial load range. The circulation pump is 

configured with the maximum heating and 

cooling capacities. Here the circulation 

quantity must be increased to ensure the 

high accuracy of the product temperature 

control, in order to reduce the Delta-T between 

the jacket inlet and the jacket outlet 

of the reactor. 

Detailed planning with experts 

Temperature control systems for stirrer 

tanks have multiple functions. As well as the 

ability to control the outflow temperature 

and product temperature, the setting of the 

maximum difference between the outflow 

temperature and product temperature – the 

Delta T control – also comes into effect. A 

protective enamel function ensures that the 

permissible temperature differences of the 

product and heat carrier are not exceeded. 

Another function of temperature control 

systems is to balance the heating and cooling 

capacity in order to collect important 

process data directly and optimise the process 

control. If large temperature fluctuations 

are to be avoided when switching 

from heating to cooling, it is recommended 

to use the temperature controller of the 

temperature control system in program and 

ramp mode. When it comes to detailed 

planning, there are further points to consider. 

For example, the installation site (indoors 

or outdoors) comes into play, as does 

the distance to the stirrer tank. In addition, 

the working temperature range of the heat 

carrier and product must be defined, the 

optimum heat carrier selected and the desired 

heating and cooling times specified. 

Experienced manufacturers of temperature 

control systems, like Lauda, will provide 

support with any questions. In our experience, 

no two projects are alike. 


Online search: cpp0319lauda 

Hall 10, BoothG39 

AUTHOR: 

FRANK KUFEN 

Project manager for heating 

and cooling systems, 

Lauda 



SPECIAL K 

Optimal powder dispersion 

All process steps 

in one machine 

Powders are used in the production of many different products. Whether in lacquers or 

paints, sealing compounds, adhesives or construction chemicals, food and cosmetics – 

the production of all these products requires the addition of powders into liquids. To 

achieve best results, the powder has to be dispersed perfectly. Using conventional 

agitators, mixers or dissolvers this is impossible or at least very difficult. However, 

there is a solution: The Conti-TDS from ystral inducts and disperses powders optimally. 

Main target in the processing of powder 

is its complete wetting, desagglomeration 

and homogeneous distribution in the 

liquid. The process starts with the transfer of 

the powder into the process tank, incorpo - 

ration, wetting and dispersion and finally 

ends with the homogenous distribution in 

the liquid. Ystral TDS machines are designed 

to handle all five steps in one single machine. 

The meaning of TDS is Transport and 

Dispersion System. This combination not 

Pictures: Ystral 

Conti-TDS between three 

process vessels 

only streamlines the overall process, but also 

reduces production costs and time. 

Dust-free handling 

Conventional powder addition from top 

into a process tank always creates dust. But 

TDS machines add the powder in a different 

way, they induct it with vacuum. The vacuum 

is created by the machine directly inside 

the liquid. This way the powder is incorporated 

dust free directly from bag, 

hopper or container. The dust-free induction 

is one of the key arguments to use that system. 

No powder is poured onto the surface 

of the liquid. No bag has to be lifted on top 

of the vessel. No dust sticks to the inner 

wall of the tank, and no powder is emptied 

onto the surface of the liquid in the presence 

of solvent vapour. 

TDS machines are available in two basic versions. 

The TDS-Induction mixer is installed 

inside the tank. It mixes homogenously and 

inducts the powder sub surface. The other 

version, the Conti-TDS, is installed in a loop 

outside the tank. Powder is inducted in line. 

Powder and liquid enter the machine via 

separate inlets and get in contact with each 

other not before reaching the high shear 

dispersing zone. Dispersion is carried out 

under maximum vacuum and high shear. If 

the powder concentration is low, it may be 

inducted completely in just one single pass. 

This method is used for example during 

filling a tank or transferring a product into 

another vessel. 

Since powder is inducted directly into the 

liquid, it can be inducted easily into flammable 

liquids as well. When using the term 

“flammable liquid” this is not quite correct: 

it’s a matter of fact, that the liquid itself is 

not inflammable, only the vapours above it. 

Using Conti-TDS the powder is inducted 

into the streaming liquid under vacuum. It 

does not get in contact with any inflammable 

vapour above the liquid. 

Wetting and dispersing 

Powder has a large specific surface. The 

powder in a normal 25 kg bag may have a 


Powders and liquids collide dust-free only 

in the dispersing zone of the Conti-TDS 

Conti-TDS module with process vessel on load cells and 

powder addition from a big bag station 

surface in the range from less than 

100 000 m² to more than a square kilometre, 

depending on particle size and structure. 

This huge surface has to be wetted 

with liquid completely. When powder is 

poured into the tank from above, it is added 

to a liquid surface of not more than a few 

square meters. Of course the powder is 

somehow getting below the liquid surface 

with the movement of the agitator, but the 

extreme mismatch of powder and available 

liquid surface causes the formation of agglomerates. 

These agglomerates have to be 

destroyed again. This takes time, requires 

energy and often destroys shear sensitive ingredients 

in the formulation. 

The Conti-TDS works differently: The vacuum 

expands the air between the powder 

particles and separates them on their way 

into the dispersing zone. The turbulence in 

the high shear zone increases the liquid surface 

a million times. This way every single 

particle is wetted completely without the 

formation of agglomerates. Normally the 

machine can be stopped after induction and 

the dispersion process is finished already. 

Not only for powders 

The TDS process is not restricted to powder 

induction alone; the same machines can be 

used for the dispersion of liquids into 

liquids as well. This is especially interesting 

for oil/water emulsions, but also, when 

liquids with totally different viscosities have 

to be mixed. In the production of adhesives, 

coatings and anti-perspirants for example 

high-viscous thickener concentrates have to 

be mixed into a low viscous basic liquid. In 

a normal agitated tank, the gel swims on the 

top or sticks to the wall. Real homogenous 

distribution is very difficult to get and takes 

long. Using the Conti-TDS the high viscous 

gel is dispersed into the liquid inline, meaning 

when it reaches the process tank it is already 

homogeneously dispersed. 

The opposite problem is mixing low viscous 

additives into very high viscous dispersions 

or pastes. The low viscous components remain 

on the surface of the high viscous material. 

With the agitator or dissolver you 

simply don’t get it in. You can see the low 

viscous material standing on the high viscous 

mix. Here, as well, the Conti-TDS provides 

immediately a homogeneous dispersion 

in the external recirculation loop. 

Rheological additives 

One of the most difficult and tricky field is 

the addition and dispersion of rheological 

additive powders. Rheological additives like 

thickeners or stabilisers are used to create a 

specific flow behaviour and texture in the 

final product. They prevent the product 

from separating and the dispersed ingredients 

from sedimenting or floating. They 

come as a powder, either inorganic or organic, 

and have to be dispersed into a liquid 

to create the required rheology. To achieve 

their maximum effect, they require a colloidal 

dispersion in the liquid phase. 

Because of their strong thickening effect, 

they are used in low concentrations only. 

They tend to form lumps and agglomerates 

which have to be broken down again. In a 

conventional powder addition, the product 

has to be further dispersed until all lumps 

are destroyed. Swelling and hydration of 

these powders starts immediately upon their 

first contact with water. They develop shearsensitive 

polymer structures and form gels. 

But from this point on, any further shear 

destroys the gel structure and reduces the 

thickening effect. Already hydrated gel is 

damaged. Finally, more powder has to be 

added since a part of the thickener is destroyed 

again by agglomerate dispersion. 

But Conti-TDS machines work in a different 

way. In the dispersing zone, the powder particles 

get in contact with the liquid under 

maximum turbulence and they are completely 

wetted on an individual basis and 

colloidally dispersed. At this moment the 

powder is not yet hydrated and therefore it 

is not yet sensitive to shear. The Conti-TDS 

wets and disperses every single particle. Agglomerates 

do not occur. Further subsequent 

dispersion when the gel gets shear 

sensitive is not required. 

Conti-TDS machines are available in different 

sizes, with a power spectrum ranging 

from 3 to almost 300 kW. Depending on the 

application, they can be equipped with a 

variety of powder inlets and tools. Optimum 

equipment for powder handling and 

dosing comes with the system. 


Online search: cpp0319ystral 

Hall 9, Booth E36 

AUTHOR: 

DR. ING. HANS- 

JOACHIM JACOB 

Process and Application 

Engineering, 

Ystral 



PROCESS ENGINEERING 

Smart controller paves the way for Filtration 4.0 

Networked filter 

technology for the future 

Wolftechnik has developed an intelligent filter system with the support of Mittelstand 

4.0-Kompetenzzentrum Stuttgart, a centre dedicated to supporting SMEs. 

This smart filter monitors its operating parameters and is therefore able to detect 

problems in the process at an early stage, so that servicing can be scheduled as the 

need arises. This reduces the number of unscheduled disruptions and helps minimise 

the costs for stocking filter cartridges. 

For manufacturers, Industry 4.0 means 

higher output, as all information is available 

in near real-time, allowing completely new 

approaches to the control of production 

systems. For this to work, the production 

systems must be able to generate reliable 

and contextual information from a wealth 

of data and make it available to people, machines 

and IT services. Wolftechnik Filtersysteme 

GmbH & Co. KG is heavily involved 

in the development of networked technology 

and future-proof solutions for industrial 

manufacturing. With the support of 

Mittelstand 4.0-Kompetenzzentrum Stuttgart, 

the filter system specialist has now designed 

a smart filter. At its core is a smart 

controller that collects and processes all relevant 

parameter data for the filter system’s 

pressure vessels. In November 2018, a 

prototype of the controller passed all tests 

with flying colours and was subsequently 

integrated into a Wolftechnik filter system. 

Advantages of the smart filter 

Smart filter controllers monitor a number of 

operating parameters such as pressure, temperature 

and flow rate or volumetric flow. A 

log file is kept of all data recorded and 

transmitted. Filter-specific information regarding 

spare parts and replacement filters 

is stored in the operator’s IT system, where 

digital maintenance and inspection schedules 

are generated. In addition, operators 

have the option of storing user instructions 

for maintenance, servicing and filter 

changes, so that personnel can call up texts 

and images to guide them through the procedures. 

This set-up not only facilitates correct 

installation; it also makes sure that 

A dashboard enables users to 

manage the entire filtration 

process via a single interface, 

where parameters can be 

configured and monitored 

and data backed up and restored. 

The dashboard also 

provides access to user manuals 

and other documents. 

Picture: Wolftechnik 


Picture: Wolftechnik/Fraunhofer IPA 

Picture: Martin Wolf Wagner 

The IT concept: smart filters read the sensor values and send them to the gateway. They also control the 

sensors by means of commands (local decisions are possible as well). Both the end user’s smart filters 

and the service provider’s systems can be integrated into a public or private cloud. 

Designing a platform that can be configured 

with control variables to cater for any filter 

system and process was one of the key objectives 

of the development project. The QP- 

Quick-Pack filter system, too, can be operated 

as a smart filter. 

maintenance and servicing tasks, including 

filter changes, can be performed quickly 

and safely. 

Thanks to the near real-time availability of 

information, the solution allows a completely 

new approach with regard to filter 

system organisation and control. With smart 

filters, it is possible to exchange operating 

data with external service technicians, e.g. 

specialists from Wolftechnik. Based on the 

data collected, they can analyse and diagnose 

faults quickly and rectify problems 

without delay. Apart from innovative services 

such as automated spare parts ordering 

and notifications, the system also enables 

preventive maintenance and optimised production. 

Supporting the production process 

An example from the paint industry illustrates 

the advantages of intelligent, networked 

filter systems. Before varnishes are 

filled into containers for end consumers, 

they are passed through a filter to ensure 

that the containers are not contaminated 

with substances originating from the production 

process. For this purpose, a 

WTGDS-type cartridge filter housing or a 

filter housing for the QP-Quick-Pack filter 

system is installed. These housings have the 

added benefit that particles collected by the 

filter remain in a protective bag, doing away 

with time-consuming cleaning. Under certain 

circumstances, both cartridge filters 

and QP-Quick-Pack filters could become 

clogged before the varnish to be filled into 

a container has passed through them. Less 

and less product leaves the filter until eventually 

the filling process comes to a halt. At 

this point, a frantic search normally starts 

for spare cartridges. Provided that these are 

actually available on site in the required 

quantity, the next step is a hurried filter 

change, so that the filling process can resume 

as soon as possible. 

Wolftechnik’s smart filter featuring a smart 

controller unit continuously monitors the 

pressures at the input and output of the 

filter system (differential pressure). This intelligent 

technology helps reduce downtime 

in the production process. As the filter load 

is constantly monitored and preliminary 

warnings are generated the moment there is 

a change in pressure, the operator can prepare 

for a filter change as appropriate without 

interrupting the flow of varnish. The 

smart filter also permits optimised stock 

management because orders for spare parts 

and consumables are generated directly by 

the system based on actual needs. 

Development of the smart filter 

Wolftechnik cooperated on the development 

of the smart filter with Mittelstand 

4.0-Kompetenzzentrum Stuttgart. This 

centre is an initiative of various institutions 

in the region that have bundled their competences 

in a number of fields. One of the 

partners is the Fraunhofer Institute for 

Manufacturing Engineering and Automation 

IPA, whose experts designed the IT concept 

and the smart controller for recording and 

transmitting sensor data while Wolftechnik 

provided the filter technology know-how. 

Designing a platform that can be configured 

with control variables to cater for any filter 

system and process was one of the key objectives 

of the development project. Additional 

sensors combined with micro controllers 

and a suitable cloud infrastructure 

had to be put in place in order to realise it. 

At the heart of the intelligent filter system is 

the smart filter controller. This micro controller 

unit (MCU) controls communication 

with the sensors and the gateway of the end 

user environment. The gateway consists of a 

PC that is part of the local IT network. The 

filter controller transmits sensor values such 

as pressure and temperature to the gateway 

and also processes commands, for instance 

to adjust the sensor sampling rate. Through 

the gateway, the system is connected to the 

Internet, so that the aggregated sensor readings 

can be sent to a database in the cloud. 

Users can monitor the state of the filter and 

its operation on a visualisation screen or 

dashboard. A specially designed application 

known as Filter Assessment Service monitors 

the filter parameters and makes smart decisions 

based on the sensor data. 


Online search: cpp0319wolftechnik 

AUTHOR: 

PETER KRAUSE 

Managing Director, 

Wolftechnik Filtersysteme 




Picture: VTA 

VTA vacuum distillation plant 

Roots pumps for vacuum distillation 

Tailored to the application 

Vacuum distillation is used to separate temperature-sensitive substances gently, for 

example in thin-film vaporisers and short-path evaporators. Maintaining the exact 

vacuum pressure required in the vaporiser is vitally important for the quality of the 

separation process and imposes considerable demands on the vacuum control 

system and the vacuum pumps used. In practice, the Roots pumping stations in 

Pfeiffer Vacuum’s Oktaline series have proven to be the ideal solution. 

Many organic substances have a boiling 

point higher than 200 °C or are temperature-sensitive, 

and in this case vacuum distillation 

is the preferred separation method. 

Especially with temperature-sensitive products, 

the dwell time in the vaporisation device 

is an important aspect. 

In many cases, batch distillation in a reactor 

is unsuitable due to the dwell time, which 

can extend to hours, and because not 

enough vacuum results from the fluid column 

in the vessel. A fill level of 10 cm, for 

instance, means a density-dependent pressure 

of about 10 hPa. For this reason, thinfilm 

vaporisers and short-path evaporators 

are used in industrial applications. In these 

cylindrical systems, a very thin film (thickness 

1 to 3 mm) of the liquid to be vaporised 

is applied to the inside surface of the 

heated cylinder using rollers or wiper 

blades. Depending on the size of the system, 

the dwell time may be only a few seconds. 

Thin-film vaporisation works best within a 

pressure range from 1 to 100 hPa. Lower 

pressures are difficult to achieve due to 

pressure losses in the vaporous substances 

flowing from the device to the condenser. 

However, pressures in the region of 

0.01 hPa are required for the separation of 

mono-, di- and triglycerides, for example. 

In this case, the so-called short-path distillation 

method is chosen. The condenser is 

located at the centre of the cylindrical 

vaporiser and the distances between the hot 

wall and the water-cooled pipe coil are in 

the order of a few centimetres, depending 

on the size of the device. Pressure losses are 

minimised because the material to be evaporated 

condenses directly on the cold surface. 

Since the mean free path of a molecule 

in a medium vacuum is similar to, or significantly 

greater than, the distance between 

the cylinder and the internal condenser, this 

method is also referred to as molecular distillation. 

If the vapour pressures of the substances to 

be separated are very close together, vacuum 

rectification columns are used. In these 

counter-current distillation systems, the vapour 

flows through a vertically aligned column 

to the condensed liquid. Installations 

such as structured packings ensure good 

mixing of the two phases, so that a phase 

equilibrium can be achieved. The dwell 

times and pressure levels are higher than 

with thin-film vaporisers, however. The two 

processes are often combined. 


Picture: Pfeiffer Vacuum 

Picture: Pfeiffer Vacuum 

Three-stage pumping station for distillation 

processes 

Okta 500 Atex: Roots pumps with a pumping speed of 280 to 670 m 3 /h 

Roots pumping stations 

Maintaining the exact vacuum pressure 

required in the vaporiser is vitally important 

for the quality of the separation process and 

imposes considerable demands on the vacuum 

control system and the vacuum pumps 

used. 

Pfeiffer Vacuum therefore offers a large selection 

of suitable vacuum equipment for 

thin-film and short-path distillation. In 

practice, Roots pumping stations with 

liquid ring pumps have proven to be the 

ideal solution. Depending on the number of 

Roots piston stages, a pressure of 10 –3 hPa 

can be achieved without much effort. It is 

also possible to operate the liquid ring 

pump with the substance that needs to be 

distilled. One example involves processing 

rolling oil. The oil contaminated by the rolling 

operation is reprocessed by distillation. 

For this, three-stage Roots pumping stations 

consisting of two Roots pumps and a liquid 

ring pump are used. The rolling oil to be 

distilled serves as the operating liquid for 

the liquid ring pump. At a pressure of approximately 

5 hPa, the rolling oil evaporates 

and is condensed in the downstream condenser. 

The possibility of leakage air saturated 

with oil vapours being sucked into the 

vacuum pump system, where these vapours 

are then condensed again in the liquid ring 

pump, cannot be completely ruled out, 

however. Yet if the rolling oil is used as the 

operating liquid, this will have no negative 

effects on the pump’s throughput. The level 

of the liquid in the circulatory container of 

the liquid ring pump rises slowly. When the 

maximum permitted level is reached, the 

operating liquid is automatically discharged 

and fed to a suitable treatment process. Depending 

on the application, dry backing 

pumps can also be employed instead of the 

liquid ring pump. 

Complete range 

Based on its comprehensive range of products, 

Pfeiffer Vacuum offers customised solutions 

to create the vacuum conditions 

required for a variety of applications. Especially 

where applications in the chemical 

industry are concerned that require a pressure 

of less than 33 hPa, the Roots pumping 

stations in Pfeiffer Vacuum’s Oktaline series 

have established themselves as ideal solutions. 

Depending on the required pumping 

speed and ultimate pressure, different 

pumping stages can be built in. Roots 

pumps with a pumping capacity of 

145 m 3 /h to 8000 m 3 /h are available as 

standard. In special cases, Roots pumps with 

a pumping speed of up to 25,000 m 3 /h can 

be manufactured. 

The gas circulation-cooled version of the 

Oktaline allows compression to ambient 

pressure and is used predominantly in critical 

processes in the chemical industry. The 

standard pumps are made of spheroidal 

graphite cast iron (GGG40), which ensures 

the high pressure shock resistance (16 bar) 

of the pump housing. This is particularly 

important for Atex applications. For highly 

corrosive applications, the Oktaline can be 

made of stainless steel. It is also possible to 

apply a plasma-polymer coating to the parts 

of the suction chamber that come into contact 

with the product. More demanding 

pump tightness requirements are met with 

the aid of magnetically coupled drives with 

leakage rates of less than 1 · 10 –6 Pa m 3 /s. 


Online search: cpp0319pfeiffervacuum 

AUTHORS: 

DR. STEFAN ZABESCHEK 

Application- & Project Manager Industry market 

segment, 

Pfeiffer Vacuum 

INGO HEITZ 

Industry market segment, 


MEIKE STRASHEIM 

Industry market segment, 





Compressed air management: service tool and app for compressors 

In the age of Industry 4.0 

The Boge connect service tool is tailored to the entire life cycle of a compressor, 

from partially digitalised commissioning and comprehensive monitoring to extended 

service functions and automatically generated optimisation proposals. All important 

operating parameters are recorded, monitored and visualised without paper. Boge 

connect replaces the airstatus option and will in future be available as standard for 

all 45 kW compressors and higher. 

Intelligent analysis and optimisation options 

are of fundamental importance for the 

efficient and future-oriented operation of 

compressed air systems. The compressed air 

expert Boge offers extensive services for this 

challenge. The currently available Boge airstatus 

option, for example, allows up to 32 

components of a compressed air system to 

be analysed, controlled and evaluated. The 

data is available almost in real time. With 

the development of the Boge connect service 

function, the family-owned company 

from Bielefeld goes one step further. With 

the associated app, the tool provides an 

ideal basis for networking intelligent systems 

and is therefore an important building 

block for Industry 4.0 processes. Boge connect 

offers clear visualisation of all data and 

reduces the administrative effort for dealers 

enormously. The service function accompanies 

the machine throughout its entire 

life cycle. In conventional commissioning, 

for example, the dealer collects data from 

the nameplate and other system parameters 

and, in many cases, records the details manually 

in documents. With Boge connect, 

commissioning is faster, easier and paperless. 

The manufacturer stores machine data 

in a QR code and attaches it to the machine. 

The Boge connect app scans the QR code 

and makes all relevant data available immediately 

in digital form. In addition, the 

tool supports the maintenance of compressors. 

In good time and before any mainte - 

nance is due, the responsible service employee 

receives a notification by SMS or 

e-mail. This leaves enough time to order 

machine parts, prepare maintenance quotes 

and schedule an appointment with the customer. 

Maintenance intervals, commissioning 

data and other information are stored in 

a digital machine file, which can be accessed 

from anywhere via password-protected 

log-in. In addition, the employee can 

use a machine-specific checklist to carry out 

maintenance work. 

Pictures: Boge 

Boge connect captures, monitors and visualises all important operating parameters 

paperlessly and available from anywhere 

Warranty and remote access 

All important operating parameters are re - 

corded, monitored and visualised via Boge 

connect. The service can be used for one 

compressor as well as for a system consisting 

of several compressors. If the service 

agreement covers several compressors, these 

are marked in colour on a digital map. This 

way you can see immediately which compressors 

are operating smoothly, which ones 


equire maintenance, and which ones have 

malfunctioned. All machines equipped with 

the service tool have a warranty of five 

years. The warranty includes professional 

service by certified service technicians as 

well as the use of original wear parts and 

operating materials. If the customer reports 

a problem with a machine, the service technician 

can immediately retrieve all machine 

data via the tool. This new service program 

therefore leads to more efficient technical 

support. If the customer agrees, the system 

can be accessed directly from a distance 

using the remote access function, for 

example to change parameters or carry out 

a software update. 

Smart solution 

Beyond the simple analysis of data, additional 

functions are required in the age of 

increasing digitalisation and networking. 

This includes, for example, precise predictions 

of the time of occurrence of a potential 

malfunction. The Boge connect portal 

enables both service technicians and dealers 

to obtain information on the condition of 

the systems at any time: The performance 

data is continuously analysed in order to 

identify leaks and potential savings. By 

evaluating large and heterogeneous amounts 

of data, such as a specific correlation of 

pressure, temperature, vibration and other 

key figures, errors and operating anomalies 

can be detected at an early stage. Machine 

maintenance can be proactive, reducing the 

risk of failure and minimising downtime. 

The machine control focus control 2.0 calculates 

the efficiency of the system and 

shows the ratio of load to idling speed. This 

can be used to establish whether the machine 

may have been incorrectly dimensioned 

or set up. The analysis takes place 

automatically, without the service technician 

having to actively display and evaluate 

the data. This increases the service life of the 

system and avoids damage. The intelligent 

data analysis ensures that the system is always 

operated according to the state of the 

art. 

Picture: Boge 

The digital map shows which compressors are running smoothly and which require maintenance 

The machine control focus control 2.0 

automatically calculates the efficiency of 

the system 

Wide range of use 

All screw compressors with an output of 

over 45 kW will in future be equipped as 

standard with the necessary hardware. Older 

or smaller models can be easily retrofitted. 

The basic functions of Boge connect - visualisation, 

service notification and use of 

the app - can be used free of charge. Additional 

functions, such as predictive maintenance, 

live view of consumption and payper-use 

can be booked optionally. The prerequisite 

for using Boge connect is good 

mobile phone reception. Boge connects the 

service program directly with the focuscontrol 

2.0 machine control of the compressors. 

Data transmission is carried out via 

the Modbus TCP or Modbus RTU protocols. 

The portal also allows third-party products 

to be integrated into the system; however, 

some functions may then be limited. 

Oil filter change on the compressor: 

continuous monitoring with Boge connect 

increases planning reliability 

Classic win-win situation 

Boge connect visualises and networks not 

only machine data. The service tool offers 

both dealers and manufacturers added value. 

Continuous monitoring along with early 

fault reports and proactive maintenance lead 

to increased planning reliability for the 

service technician. Regular maintenance ensures 

that the warranty conditions are met. 

In addition, dealers benefits from the automatic 

display of potential savings, allowing 

them to operate the customer‘s system 

highly efficiently. Thanks to the detailed 

analyses, the compressed air expert is provided 

with important information regarding 

the further development of its compressors. 


Online search: cpp0319boge 

AUTHOR: 

MARKUS HENKEL 

Team Leader Aftermarket, 

Boge 




Picture: BillionPhotos.com – Fotolia.com 

Compressed air is an important medium in the chemical and pharmaceutical industries and is used, for example, in the manufacture 

of pharmaceuticals 

Cloud solution captures and visualises compressor and compressed air system data 

Digital transparency on 

compressed air treatment 

There is considerable demand in the market for forward-looking digitalisation of 

processes related to compressed air treatment. This calls for innovative and useroriented 

solutions that support increasingly networked machines as well as Internet 

of Things technologies. There is no alternative for users seeking maximum possible 

transparency on their compressed air treatment processes or on their compressed 

air quality in everyday operations. 

Industrial companies that use compressed 

air in their production processes need maximum 

possible transparency when it comes to 

compressed air treatment. The chemical and 

pharmaceutical industries in particular demand 

to be informed about compressed air 

quality at all times to be able to react quickly 

to deviations. This is because compressed air 

is employed in many sensitive applications 

and often comes into contact with the product 

directly – from tabletting or cleaning systems 

and containers through component 

transport and packaging systems to air curtains 

for defining safe and clean areas. In 

order to ensure safe and stable processes and 

products, companies in this sector are reliant 

on a constant supply of absolutely oil-free 

and sterile compressed air. The compressed 

air quality must be comprehensively monitored 

for this purpose. 

Seamless quality control 

If the compressed air is contaminated by oil 

particles, germs or moisture, for example, 

this can have a decisive influence on the 

manufacturing process and cause considerable 

damage. Contaminated compressed air 

in tablet production can lead to breakage or 

colour variations and pose health risks for 

end users. To guarantee safe applications, it 

is important to treat the compressed air 

using filtration, drying and catalysis technology 

and monitor it continuously. 

Pfizer Manufacturing Deutschland GmbH is 

a pharmaceutical company which relies on 

continuous quality controls of compressed 

air. The medium is in direct contact with the 

drug during coating, i. e. when the protective 

layer is sprayed onto film tablets, as 


well as during blow-out processes on 

production machines. Pfizer monitors the 

residual oil content using measurement 

technology with an integrated alarm 

system, enabling countermeasures to be 

initiated before the defined limit values are 

exceeded and resulting in higher overall 

process reliability. 

Monitoring the compressed air system 

Intelligent measurement technology 

provides companies using compressed air 

in their production processes with the 

transparency they need to manufacture 

safely and reliably. Measuring systems from 

Beko Technologies GmbH, for example, let 

users continuously record key compressed 

air parameters such as residual oil vapour 

content, pressure and relative humidity and 

keep an eye on the compressed air quality at 

all times. They can then react quickly to any 

quality deviations and design more energyefficient 

compressed air systems overall. 

They are supported by individually adjustable 

alarm functions, which forward important 

information via various channels 

such as text messaging or e-mail. 

When monitoring compressed air quality 

The quality of compressed air can be continuously monitored using intelligent measurement technology 

systems – for safe and stable production processes 

and setting up an efficient treatment 

process, it is vital to take a holistic view of 

the compressed air system – including the 

compressor required for compressed air 

generation. This is because oil-lubricated 

and even oil-free compressors can be a 

source of residual oil vapours in the compressed 

air network. Although a compressor 

which compresses without oil does not 

allow any additional oil to enter the compressed 

air network, it also does not afford 

absolute safety since impurities such as oil 

aerosols or microorganisms are already 

contained in the intake air or can get into 

the compressed air network through other 

components. “Against this background, as a 

specialist for compressed air treatment and 

monitoring, we have once again addressed 

Picture: Beko 

Rethink your 

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The production of plastics involves the use of numerous 

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and granulates are dissolved, completely wetted 

and dispersed are high-quality products created. 

ystral develops and manufactures customized process 

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Picture: Beko 

Metpoint MEQ – the data assistant for total visualisation of compressed air systems 

current clamps, making it possible to record 

compressor energy consumption in real 

time and demonstrate efficiency increases 

transparently in the entire compressed air 

system. 

Together with the information from the 

compressed air quality sensors, all data is 

visualised in a cloud GUI. Users can hence 

check the condition of their compressed air 

system anywhere at any time and retain full 

control over the system and compressor 

data. If required, an automated energy or 

quality report can be called up at the touch 

of a button in order to analyse the efficiency 

potential. Compressor operating hours can 

also be viewed centrally. Servicing and 

maintenance cycles can be planned more 

efficiently as a result with the help of automated 

reports and notification functions. 


Online search: cpp0319beko 

the central issue of optimum transparency 

in the compressed air treatment process”, 

says Yannick Koch, Head of Global Corporate 

Development at Beko Technologies. 

Data assistant enables full control 

The company, based in Neuss (Germany), 

has consequently expanded its measurement 

technology solutions with Metpoint MEQ, 

thus taking a further step towards energy 

efficiency and digital transparency. The data 

assistant not only records the data of the 

treatment plant but also the energy and performance 

data of the upstream compressors. 

The system measures the real current consumption 

at these compressors by means of 

AUTHOR: 

FRIEDERIKE WAGNER 

Freelance specialised 

journalist 

INTERVIEW: 

METPOINT MEQ DATA ASSISTANT 

Picture: Beko 

Yannick Koch, Head of Global Corporate 

Development at Beko Technologies 

Mr. Koch, Beko Technologies 

has added the Metpoint MEQ 

data assistant to its measurement 

technology family. How 

did this idea come about? 

Koch: The idea for the product 

originated in an interdiscipli - 

nary working group called 

Products & Services 2020 and 

led us to consider how best to 

provide compressed air users 

with maximum possible transparency 

on their compressed air 

preparation process while leveraging 

the opportunities arising 

from digitisation. This thought 

process resulted in a cloud solution 

that was unveiled at this 

year’s Comvac in Hannover. 

What does the “Q” in the product 

name stand for? 

Koch: The aim of comprehensive 

compressed air treatment, 

which we enable with our 

solutions, is always to ensure 

the compressed air quality 

required for a particular application 

– hence the “Q” in the 

product name. The quality of 

compressed air and continuous 

monitoring play an important 

role for our customers because 

they have an enormous influence 

on their manufacturing 

processes and the quality of 

their end products. 

The new measuring technology 

system is characterised in particular 

by a holistic view of 

compressor and compressed air 

treatment system and a digital 

alignment. How did you consider 

these aspects in the deve - 

lopment of the solution? 

Koch: We cooperated with experts 

from the energy and com- 

pressor sectors during the deve - 

lopment process and bundled 

their expertise with our knowhow. 

About two and a half years 

passed from the idea to the market-ready 

product in line with 

our quality standards. Apart 

from developing an intelligent 

measurement system, we also 

wanted to offer our customers 

even better service. We therefore 

addressed aspects such as mobile 

connectivity, software as a 

service and online support in 

the course of the development 

project. The digitally oriented 

business model which was the 

outcome of all this meets 

customers’ need for self-information 

independent of place 

and time as well as support on 

demand. 




Gentle pumping of pastes and non-flowable substances 

Drum emptying system 

with follower plate 

Even high viscosity pumps come to their application limits very fast, when trying to 

pump high-viscous, non-flowable substances. The newly developed drum emptying 

system with follower plate from Lutz exceeds these limits and the infinitely variable 

operation enables particularly gentle pumping of pastes and non-flowable 

substances in the food, pharmaceutical and industrial sectors. 

The drum emptying system is supplied on 

a mobile trolley, which ensures maximum 

mobility and flexibility. The ergonomic design 

simplifies the operation for the user. A 

simple and convenient control system enables 

the commissioning. The manual, infinitely 

variable control of the FDA-compliant 

hydraulics gently deposits the follower plate 

on the medium. The conveying speed is infinitely 

variable and the containers are emptied 

almost pulsation-free. 

Sealing lips made of EPDM (also available in 

FKM or PTFE) adapt perfectly to the container. 

Due to the pressureless guidance, the 

pumped medium is not pressed out at the 

wall. Only a small amount remains in the 

container after emptying which is both 

cost-effective and environmentally friendly. 

An integrated sensor ensures that the pump 

is protected against dry running. Cylindrical 

drums, but also slightly conical containers, 

with or without drum inliner, can be emptied. 

Adjustable drum retaining clamps secure 

the containers from the outside when 

the follower plate is removed. This is additionally 

supported by the application of 

compressed air. 

Fast cleaning no problem 

To ensure fast and cost-effective cleaning, 

the plate and pump tube can be dis - 

assembled quickly by using Tri-Clamp 

connections. Generally, the follower plate is 

operated with a 3A-approved free of bacteria 

traps and thread-free pump. The mobile 

trolley, the hydraulic unit and the follower 

plate are also made of polished stainless 

steel. 

Depending on the pump size and the drive 

motors that can be combined with it, flow 

rates of up to 120 l/min can be achieved. 

The range of drive options extends from 

standard three-phase motors with frequency 

converter to compressed air motors and 

gear motors. 

When retracted, the total height of the system 

is only 2.12 m and is therefore ideally 

suited for low ceiling heights and transport 

in elevators. The weight of the mobile unit, 

without pump, is approx. 140 kg. 

In order to cover the largest possible range 

Pictures: Lutz Pumpen 

A simple and convenient control system 

enables the commissioning 

of tasks, the system can also be used without 

the follower plate as a pure, mobile lifting 

stand together with the pump. 

The follower plate system can be used to 

pump highly viscous, pasty and viscous 

substances which are not capable of flow - 

ing. Examples from the various application 

fields are lipsticks, mascara, ice cream, to - 

mato paste, infant food, ointments, fats and 

colours. 


Online search: cpp0319lutz 

The ergonomic design of 

the drum emptying system 

simplifies the operation 

for the user 




Keep your process plant up to date at all times 

Cloud services for digital 

twins 

Plantsight, a suite of cloud services developed by Siemens and Bentley, enables the 

delivery of constantly updated, true-to-life digital twins. Real process equipment 

and engineering data are synchronised. Multiple data sources, including dark data, 

are integrated to create an immersive environment with visible analysis for more 

efficient operations and better informed decisions. 

Plantsight is a set of digital twin cloud 

services that provides an evergreen digital 

twin environment for process plants in 

which to consolidate and aggregate plant 

models and data, validate, visualise and analyse 

them to facilitate informed decisions. It 

transforms raw data into one complete, 

living digital twin that is continuously updated. 

The digital twin can include process 

and plant engineering, physical layout 

modelling, project and construction planning, 

maintenance, reliability and asset performance 

modelling. 

One decisive factor is the federation of data. 

Thanks to intelligent scanning and data interpretation, 

imaging technology allows access 

to previously inaccessible information. 

This allows data to be validated and linked 

with other information; changes can be 

tracked in order to improve not only the accuracy, 

completeness and trustworthiness of 

asset data and documentation but also compliance 

and decision making. The solution is 

scalable, secure and extensible and will reduce 

the IT footprint and costs. 

Introducing Plantsight 

Plantsight is a cloud-based plant engineering 

and operations solution that scales from 

the simplest plant modification to the workflows 

required for complex capital projects. 

The solution shares a common data model 

across an open and connected data environment 

(CDE), which integrates services from 

both Siemens and Bentley. 

These services include data acquisition – 

which apart from Comos and Openplant 

can also load plant design information from 

Aveva and Hexagon –, data aggregation 

services to consolidate and aggregate data 

into the CDE and ensure that all data is correctly 

synchronised and a tag registry service 

that manages tags across all these 

multiple systems. Tags are used to identify 

assets and are typically the common de- 

Pictures: Bentley Systems 

Plantsight side-by-side comparison model 


Operation and maintenance engineers keep 

an eye on plant health from Plantsight dashboards 

nominator between different engineering 

and operations systems. They are also one of 

the hardest things to consolidate and keep 

updated across such systems. 

Thanks to Siemens’ know-how in functional 

information and Bentley’s expertise in 3-D 

spatial information, Plantsight solves this 

problem. In addition to aggregating data 

from plant design systems, it can also aggregate 

information from Excel, ISO 15926 

and other sources, giving the operator instant 

access to accurate tag information. The 

Plantsight tag registry is likewise integrated 

directly with Comos and Openplant, so that 

they share this capability with design workflows. 

Other Plantsight services can similarly 

be shared as user requirements demand. 

Yet what if there is no 3-D model of the 

existing plant? Plantsight can also combine 

a reality mesh of this plant with any 3-D 

models that may be available and link tag 

information to the geospatial coordinates of 

the tagged component. 

No more dark data 

A digital twin combines data from many 

online and offline sources with open IT integration. 

It helps incorporate data from digitally 

inaccessible sources, sometimes referred 

to as “dark data”, and mobile sources 

used in the field. 

An accurate, up-to-date, accessible digital 

twin reduces the time to operational readiness 

and can also influence the time to market. 

The ease with which this digital twin 

can be updated during operation or modified 

during projects meets the need for increased 

flexibility and adaptability. The 

seamless and ongoing integration of process 

engineering, maintenance, 3-D representation 

and operational performance information 

speeds up and supports continuous 

improvements and hence efficiency, 

sustainability and the return on assets. The 

digital twin makes it more straightforward 

to engineer for safety and compliance and 

verify the as-built and as-maintained facility. 

In addition to information which is accessible 

online, there is a category of inaccessible 

sources such as PDF documents, drawings 

or paper documentation as well as electronic 

data in legacy systems that can benefit 

a broader set of users if made available. 

Plantsight includes intelligent services to 

help incorporate, analyse and connect data 

from these dark sources. As data quality may 

be inconsistent, validation steps allow useful 

data to be differentiated from poor data. 

Change synchronisation 

For operation and maintenance, one of the 

biggest challenges is knowing what has 

changed and when, so that accurate decisions 

can be made. Not just the most recent 

change is relevant but every change historically 

on record. P&IDs are probably among 

the most important operational documents, 

so it makes sense to view those same 

changes you saw in 3-D visualised on the 

P&ID. Visualising changes using the context 

of a familiar document adds real value for 

operators. 

Today, it is possible to hand over the complete 

digital twin and keep it evergreen. 

When the twin starts deviating over time 

because the equipment is modified or there 

are add-ons, it is possible to create a new 

project digital twin (based on the most current 

performance digital twin) and engineer 

the modifications in parallel with operation 

of the plant until shutdown. Any changes 

compared to the design are captured in the 

project twin, then a simple reconciliation 

step combines the latest changes in the performance 

digital twin with the information 

from the project twin. This is easy to do in a 

side-by-side view of differences and a stepby-step 

process for approving or rejecting 

changes. 

With its ability to leverage new technologies 

such as reality modelling, 3-D webbased 

visualisation, cloud services and IoT, 

Plantsight is the next-generation asset performance 

management system for consolidating 

and aggregating information and 

supporting constant and continuous change 

management, leading to better – and better 

informed – decisions on asset performance 

and reliability. 

Plant operation and maintenance can now 

manage as-operated digital twins of their 

assets. 


Online search: cpp0319bentley 

AUTHOR: 

SANDRA DIMATTEO 

Director of Marketing, 

Digital Twin Solutions, 

Bentley Systems 




Collecting representative samples 

Grab sampling systems for 

accurate lab analyses 

Grab sampling systems provide an effective way to safely collect samples from a 

pipeline, tank or process vessel to be transported to a lab for offline analysis. The 

key to accurate analysis is ensuring the captured sample is representative of process 

conditions when collected and analysed. This article provides tips to help realise 

more efficient and accurate grab sampling analyses. 

Grab sampling systems are ubiquitous 

throughout processing plants, refineries and 

other industrial facilities. They play a key 

role in quality and process controls, compliance 

with regulations and verifying the 

performance of process analysers. To perform 

grab sampling, operators must capture 

a sample in a container, typically either a 

cylinder or a bottle, at a collection point 

and then promptly transport it to a remote 

laboratory for offline analysis. The sample 

must be representative of the process conditions 

at the time it is collected, and it must 

remain as close to those conditions as possible 

when it is analysed. 

Pictures: Swagelok 

The GSM-G-2(-N) grab sampling system is for sampling gas without using a separate purge line. With 

the sampling system valves and the cylinder valves open, process fluid flows through the cylinder and 

out via the hose to the outlet port, where it returns to the process. When retrieving a sample, the operator 

will close the cylinder valves and turn the system to vent, in order to isolate the supply and return 

lines and allow the fill lines to vent. Next, the operator will turn the system off before disconnecting 

the cylinder and transporting the sample for offline analysis. 

Specifying a grab sampling system 

When configuring a grab sampling system, 

designers must first decide which sample 

transport vessel to use – either a sealed 

metal cylinder or a glass or polyethylene 

bottle. Both the system pressure requirements 

and the sample phase influence this 

decision. Cylinders may contain pressure 

and can be used for gas or liquid samples, 

while bottles cannot contain pressure and 

are used for liquid samples only, as they are 

not airtight. Other key criteria driving system 

design considerations include: 

• Pressure: To ensure safe operation, the 

maximum rated pressure of a grab sampling 

system must not be exceeded. Additionally, 

a rupture disc or relief valve 

should be fitted to enhance safety when 

using chemicals that can rapidly expand 

and pressurise due to temperature changes. 

• Temperature: The sampling system’s 

maximum fluid operating temperature 

must not be exceeded, to protect the integrity 

of its seats and seals. Conversely, 

the system must operate above its minimum 

operating temperature, so that the 

process fluid flows at a sufficient rate for 

timely analysis. If the supply temperature 

exceeds 60°C, the option of cooling the 

sample should be considered in order to 

reduce the risk to operators retrieving 

samples, while keeping in mind that this 


lower temperature could affect the 

sample’s representativeness. 

• Material compatibility: The materials 

used in a grab sampling system must be 

compatible with the process fluid as well 

as with the operating environment. The 

standard construction material is 316 

stainless steel, but system requirements 

may dictate the use of alternative materials 

such as alloys 400 and C-276. 

• Purging needs: Some chemicals may 

contaminate or corrode grab sampling 

lines, or possibly pose a hazard to the 

operator if not flushed from the system. In 

such cases, designers should add a purge 

setup to remove residual process fluid 

from the lines. 

Capturing samples in cylinders 

There are a variety of options for confi - 

guring grab sampling systems that capture 

gases or liquids in a sealed cylinder. Perhaps 

the most efficient design is a closed-loop 

system with the sample continuously circulating 

through the cylinder while the operator 

takes a sample. A closed-loop system 

pulls samples from a positive-pressure process 

and returns them back to the process at 

a lower-pressure location – for example, upstream 

of a pump – using the differential 

pressure to drive the fluid through the 

sample system. Such a design can reduce or 

eliminate system purging needs, as the sampling 

system becomes an extension of the 

process system. Upon opening the inlet 

valve of the Swagelok GSM-G-2(-N) grab 

sampling system with continuous flow and 

without purging, for example, process fluid 

will flow through the system tubing and the 

sample cylinder before flowing out via a 

hose to the outlet port. Any older process 

fluid remaining in the short inlet line will 

quickly move through the closed loop path 

and return to process as the cylinder fills. 

When the sample vessel is ready for removal, 

the operator can simply close the 

cylinder’s inlet and outlet valves and turn 

the system to vent, isolating the supply and 

return lines and allowing fill lines to vent. 

Finally, the operator will close the system’s 

inlet valve to halt all flow and remove the 

cylinder for lab analysis. The fluid in the 

cylinder remains under the same process 

conditions that existed at the time of the 

sample, except for temperature, and is 

therefore always representative of the 

process. 

For gas and liquid samples 

While grab sampling systems with cylinders 

can be used for gas or liquid samples, design 

considerations differ between the two 

types. Most notably, the flow path should be 

different for liquids and gases to purge outof-phase 

fluid from the cylinder. Gases 

should flow from the top of the cylinder 

down, pushing out any liquid or condensate 

from the sample cylinder as it fills, to ensure 

liquid doesn’t collect in the cylinder 

and skew lab analyser readings. Liquids 

should fill from the bottom up to displace 

the vapour space and ensure the cylinder is 

full. Designers may also add an outage tube 

to cylinders capturing liquid samples to 

keep expansion space in the cylinder, as the 

trapped vapour may compress under pressure. 

Swagelok offers a variety of sampling 

cylinder (GSC) configurations, including 

options for purging bypass tubes, quick 

couplings with plug or body caps, outage 

tubes and specific certifications. 

EXCELLENCE IS: 

Precise DO Measurements 

with Less Frequent Calibration 

See the Sensor 

That Reduces 

the Negative 

Impact of SIP and 

Photobleaching 

Hamilton Bonaduz AG | CH-7402 Bonaduz, Switzerland 

contact.pa.ch@hamilton.ch | www.hamiltoncompany.com 

Hamilton 

30YEARS 

Process Analytics 




The Swagelok GSL3 bottled grab sampling system design is used when continuous flow 

is required from the inlet to the outlet. The inlet port supplies the sample panel and the 

outlet port allows bypass flow. 

Outage tubes help to prevent cylinder overfilling 

when capturing liquid samples 

Capturing liquid samples in bottles 

Liquid-only grab sampling systems draw 

fluid into a non-pressure-containing bottle. 

Operators draw the fluid directly from the 

process – perhaps after some conditioning – 

and then transport the vessel without risk of 

spillage or evaporation. Such systems can be 

used in a number of liquid applications, 

where the process fluid is not at risk of fractionating 

or evaporating when stored at atmospheric 

pressure to ensure the sample remains 

representative. This precaution allows 

designers to use less expensive glass laboratory 

bottles for samples, with the added 

benefit of gaining immediate feedback on 

the visual quality of the sample stream.With 

bottle sampling, the sample is taken at atmospheric 

pressure. Any increase in internal 

pressure may cause loss of sample through 

the lid or septum cap seal. Therefore, liquid 

grab sampling systems with bottles are typically 

used with water or other low vapourpressure 

liquids. If bottle sampling is suitable, 

designers must determine whether 

continuous flow and purging are required 

or whether a fixed-volume option would be 

more appropriate. 

Continuous flow during sampling 

Continuous flow is useful during sampling 

when the sample requires constant motion 

– to keep it from freezing, for instance – or 

if a long tubing run leads up to the sample 

point. The sample flow runs continuously 

through a bypass loop in the grab sampling 

system, as shown in the Swagelok GSL3 

“Continuous Flow Sampling System Design”. 

This ensures that the sampled fluid 

remains representative of the process, as it 

will not be sitting in the tubes for an extended 

period of time. An operator can then 

fill the sample bottle, using a spring-loaded 

sampling valve to retrieve the sample. If the 

sampled fluid has the potential to solidify in 

place, a purge assembly is advised to aid in 

cleaning the dispensing needle and internal 

tubing. If the sampled fluid is under high 

pressure or hazardous, designers should 

consider a fixed-volume system, which effectively 

isolates the process pressure from 

the user while limiting the volume of dispensed 

fluid. In a fixed-volume system, the 

sample first fills a metal cylinder and is then 

gently pushed into the sampling bottle by a 

low-pressure purge gas. This precaution 

helps prevent accidental overfilling. 

Outage tubes as a safety mechanism 

System designers should consider using an 

outage tube as a safety mechanism for any 

grab sampling system that captures a liquid 

sample in a cylinder. The outage tube enables 

a defined volume of vapour space to 

remain inside the cylinder when capturing 

a sample. This vapour space will allow the 

liquid in the cylinder to expand if the temperature 

increases. Without enough space, 

even a small temperature increase can cause 

the liquid to expand and the pressure to increase 

dramatically. During sampling, the 

cylinder is held vertically with the outage 

tube at the top, as shown. The length of the 

outage tube determines the amount of vapour 

space, which is expressed as a percentage 

of the cylinder’s total volume. 


Online search: cpp0319swagelok 

AUTHOR: 

MATT DIXON 

Senior Principal Design 

Engineer, 

Swagelok 



PRODUCTS 

Hygienic safety valve with ASME approval 

Picture: Goetze 

OUR ENGINEERING IS 

YOUR SYSTEM SOLUTION 

The valve specialist Goetze’s 

Series 4000 safety valve is now 

available with the ASME certification. 

The extended certification 

makes the valve even 

more versatile in applications 

where particularly high requirements 

must be met with regard 

to the cleanability of surfaces in 

contact with the medium. 

Particularly for applications in 

the medical or pharmaceutical 

sector, the requirements for the 

manufacture and cleanability of 

the valves are very high. As with 

the safety valve 4000, contamination 

can be avoided by not 

allowing nests and dead spaces. 

For this purpose, the area of the 

spring chamber is separated 

from the media chamber by an 

elastomer diaphragm. The media 

chamber itself can be opened 

with the aid of the clamp connections. 

This ensures simple 

and professional cleaning. 

The valve is secured against unauthorised 

adjustment by a visible 

sealing disc pressed into the 

cap. This means that the usual 

sealing wire, which is not easy 

to clean, can be dispensed with. 

This allows simple assembly or 

disassembly with standard tools 

without any changes or effects 

on the set pressure of the valve. 

The set pressure can vary between 

0.4 and 16 bar. 


Online search: cpp0319goetze 

Rapid delivery 

Made in Germany 

ISO 9001 

Protection module monitors pumps 

The Amacontrol III device 

monitors the phase sequence 

and detects any phase failures, 

overvoltage/undervoltage or 

voltage asymmetry that may 

occur. It can also monitor temperature 

sensors, two conductance 

sensors for leakage monitoring 

and a 4...20 mA vibration 

signal. Additional functions 

include logging the frequency 

of starts, recording the 

number of operating hours and 

detecting any failures of connected 

sensors. 

A fault relay and warning relay 

ensure the units are reliably 

stopped or, respectively, a warning 

is emitted. This makes it 

possible to control the monitored 

units via an app on a 

smartphone or tablet computer. 

The device is mounted in the 

control cabinet on a 35 mm 

Bild: KSB 

standard rail and wired with removable 

spring-loaded terminals. 

The module requires 

either a supply voltage of 

24 V(DC) or single-phase AC 

from 115 to 230 V and a frequency 

of 50 to 60 Hz. The 

modules supplied by KSB are 

preset with all the values 

required for operation. 


Suchwort: cpp0319ksb 

Multi-coupling 

li 

The perfect interface. A customizable multi-coupling system 

that combines multiple process media connections in 

a single interface. Robust, extremely reliable and easy to use. 

• Fast, simultaneous connection and disconnection 

of up to 20 couplings 

• Arrangement can include different coupling types and sizes 

• Customer-specific configurations possible 

www.gather-industrie.de · kupplung@gather-industrie.de · +49 2058 89381-23 

cpp 03-2019 53 

Pump Technology · Metering Technology · Coupling Technology


PRODUCTS 

Intelligent infrastructure plug-in connector 

The development of plug-in 

connectors is influenced by 

three trends: digitalisation, decentralisation 

and miniaturisation. 

In decentralisation, increasing 

numbers of functions 

in the industrial environment 

are shifting to the device and 

field level, meaning that there 

will be an increasing demand 

for a comprehensive connection 

between devices along the horizontal 

and vertical axes of the 

automation pyramid. This also 

includes supplementation with 

intelligent functions. Integrating 

sensor and diagnostic functions 

directly into the connectors 

opens up completely new application 

fields and renders additional 

sensors superfluous. 

Measured variables like current, 

voltage, power and temperature 

can be measured, as well as 

saved and evaluated with an 

app, an ERP/SCADA system or a 

cloud. Weidmüller developed 

such an intelligent plug-in connector. 

The smart connector was 

created as part of the German 

Federal Ministry of Education 

and Research (BMBF) funded 

Picture: Weidmüller 

project: “Intelligent electric 

plug-in connector and connection 

technology with electronic 

signal processing (ISA)”. 



cpp0319weidmüller 

Compact chamber dryer 

Safety laser scanner for outdoor use 

The chamber dryer H01compact 

from Harter is perfectly suited 

for laboratory testing very small 

quantities or for developing 

new products. The H01compact 

has a drying chamber designed 

for inserting plates or trays 

straightaway. As in the H01, 

products placed separately or at 

filling heights of 200 mm maximum 

may be dried. Batch sizes 

range between 30 and 70 kg depending 

on the specific application 

and the product to be 

dried. Essentials of heat pump 

based condensation comprise 

the use of extremely dry air and 

adequate routing of this air 

which ensures very high process 

reliability. Drying is effected at 

temperatures which may be varied 

and controlled at 15 to 

75 °C as required for the specific 

application. This drying 

process ensures gentle drying of 

products to the desired residual 

humidity level. As the system is 

closed air-wise, drying is independent 

of the climate. The processes 

may be validated for 

pharmaceutical applications and 

are thus eligible for GMP 

qualification. 


Online search: cpp0319harter 

Picture: Harter 

The safety laser scanner Outdoorscan3 from Sick is certified 

to IEC 62998 for use in outdoor applications. Thanks 

to its outdoor-safe HDDM scanning technology, Outdoorscan3 

works safely and reliably in all weather – thus 

closing a major gap in the automation of industrial processes. 

This technology means the laser scanner can work 

without errors when exposed to sunlight with an illumination 

intensity of up to 40,000 lux. In addition, the intelligent 

software algorithm of the laser scanner detects 

rain and snow, easily filtering out these environmental 

influences – rain, for example, up to a precipitation intensity 

of 10 mm/h. Even in fog with a meteorological 

visual range of up to 50 m, it detects all obstacles with 

total reliability, due to its special fog function. 


Online search: cpp0319sick 

Picture: Sick 

T +49 2961 7405-0 | info@rembe.de 

Gallbergweg 21 | 59929 Brilon, Germany 

F +49 2961 50714 | www.rembe.de 

Your Specialist for 

EXPLOSION SAFETY 

and PRESSURE RELIEF 

Consulting. Engineering. Products. Service. 

© REMBE® | All rights reserved 


Profinet Gateway for remote I/O 

With the LB Profinet gateway, 

Pepperl+Fuchs is connecting LB 

remote I/O systems to the 

Profinet world. End-to-end 

communication also ensures optimal 

use of existing intelligence 

in the field, representing a crucial 

step toward making plants 

suitable for future requirements 

and Industry 4.0. The LB Profinet 

gateway delivers not only 

conventional Profinet functionality, 

but also full access to 

all connected Hart devices. In 

practical terms, this will give 

users access to Hart auxiliary 

variables as a second measuring 

value in addition to process 

variables. Furthermore, the 

diagnostic data from the field 

devices can be read out via Hart 

IP, thus significantly increasing 

transparency and plant availability. 

The gateway also offers 

maximum flexibility since different 

protocols can run via the 

same cordset (e.g., Profinet and 

Hart IP), and, of course, it represents 

a high-performance solution: 

up to 80 field devices can 

be connected to a fully occupied 

remote I/O system. These devices 

communicate without a 

time delay. 

Picture: Pepperl + Fuchs 

Another highlight of the gateway 

is the intelligent redundancy 

concept. An integrated switch 

ensures the functionality of the 

network at all times based on 

the medium redundancy protocol 

(MRP). If a line fails, the 

ring network is reconfigured to 

send the data packets via the alternative 

route. Since the potential 

for hazards increases as a result 

of big data being used 

alongside increased networking 

of industrial plants, the gateway 

also fulfills the appropriate 

safety requirements. 


Online search: cpp0319pepperl 

30 th international exhibition 

for industrial automation 

Nuremberg, Germany 

26 – 28 November 2019 

sps-exhibition.com 

Bringing Automation to Life 

Magnetic pump range expanded 

Picture: Munsch 

The CM series magnetic pumps 

have experienced a significant 

increase in performance in their 

conveying distance to up to 

85 m. They are intended to convey 

critical or environmentally 

harmful liquids, or liquids that 

are hazardous to health such as 

acids, alkalis, solvents and 

chemically contaminated materials 

containing few solids. The 

CM-FA series magnetic pump, 

however, is also suitable for 

conveying material containing 

solids. The spacer can of the CM 

series is designed as a vacuumtight, 

metal-free double-wall 

composite unit with no edgy 

currents, meaning no heat 

transfer to the material being 

pumped, no loss to magnetic 

performance, meaning no losses 

to efficiency, and the spacer can 

is protected against mechanical 

contact with the drive rotor. An 

electronic monitor is also possible 

as an option. 


Online search: cpp0319munsch 

Hands-on. Visionary. Personal. 

Find answers to your current needs on-site, as well as 

possible solutions for the challenges of tomorrow. 

Register now and get 

30% off with the discount code: SPS19BESV12 

sps-exhibition.com/tickets 




Picture: Wipotec-OCS 

The TQS serialisation system accomplishes modular labelling of medication according to all country-specific particularities 

Process reliability in track and trace systems 

Position indicator for 

supervised format change 

The European Falsified Medicines Directive (2011/62/EU), which entered into force 

on 9 February 2019, requires all prescription medicines to be clearly labelled in a 

way that allows the entire production and transport process to be traced. What is 

needed in this context are track and trace systems such as TQS. If the machines are 

equipped with electronic position indicators, process reliability and easy batch 

changes between various packaging sizes are ensured. 

The introduction and starting date of the 

new anti-falsification directive have been 

known since 2016, yet increased demand 

for suitable track and trace systems was only 

evident in the months preceding its entry 

into force. Wipotec-OCS, which specialises 

in weighing and inspection solutions, including 

mechanical engineering for processes 

such as printing, reading and labelling, 

confirms this trend: “This is a massive 

drag on the market now. As of February, 

every company that produces prescription 

medication and wants to bring it onto the 

market needs to ensure that serial numbers 

are assigned to each drug and that a track & 

trace solution is integrated into the production 

line”, explains Daniel Anders, product 

manager for track and trace at Wipotec- 

OCS. “It is useful to have systems that can 

be incorporated into the production line 

quickly without major expense and that do 

not slow down the production process unnecessarily, 

with severe negative impacts on 

manufacturing efficiency”. 

Modular labelling 

With its TQS solution, Wipotec-OCS has established 

a system for the pharmaceutical 

sector that accomplishes highly modular labelling 

of medication according to all 

country-specific particularities. Serial numbering 

involves several potential process 

steps – printing, reading, labelling and 

weighing – which the TQS-HC-A machine 

combines into one unit. It is designed for 

folding boxes, which make up at least 90 % 

of all medication packaging in the European 

market. The boxes are labelled on the front 

and/or back, as well as optionally on the 

top, and then weighed with a high-precision 

load cell from Wipotec to determine 

whether they are fully packed. Faulty products 

are automatically removed in this process. 

Where needed, tamper-evident labels 

can be applied to secure the packaging 

against manipulation. 

For pharmaceutical clients, who often have 

long production lines, it is important to 


have a track and trace solution that is as 

compact as possible. In fact, the new European 

directive requires high initial investments 

and commitment of resources on the 

part of pharmaceutical manufacturers. Acceptance 

is therefore much higher if the 

track and trace machines fit smoothly into 

the overall concept – and additional benefits 

are created as a result. 

Supervised format change 

A small but highly significant component 

on the machine offers further advantages. 

Siko’s AP05 position indicator provides an 

option for supervised format changes. Optimised 

format changes facilitate batch 

changes between various packaging sizes. 

The present trend is towards smaller 

batches, which also means more frequent 

changes. All units generally need to be 

shifted on two axes. Up to 13 Siko indicators 

may be installed in a TQS-HC-A. 

These shifts are best carried out quickly in a 

controlled and reliable manner. Electronic 

AP05 indicators are bus-compatible and can 

be integrated into the machine controls, 

where new target values for the next folding 

box size (stored in the machine controls in 

a recipe list for each product) can be transmitted 

to the position indicator and shown 

on its display under the current actual value. 

If the actual and target values match, the 

LEDs on the position indicator change to 

green. If not, the LEDs are red (position not 

yet reached). The machine is ready for operation 

again only when all LEDs are green; 

only then can production be started safely. 

Incorrect settings no longer occur. The operator 

can see from the LEDs which shift 

points still need to be adjusted. This prevents 

defective products and improves process 

reliability. Another advantage is that 

with supervised format changes the changeover 

times are significantly shorter and 

hence more efficient. 

In the past, Wipotec-OCS’s TQS machines 

were equipped as standard with mechanical 

position indicators from Siko to indicate the 

current position of the axes. The AP05, the 

supervised electronic variant, is mechanically 

compatible and can be retrofitted at 

any time. 


Online search: cpp0319siko 

Picture: Christian Fischer – Siko 

The bus-compatible AP05 electronic position 

indicator ensures a secure and efficient 

changeover to different folding box sizes 

AUTHOR: 

MICHAELA 

WASSENBERG 

Freelance journalist 

Versioned catalog production 

intelligent 

Medien 

produzieren 

Perfect project management for highly complex jobs 

Tools for an efficient workflow 

www.konradinheckel.de 




Dust-free thanks to state-of-the-art vacuum technology 

Bagging carbon black 

efficiently 

Products with such low bulk densities as carbon black place very high demands on 

bagging technology in the packaging process. Using Greif-Velox’s Velovac system, 

speciality graphite supplier Imerys Graphite & Carbon was able to increase its bagging 

capacity to 90 bags per hour and reduce the costs for storage and logistics by 

75 %. At the same time, dust pollution during bagging and transport was completely 

eliminated. 

Carbon black is an extremely valuable industrial 

raw material consisting of tiny, 

mainly spherical, so-called primary particles. 

In most cases, these particles have a 

size of 10 to 300 nm, which is why they are 

also referred to as nanoparticles. Their specific 

surface area can be anything between 

10 and 1000 m 2 /g. On the one hand, carbon 

black manufacturers can take advantage 

of these properties and influence them by 

means of the production process or by varying 

the process parameters. On the other 

hand, they also face challenges, especially 

with regard to the packaging process. 

Cost-intensive with high health risk 

Products with such low bulk densities as 

carbon black place very high demands on 

bagging technology in the packaging process. 

Many packaging solutions involve a 

large amount of air in the filled bags. These 

voluminous and unstable bags result in an 

untidy pallet appearance in two respects: 

since extreme dust is produced during filling, 

the bags are often contaminated with 

residues. In addition, the air-pumped bags 

can no longer be stacked precisely. Apart 

from losing valuable product, this also 

means paying for logistics and transport of 

bulky bags filled with up to 70 % air. However, 

high dust loads contaminate not only 

the bags themselves but also the production 

environment. Cleaning is exceedingly timeconsuming 

and flying particles pose an immense 

health risk to employees. Technical 

rules for hazardous substances, in particular 

TRGS 900, describe the limit values for a 

large number of dust types. 

Dust-free bagging 

Imerys Graphite & Carbon turned to Lübeck-based 

packaging machine specialist 

Greif-Velox Maschinenfabrik GmbH for support 

optimising the packaging process for 

carbon black in general while meeting the 

above-mentioned protection requirements. 

The solution: the highly efficient Velovac 

system. Ultra-lightweight materials with 

particle sizes of less than 200 mm and bulk 

densities from 10 to 450 g/l are bagged in a 

completely closed vacuum chamber. The 

product is sucked into the vacuum bags by 

creating an atmospheric vacuum. Any dust 

which escapes is sucked off and returned to 

the bagging process directly, saving product 

and air. Even without upstream compaction 

equipment, little or no air gets into the vacuum 

bags. Depending on the material to be 

packed, up to 400 % product compaction is 

possible. 

Pictures: Greif-Velox 

Velovac vacuum packer for dust-free filling 

Excellent sealing technology 

After filling, the bags are hermetically sealed 

using patented methods for external valve 

cutting and ultrasonic sealing. The valve cutting 

technique has been optimised by Greif- 

Velox in a way that leads to more process 


Thanks to the Velovac vacuum packer, valve bags are up to 50 % narrower as well as considerably more 

compact and stable (left stack) 

reliability, better knife performance and increased 

productivity. The improved knife 

system is particularly durable; modern sensor 

technology provides users with dynamic 

predictions for upcoming maintenance 

cycles and warns of imminent failure or a 

deterioration in performance. In addition, 

an integrated self-regulating process is controlled 

by an intelligent algorithm, preventing 

operators from selecting the wrong parameters. 

The cutting time is automatically 

adjusted to between 50 and 500 ms and the 

cutting pressure to between 2.6 and 5 bar. 

No unnecessary time is wasted after cutting, 

as no cooling is required and the bags can 

be processed immediately. The patented 

wafer closure prevents incorrect sealing. The 

cutting edge is additionally welded in line 

with the motto “better to be on the safe 

side”. 

More stable, cleaner, safer, faster 

Instead of seven precariously balanced 

layers, Imerys Graphite & Carbon now has 

secure pallets with 22 stable and steady 

layers each. The bagging capacity has been 

increased to 90 bags per hour and the costs 

for storage and logistics reduced by 75%. At 

the same time, dust pollution during bagging 

and transport has been completely 

eliminated. The entire process remains absolutely 

dust-free. The Greif-Velox Velovac system 

thus benefits Imerys and its customers 

right down the line. 


Online search: cpp0319greif 

AUTHOR: 

DR. ALEXANDER 

MILDNER 

Head of Research & 

Development, 

Greif-Velox 

Industrie 

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LIST OF ADVERTISERS 

AZO GmbH & Co. KG, Osterburken 5 

Bausch + Ströbel Maschinenfabrik 

Ilshofen GmbH + Co. KG, Ilshofen 19–20 

Brabender Technologie GmbH & Co.KG, 

Duisburg 27 

C. Otto Gehrckens GmbH & Co. KG, Pinneberg 23 

Ecolab Engineering GmbH, Siegsdorf 15 

Fette Engineering GmbH, Schwarzenbek 2 

GATHER INDUSTRIE GmbH, Wülfrath 53 

Hamilton Bonaduz AG, CH-Bonaduz 51 

Dr. Jeßberger GmbH, Ottobrunn 61 

Amandus Kahl GmbH & Co., Reinbek 29 

KELLER AG für Druckmesstechnik, 

CH-WINTERTHUR 62 

Mesago Messe Frankfurt GmbH, Stuttgart 55 

Orbitalum Tools GmbH, Singen 33 

Rembe GmbH Safety + Control, Brilon 54 

Robu Glasfilter-Geräte GmbH, Hattert 7 

Georg Schünemann GmbH, Bremen 22 

VACUUBRAND GmbH & Co. KG, Wertheim 3 

VIBRA MASCHINENFABRIK 

Schultheis GmbH & Co., Offenbach 31 

Witte Pumps & Technology GmbH, Tornesch 30 

ystral GmbH, Ballrechten-Dottingen 45 


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cpp – Process technology for the chemical industry 03.2019

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