cpp – Process technology for the chemical industry 02.2022

02-2022
ACHEMA
TRADE FAIR ISSUE
18 COVER
LEVEL SENSORS AND
INVENTORY SYSTEM
RUN LIKE CLOCKWORK
PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY
WWW.CPP-NET.COM

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cpp
EDITORIAL
Beach or fair
Beach or fair? This is one question raised by Achema 2022 in what
for several European countries is the middle of the summer holidays.
When the organisers announced their intention to switch the
event from April to August, there was a distinct lack of enthusiasm
in many places – especially in Southern Europe, where August is the
classic holiday month. In Germany, too, the new date from 22 to
26 August caused quite a bit of head-scratching. The mood has
calmed down again in the meantime and one or two firms who had
previously cancelled their attendance have decided to exhibit at this
year’s Frankfurt Achema after all.
Although the number of exhibitors will fall slightly short of the
traditional level due to a combination of the Ukraine war, the
Covid-19 pandemic and the holiday season, the trade fair has a lot
to offer nevertheless, as my colleague Lukas Lehmann learned in
conversation with Dr Björn Mathes, Executive Director of Dechema
Ausstellungs-GmbH. You can read his interview on page 8.
Although the employees of Itelyum, the Italian specialist for waste
oil regeneration, know a lot about making processes run smoothly,
they always had difficulty keeping track of the inventory held in the
company’s numerous storage tanks. However, the use of radar sensors
and the introduction of a vendor managed inventory system
changed everything, as our cover story on page 18 explains.
Continuous direct compression offers numerous process advantages.
Nevertheless, it has not yet become a reality for many manufacturers.
Pharmaceutical and food producers sometimes associate high
investment and conversion costs with the changeover from the
batch process. But there is another way, Fette Compacting’s new
process line on page 46 shows.
I hope you enjoy reading our Achema issue, whether on the beach
or at our booth, which you are cordially invited to visit. You can
find us in Hall 11.1, Booth E13.
THE TEACHINGS
OF THE SCHOLARS
Representing the groundbreaking
special centrifugal pumps from the
Bungartz collection,
series production
There‘s an art to emptying a
container or tank wagon right up to
the last drop. The contemporary
Opus VKG is excellent at this.
The dry-running centrifugal pump
is made with great detail. Form and
function become one. The object
dominates the process, especially
when it encounters liquified
petroleum gases.
A worthwhile investment!
Dr. Bernd Rademacher, Editor
More information on
+49 211 57 79 05 - 0 and online at
www.bungartz.de/masterpieces4
Visit us at ACHEMA 2022,
Hall 8, Stand C 1
cpp 02-2022 3

cpp CONTENTS 02-2022
18 Cover The use of
Vega radar sensors and
the Vega Inventory System
changed everything in
the production of
Itelyum.
8 Ukraine war, the
Covid-19 pandemic and
the holiday season are affecting
Achema 2022, as
Dr Björn Mathes explains
in an interview with cav.
28 Cyber attacks on
plants in the process industry
can cause considerable
damage. Therefore,
secure applications
as well as protection concepts
are necessary.
CPP NEWS
8 Summer. Sun. Frankfurt.
Sustainability and digitalisation will be key issues
at Achema
INSTRUMENTATION, CONTROL, AUTOMATION
16 PAT modular system extended
From sensor to fully automated measuring point
18 COVER Runs like clockwork
Vegapuls level sensors and Vega Inventory System enable
optimal stock maintenance
22 Levaco relies on digital transformation
Web-based process control system allows a view into
the reactor
SAFETY, SECURITY
28 Security solutions for the process industry
This is how structures and systems should be designed
PLANTS, APPARATUS, COMPONENTS
30 Multi screw pumps at the tank farm
Efficient pumping of heavy fuel oil
32 Intelligent piping systems
Modular all-in-one solution increases process efficiency
34 Effortless consistency
How engineering consolidation makes plant
manufacturers faster
36 Touch panel connects man and machine
Increased productivity and time saving
PROCESS ENGINEERING
38 Careful handling of valuable high concentrates
Mixers and dryers in the production of pesticides
41 Communication is the key to success
Managing international projects successfully
44 One-stage filtration is the charm
Solids, water and gels separation in silicone production
PHARMACEUTICAL ENGINEERING, PACKAGING
46 Continuous tablet production
A modular direct compression line
48 Sustainability in pharmaceutical packaging
Paper-based solutions without quality loss
4 cpp 02-2022

Visit us!
ACHEMA, Frankfurt a. M., Germany
August 22– 26, 2022
Hall 3.0, Stand F50
41 The key to completing
international projects
on time and on budget is
communication, says
Frank Betzold of VAU
Thermotech.
46 Continuous direct
compression offers numerous
process advantages,
as demonstrated by
Fette Compacting’s new
process line with integrated
process analysis.
COLUMNS
3 Editorial
4 Contents
6 News
12 PRODUCTS ACHEMA
25 PRODUCTS ACHEMA
50 Contact the editors
50 Advertisers
50 Imprint
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
SOME THINK
THAT STACK
QUALITY
AND HIGH
THROUGHPUT
ARE MUTUALLY
EXCLUSIVE.
WE THINK
DIFFERENT.
cpp 02-2022
beumer.com 5

cpp
NEWS
Picture: Nürnberg Messe
Held in parallel for the first time in September 2022
TRADE FAIR DUO FACHPACK AND POWTECH
Fachpack and Powtech will be held in parallel this year
Fachpack and Powtech will be staged simultaneously
as a trade fair duo for the first
time from 27 to 29 September 2022. In
times when the industry is facing major
challenges in view of supply bottlenecks
and the energy crisis, a face-to-face exchange
is more important than ever. Nürnberg
Messe expects a total of about 1600
exhibitors from Europe, of which about
1100 will present themselves at Fachpack
and about 500 at Powtech. The decision to
hold the two exhibitions in parallel was
taken in order to find a “window outside
the European holidays” for Powtech, which
had to take a break in 2020 due to the pandemic.
Both exhibitions address users from
the food and feed, chemical, pharmaceutical,
plastics processing and mechanical engineering
sectors and bring together the entire
value chain from process to technology
to packaging in three days. Visitors can visit
both trade fairs with one ticket. Fachpack
occupies nine exhibition halls, Powtech
four. The two fairs are well connected by
transitions. Hall 4 is a so-called mixed hall
with exhibitors who have offerings for both
bulk goods and packaging experts. For
Fachpack, as in the previous year, there is a
digital offer in addition to the presence fair.
From 16 September, the Myfachpack tool
will offer visitors the opportunity to network
with exhibitors, partners and speakers.
Powtech brings together innovations for
mechanical processing technology and for
the analysis and handling of powder, granulate
and bulk solids. Plant designers and operators
from almost all industries, including
food, chemicals and pharmaceuticals, come
together to update their knowledge, examine
state-of-the-art process technology and
prepare and make investment decisions. In
addition to the expert forum Stagetalks, the
trade fair’s technical programme also includes
the Pharma Manufacturing Excellence
forum, on the first day dedicated to
the analytical area, on the second day on development
and production, and on the third
day on pharmaceutical packaging.
Expansion for chlorine electrolysis plant
THYSSENKRUPP NUCERA
WINS ORDER IN INDIA
Thyssenkrupp Nucera will grant the license
and supply proprietary equipment to the
expansion plans of the Caustic Soda
(NaOH) plant for Kutch Chemical Industries
in Padana, Gujarat, India. The current
plant is operating since 2020 and consists
of five electrolysers with Thyssenkrupp
Nucera’s proprietary BM Single Element
technology. With this expansion the capacity
will be more than doubled to an additional
670 t/d NaOH (100 %). Completion and
commissioning are planned for 2023; the
contract size is in the lower double-digit
million-euro range. With this investment,
Kutch Chemical Industries intends to
strengthen its market position and meet the
growing demand for basic chemicals.
Caustic Soda is essential for a large number
of end products, like detergents, soaps and
disinfection, as well as used to process raw
aluminum for example.
Denis Krude, CEO of Thyssenkrupp Nucera:
“Thyssenkrupp Nucera together with its
long-lasting partner Thyssenkrupp Industrial
Solutions India is an expert for system integration
of holistic chlorine electrolysis
plants catering to each project’s individual
needs. With this second project for Kutch
Chemical Industries, we are very proud to
continue a successful business partnership
and support our client on their growth
path.” Thyssenkrupp Nucera’s scope in the
chlorine electrolysis business includes the
supply and services around engineering,
supply of all major plant equipment, supervision
of the erection and commissioning
activities, training of the operating personnel
as well as holistic 360-degree service
solutions for the entire lifecycle of a plant.
Chemical recycling project in Porvoo
NESTE RECEIVES FUNDING FOR RECYCLING OF WASTE PLASTIC
Picture: Neste
Neste receives funding from the EU Innovation
Fund for a chemical recycling project
Neste has received a positive grant decision
for up to 135 million euros from the EU
Innovation Fund for the project to build
chemical recycling capacities at its Porvoo
refinery in Finland. Project Pulse (Pretreatment
and Upgrading of Liquefied Waste
Plastic to Scale Up Circular Economy) aims
to implement Neste’s proprietary technologies
to pretreat and upgrade liquefied waste
plastic and integrate the technologies into
the refinery operations. The Pulse project targets
pretreatment and upgrading capacities
of 400,000 t/a, contributing to Neste’s goal
of processing over 1 million tonnes of waste
plastic per year from 2030 onwards. A feasibility
study evaluating the investments related
to Pulse was announced in March
2022. Investment decision readiness is targeted
for 2023 and gradual implementation
is expected to start in 2024. Project Pulse
plays an important role in commercialising
chemical recycling of waste plastic as it
allows scaling up chemical recycling and
bridging the quality gap between unprocessed
liquefied waste plastic and the industry’s
raw material requirements.
6 cpp 02-2022

Continuously rising demand for carboxylic acid
PERSTORP TO DOUBLE PRODUCTION CAPACITY
Picture: Perstorp
Perstorp will build a new plant on the site
of its existing carboxylic acid production
operation in Stenungsund, Sweden
Leading specialty chemicals company Perstorp plans to have extra
capacity of around 70,000 t/a for production of carboxylic acids onstream
during 2024. The investment will enable Perstorp to increase
output significantly and strengthen its position as the sustainable so -
lutions provider. Increased capacity will meet growing demand in
various high-value applications, including non-phthalate plasticisers
for PVC, engineered fluids for applications such as refrigeration lubricants,
and various propionates used in food preservation and carboxylic
acids for use in animal feed gut health and preservation products.
Most of the output will be used in downstream production operated
by Perstorp itself. Perstorp will build a new plant on the site of its
existing carboxylic acid production operation in Stenungsund,
Sweden. Like the original unit, it will be capable of producing acids
from C3 to C9 chemistry. Both plants will be fully integrated into
Perstorp’s Oxo production platform.
Investment of double-digit million euro sum
EVONIK EXPANDS CAPACITIES FOR PETROCHEMICAL SPECIALTIES
Picture: Evonik
The petrochemical specialties are used in
high-performance synthetic lubricants
Evonik has invested a double-digit million
euro sum to increase production capacity
for isobutene derivatives at its Marl location.
The isobutene part of the C4 production
network produces the petrochemical
specialties Tertiary Butanol (TBA), Di-isobutene
(DiB) and 3,5,5-Trimethylhexanal
(TMH). The expansion, which was recently
completed, increases capacity for isobutene
derivatives by more than 50 %. Evonik’s isobutene
specialties are already in high demand
as intermediates for the pharmaceutical
and chemical industries. “We willingly
rise to the challenge of supporting our cus-
tomers’ dynamic growth and continue to
invest in product quality and security of
supply,” says Dr. Hinnerk Gordon Becker,
head of the Specialties market segment at
Evonik Performance Intermediates. “That’s
why, in June 2020, we already began the
targeted expansion of our C4 Verbund and
to eliminate existing bottlenecks in production
and logistics.” The conversion work has
increased the purity of the 3,5,5-Trimethylhexanal
produced from around 88 % to
more than 95 %. In future, customers will
be able to use the isobutene derivative directly
in their production process.
cpp NEWS TICKER
European Investigators 2022.
ployees at the Reinach location
Thi Hoang Duong Nguyen, born
has grown by 20 %. At the same
in 1987, receives the 20,000 euro
time, the number of units pro-
Picture: Eppendorf
Eppendorf awards young
female scientist
For the 27th time, the Hamburg-
award for her pioneering work on
the structure and function of two
RNA-protein complexes.
duced has significantly increased
and the digital solutions portfolio
has expanded. Therefore, the
measurement and automation
technology specialist invested 60
million Swiss francs in the Rein-
Picture: Beumer
Rudolf Hausladen is new
CEO of the Beumer Group
based life sciences company Eppendorf
SE is awarding its prestigious
research prize this year.
The independent jury chaired by
Prof. Reinhard Jahn selected Dr.
Thi Hoang Duong Nguyen, MRC
Endress+Hauser opens
campus in Reinach
Picture: Endress+Hauser
ach campus. After beginning
work on the foundations in 2019,
Endress+Hauser celebrated the
opening of the building in Reinach
on 1 July 2022. The new facility
boasts more than 25,000 m 2 of
Since 1st of June 2022, there is
a change of leadership in the
family-run company Beumer
Group, Germany. Rudolf Hausladen
is the new CEO and succeeds
Dr. Christoph Beumer,
Laboratory of Molecular Biology,
Endress+Hauser continues on the
space, and is home to End-
who has led Beumer Group as
Cambridge, UK as the winner of
path to growth. Over the past
ress+Hauser Flow as well as End-
CEO very successfully since
the Eppendorf Award for Young
five years the number of em-
ress+Hauser Digital Solutions.
2000.
cpp 02-2022 7

cpp
NEWS
Picture: Dechema
Dr Björn Mathes is Executive Director of Dechema Ausstellungs-GmbH
Sustainability and digitalisation will be key issues at Achema
Summer. Sun. Frankfurt.
Was it a mistake to move Achema to the holiday season? How will the war in
Ukraine influence events beneath Frankfurt’s trade fair tower? And how many trade
visitors will be making the trip to Frankfurt at the end of August? Dr Björn Mathes,
Executive Director of Dechema Ausstellungs-GmbH, answers these and other
questions in an interview with cpp.
In a normal year, about 3700 exhibitors register for Achema.
Nearly 2200 firms have so far confirmed their attendance at the
2022 event. Dr Mathes, was it a mistake to move Achema 2022
from April to the end of August, in other words during the peak
holiday season?
Dr Björn Mathes: In retrospect, it would have been almost impossible
to hold an event with such a strong international bias as Achema
during the first week of April as originally intended. From that
point of view, yes, it was the right decision. With close on 2200 exhibitors
divided between 12 exhibition groups and spread across 13
hall levels, Achema will continue to live up to its claim as the leading
international trade fair for chemical and pharmaceutical technologies.
The reason for postponing it was the rising infection rate due to
the Omicron variant. The pandemic is not over yet and the number
of new cases reported daily is rocketing again. Will Achema
really be able to take place?
Dr Mathes: Definitely. It’s true that the Omicron variant BA5 is rampant
at the moment. However, like other exhibition organisers,
we’re much better equipped to deal with it than we were in the
past. Health and safety concepts have been developed that have
meanwhile proven themselves at numerous trade shows. They’ll also
be in place at Achema this summer.
Will the lower exhibitor numbers have any effect on the hall
layout?
Dr Mathes: Achema will be slightly more compact this year. We’ll
be occupying 13 hall levels at the Frankfurt exhibition grounds.
How many do you occupy normally?
Dr Mathes: There are normally 16 hall levels. We cancelled a few of
them after deciding to postpone, but we’ll continue to occupy the
entire exhibition grounds apart from Halls 1 and 10. We’ll be using
Hall 12 for the first time to accommodate Mechanical Processes. As
usual, trade visitors will find Pharmaceutical Techniques in Hall 3.
Pumps, Compressors, Valves and Fittings will be located in Halls 8
and 9.0.
The Digital Hub exhibition group is brand new. Where will its
space be?
Dr Mathes: It will be sharing Hall 11.0 with Instrumentation, Control
and Automation Techniques.
8 cpp 02-2022

Picture: Messe Frankfurt
The new exhibition hall 12 will accommodate the mechanical processing technology
What influence will the war in Ukraine and the various sanctions
imposed in that context have on Achema? I’m particularly thinking
here of exhibitors and visitors from Russia, Belarus and
Ukraine.
Dr Mathes: Russia was never a major exhibitor market for us. As we
sit here talking, we’re expecting two Russian firms that are neither
state nor semi-state-owned and not affected by any sanctions. It’s a
similar story when it comes to visitors. Russia, Belarus and Ukraine
have never been dominant in terms of quantity. Having said that,
though, Russian visitors have been very strong investors in recent
years.
The chemical industry is more dependent on fossil fuels and raw
materials than almost any other sector and the shortages here are
likely to become even more acute as a result of the Ukraine war.
That will further increase the pressure to decarbonise the chemical
industry. Dr Mathes, will this mounting pressure to act also be
visible at Achema?
Dr Mathes: Absolutely. The uncertainties and the dwindling raw
material base are forcing the chemical and pharmaceutical industries
to invest in sustainable, carbon-neutral technologies much
sooner than they would have done otherwise. That won’t be easy, of
course, because the industry is under tremendous pressure due to
the war and a recession may well be looming. On the one hand,
that makes it more difficult to invest in new, sustainable technologies.
On the other hand, the political framework is not going to
change and nor is the pressure to achieve climate targets. And an
awful lot of exhibitors – in fact virtually all of them – will be
showing technologies to help achieve these climate objectives.
The exhibition and congress programme will be even more closely
integrated at this year’s Achema. Dr Mathes, what does that mean
specifically for visitors and exhibitors?
Dr Mathes: We know from past experience that many trade visitors
only visit those halls where they can be sure of finding exhibition
groups that interest them. Many of them shy away from the long
walk across the exhibition grounds to the Congress Center CMF, not
least because of the time it takes. That’s why we’ve traditionally
looked for ways to bring the Congress, the Praxisforums and
discussion formats closer to thematically related exhibition groups.
And we’ve made a very good job of that this year. The result is shorter
distances and more thematic interaction between the lectures in
the congress programme and what’s going on at the exhibition and
the booths.
Isn’t that simply a clever move right now to divert attention away
from exhibition space that would almost certainly remain unused?
Dr Mathes: I wouldn’t put it quite like that. But it is indeed the case
that we’ve gained extra space due to the smaller number of exhibitors,
and that’s made it easier to realise a goal we’ve been pursuing
for a long time. All in all, though, only 6 out of 21 stages are located
directly in the exhibition areas.
MORE INFORMATION:
PROZESSTECHNIK.TV
At the video shooting: Dr Björn Mathes (right) and Lukas Lehmann
At the beginning of July, the cav/prozesstechnik.tv editorial
team was a guest at Dechema in Frankfurt/M. On
this occasion we recorded the interview with Dr. Björn
Mathes. You can find the video on prozesstechnik.tv.
Picture: Harald Frater – prozesstechnik.tv
cpp 02-2022 9

cpp
NEWS
View of Hall 8 – traditionally
the home of pumps, compressors,
valves and fittings
along with Hall 9.0
Picture: Dechema
Do you also plan to stick with the strategy of a more closely integrated
exhibition and congress at Achema 2024?
Dr Mathes: Yes, that’s what we’re planning.
But let’s get back to the congress programme. There are five theme
days on the agenda this year. What topics will they address?
Dr Mathes: The first day will be dedicated to the “Hydrogen Economy”.
“Fossil Free Production” and “Perspectives in Laboratory &
Analytics” will follow on days two and three of the fair. The fourth
day will be devoted to “Digitalisation in Process Industry” and the
fifth to “Novel Bioprocesses and Technologies”.
„Achema will be slightly more compact this
year. We’ll be occupying 13 hall levels with
close on 2200 exhibitors divided between
12 exhibition groups.“
Sustainability and digitalisation will be key issues at Achema
2022. The former will be highlighted in the “Green Innovation
Zone”, for instance. Dr Mathes, what can visitors expect to find in
this exhibition area?
Dr Mathes: Everything in this special area will revolve around the
green transformation of the chemical and pharmaceutical industries.
It will bring together pioneers, experts and solution providers
from industry, politics and science with decisionmakers and users.
For example, there will also be contributions from the financial
sector on green investments and ESG ratings. Representatives of
NGOs will likewise have their say. Last but not least, we’ll be presenting
successful sustainability projects that have benefited from
public funding.
Key issue number two will be digitalisation, as reflected by the
new Digital Hub exhibition group and the Digital Lab Action Area.
What will be going on in these two exhibition areas?
Dr Mathes: The Digital Hub will be the central meeting point for
digital experts and all participants interested in, or actively involved
in the digital transformation of the process industry. The exhibition
group will put digital showcases of the process industry firmly in
the spotlight. The central anchor point of the Digital Hub will undoubtedly
be the “Siemens Digital Innovation Stage”, which will
spark productive discussions of the process industry’s hottest digitalisation
topics. In the Digital Lab Action Area in Hall 4.1, we’ll be
collaborating with various exhibitors to build the fully automated
and digitised laboratory of tomorrow.
Dr Mathes, I’d like to end this interview with a prediction from
you: How many trade visitors do you estimate will be making the
trip to Achema 2022?
Dr Mathes: We know from other fairs that the lower number of exhibitors
is in direct correlation to the number of trade visitors. The
current level of registrations is around 60 percent compared to the
last Achema, so I’m confident that we’ll manage to attract between
70,000 and 80,000 visitors.
Summer, sun, beach, family – or stuffy exhibition halls full of
pumps, compressors and process control technology? Can you
sympathise with potential Achema visitors who choose the family
and holidays option instead?
Dr Mathes: Visitors to Achema generally come for a day. Summer
lasts longer than a day and it lasts longer than the final week of August.
If you look at it that way, it’s not so much an either-or deci -
sion as a both-and.
Dr Mathes, thank you very much for the interview.
THE INTERVIEW WAS CONDUCTED BY:
LUKAS LEHMANN
Editor (responsible under German Press Act)
10 cpp 02-2022

cpp ACHEMA PRODUCTS
Unaffected level measurement
In industrial plants, non-destructive testing is regularly
carried out using gamma sources. However, radiometric
level measurements can be influenced by exactly this
radiation. The XIP function implemented by Berthold
can prevent the measured value from being falsified by
external radiation. The measured value is frozen when
interfering radiation is detected and signalled accordingly
via a digital output. The external radiation detection
takes place in two ways: exceeding a threshold
value that would not be reached during normal
measurement and/or a sudden change in the count rate
that would not occur during normal operation.
www.cpp-net.com
Online search: Berthold
Hall 11.1, Booth E88
Picture: Berthold
Modular Ex p control and monitoring system
With the Ex p x621 control and
monitoring system, R. Stahl
presents a modular solution for
easier construction of pressurised
control panels with Ex p
type of protection. The combination
of an Ex p control unit,
Ex p pressure monitors that simultaneously
also function as
pressure outlets, and Ex p purge
valves with digital and proportional
control is able to meet all
requirements, from very small
enclosures with a volume of 10 l
to Ex p control cabinets with
volumes of 4000 l. In this way,
the Ex p controller makes control
processes available for all control
cabinet sizes and enables them to
be adjusted easily to meet users‘
requirements. The certified system
is used in Ex Zone 1/21 as a
redundant version and in Ex
Zone 2/22 as a more cost-effective
simple version.
www.cpp-net.com
Online search: R. Stahl
Hall 11.1, Booth C45
Picture: R. Stahl
Sampling & Analysing Systems
AUTOMATION
AutoFlow
Automatic flow control
RENEWABLE for sampling systems
Digox 6.1 H2-S
Analyser for dissolved hydrogen
and hydrogen in the gas phase
TECHNOLOGY
CatControl edi
Automatically regeneration
cation exchanger for
maintenance-free operation
22. - 26. August 2022
hall 11.1 / booth E63
cpp 02-2022 11

cpp ACHEMA PRODUCTS
FCC catalyst maximises butylens
BASF’s Fourtitude Fluid Catalytic Cracking (FCC) catalyst
is designed to maximise butylenes from resid feedstocks.
Fourtitude, the latest product based on BASF’s
multiple framework topology (MFT) technology, is optimised
to deliver superior selectivity to butylenes while
maintaining catalyst activity.
MFT technology enhances performance through the use
of more than one framework topology working together
to tailor the catalyst selectivity profile. Fourtitude
combines the benefits of MFT and metals passivation
technologies to deliver superior butylenes selectivity
and metals resistance for resid feedstock applications.
The superior butylenes selectivity is achieved by employing
a specialty zeolite framework that is more effective
at cracking small olefins to butylene.
Fourtitude refinery trials have validated its ability to deliver
improved performance for refiners through increased
butylenes and propylene yields, increased gasoline
octane, and improved coke selectivity.
www.cpp-net.com
Online search: BASF
Hall 8.0, Booth C37
Picture: BASF
Intelligent vacuum pump control
The Ejgo vacuum pump controller
from Edwards intelligently
manages, commands, directs,
and regulates the operation
of vacuum pumps. The
one-stop solution has all the
necessary pump information
and metrics in one place. This
includes pump health assessment,
vacuum performance, and
operating economy, multiple
KPI score and insight cards to
monitor vacuum pumps or systems.
It offers various connectivity
options and integrates
with the existing vacuum installation
seamlessly.
Users can easily pull up relevant
data on a touch HMI or a web
browser on their laptops, tablets,
or mobile phones. The controller
is able to generate trends
maps, enabling customers to
compare multiple metrics across
pump cycles and at various
times. Available in standard and
premium options, the EjgoMC
controller can control up to 20
vacuum pumps.
They also support a wide range
of connectivity options. Ejgo
and Ejgo MC support a wide
range of fieldbus communication
and network protocols,
such as Ethernet/IP, Ethercat,
Profinet, Modbus TCP, Modbus-
RTU, Profibus and OPC UA.
www.cpp-net.com
Online search: Edwards
Hall 8.0, Booth A31
Chemically resistant explosion-proof pump
Picture: Edwards
Hydrogen analyser
Designed for process pressures
up to 40 bar, the Digox 6.1
H2-S from Dr. Thiedig can
measure dissolved hydrogen up
to 10 ppm and up to 5 vol.-% in
the gas phase. The Digox 6.1
Picture: Dr. Thiedig
H2-S is suitable for a wide
range of industrial applications,
such as in water-steam cycles,
conventional and nuclear power
plants as well as in the chemical
and petrochemical industries.
The heart of the hydrogen
measuring device is the sensor
based on the principle of a fuel
cell with a maintenance-free operating
time of about 10 years.
The measuring device has a
built-in self-diagnostic system
that monitors the function of
the sensor without interrupting
the normal operation.
www.cpp-net.com
Online search: Dr. Thiedig
Hall 11.1, Booth E63
Strict regulations are in place for
the processing and distribution
of explosive gases. KNF meets
current standards with its new
ex-proof pump. The N 680.1.2.
belongs to a small group of
pumps which run oil-free and
which are Atex-compliant in
their performance category to
be used for emission protection
and product recovery. It combines
the safety of an explosionproof
diaphragm pump with reliability
and high-quality, lowmaintenance
performance.
Highly chemically resistant, the
Picture: KNF
N 680.1.2 Ex transfers explosive
gases and vapours. A flow rate
of 220 l/min and an ultimate
vacuum of 150 mbar abs make
for a high-performance pump
for important tasks in process
manufacturing. Thanks to these
features, the ex-proof pump is
particularly suitable for all applications
in which flammable
gases are recovered or where the
escape of those gases must be
prevented.
www.cpp-net.com
Online search: KNF
Hall 11.1, Booth E85
12 cpp 02-2022

Pressure sensor module available for Ex areas
Wika’s MTF-1 pressure sensor
module is now also available in
a version with Atex and IECEx
approval. The new variant of the
compact module supports
manufacturers in their development
of end products for applications
in potentially explosive
environments. Having Atex and
IECEx component certificates for
Picture: Wika
the MTF-1 simplifies the Ex approval
of the entire system.
Designed for pressures up to
1000 bar, the pressure sensor
module has features that enable
it to be used in critical and sensitive
applications. Its stainless
steel measuring cell is welded to
the process connection and
therefore suitable for aggressive
media. In addition, the “dry”
and seal-free sensor element
minimises the risk of contamination
of the medium.
In the version with Ex approval,
the MTF-1 transmits the
measured pressure value via an
energy-saving I2C signal. The
digital protocol also outputs a
temperature value for the sensor.
This information, in turn,
can be used for condition monitoring
of the end device.
www.cpp-net.com
Online search: Wika
Hall 11.0, Booth C35
IO-Link positioner for control valves
The latest generation of the Schubert & Salzer 8049
digital positioner for pneumatic control valves is
equipped with IO-Link. Diagnostic data from the controller
and the valve are thus available to plant operating
companies. Valve parameters such as dynamics, accuracy
and characteristic curve can be adapted at any time
without physical access. A single cable with an M12
plug bundles the positioning signal, position feedback,
data transmission and even the power supply. The integration
of the IO-Link industrial standard in its version
1.1.3 facilitates the installation and maintenance of the
valves in complex plants. Incorrect connection is technically
impossible due to the coded connecting plug. In
case of a replacement the controller adopts the previously
used parameterisation automatically.
www.cpp-net.com
Online search: Schubert & Salzer
Hall 11.1, Booth F46
Picture: Schubert & Salzer
cpp 02-2022 13

cpp ACHEMA PRODUCTS
Intelligent peristaltic metering pump
Picture: Prominent
Turnkey plants for CBD and THC extraction
De Dietrich Process Systems is
expanding its range of turnkey
plant extraction solutions to
cover all steps in the extraction
of cannabidiol (CBD) and THC.
In the field of plant chemistry,
the molecules currently being
extracted from cannabis and
hemp are mainly cannabidiol
(CBD) and THC. The extraction
of these compounds is based on
processes for which the group
already has considerable knowhow.
The first step in many cases
is solvent extraction using
supercritical CO 2 or organic solvents.
A variety of subsequent
steps then determine specific
The Dulcoflex DFYa peristaltic
metering pump combines the
advantages of peristaltic and
metering pumps. It ensures precise,
linear and repeatable metering
under all process conditions.
The pump delivers quantities
between 5.5 and 410 l/h.
It can be controlled electronically
and is operated via the intuitive
user interface with four
buttons and a click-wheel. The
DFYa meters valvefree with high
precision. All the advantages of a
peristaltic pump remain. Highly
outgassing, viscous, abrasive,
particle-containing or shearsensitive
fluids can be metered.
For changing the hose, the operator
receives precise instructions
on the steps to be taken via the
display. The rotor automatically
moves to the correct positions
for the hose change. Different
hose materials, such as NR,
NBR, NBR-A, EPDM and Hypalon,
enable a very wide range of
media to be metered.
www.cpp-net.com
Online search: Prominent
Hall 8.0, Booth J94
qualities or types of use,
whether preference is to be
given to extracting CBD or THC.
De Dietrich Process Systems develops
turnkey solutions for the
installation of these processes at
the customer’s request by carrying
out simulations and tests inhouse.
The engineering team
draws on its knowledge of plant
extraction system implementation,
both standard solutions
available on the market and the
group’s own solutions.
www.cpp-net.com
Online search: De Dietrich
Hall 12.0, Booth A21
Picture: De Dietrich
Track samples by their ID
The Eppendorf Safecode system enables a safe sample
vessel tracking at all stages of the lab workflow. Safecode
is based on a multi-level coding of the consumables
based on prelabeled datamatrix codes. The coding
can be read by the Rackscan instrument, any handheld
datamatrix scanner, or even the smartphone. The Safecode
cryostorage vial family is now expanded by a
series of barcoded classic conical tubes: 5, 15 and 50 ml
for daily routine usage at the bench. The conical tubes
are digitalised – on the tubes as well as for documentation
purposes. Specific support material like lot
number, certificates, technical drawings, etc. are available
online based on the consumable ID.
www.cpp-net.com
Online search: Eppendorf
Hall 4.1, Booth B35
In-line total cell density measurement
The Dencytee Arc sensor from
Hamilton Bonaduz presents a
new generation of in-line total
cell density biomass measurement.
Unlike the conventional
measurement method of total
cell density, where only the
transmitted light is measured,
Hamilton has combined the advantages
of transmission and reflection
measurement. By upgrading
to two detectors, higher
measurement resolution can be
achieved. The high linearity over
the entire measuring range from
0 to 200 g/l and accuracy of
±1 % allows almost complete
process monitoring and the establishment
of process control,
both in real-time. Dencytee Arc
takes advantage of the Arc intelligent
sensor technology. Arc
products offer direct communication
with the process control
system using common standards
such as Modbus digital protocol
and 4...20 mA output signals.
The sensor not only sends a
compensated measured value
for controlling processes. It also
offers a wide range of diagnostic
functions.
www.cpp-net.com
Online search: Hamilton
Hall 11.1, Booth F43
Picture: Eppendorf
Picture: Hamilton
14 cpp 02-2022

SIL 2 filling level measuring devices
User-friendly Raman spectroscopic analyser
The JSP (Jumo Safety Performance) portfolio is being
expanded to include the detection and measurement of
process-critical point levels and filling levels for liquids.
The system solution based on the products of the Nesos
series are offered up to SIL 2 according to IEC 61508.
The JSP complete solution in the filling level field can
reliably detect line faults, such as short circuits and
cable breaks, ranging from the sensor to the actuator.
Solutions can also be implemented in combination with
applications in explosion-protected areas (intrinsically
safe Ex i and flameproof enclosure Ex d).
www.cpp-net.com
Online search: Jumo
Hall 11.1, Booth E41
Picture: Jumo
The Thermo Scientific Ramina
process analyser offers non-destructive
and continuous analysis
without the need for sample
preparation, with rapid system
setup and deployment in as little
as 15 min to generate spectral
data on target analytes within
seconds. This compact system
utilises a range of patented
probes to maximise the speed
and sensitivity of results, enabling
fully automated in situ
measurements to calculate concentrations
in a reaction vessel.
The Ramina process analyser
offers a rapid and easy-to-use
Picture: Thermo Fisher
alternative to offline manual or
automated wet chemistry testing,
and is simpler to install and
use. It comes with everything
the user needs to start collecting
data, including a Raman spectrometer
and fibre optic probe,
as well as a portable monitor,
mouse, keyboard and laser
safety goggles. Factory calibration
ensures the Ramina system
is ready to use without
delay.
www.cpp-net.com
Online search: Thermo Fisher
Hall 4.1, Booth N50
ENEXIO Water Technologies is now
part of Brentwood. We are excited
to combine our expertise and
leverage each other’s strengths in:
• Water & Wastewater Treatment
• Stormwater Management
• Cooling Towers
• Mass Transfer
• Aquaculture & Agricultural
Engineering
Learn more:
Visit us at:
ACHEMA
in Frankfurt / Germany
August 22 - 26, 2022
Hall 4.0 – Booth D9
drinktec
in Munich / Germany
September 12 - 16, 2022
Booth A3.265
Taking Confidence to the Next Level. Today, Tomorrow, Together.
cpp 02-2022 15

cpp ACHEMA INSTRUMENTATION, CONTROL, AUTOMATION
From sensor to fully automated measuring point
PAT modular system
extended
The process engineering industry is dependent on accurate measuring systems that can
determine a wide range of measured values in a medium, from oxygen content and conductivity
to pH or ORP. The application, the medium, and the ambient conditions can all
place highly exacting demands on the measuring technology. At Achema 2022, Knick
will be showcasing several new components for its in-house PAT modular system.
The Knick modular system comprises sensors,
fittings, transmitters, and systems for
cleaning and calibration. The transmitter
range includes simple head-mounted transmitters
and compact transmitters in a
modular housing, portable devices, and
smart premium transmitters that are also
available for use in hazardous locations. In
time for Achema 2022, Knick is extending
its modular system to include the Stratos
Multi E461N multiparameter transmitter,
the transmitters in the Memotrans MT201N
line, and the Progalog 4000 PC configuration
tool.
Also transfer diagnostic data
In many applications, industrial Ethernet
protocols are the key to digitisation, as they
greatly simplify connections to higher-level
systems. Now making sure the sensors are
also connected, Knick is launching the Stratos
Multi E461N multiparameter transmitter,
which is equipped with a Profinet
interface. Profinet, which is standardised in
IEC 61158 and IEC 61784, can be used for
easy connections to all common process
control systems from leading manufacturers.
This ensures continuous communication,
from the field level to the control
level, to the ERP systems at company level.
Pictures: Knick
Knick’s modular system offers custom solutions from the sensor to the fully automated measuring point
16 cpp 02-2022

The Stratos Multi E461N features a Profinet
interface
Ultra-compact transmitter MemoTrans
MT201N for Memosens sensors fits directly
in the fitting
The Progalog 4000 PC configuration tool
for configuring Knick transmitters
Now also with Profinet
The Stratos transmitters work equally easily
with sensors from different manufacturers,
regardless of whether they transmit
measured values via Memosens, digital, or
analogue signals. All key process variables
such as pH, ORP, conductivity, or oxygen
content can thus be measured. Thanks to
smart diagnostics management, the user can
keep their eye on the sensor condition at all
times. A sensor wear monitor also assists
with predictive maintenance, allowing, for
example, the calibration intervals to be optimised.
The range of diagnostic data acquired
can be easily transmitted using Profinet. All
this increases the system’s availability. When
operating the system directly, the colour
graphic display and full-text menu navigation
in numerous languages ensure optimum
usability.
Transmitter for Memosens sensors
Memosens sensors have acquired a strong
market position in recent years, and it’s not
hard to see why: thanks to a plug connector
with inductive transmission that is protected
from external impacts, they are ideal
for use in difficult environments. Transmitters
are then used to enable easy data
transfer, and Knick is now expanding its
range for Memosens sensors with the
Memotrans MT201N, a transmitter solution
that is space-saving and flexible.
The transmitters in the Memotrans MT201N
product line are suitable for use with all pH,
ORP, oxygen, and conductivity sensors that
use Memosens technology. Users can be assured
of both flexibility and safety. The
Memotrans MT201N transmitters are extremely
compact in design and thus take up
little space, allowing them to fit directly
into existing Knick fittings. Installation is
therefore possible without the use of special
tools. The transmitters are available in two
versions – the multiparameter version with
4…20 mA Hart protocol for full device and
sensor configuration, as well as calibration
and diagnostics with the FDI package, and
the fixed parameter version with preset
4…20 mA outputs for each parameter for
quick commissioning. The transmitters feature
a green/red LED for on-site diagnostics
and the use of precalibrated sensors minimises
maintenance and plant downtime.
In terms of data transfer, too, the compact
transmitter is also in no way inferior to its
larger cousins. With Memosens on board,
reliable data transfer is assured with ease.
The measured values are digitised directly in
the sensor and relayed to the transmitter in
a contactless process.
Configure transmitters offline
Configuring Knick transmitters such as
those in the Stratos or Protos product lines
is a simple affair thanks to the devices’ intuitive
menu navigation and clear displays.
Nevertheless, sometimes it’s more conven -
ient if configuration can be carried out offline
on a PC in the office. For such cases,
Knick now offers the new Progalog 4000 PC
configuration tool. The software supports
the Stratos Multi Transmitter and the Protos
II 4400.
Just one software application is required for
all device configurations of the two flexibly
configurable transmitters. The user selects
the transmitter, the installed firmware, and
the modules in the configuration tool and is
presented on their PC with the same menu
structure as displayed on the device. If a
new firmware version is available for one of
the devices, it can be selected in the current
version of Progalog 4000 after an update.
The transmitter can be fully configured in
the configuration tool; each menu item is
clearly displayed, making the user’s work as
easy as possible.
Error-free parameterisation
All inputs are actively checked for plausibility,
with any errors or gaps in the configuration
displayed during use with a direct reference
to the source of the error. When configuration
is complete, it is stored on a data
card via a USB interface. The card can then
be simply inserted into the transmitter. This
removes the need to use a PC on site. In addition,
the configuration can be exported
and saved in a range of file formats, e.g. .txt,
.pdf. or .xlsx. For documentation purposes,
these are important in many applications,
e.g. when specified in audit requirements.
www.cpp-net.com
Online search: Knick
Hall 11.1, Booth A45
DR. BERND RADEMACHER
Editor
cpp 02-2022 17

cpp ACHEMA INSTRUMENTATION, CONTROL, AUTOMATION
Pctures: Vega
Vegapuls level sensors and Vega Inventory System enable optimal stock maintenance
RUNS LIKE CLOCKWORK
Although the employees of Itelyum, the Italian specialist for waste oil
regeneration, know a lot about making processes run smoothly, they always
had difficulty keeping track of the inventory held in the company’s
numerous storage tanks. However, the use of Vega radar sensors and the
introduction of a Vendor Managed Inventory System changed everything.
18 cpp 02-2022

There are companies today who are trendsetters and don’t even
know it. Itelyum Spa in Pieve Fissiraga, Italy, for example, has been
focusing on circular economy and ecological sustainability for more
than half a century already. The company specialises in the treatment
of lubricating oils, the purification of solvents and chemical waste,
as well as environmental services for industry. In the course of its
long history, the company has been constantly developing new
proc esses and technologies in order to produce high-quality lubricant
base materials from waste oils. These are then used in various
lubricating applications in the automotive sector, as well as in other
industries. At least 95 % of the lubricating oil they process is converted
into new products or further refined by third parties. Any entrained
water is returned to the environment as purified water.
Today, more than 850 employees at 26 production sites serve more
than 30 000 customers in more than 60 countries. The company is a
leader in the production of regenerated lubricant bases (Regeneration
Solutions) and high-purity solvents from by-products generated
during manufacturing processes. They are also involved in the
purification of chemical waste and used solvents from the chemical
and pharmaceutical industries (Purification Solutions). Besides that,
the company provides a range of integrated services for producers
of hazardous waste. This includes collection, storage, transport, pretreatment,
brokerage, consultancy, chemical analysis and treatment
of industrial water.
The plant in Ceccano, in the province of Frosinone, can process up
to 84 000 t of used mineral oil per year; in 2021 it processed over
64 000 t. This annual quantity yields around 44 000 t of lubricants,
8000 t of bitumen, 5000 t of diesel oil and 6000 t of purified water.
These raw materials, i.e. the intermediate and end-products, are
stored in more than 100 tanks.
Four steps to the end product
To produce a usable product, the raw waste materials have to
undergo multiple treatments. First, water and light hydrocarbon
fractions are separated from the waste oil in two pre-separation facilities.
This is followed by purification using propane deasphalting
technology. In the first step, the main asphaltenes, heavy metals, additives
and ash (which constitute the base materials for bitumen)
are removed. The deasphalted oil is then fed to the subsequent fractionation
phase, while the bituminous component is stored. In the
second propane deasphalting unit, the bottom residue of the vacuum
fractionation is treated again to remove any remaining asphaltenes,
heavy metals, additives and ash. The deasphalted oil forms the
semi-finished product ‘BR’, while the bitumen fraction is sent to
the extraction column of PDA 1. The deasphalted oil is then proc -
essed in a vacuum distillation column, from which diesel oil is
taken at the top, plus three ‘side cuts’ and the bottom residue are recovered
and fed back to the second propane deasphalting unit. Finally,
the semi-finished products are treated in a catalytic hydrogenation
unit (hydrofinishing) to obtain the quality of finished base
materials.
Difficult measuring environments
To maintain a good overview of all the processes, Vega sensors have
been installed at various measuring points since 2020. They monitor
the levels of raw materials, in the intermediate and finished
product containers, as well as the stored chemical products. They
are also used on some of the processing systems and in the wastewater
treatment facilities.
In the years before, the plant technicians were not really happy with
the level measurement solutions used – in some places the level was
Sensors of the Vegapuls series are installed in the approximately 60 storage
tanks for spent oil. The operational conditions for sensors here are
anything but easy.
only monitored by eye through viewing windows, without any way
to transmit data. For example, before the Vega sensors were introduced,
continuous guided microwave level sensors were used. These
devices didn’t work reliably and required constant maintenance. The
reason was that the cable of the TDR sensors tended to get dirty
with buildup within a few weeks, which in turn affected the
measurement. The plant technicians had to climb the tanks, remove
the sensors and clean the cables by hand. If a cable was not cleaned
regularly, the actual level would not be detected by the sensor. Incorrect
values were transmitted due to the contamination.
Finding a good level solution wasn’t easy. For one thing, the plant
operator wanted to keep the existing process fittings and not make
any major modifications to the tanks. And for another, the products
themselves are quite challenging to handle. The oil-based products
are viscous, and have poor reflectivity due to a low dielectric constant.
These properties also change depending on how the products
are being processed. And lastly, some areas of the plant are Ex hazardous
and considered a great risk to the environment – SIL-classified
measurement technology was therefore required.
Radar level sensor maintains a complete overview
“We were already using some sensors from Vega, but we wanted an
overall solution”, explains Jacopo Jirillo, works manager at Itelyum.
“Vega is a leader in radar level measurement. So we decided Vega
would be the best choice.” The company first started with a pilot
project with two tanks, testing the suitability of the sensors as well
as Vega Inventory System. “Level information is very important for
the operation of production and logistics. The information about
the raw materials and end products in storage is passed on to the
Quality and Production Office, which in turn plans and prepares
production based on the incoming products”, explains Jirillo
further. The logistics department also needs to know how much
space is available in the various tanks in order to plan the storage of
product. The system sends orders with predefined quantities directly
to the chemical suppliers. “But we also have to monitor the
processes correctly and, of course, continuously check the oil tanks
for environmental and safety reasons”, adds Jirillo.
cpp 02-2022 19

cpp ACHEMA INSTRUMENTATION, CONTROL, AUTOMATION
The implementation of VIS was a further step in simplifying the processes. The web-based software records
and visualises the level data in any standard browser.
“We wanted a complete solution for level
measurement”, says Jacopo Jirillo, works
manager at Itelyum
Radar level sensor not bothered by harsh conditions
Non-contact Vegapuls radar level sensors have been installed in the
approximately 60 waste oil tanks, that store it before being sent to
the refinery for processing. The ambient conditions here are not
pleasant for sensors. For example, temperatures can reach 230 °C in
some cases. In addition to the usual contamination from crude oil,
corrosive substances and explosion hazards can also be present. And
then there are the challenges typical of the industry, such as turbulence
and fumes that can cause disturbances in some phases.
For Jirillo, the use of Vega sensors brings enormous advantages:
“With these sensors, we have better calibration and thus more reliable
process monitoring. Troubleshooting is simpler and much less
maintenance is required. And thanks to the continuous monitoring,
problems that occur outside normal working hours are detected
and reported to the appropriate personnel. Orders to suppliers of
chemical products can also be automated in the same way.”
Measurements have become more stable overall. The contactless
measurement by the Vegapuls is not affected by buildup of dirt or
product emissions. Once installed, the sensors never require cleaning
or maintenance. Additionally, the data transmission system is
based on 4G and cloud technology which does not require any
special wiring or hardware systems (PCs, servers) to display and
process the data.
Everyday life made easier with VIS
All sensors were set up and commissioned by one of Vega’s own
technicians. After the installation was finished, he configured Vega
Inventory System (VIS) and got it up and running. The implementation
of VIS was a further step in simplifying the processes. The
web-based software records and visualises the level data in any standard
browser. It can do this both in the local network and throughout
the whole world via the Internet. A local installation of application
software or plug-ins is not required for measured value dis-
play. The measured values are transmitted either via network, Internet
or mobile telephone systems.
The software continuously receives level data from the Vegapuls sensors.
If desired, the current measured values can also be sent cyclically
at any time via e-mail or SMS. “We’ve transferred responsibility
for procurement to our suppliers. They now know the status of
our stocks in real time”, says Jirillo, describing the benefits. Options
for data exchange with other systems (ERP, SAP, etc.) or cloud
platforms via a data client or a Restful API are also available. This
allows the supplier to manage the delivery of replenishments on
their own.
Conclusion
The decision to implement radar measurement technology and Vega
Inventory System was a completely successful one for Itelyum. Apart
from the reliable, continuous measured values, Jirillo was particularly
impressed by how easy it was to install the equipment. “Beside
the reliability of the measurement, which was tested during the
pilot project, we also appreciated how quickly we were able to get
VIS up and running. The data was immediately available after the installation
of the sensor”, says Jirillo in conclusion.
www.cpp-net.com
Online search: Vega
Hall 11.1, Booth C63
AUTHOR
CLAUDIA HOMBURG
Marketing,
Vega
20 cpp 02-2022

HOW INDIVIDUAL AND
RELIABLE DO YOU WANT
YOUR PROCESS SOLUTION?
CUSTOMIZED PROCESS GAS
COMPRESSORS AND BLOWERS
Technological excellence and experiences, for more than 150 years
Customized engineering and flexible compressor concepts
Efficient and reliable process solutions
Innovative solutions for process gas and hydrogen compression
www.aerzen.com/achema
PRODUCT LAUNCH HYDROGEN SOLUTIONS
Monday, 22. August 2022 at 10:30 am
Hall 8.0 | Stand D38 or with LIVE STREAMING
Michael Leitsch, Sales Manager Process Gas
Phone: +49 (0) 175 9335602
E-Mail: michael.leitsch@aerzen.com
Web: www.aerzen.com
Compressed air, gas
and vacuum solutions
cpp 02-2022 21

cpp ACHEMA INSTRUMENTATION, CONTROL, AUTOMATION
Picture: Levaco
The control engineers Thomas Sonnborn (left) and Stephan Wolf (right) draw a conclusion on the new web-based distributed control system at Levaco
Web-based process control system allows a view into the reactor
Levaco relies on digital
transformation
How can a process plant modification be used as a sustainable investment in the
future? By focusing on digitalisation already today to open up many possibilities for
tomorrow. Levaco did exactly this and chose the web-based distributed process
control system Simatic PCS neo. After operation started, we asked the engineers
Thomas Sonnborn and Stephan Wolf about their experiences with the daily use of
the new distributed process control system.
Mr. Sonnborn, at Levaco a new distributed process control system
is in use. What is it used for and in what environment?
Thomas Sonnborn: The implementation took place in the course of
a major rebuild of a reactor. One can imagine such a reactor as a large
cauldron in which chemical intermediates are produced. In concrete
terms, this mainly involves defoamers and surfactants, i.e.
components that make products water-soluble. For this reactor,
Simatic PCS neo is now used as the superordinate control systemthat
controls the process. We want to be well-prepared for the fu -
ture. It replaced an outdated system that had mainly worked with
binary signals, and many operating steps still had to be carried out
manually. For example, valves were previously switched by hand.
You specifically chose this distributed process control system –
why?
Sonnborn: The main factor for the decision was the system’s focus
on digitalisation. We wanted to keep up with the latest technology
and have a foot in the new world. We are talking about a web-based
control system – with all its advantages: for example, one has access
to all information from serval locations and you can call up the visualisation
regardless of location. This transparency is a real progress.
Please explain why you chose Siemens.
Sonnborn: This was a pragmatic decision insofar as we already had
experience with the good on-site support from Siemens through the
22 cpp 02-2022

Picture: Levaco
Picture: Siemens
In the course of a partial reorganisation, Levaco was also faced with the
question of a new process control system. The main factor for the decision
in favour of the web-based PCS neo system was the system‘s orientation
towards digitalisation.
Simatic PCS neo is completely web-based with object-oriented data management.
Everyone can reliably access the same information from anywhere
and at any time.
Simatic PCS 7 distributed process control system. Since 70 % of our
plant is already running with Simatic PCS 7, our programmers and
electricians are already trained in Siemens hardware and software.
Stephan Wolf: Additionally, the IO level with its hardware components
is the same as with Simatic PCS 7. Therefore, an efficient transition
towards Simatic PCS neo in the whole plant is possible at any time.
Sonnborn: Exactly – this enables us to be flexible and keeps all opportunities
open for the future.
By now, you have already gained experiences with the new distributed
control system – which advantages have you seen so far in
your operations at Levaco?
Sonnborn: Here I want to pinpoint the visualisation: There are more
setting options and very precise, good visualisations, such as curve
diagrams. Especially fast zooming and the large variety of specific
symbols, for example for temperature probes, make operation easier.
A very important aspect compared to the outdated automation system
previously installed in the plant is that with Simatic PCS neo, we
“We want to have a foot in the digitalised
world with the web-based control system.“
have regained the power over the plant – through transparency. This
is because the control system allows us to take a look inside the
plant, which was previously a black box. Now, we can intervene and
change processes or optimise them. Thanks to numerous basic functions,
we have many more options – whether it involves the temperature
or the dosage. What used to have to be set by hand is now done
automatically, such as opening valves to reach a defined temperature.
Now, you simply enter a set point – and the plant regulates it.
That sounds like huge changes with high potential.
Sonnborn: Absolutely.
How do these improvements affect the performance of the plant?
Sonnborn: The possibilities for quick fine-tuning have a positive
impact on the quality. This has improved of course. In addition, the
processes are much safer. The new safety considerations have led to
optimised processes, for example by replacing manual equipment
with automatic equipment. Many things havo also become faster,
not least thanks to the new computers. Overall, the performance has
definitely improved.
What would you describe as the most important feature of the
new system?
Sonnborn: In short: with Simatic PCS neo, all information is available
on every computer and one has insight into the whole plant.
This extends to remote maintenance. Since we have implemented
remote maintenance access to our plant, we have been able to access
the required information very conveniently and securely, regardless
of location. This is also a big step and offers many advantages.
Let’s take one step back in the chronology and look at the implementation
of the new system. Can you briefly describe this phase?
Sonnborn: When looking back, it was a complex conversion with
high requirements – sometimes a rocky road for both sides – for
Siemens and for us. We also had to do our homework and rethink
and describe all the processes and basic functions in detail. But it
was worth it. In the end, we have got a significantly better result.
And it was an investment in the future. Further development can
build on this basis. But let‘s be specific about the implementation:
First, the system was set up at Siemens and the individual step
chains and basic functions were tested live. After successful testing,
the system was set up at Levaco. After everything was wired on site,
the next step was to test the basic functions via IO test. Following
this phase, we demolished the old plant in just a few weeks and
built the new one – and operation started immediately. We were
able to successfully implement our optimistic timing.
Can you specify the part regarding the collaboration?
Sonnborn: Yes, of course,the collaboration worked very well. We
were always in close contact with the programmers and the project
coordinator and discussed the current status: whether it was the wiring
or the status of soft- and hardware. And we always received direct
feedback on our wishes and ideas, for example with regard to
the design of the basic functions. There were many conversations –
no matter what they were about – we always had a contact person
at Siemens. That worked out really well.
Following the implementation there was a start phase: how did
you experience the incorporation in Simatic PCS neo?
Sonnborn: As Simatic PCS 7 experts, it was quite easy, and a routine
was established very quickly. But especially for programming we
plan to take a course.
cpp 02-2022 23

cpp ACHEMA INSTRUMENTATION, CONTROL, AUTOMATION
Picture: Siemens
Visualisation of a reactor: the web-based process control system allows a view into the plant
Do you already have first experiences in readjustments and
changes in daily use? How well can these be realised in the new
distributed process control system?
Wolf: We are very familiar with the system, so we can implement
changes without any problems.
With 3.0 as one of the first released versions, you are one of the
so-called “early adopters”. Which of the upcoming features is the
one you are most looking forward to?
Sonnborn: I‘m thinking of two features: integration of a failsafe
control and realisation of batch processes. As far as we know, both
are on their way and will be released in the upcoming versions.
ny clients clearly benefit from Simatic PCS neo: without the need to
configure individual clients, the web-based system can be launched
quickly and cost-effectively.
Mr. Sonnborn, Mr. Wolf, thank you for the interview.
www.cpp-net.com
Online search: Siemens
Hall 11.0, Booth E14
Let us take a look into the future – which long-term perspective
do you see for this plant?
Sonnborn: With this plant, we are well-equipped for the upcoming
decades if we update it accordingly.
If you draw a short conclusion: for whom would you recommend
the web-based control system?
Sonnborn: Those who want a good visualisation and who have ma-
THE INTERVIEW WAS CONDUCTED BY:
DANIELA HELD
Editor
Process engineering
Hygienic, Perfect Fit?
High-Precision Process Measuring and
Control Technology from AFRISO
Pressure, temperature and level –
mechanical and electronic
Hygienic Design, 3A certified
Suitable for CIP and SIP
Versatile process connections, FDA-listed
materials for your specific application
74-03
24 cpp 02-2022
22.–26. August 2022
Frankfurt am Main
Visit us
in hall 11.1,
stand F45

cpp ACHEMA PRODUCTS
Robotised packaging line
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!
Picture: Marchesini
The Integra 720V from Marchesini Group is a robotised
integrated line for packaging blisters in cartons. The line
can be equipped with the BL-A525 CW labelling machine
complete with incorporated checkweigher for dynamic
weighing and control of the cartons. A unique
software package aggregates the blister to the carton.
This is a strategically important solution for all contexts
where blisters are sold, distributed or separated from
their original pack. The Integra line can be further
equipped with a predictive maintenance solution. The
data of the sensors installed on board the machine is
collected, analysed with the aid of artificial intelligence
algorithms, transformed into information useful to the
operator and displayed by means of a dedicated web
platform.
www.cpp-net.com
Online search: Marchesini
Hall 3.1, Booth G3
Tel.: 0800/50 30 300 (free of charge)
IBAN DE22 4306 0967 2222 2000 00
BIC GENO DE M1 GLS
www.sos-kinderdoerfer.de
SOSKD_Anzeige_Fingerabdruck_E_92x133_4c_RZ.indd 1 29.03.17 09:12
2016/1
Atex-certified roots pumps series expanded
Pfeiffer Vacuum’s Oktaline roots
pumps are ideal for use in processes
in potentially explosive
environments or for evacuating
explosive gases. Designed in accordance
with the Atex directive
with pressure surge resistance of
PN 16, they meet the highest
explosion protection requirements.
Zone entrainment of explosive
gases is ruled out as a
result. Pumping speeds range
from 280 to 8100 m 3 /h. Depending
on the application,
Picture: Pfeiffer Vacuum
there is a choice between equipment
category 2G or 3G. All
pumps are suitable for temperature
class T3. Installation is pos -
sible without flame arresters.
This means that, effectively, the
full pumping speed of the
pump is available.
All pumps can be used at ambient
temperatures ranging
from -20 to + 40 °C.
In view of their magnetic coupling,
Oktaline pumps are hermetically
sealed and achieve extremely
low leak rates of 10 to
6 Pa m 3 /s. The magnetic coupling
eliminates the need for
shaft seals. Oktaline Atex pumps
are pressure surge resistant up
to 1600 kPa.
www.cpp-net.com
Online search: Pfeiffer Vacuum
Hall 8.0, Booth J37
COG MAKES ITS MARK:
The right chemistry
Come and see us at ACHEMA, and learn
what chemical-resistant O-rings can do.
22 – 26 August 2022
Meet us: hall 9.0, booth B4
cpp 02-2022 25
www.COG.de/en

cpp ACHEMA PRODUCTS
Single-use pharmaceutical separator
From powder to finished tablet
Picture: GEA
GEA’s kytero single-use pharma
separator convinces with its
high separation efficiency, the
simple and safe handling, gentle
product handling and the elimination
of cleaning procedures.
This type of technology is in
high demand for pilot plants,
university laboratories, and
small-scale production by
biopharmaceutical manufacturers,
as it relies on the wellestablished
technology of disk
separators. The use of filtration
technology can thus be reduced.
The kytero 500 was developed
for a capacity of up to 150 l/h
and is thus suitable for laboratories
and small batches. For reliable
scale-up, another model
will follow in the short term.
The GEA experts succeeded in
developing a single-use sepa -
rator for the biopharmaceutical
industry that offers the same
high-quality performance as the
stainless-steel separators commonly
used to date. The proven
feed system guarantees particularly
gentle product treatment,
and the vitality of shear-sensitive
products is preserved. Product
runs and scientific tests at
the ZHAW School of Engineering
in Zurich have confirmed
this.
www.cpp-net.com
Online search: GEA
Hall 4.0, Booth G66
With the modular solutions for continuous processes
called Modcos, Glatt offers specific solutions in direct
compression as well as wet granulation for product
quantities from 100 g/h to 1000 kg/h. The modular
process technology allows flexibility from product development
to commercial production. Glattview Conti
is the control system for the Modcos production line,
where all process parameters come together. These are
continuously monitored and provide the basis for automatic
process control. The production process is controlled
by recipes. Product residence times and the distribution
of residence times are embedded in the automation
software and stored as recipe parameters.
www.cpp-net.com
Online search: Glatt
Hall 3.0, Booth H26
Picture: Glatt
REMBE® Pressure Relief
and Explosion Safety.
The future of wastewater treatment for
chemicals/pharmaceuticals: safe & efficient
hall 9.1 / stand D21
Complex substances require
complex treatment methods?
Not with us! Because
our VACUDEST vacuum
distillation systems combine
the safety of reliably
separating unwanted
substances from wastewater
with high efficiency and costeffectiveness.
Save time, money and
stress: get to know us at the
ACHEMA Frankfurt: hall 9.1,
stand D21!
26 cpp 02-2022
H2O GmbH | +49 7627 9239-0 | www.h2o-de.com

Expanded screw blower series
Aerzen added smart features, and further improved
functionality to its screw blowers Delta Hybrid. The additional
blowers provide more energy efficiency, a simplified
service and maintenance concept as well as reduced
dimensions or smaller footprint. Thanks to a
compressor stage with high-efficiency screw profiles,
internal flow optimisation, coupled with motors of
energy efficiency class IE4, optimised process and cooling
air flow as well as a self-tensioning belt drive with
an efficiency of over 98 % in conjunction with a pinpoint
design, energy savings of up to 30 % are achieved.
The control range was extended to 1:5. The bearing enables
a service life of 70,000 h and more. The four additional
assembly sizes cover volume flows from about 2
to 30 m 3 /min and driving power from 7.5 to 55 kW.
www.cpp-net.com
Online search: Aerzen
Hall 8.0, Booth D38
Infrared welded PVC-U piping system
operating pressure of 16 bar. In
the beginning, two metric dimensions,
d25 and d50 will be
available. The welding process
offers integrated quality control
and traceability for each joint.
Existing IR machines can be updated
to process the new IR
PVC-U system.
www.cpp-net.com
Online search: GF Piping
Hall 8.0, Booth E64
Picture: GF Piping Systems
Picture: Aerzen
With IR PVC-U, GF Piping Systems
introduces an infrared
welded PVC-U piping system
that allows reliable joints in a
machine-controlled process. The
solution combines the PVC-U
piping system and the infrared
welding machines to produce
reliable, reproducible joints.
The system consists of the
necessary weldable fittings,
valves and pipes designed for an
The fastest way
to the perfect
LIB electrode mix
The future of batteries with Eirich:
Easy scale-up, highly efficient process, clean
turnkey solutions and continuous supply of
coaters. Eirich simply makes your batteries
better - today and tomorrow!
eirich.com
cpp 02-2022 27

cpp ACHEMA SAFETY, SECURITY
This is how structures and systems should be designed
Security solutions for the
process industry
The recent cyber attacks on plants in the process industry emphatically underline the
fact that such attacks can cause considerable financial, health and other damage to
companies as well as their customers. To prevent such drastic consequences,
Phoenix Contact offers various solution approaches with which secure applications
as well as protection concepts can be implemented.
Digitisation is sweeping through the various
sectors of the economy and does not
stop at the process industry. For example,
field devices are being connected directly to
the control system via appropriate interfaces
and access is being created for mobile end
devices so that all the possibilities of process
monitoring can be fully exploited. If the
aspect of cyber security is not taken into account,
the increasing networking of systems
can open up gateways for attackers. Vulnerabilities
such as insecure or faulty device
configurations, outdated software versions
or unfavorable network infrastructures, for
example, enable malware to be implemented,
denial-of-service attacks to be
carried out or sensitive data, such as
recipes, to be stolen.
However, not only intentional attacks, but
also negligent misconduct – for example
during a service call – can lead to sabotage,
resulting in component or system failures.
Due to the critical processes within the process
industry, this can result in considerable
personal injury, environmental damage and
damage to the company‘s image. And
although more than half of industrial companies
have already been victims of cyber
If field devices are directly connected to the control system as well as access for mobile end devices
is created and the aspect of cyber security is not taken into account, the increasing networking of
the systems can open up gateways for attackers
Picture: Mohok@shutterstock.com
attacks, there are still companies that are not
aware of these risks and do not implement
countermeasures.
In order to protect supply chains from potential
consequences nonetheless, critical
infrastructure thresholds are constantly
being developed and tightened. This puts
the obligation on more and more companies
to look at the risks of cyber attacks
and integrate appropriate measures into
their security management mechanisms.
Companies are receiving support from various
efforts. While the ISO 27000 series has
established itself in the office or IT environment,
the international IEC 62443 series of
standards sheds light on OT areas, which
comprise completely different systems and
structures compared to IT environments.
Against this background, Namur has, for
example, developed the Namur Open Architecture
(NOA) so that the data generated by
smart field devices can be made more usable
and plants can be operated more efficiently
due to additional monitoring and
optimisation functions. The concept described
in NE 175 is implemented by adding
a parallel NOA side channel to the
automation pyramid. This picks up data
from the field and sends it to the superordinate
control level without retroactive effects,
so that sensitive processes are not
negatively influenced.
The NOA Security Gateway, which is to be
installed between the process and monitoring
areas, ensures that there is no retroactive
effect. The gateway is defined in NE 177 by
basic requirements based on the component
and system requirements of IEC 62443. In
addition, a zone model describes the mutual
28 cpp 02-2022

delimitation of the individual components
of the gateway. On the one hand, the NOA
Security Gateway consists of the Data Aggregator
module, which establishes the coupling
to the core process and is responsible
for data acquisition. In addition, there is the
module for one-way data transfer, which
provides secure protection against backlash
and decouples the data accordingly. The
third module makes the data available for
the monitoring area via OPC UA, for
example. With a PLCnext controller and a
Hart gateway, Phoenix Contact already offers
a device combination with which the functions
of the NOA Security Gateway can be
implemented while largely meeting the
requirements. The concept shows that future
structures and systems can be designed securely,
using IEC 62443, which was
specially designed for automation areas and
is constantly being further developed, as a
basis. This approach is supported by secure
components from Phoenix Contact, which
are designed according to a certified development
process in compliance with
IEC 62443.
Components of the NOA Security Gateway
Picture: Phoenix Contact
Cycle according to the international series
of standards IEC 62443
Picture: Phoenix Contact
Holistic security concept
In order to support its customers in the
design of a security concept based on
IEC 62443 and the implementation of effective
components, Phoenix Contact has been
following a blueprint approach for several
years. In this process, the specialists work
out a holistic security concept with organisational
and technical protective measures
on the basis of a generic application in
accordance with IEC 62443 – taking into
account a prescribed cyclical process. The
resulting solution ultimately contains
measures to be implemented at the enterprise,
solution, and component levels.
At the enterprise level, Phoenix Contact
recommends, for example, restricting and
monitoring access to solutions. In addition,
components should be used for remote
access that support VPN (Virtual Private
Network), for example, and provide options
for user authentication. One of the most
important measures is to train and sensitise
employees so that they live the measures
developed and act accordingly.
At the solution level, the security experts
advocate measures such as segmenting the
solution into zones and protecting them
with firewalls to prevent the spread of
malware. Furthermore, activities within the
solution should be monitored and any
unusual occurrences should be responded
to. This can be implemented through
proper logging or an anomaly detection
Illustration of the main security efforts and the NOA concept
system implemented in the solution.
For the component level, appropriate
devices that support secure protocols and
provide device hardening measures should
generally be selected. In any case, default
user names and passwords should be
changed and unused services and interfaces
should be disabled. Finally, the company‘s
customers can refer to such recommendations
and the associated detailed descriptions
of measures.
The security specialists at Phoenix Contact
are currently working on industry-specific
security blueprints that users can use as
templates for real systems. In this way, existing
topologies with selected components,
verified documents, and tools can be used,
thus benefiting from the company‘s experience.
Another advantage of security blueprints
is that only deviations from the generic
application or its security concept need
to be re-examined in real systems. This
makes it possible to develop security concepts
much faster and more cost-effectively.
www.cpp-net.com
Online search: Phoenix Contact
Hall 11.1, Booth A27
AUTHOR:
NIKLAS LECKER
Global Industry
Management Process,
Phoenix Contact Electronics
Picture: Phoenix Contact
cpp 02-2022 29

cpp ACHEMA PLANTS, APPARATUS, COMPONENTS
Efficient pumping of heavy fuel oil
Multi screw pumps at the
tank farm
Large tank farms always supply container ships with the necessary quantities of fuel.
Especially when refuelling with heavy oil, one has to deal with strongly fluctuating
viscosities. This is where positive displacement pumps have particular advantages
over the centrifugal pumps that are often used. The operator of a tank farm in Texas
also experienced this: switching to Notos screw pumps not only increased reliability,
but also reduced energy costs in the long term.
To keep sea transport running, tank farms
are located at crucial ports around the
world. These oil terminals consist of a large
number of tanks for storing fuel, among
other substances. Owners of the tank farms
often also rent out storage capacities – a
company in Texas in the US is an example of
this. Because fuel is so crucial for the global
supply chains, reliable availability of the
HFO (heavy fuel oil) and VLSFO (very low
sulphur fuel oil) used in shipping is of the
utmost importance to the customers of the
Texan oil terminal company. HFO is used at
high sea, while VLSFO is intended to be
used near the coast, where stricter
emissions guidelines apply. To be reliably
mobile and to be allowed into all relevant
ports, transport ships always have to have a
sufficient amount of each fuel onboard unless
they are equipped with an emission
control system.
Refuelling a modern container ship takes
many hours, as the fuel tanks have huge capacities.
Special conditions apply, particularly
when pumping HFO: In contrast to
VLSFO, this fuel is highly viscous at room
temperature. To ensure that HFO is sufficiently
free-flowing, it has to be continuously
maintained at the right temperature.
Fluctuating conditions
As the ambient temperatures in the tank
farm are subject to natural fluctuations, the
owner has frequently had problems with
the changing viscosities of the oil to be
pumped. This is compounded by changing
Pictures Netzsch
To keep maritime traffic running, there are tank farms at important ports around the world: the facilities consist of a large number of
tanks in which fuels are also stored
30 cpp 02-2022

The Notos-screw pump ensures efficiency
and reliability in the oil terminal
The Notos screw pumps reliably maintain the flow rate at different viscosities
heating conditions in the pipes up to now.
Even the feed pumps have to be heated in
order to maintain flowability, including
during idle phases. As in many other tank
farms, the oil terminal in Texas also uses
centrifugal pumps for the oil. But the
pumps often have difficulties with this application
due to their design. Pumping
highly viscous liquids is difficult for centrifugal
pumps by design. The required
energy input also rises rapidly as the viscosity
increases.
For companies who use centrifugal pumps
for pumping fuel oil, this means that several
disadvantages add up: Transport is unreliable,
in particular, if the viscosities fluctuate,
and the delivery volume can enormously
decrease depending on the prevailing
ambient conditions. In addition to this,
high viscosities significantly reduce the efficiency
of the centrifugal pumps, which
leads to higher energy costs. To prevent the
pump from running in overload, it had
been common practice at the Texan tank
farm to throttle the pump and run the system
at the BEP (best efficiency point). A
common but complicated and expensive
procedure. It artificially generates resistance,
which eliminates energy for adapting the
system to the pump characteristic.
The displacement pumps from Netzsch now
ensure greater efficiency and reliability in
the oil terminal. Notos multi screw pumps
can reliably operate with a constant flow
even within a wide range of viscosity and
pressure changes. Due to their operating
principle, they have a different characteristic
with operating points independent of a BEP.
Therefore throttling and strong flow rate
fluctuations at changing viscosities do not
apply here. And this, in turn, saves a lot of
energy.
Installed in short time
However, a drawn-out delivery period was
not an option for the tank farm in Texas: As
the previously installed centrifugal pumps
had become increasingly problematic, the
oil terminal owner could not afford to wait
out long delivery and installation periods.
The new pumps had to be delivered and installed
within five weeks. The RFQ is comprised
of a total of five pumps with two different
delivery rates. All had to be equipped
with an overpressure valve and a bypass as
well as electric heating.
The five pumps are installed for parallel
pumping of the fuel from the tank farm to
several ships. The viscosity fluctuates between
100 and 500 mPas, regardless of the
ambient temperature. Overall, distances of
around two and a half kilometres have to be
covered. The liquids are pumped with
4.1 bar and a temperature of 55 °C. Two
pumps have to provide a delivery rate of
122 m 3 /h, while three other units have to
transport up to 408 m 3 /h of fuel oil in the
same operating conditions.
In light of the required short delivery
window, the global production and service
network of Netzsch was a great advantage.
Although the requested delivery time was
unusually short, five Notos multi screw
pumps with exactly the right specifications
could be commited to delivering on the
required date.
Reliable operation
The tank farm owner immediately commissioned
the pumps and was able to share
their first experiences with Netzsch after a
short time. With the installed Notos pumps,
not only refuelling is much faster, but also
reliability can also be increased and the
energy consumption reduced. This results in
great savings right from the start. The displacement
pumps can easily master the
required high flow rate. They reliably maintain
the delivery volume at different viscosities.
The widespread network of Netzsch locations
and service partners has proven successful
by adhering to the short delivery
time. But even during the operation of the
pumps, the oil terminal company can enjoy
the benefits. In particular for critical processes,
where every single hour of downtime
costs money, fast and on-time maintenance
and repairs on pumps are absolutely
essential.
www.cpp-net.com
Online search: Netzsch
Hall 8.0, Booth C27
AUTHOR:
ULRICH EIBL
Head of the Oil and Gas,
Midstream/Downstream
Business Field,
Netzsch
cpp 02-2022 31

cpp ACHEMA PLANTS, APPARATUS, COMPONENTS
Modular all-in-one solution increases process efficiency
Intelligent piping systems
Piping systems are crucial networks that distribute, mix and dispense media such as
process water, chemicals or cooling agents. They ensure a reliable operation but also
the safe handling of hazardous substances. Intelligently automated, piping systems
are easy to implement and allow operators to monitor, analyse and regulate processes
at all times.
Water is one of the most important resources
for production processes. A study
looking at the water usage by the German
manufacturing sector conducted by the Federal
Environmental Agency in 2016 found
that the industry consumed around 4,5 billion
m3 of water throughout that year.
However, the quality standards can differ
greatly, depending on the industry sector or
application. At the same time, the process
industry produces large amounts of contaminated
water that must be treated. Sustainability
and quality must not be mutually
exclusive in both water supply and disposal.
For this reason, it is important to implement
solutions that require as little manual
intervention as possible. The answer is the
combination of a modern piping system
made of durable and, as far as possible,
maintenance-free materials and a holistic
approach to process automation. Plastics
such as PVC-U and polypropylene in particular
have established themselves as stand -
ard materials for piping systems as they are
corrosion-free compared to metal and
require minimal maintenance. Many plastics
also have a high chemical resistance and do
not introduce any foreign substances into
the transported medium, while smooth
inner surfaces and a lack of dead space ensure
a clean flow.
Many production processes rely on intelligent piping systems in order to guarantee a consis -
tently high quality
Pictures: GF Piping Systems
Intelligent processes
Real-time data on flow, pH-values, level or
temperatures provide insights into what is
happening within the piping system, which
can reduce both maintenance effort and the
risk of system failures. Depending on the
application, industrial valves such as butterfly
valves or ball valves can be controlled
with pneumatic and electric actuators,
while smart actuators can be accessed re-
32 cpp 02-2022

UPGRADED:
BALL VALVE GOES DIGITAL
The 543 Pro ball valve can be seamlessly
integrated into the user‘s control and
automation systems
motely with an app. That way, operators always
carry the most important information
in their pocket.
Efficient production
The various forms of data that are collected
by sensors are not only important for a reliable
plant operation. Data also unlocks
hidden potential in piping systems by offering
valuable insights that lead to smart decisions
and concrete actions. Possible improvements
include switching to smaller
pumps or improving pressure management
– and therefore saving costs. Here too,
plastics offer a number of benefits, as the
lower operating torque of pneumatic and
electric actuators reduces energy consumption
and allows for smaller valves. But for
maximum efficiency, modularity also plays
an important role. Customised all-in-one
solutions guarantee compatibility and help
companies find the best possible solutions
for their processes.
Sustainable components
For companies in the chemical process industry,
even the piping system itself can become
an important part of their sustainability
efforts. The long-lasting nature and low
weight of plastic components ensure a long
operational lifetime that can be increased by
additional quality assurance. Depending on
the type of piping system, companies can
check pipe connections with the help of
ultrasonic NDT (non-destructive testing) or
analyse infrared welds with photosensory assurance.
The low weight of plastics also reduces
emissions during transport, while the
digital tracking of individual components
replaces extensive paper documentation. And
at the end of their lifecycle, plastics used in
certain applications can be recycled.
The ball valve 543 by GF Piping
Systems is a durable and flexible
solution used for mixing and
distribution in complex chemical
and pharmaceutical processes.
Now, sensors and drives
have been added to the 543 Pro
model, opening up new possibilities
for process automation.
On a mechanical level, the
three-way ball valve increases
safety with a new lever that prevents
unintentional operation
thanks to a locking ring. For an
extra layer of security, a padlock
can also be fitted in order to
protect the valve against un -
authorised usage. Regarding the
digital functionality, the 543 Pro
features a retrofittable position
feedback sensor with an LED
Interoperable all-in-one solution
GF Piping Systems offers a wide range of
plastic piping systems as well as Interoperable
all-in-one solutions for process automation.
As a result, lightweight and longlasting
valves such as the Butterfly Valve 565
or the Ball Valve 543 Pro are combined with
standardised digital interfaces. From pneumatic
actuators and electro-pneumatic positioners
to smart electric actuators, they can
be implemented in many different applications.
Processes are monitored with the
help of measurement and control instruments
such as the Flowtramag magnetic
flow meter, the 9900 Smartpro transmitter
or the Ultrasonic Flowmeter GF U1000 V2.
Thanks to a modular approach, the best
possible system can be configured for every
application.
Companies like Pure Life Carbon in Canada
demonstrate how effective this kind of complete
solution can be. It has developed
CO 2 -negative growing mediums for the agricultural
industry that are made of carbon.
During production, wood is subjected to
very high temperatures before it is enriched
display which reliably records
the position of the control
leaver. The compact double sensor
can be easily mounted with
a snap-on design and is suitable
even for tight spaces within the
piping system. And, in addition
to traditional manual operation
and a pneumatic control unit,
the ball valve can be operated
fully automatically with an electrical
actuator. As a result, it can
be seamlessly integrated into the
end user’s process control and
automation systems. Finally, the
543 Pro features a scannable
data-matrix-code which simplifies
the storage of all component
information and enables
individual traceability.
with essential nutrients in large tanks. Here,
Pure Life Carbon uses a mix of process
water and proprietary chemicals that are
subsequently purified in a filtration plant
and reused. In order to achieve maximum
efficiency, the company selects a complete
solution by GF Piping Systems that closes
the control loop and automates all processes
– the result is a sustainable cycle and a consistently
high quality. Due to the close collaboration
with GF Piping Systems, the production
plant can also be continually optimised.
www.cpp-net.com
Online search: GF Piping Systems
Hall 8.0, Booth E64
AUTHOR:
ANTOINE WALTER
Senior Business Development
Manager Waste Water
Treatment,
GF Piping Systems
cpp 02-2022 33

cpp ACHEMA PLANTS, APPARATUS, COMPONENTS
How engineering consolidation makes plant manufacturers faster
Effortless consistency
Anything can be consolidated: finances, political positions, companies, supposedly
even marriages. But engineering? That especially! Consolidating means „bringing together
several parts to form a whole“ or put simply: unifying, strengthening or securing.
Engineering can be consolidated by bringing together the various planning
disciplines and tools in plant construction. Result: one source, one authoring system,
significantly reduced interfaces, no waiting times and transmission errors.
Especially engineering, procurement and
construction contractors (EPC), faced daily
with an enormous variety of tools and suppliers,
know how valuable consistent data is.
It starts with EPCs having to juggle different
sources of information: descriptive texts,
e.g. on required standards or legal frameworks,
capacity specifications, documentation
requirements and much more. The
Excel files, PDFs, DOCxs are then collected
as files, in folders, document management
systems or similar – depending on the
client, highly variable in quality and detail.
But in this state the information is only
archived, it does not usually fit together, let
alone go on to be directly editable.
Consolidating the input
The diversity cannot be changed, but the
usability of the data can, however. Because
all the different information can flow into
the software developer Aucotec’s Engineering
Base (EB) cooperation platform right
from the start – whether labelling lists,
specifications for ambient pressure, named
devices, templates, standards or functional
structures – all this data can be created as
objects in EB without even having to create
a single document. In this way, engineers
can build up the desired plant structure
right from the start. In this way, they consolidate
the diverse input, and the original
documents no longer need to be consulted.
EB itself then consolidates all inputs as an
authoring system virtually by itself. Since
the platform is the single source of truth
(SSoT) for all parties involved – from the
initial concept to process design and detail
engineering with instrumentation and wiring
to the function charts for automation
and configuration of the control system
modules – it cannot do otherwise. Once the
structure has been created according to the
specifications, anyone making further entries
follows it automatically. If PFDs and
P&IDs are developed in different tools, they
are never based on the same data, even if
the tools come from the same manufacturer.
Not so in EB. The active consolidation of engineering
disciplines is simply not necessary.
Everything that the PFD experts have
contributed is at the same time the basis
and available for elaboration by the P&ID
professionals and so on. This creates effortless
consistency incidentally, a particular advantage
for EPCs. The usual synchronising
and data transfer as well as the associated errors
are saved by EB as SSoT „by nature“.
But uniting engineering disciplines in a
central data model is only part of Aucotec’s
consolidation principle. This is because
there are still numerous supplementary systems
with data relevant for engineering,
such as ERP, simulation tools, 3D or the
control systems.
As the single source of truth for all those involved, the EB platform consolidates its entries
virtually by itself
Seamlessly to engineering
In many cases, simulation is one of the tasks
of EPCs. Almost every chemical process has
its own tool. Some are available on the market,
many are developed by the clients
themselves. In the case of large plants, certain
sections are simulated module by module.
First one mass flow, then the adjacent
34 cpp 02-2022

one. Different constellations result in a corresponding
number of scenarios. In order to
compare them, experts usually place XLS
tables next to each other and sort through
them. The scenarios finally selected must
then be transmitted to the engineering system
in order to pass the results on from
there to calculation tools for further calculations
as a direct transmission from simulation
to calculation is not possible.
EB saves transferring and sorting. The simulation
results can be automatically imported
into EB and consolidated, for example, into
continuous flowstreams. In addition, the
platform automatically compares the imported
scenarios. It shows all the differences
in an instant, without the hassle of jumping
back and forth between Excel spreadsheets
and without the risk of missing anything.
Another plus: the finally selected scenarios
are already in EB and are thus the basis for
seamless further editing by the engineering
specialists or for passing on to a calculation
tool. If a parameter changes, a new simulation
is quickly compared and incorporated
into a new calculation. Even the experts
who have already started an object specification
can see immediately if there have
been any changes. All integrations and comparisons
take place in EB’s data model,
which has central access to the entire plant
knowledge, including the engineering-relevant
information from 3D, ERP and automation.
In EB’s SSoT, the editors keep enhancing the
model according to the given structure until
a comprehensive, consistent digital twin has
been created, which not only serves as the
origin of the plant to be built, but also as an
easily updated image of the finished physical
plant.
Neutral data hub
No matter how many simulation tools,
phases and scenarios, how many calculations,
which 3D tools, ERP or control systems
are in use, EB can work with any of
them, also thanks to its communication
standard EBML. When consolidating the
various external data, the platform also
merges, for example, different terminology
for the same object into a neutral designation
or transforms different units of
measurement from the tools into a generally
understandable unit. Users do not need to
know how the various systems work and do
not have to worry about anything, EB ensures
consistency.
In addition to the many complementary
tools, EPCs also have to deal with a wide
variety of suppliers. Their data must also be
The versatile model in EB consolidates the data of all core disciplines of the plant engineering,
and communication with complementary systems
EB also passes on its neutral data to other systems, e.g. control system configuration
integrated and consolidated. Before that,
however, the suppliers need a specific brief,
for example to obtain tenders or approvals.
If an EPC wants to send a hardware request
to different manufacturers, he pulls all the
relevant specifications from EB’s central
model into an intelligent data sheet. Searching
and collating this data from various discipline-specific
tools is a thing of the past.
Suppliers complete the sheet according to
their capabilities; the changes are immediately
identifiable from the automated revision
of the datasheets. With a document
management system, the tender could at
best be filed as a document, but in EB the
data itself ends up there, directly reusable.
EB also passes on its neutral data to other
systems, for example for calculations or
control system (DCS) configuration. In addition,
the platform can output signal assignment
lists or feed a predictive maintenance
system with the information that enables
it to correctly interpret the signals
from the running plant.
Consolidation therefore has many aspects,
but always one result: an enormous gain in
consistency and time from numerous synergies
– because everyone is pulling in the
same direction.
www.cpp-net.com
Online search: Aucotec
Hall 9.1, Booth B4
AUTHOR:
REINHARD KNAPP
Director Global Strategies,
Aucotec
Pictures: Aucotec
cpp 02-2022 35

cpp ACHEMA PLANTS, APPARATUS, COMPONENTS
Increased productivity and time saving
Touch panel connects
man and machine
In future, all subsidiaries of Haver & Boecker will introduce and use a consistent
presentation concept for the design and usability of systems and machines. At
Achema, the Feige WEB HMI will for the first time be presented live on the semiautomatic
drum filling station Elementra 19. The interface offers the latest form of
HMI and thus some exciting novelties.
Pascal Strehlau, responsible project manager
at Feige Filling: “One of the biggest advantages
of the WEB HMI – it is web-based.
Hence, the interface can be used on virtually
any end device, also on mobile phones and
tablets, is platform-independent and can be
operated on several devices at once.
Equipped with multitouch and gesture control,
operation is adapted to the usual end
devices and with scrolling, touch and similar
features thus offers the user a comprehensible
design.”
To configure the new WEB HMI in the long
term to the satisfaction of customers and
employees, the developers joined forces
with the service and took a look at some of
the machines on site during production. It
was important to them to see how the operators
are coping with the current HMI and
to examine the layout of the design. “This
gave rise to some ideas as to how the new
interface can be developed to make it as
simple as possible for the operator while at
the same time allowing complex contents
such as statistics and filling curves to be integrated,”
explains Jörn Czysch, automation
engineer with Feige, who together with Pascal
Strehlau forced the implementation of
the WEB HMI.
User interface rethought
Putting the emphasis on the user – that was
the motto for the new and improved user
interface. The result is a more compact content
summary that is only of relevance to
the user. The simplified application allows
the productivity of the operator to be increased
to a high degree. The training
requirement for new employees is reduced,
thus shortening the familiarization periods.
Besides, tasks can be completed by different
employees without them requiring extensive
training. Feige Filling will also integrate
the new touch panel into the smaller semiautomatic
machines. “Depending on the
machine the customer opts for, employees
will come across the same HMI both on the
large and on the small machines and will
need no additional training,” adds Pascal
Strehlau.
When it comes to new automation projects, Pascal Strehlau is on fire. With a group-wide
project team, the expert developed the new intuitive touch panel with the web-based HMI.
Pictures: Feige Filling
Design as function
A group-wide project team has extensively
dealt with the topic ‘design’ and has applied
this knowledge very specifically to the
product functions. The new user interface of
the WEB HMI convinces with its intuitive
design that makes operation easier for the
user and ensures fast orientation and considerable
time saving. In addition, unneces -
sary operating steps, accidents or operating
errors are prevented. Modern items such as
drop-down boxes and slide switches, with
36 cpp 02-2022

Jörn Czysch, automation engineer at Feige
Filling, has driven the realisation and implementation
of the new WEB HMI together
with Pascal Strehlau
A schematic representation of the machine supports the operator and ensures quick
orientation and navigation
which the user is already familiar from his
smartphone, increase the ease of use and
substitute menu options in need of explanation.
Even during the design process,
Feige Filling was as closely as possible
guided by customer requirements to guarantee
an efficient as possible interaction.
Improved help concept
Of particular importance was to enhance
the help concept so as to offer the user an
even more comprehensive description of
possible failures. 3-D-pictures and videos,
operating instructions and PDFs support the
employee in reacting quickly to alarms. In
addition, an integrated commentary function
permits the operator to write his own
notes with regard to a particular failure. This
is of great help in reminding oneself or
other employees of factors that may pos -
sibly have influenced this failure.
A sophisticated layout
“The new HMI offers customers the opportunity
of flexibly creating a name entry for
each of their employees,” says Czysch. “In
the user administration, they are able to distribute
roles and rights and can for instance
decide whether the operator may adjust
parameters or carry out a manual operation,”
explains the automation expert. The
latest system feature is the logbook that is
used to record different machine states and
user operations. This includes among others
entries of the parameters that were adjusted
or the information which operator has just
logged on to the system. The recipe administration
in particular was a very important
development issue. Although referring to
The interfaces are clear, self-explanatory and user-friendly, adapted to the structures of
mobile devices
the same content, the name the recipe management
had been given differed across the
group. A recipe in the context of the Feige
WEB HMI describes a collection of param -
eters such as target weight, tolerances,
masses, consistency, etc., which can be individually
saved and exported by the customer.
A recipe, e.g. milk, is made up of subrecipes
such as product or container.
Conclusion
The jointly newly developed HMI places the
focus on the operator and thus convinces as
ideal interface between man and machine.
Increased productivity and time saving are
two great advantages customers can expect
to gain with the use of the WEB HMI.
Feige Filling is a pioneer in touch panel integration
and has already delivered machines
with the new interface. The next step
is the consistent implementation of the WEB
HMI across the entire Haver & Boecker
Group. An existing machine can be converted
to the new touch panel, provided the
control system is also replaced.
“Especially for users who have machines or
plants from more than one of the companies
of the Haver & Boecker Group,the
use of a uniform HMI would make things
easier. We have oriented the development
strictly to the needs of the operator. We already
have ideas how the interface could be
put to even broader use,” Strehlau sumps up.
www.cpp-net.com
Online search: Feige Filling
Hall 3.0, Booth F38
AUTHOR:
ALINA RISTAU
Freelance journalist
cpp 02-2022 37

cpp ACHEMA PROCESS ENGINEERING
Mixers and dryers in the production of pesticides
Careful handling of valuable
high concentrates
To manufacture pesticides, modern processing facilities are necessary. This is
because the highly effective substances are not only valuable, but also not without
hazards for the machine operator due to their high concentration in the process. For
greater safety, the multi-stage syntheses and formulation steps therefore take place
in enclosed systems. Due to their special design features, Amixon devices contribute
a great deal to the efficiency of processes in pesticide production.
The term pesticides groups together substances
with different effectiveness levels.
These are chemical or biological high-tech
active ingredients, which are used against
undesirable organisms found in the agriculture
sector with the aim of maximising
yield.
It takes about ten years of intensive de -
velopment work, however, before an
approved pesticide can be launched on the
market. During this period, a manufacturer
will invest about 200 million euros,
conduct around 200 studies and perform
tests using more than 800 parameters.
First of all, a search for suitable substances
takes place and pilot projects are tested in
the laboratory. Even for these tests, the active
ingredients are converted from formulations
into products that can be applied in
agriculture. For this purpose, so-called
carriers – powdered minerals or organic
solvents – as well as additives (usually
surfactants acting as emulsifiers, wetting or
adhesive agents) are used. The job of the
coformulants is to make the active ingredients
technically safe and usable so that
spreading them is safe and their effectiveness
is optimal.
Different preparation technologies are then
weighed up against each other: for example,
micronisation – grinding very finely for a
uniform suspension in water and then later
safely spraying or dripping it on the crop
plants – or encapsulation, which automatically
regulates the availability and effect of
the substance.
Once all parameters and other attributes
relating to the application have been optimised,
pilot trials are carried out in the test
centre. The aim is to synthesise the active
ingredient in a way that makes it pure,
stable, highly concentrated and reproduc -
ible. This project phase is particularly
challenging from a process engineering
point of view, because the piloted apparatus
must be adequately capable of being scaled
up in order to overcome the subsequent
mass flows and batch sizes, which are larger
by a factor of 20 to 100 as a rule.
Flowchart of a typical multi-purpose synthesis line with amixon equipment: reactor/precipitation,
paste bunker, vacuum dryer and mixer-cooler, final high-performance mixer and vacuum dryer for
processing residue
Pictures: Amixon
Multi-stage production process
The synthesis steps for manufacturing pesticides
differ depending on the active ingredient
and preferred spreading method.
The basic process steps are similar, however,
for the basic powdered substances.
First of all, a solvent is placed in the reactor,
powdered reagents are added and dissolved
or homogeneously suspended. The first
reaction step takes place during this liquid
phase. The stirring process can be supported
by circulation pumps to enhance the reaction
kinetics. Once the reaction has com-
38 cpp 02-2022

pletely finished, the new substance is pre -
sent in liquid form. It is mixed with additives
to trigger a crystallisation of the active
ingredient, which is promoted by skilful
temperature changes. At the moment of the
phase transition, a particularly effective
mixing effect is necessary – especially when
very rapid, even and gentle cooling is
required.
The still suspended solids mostly remain capable
of being pumped and are now subjected
to a multi-stage washing process. The
cleaned product is mechanically separated
into a solid and liquid phase. Continuously
working centrifuges or even filter presses
are also used. As a rule, gastight, sealed
systems are preferred. Finally, the thermal
drying process takes place.
The concluding vacuum drying produces an
initial synthesis result, which can act as a
starting material for a second synthesis step.
Highly effective, modern powdered chemicals
are usually the result of several synthesis
steps, which nearly always finish with
a vacuum mixer drying stage. During the
process, the active ingredient becomes more
valuable and often more sensitive with each
synthesis step. Thermal and mechanical
stress must therefore be avoided during
drying.
Gentle drying and rapid cooling
If, at any point in the process, the method
of production is transferred from batch
processing to continuous or vice versa,
the material flow must be collected in
buffer tanks. These buffer tanks for damp
materials are also called paste bunkers.
Paste bunkers must continue to work perfectly
even if the damp materials are
thickening or reacting as a dilatant. They
must store the goods gastight according to
requirements and discharge them as completely
as possible. At the same time, paste
bunkers should only agitate the mass as
little as possible so as to preserve its granulometric
characteristics. Sometimes it is
even necessary to slightly adjust the temperature
of the wet mass.
This is also the case in the manufacture of
pesticides. At the end of the filtration process,
the product resembles a crumbly,
damp bulk material. Actually, it is usually
pseudoplastic and its consistency soon
changes when it is agitated. It can then become
adhesive and sticky.
From the paste bunker, the product takes a
short route to the contact dryer installed
underneath, which dries the product in
batches with gentle continuous flow drying.
At this point, all components in contact
with the product are heated in the amixon
dryer: the entire mixing chamber, the mixer
shaft, the mixer arms and the helix. If
needed, High Shear Blades deagglomerate
the batch or distribute liquid admixtures.
When they enter the mixing-dryer, the wet
masses contain around 15 to 40 % liquid by
mass. This can be water, solvents or mixtures
of the two.
The suspension is dried under vacuum, as
the stability of the substance and its subsequent
effect must not be impaired by thermal
stress. Some active ingredients may not
Schematic diagram of a vacuum mixer-dryer
be heated above 35 °C in this respect.
The Amixon vacuum conical mixing-dryers
are therefore suitable for rapid, gentle vacuum
drying using short cycle times. In the
case of vacuum drying, the drying temperature
is lowered, because pure water, for
example, boils in the drying chamber at just
21 °C when the system pressure reaches
25 mbar.
Ideal mixing tools
The drying time can be reduced if particularly
large amounts of heat are introduced
into the mixed material and each particle
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from ecom by Pepperl+Fuchs
cpp 02-2022 39

cpp ACHEMA PROCESS ENGINEERING
Koneslid intensive mixer for active ingredient formulation with
very fast complete emptying
touches the mixer-dryer’s heated surfaces as
often as possible. Three-dimensional flow
mixing of the products at a low mixer rotational
speed is beneficial here, regardless
of their rheological changes. It is not rare to
have a well-flowing, pumpable suspension
at the start, which then turns highly viscous,
tough and pasty – like chewing gum –
to gradually form large, crumbly lumps.
During the course of the drying progress,
these disintegrate resulting in a free-flowing
active powder with ideal homogeneity.
These changes in consistency can only be
controlled if the mixing tools are ideally
formed.
The thermal fluid is directed to all areas in
contact with the product using half-pipe
coils or the classic double-shell. This also
applies to the rotating mixing tool, whose
shaft, mixer arms and helix agitators have
internal thermal fluid ducts. The base and
top of the mixing chamber are also temperature
controlled. Uniform temperature
control is particularly challenging when the
thermal fluid enters as steam and leaves the
apparatus as condensate. The enthalpy
change of the thermal fluid then allows the
introduction of particularly large amounts
of heat into the mixed material.
Special mixer-coolers
After drying, the mixed materials must be
cooled before the filling process. Naturally,
the cooling process can also take place in
the vacuum mixer-dryer. In practice, however,
an extra mixer-dryer increases production
efficiency. A suitably sized mixer-dryer
below the vacuum-dryer can thus considerably
increase the output quantity of an installation.
It then also takes over the filling
of big bags and containers in portions, or
also the feeding of automatic filling lines.
In this respect, the cooling of large powder
masses in batches is not a simple matter, because:
• The cooling surfaces and dry particles
touch each other here and there at best,
which does little to support the transfer of
heat
• The thermal conductivity of the powders
is usually low
• Any stirring/mixing energy introduced
increases the temperature of the mixed
material, which is actually supposed to be
cooled
• The cooling brine used must not be that
cold, as condensation is to be prevented
In order to adhere to all these requirements,
very large heat exchange surfaces must be
available and the mixed materials may only
be moved with very little energy – this is
where amixon mixer-coolers make full use
of their design benefits.
The formulation line
The active ingredients are blended, crushed,
mixed, moistened or agglomerated in the
so-called formulation line so that the user
can apply them safely and evenly. For blending,
the part compositions are up to
1:1,000. Besides water-soluble substances,
bentonite, kaolin or powdered limestone
can be used as carriers. Air separation mills
micronise the active substances so finely
that they aggregate with the carrier without
segregation. The mixing and wetting process
is intensified by the Amixon High Shear-
Blades. The more accurately the intensive
mixer mixes and empties, the safer the process.
Achieving ideal mixed materials in a particularly
short time is something that precision
mixers can do these days in a reproducible
manner. If, however, the precision
mixer is supposed to empty in just a few
seconds, there are hardly any alternatives to
the Amixon Koneslid mixer.
The Koneslid mixer is a vertical precision
mixer whose mixing tool is only supported
and driven at the top. It is ideally adapted to
the cylindrical-conical mixing chamber. The
special thing about it is the inverted conically
shaped displacer inside the cone. This
helps the materials to flow without dead
spaces during the mixing process and it also
ensures the particularly fast complete discharge
of the mixed materials when it
moves downwards a few centimetres.
Formulation lines are used for small
batches. Afterwards the apparatus is thoroughly
cleaned with water. The Koneslid
mixer even completes this wet cleaning and
drying automatically in just a few minutes
using fitted orbital jet cleaners at a water
pressure of 15 bar. These jets are then controlled
with pressurised air for drying purposes.
Thanks to several particularly large inspection
doors, the Koneslid mixer can be
conveniently maintained.
After mixing, the powdered pesticides are
packed in small containers so that the user
can conveniently dissolve them in suitable
water feeds.
www.cpp-net.com
Online search: Amixon
Hall 12.0, Booth C21
AUTHOR:
LUDGER HILLEKE
Technical Manager and
Member of the Management
Board,
Amixon
40 cpp 02-2022

Managing international projects successfully
Communication is
the key to success
Carrying out international projects on time, on budget and to the complete satis -
faction of the customer is no easy task. For Frank Betzold, Project Engineer Hybrid
Tubular Plate Heat Exchangers at VAU Thermotech, the key to success lies in
communication. He describes his experiences in the petrochemical and oil and gas
industries below.
Picture: Blue Planet Studio – stock.adobe.com
Project managers have the task of coordinating
all parties (planners, engineers, suppliers,
installation companies, etc.) to ensure
that an international project is executed
on time, on budget, and to the client’s complete
satisfaction. In order to find the best
possible technical solutions, they therefore
prepare comprehensive technical specifications
and requirement specifications as
well as formalised processes for document
approval and technical clarification.
These rules form the framework within
which proposal and project engineers, e.g.
from component suppliers, operate. During
project execution, they are faced with the
challenge of finding a feasible way through
the plethora of technical and bureaucratic
requirements and, at the same time, implementing
a technically feasible solution
within the agreed time and cost framework.
In an international environment, there are
often additional cultural factors that may
call for the responsible persons to adopt
new ways of working.
A structured approach that focuses on the
essentials first and then deals with detailed
questions has proven its worth. At the same
time, it is helpful for those involved to constantly
reflect on their own actions and to
communicate openly and confidently with
all parties. The reward is a successfully completed
project and an enrichment of individual
professional and personal competencies.
Project managers have the task of coordinating all parties to ensure that an international project is
executed on time, on budget, and to the client’s complete satisfaction
Bidding phase: Stay connected
Tender portals are commonly used internationally,
providing important information
about the project and enabling communication
with the company requesting proposals.
Since each platform has its own user
interface, familiarisation with the subjectmatter
can be facilitated by calling the contact
person named in the invitation and asking
for help and instruction. The same
applies to clarifying technical details or
content-related questions about the tender
text. Here, too, a time-saving telephone call
is preferable to a written exchange. For reasons
of transparency, a summary of the conversation
should always be archived in the
portal afterwards.
The fully downloaded documents are
searched for relevant specifications, as these
are the basis for a realistic offer. The following
should be given special attention:
• General design requirements
• Welding and non-destructive testing
• Additional material requirements for use
in sour gas applications
• Definition of the scope of Positive Material
Identification (PMI)
• Requirements for the manufacturing documentation
and required documents for the
final documentation (Manufacturing Record
Book – MRB)
• Definition of the inspection effort, i.e.
scope of the Inspection and Test Plan (ITP)
in terms of specified Hold and Witness
points for inspections
The benefit of specific offers
The use of supposedly time-saving lump
sums for additional specification require-
cpp 02-2022 41

cpp ACHEMA PROCESS ENGINEERING
Picture: VAU Thermotech
Picture: VAU Thermotech
The offer that the customer finally receives
should clearly state what is technically feasible,
what additional costs will be incurred
or the extent to which extraordinary resources
of the company will be required
Once the client has placed the order, the project can be implemented
ments is not advisable. These usually result
in time-consuming inquiries from the customer.
Experience has shown that the following
topics require additional effort,
which should already be considered during
the bidding phase:
• Higher effort for non-destructive testing
(NDT) – especially RT + UT – compared
to applicable regulations
• Higher testing and inspection effort based
on different requirements of the customer
regarding equipment criticality rating. It is
worth searching for terms such as “criticality
rating” in the tender documents
• Welding procedure qualifications and/or
production weld test specimens on the
vessel that go beyond the applicable rules
and regulations
• Detailed requirements of the methods, work
equipment, and personnel requirements to
be used for NDT that can possibly only be
met by specialised third-party providers
• High documentation effort for comprehensive
Positive Material Identification
• Customer-specific requirements for materials,
welding procedures, and test scope
for equipment in sour gas applications
(gases containing hydrogen sulfide) that
exceed NACE MR0175 / ISO 15156 standards,
for example
• High required nozzle loads resulting in
higher material usage. Verification may
have to be performed using calculation
methods that require additional software
or by means of cooperation with thirdparty
suppliers
The offer that the customer finally receives
should clearly state what is technically feasible,
what additional costs will be incurred
– e.g., through the involvement of thirdparty
providers – or the extent to which
extraordinary resources of the company will
be required. In addition, the offer should be
accompanied by technical comments and –
almost more importantly – should include a
detailed list of any deviations from the request
specification.
Negotiation: Maintain the dialogue
If the customer is interested in the offer, an
invitation to technical negotiations will be
issued, which is conducted by representatives
of the various departments. International
projects often involve very stringently
working through a formal list in
which the project requirements are compared
with the submitted offer in detail. The
reason for this procedure is that the head of
departments have a precisely defined decision-making
corridor and are personally responsible
for the successful completion of
their project.
Deviations from the specification by the
bidder must be explained and usually result
from the fact that technically unfulfillable
requirements could arise if the order is fulfilled
to the letter. For the quote creator, it is
important to weigh up in the negotiations
whether fulfillment of the requirements or
withdrawal from the bid is preferable.
In this case, it is practicable to use open and
agreement-oriented communication as well
as appropriate negotiation. In this way, formulations
can be worked out together that
describe a technical alternative, but at the
same time allow the person responsible on
the customer side to confirm that the specification
can be fulfilled in a technically reasonable
way.
Successful project implementation
If the offer is finally accepted, the individual
suppliers must first fill out pre-formatted
document lists (master/vendor document
list), especially for large projects in the oil
and gas sector, and list all documents with
designation, document number, and submission
date. This can be used very effectively
to structure the required production
documentation.
It makes sense to start working through the
list of production-relevant documents such
as drawings, welding plans, parts lists, ITP
42 cpp 02-2022

has the
solution!
Picture: VAU Thermotech
Special
couplings –
the ideal
interfaces
Frank Betzold, Project Engineer Hybrid Tubular Plate Heat
Exchangers at VAU Thermotech: “The key to success is
communication.”
plans etc. After this, the usually required and
less urgent procedures for NDT, colouring,
PMI, pressure test etc. are submitted. At the
same time, a time schedule for design,
document handling, inspections and manufacturing
should be prepared.
The document submission is followed by an
often time-consuming approval process. EPC
(Engineering, Procurement and Construction)
companies are responsible for reviewing
the enormous volume of documents.
Their specialists check the submitted documents
in extensive detail for deviations
from the required specifications.
In order to achieve technically reasonable
solutions within an acceptable period of
time, it is important to identify a contact person
who can be contacted by telephone. In
contrast to the anonymous approval process,
detailed questions can be clarified much
more efficiently in a personal conversation.
Once the approval for all relevant documents
has been granted, production starts.
The importance of the Inspection and Test
Plan (ITP) should be noted at this point.
Typically, a large number of stops are scheduled
for inspections with the client’s or EPC
contractor’s representatives to monitor production
quality and compliance with the
agreed tests. These must be notified approximately
10 to 14 days in advance. Missed notifications
or non-compliance with deadlines
can lead to considerable production
delays, and thus penalty claims from the
customer.
Conclusion: Minimise time and effort
To better estimate the effort for tender and
project engineers seeking to tender in a
major international project for the first
time, a few things should be kept in mind:
During the bidding and negotiation phases,
extensive specification requirements are to
be expected, which often go beyond the
usual applicable sets of rules. Since the processes
for creating and approving manufacturing
documentation and for inspection
notifications are anonymised and formalised,
it is important to ensure strict compliance
with them. This often requires a
considerable amount of additional time. If
deviations from the technical specification
are unavoidable, suitable solutions must be
developed together with the customer in a
timely manner.
Also important are technical competence,
communication skills, and an open and approachable
personal relationship with
others.
www.cpp-net.com
Online search: VAU Thermotech
Hall 4.0, Booth F46
Visit us at ACHEMA:
Hall 8.0 · Booth G38
GATHER special solutions
+ Adapter for 2'' barrel
connections
+ Colour coding
+ Adapter for IBC containers
Learn more!
www.gather-industrie.com
GATHER Industrie GmbH
42489 Wülfrath · Germany
Made in Germany
cpp 02-2022 43
+ conveying + coupling + metering

cpp ACHEMA PROCESS ENGINEERING
Solids, water and gels separation in silicone production
One-stage filtration is the
charm
Silicone manufacturing depends on a complex network of process technologies including
the removal of solids, traces of water and gels from the intermediate silicone
product. Traditionally, this activity has been a two-stage operation. With the development
of a special filtration technology, Eaton was able to meet all the requirements
in a single-stage process, helping a silicone manufacturer streamline its production
processes and improve operational efficiency.
Specialist silicones are produced in many
different grades at highly integrated manufacturing
plants which use multi-stage processes
to deliver consistency and repeatability.
The manufacturing process is complex
and carefully refined: silicates in sand or
rock are first processed to obtain silicon.
Chemical reactions then produce silanes
and, in further steps, polysiloxane precursors,
which are the basis for different grades
of silicone products.
These precursors contain a silicon-oxygen
backbone along with other organics, and
they can be processed into end-products
such as silicone oils, silicone resins and
elastomers. The composition of silicone
offers several desired performance characteristics
such as thermal and oxidative stability,
chemical inertness and excellent dielectric
strength.
During the production process which involves
hydrolysis of organohalosilane and
condensation of chemical compounds
forming salts, among other things, silicone
manufacturers have to ensure that any unwanted
residues and particles are removed,
to protect the quality of the finished product.
This requirement is met through the use
The Beco Compact Plate A600 premium multi-sheet filtration system is a high-quality reliable filter
system that enables silicone manufacturers to increase their product quality and reduce downtimes
Pictures: Eaton
of advanced filtration techniques, which
have to be performed without having any
adverse impact on volume throughput on
the line. Filtration has to be carried out to
exacting standards, using equipment that is
reliable and easy to maintain.
High demands
One of Europe’s silicone manufacturers
came to Eaton with a requirement for a
more effective means of carrying out solid
separation as well as liquid traces separation
at one of its large production plants. The
company was producing on a regular basis
about 3000 kg (6,614 lbs) of intermediate
silicone oil at 5 m 3 /h (22 gpm). The production
process involved a carbonation
technique using sodium carbonate to neutralise
hydrogen chloride. This process resulted
in the generation of water residue
and solids, which needs to be removed in
an effective way. Failure to do so can increase
the viscosity of the final product
through the creation of gel in the silicone –
identified as a highly undesirable outcome.
Historically, a two-stage process is used. In
this process, solids are separated from the
silicone intermediate, and water residues
are removed using chemical additives. However,
the silicone manufacturer wanted to
implement a more advanced system that
could offer highly controllable removal of
solids, traces of water and gel particles in a
single-stage operation. By implementing
such a unique approach, the company
would be able to simplify its production
processes, saving time and reducing byproduct
waste.
44 cpp 02-2022

Beco KD 7 depth filter sheets consist of finely fibrillated cellulose fibers from deciduous
and coniferous trees that provide an especially high water-retention capacity
Technical realisation
Eaton’s engineers forged a strong customer
relationship with the silicone manufacturer,
working with its technical team to devise an
effective solution. The answer came with the
combination of Beco depth filter sheets,
fitted to a Beco Compact Plate plate and
frame filtration system, allowing for the removal
of nearly all water residue and solids
through adsorption, without causing any
significant pressure drop on the production
line.
In laboratory tests with different types of
depth filter sheets, an optimised solution
was jointly developed. Beco depth filter
sheets have a nominal retention rate ranging
from 0.1 to 40 µm, and the analyses identified
Beco KD 7 depth filter sheet as the
most suitable grade for the task at hand. In
terms of specific performance characteristics,
it has a nominal retention rate of
1.5 µm, making it suitable for filtration of
highly deformable particles. The tests
showed that the use of 10 m² (108 ft²) of
this depth filter sheet could effectively filter
about 3000 kg (6,614 lbs) of the initial
product with approximately 70 kg (154 lbs)
of cake and less than 2% of residual water.
Such a high level of performance was a result
of the specific composition of the KD 7
depth filter sheets. This product range is
made of pure natural materials and cationic
charge carriers. It combines finely fibrillated
cellulose fibers from deciduous and coniferous
trees with precisely dosed quantities of
high-quality diatomaceous earth. A key
property of the cellulose fibers is the water
absorption capability. In addition, the ideal
pore structure of the depth filter sheet
allows a reliable retention of gel particles.
This enables the KD 7 depth filter sheet to
provide the optimal ratio of performance
and throughput.
The depth filter sheets need to be inserted
in a reliable filtration system. After assessing
available options, the company selected the
Compact Plate A600 system. This particularly
high-class multi-sheet filter system
comes with either an electrically or pneumatically
operated hydraulic system. Quality
was an important consideration for the silicone
company. The company wanted a reliable
filter system that would not cause any
unnecessary downtime. This requirement
was met through the use of a solid chassis
design, with robust filter frames, that ensure
that the hydraulic pressure is effectively directed
onto the depth filter sheets. The components
of the system are designed to withstand
maximum operating temperatures of
121 °C (249.8 °F), ensuring reliable performance
even during extended periods and at
high temperatures. The silicone manufacturer
also needed a solution that was flexible
enough to fit within the restricted space
parameters of its production line. The Compact
Plate A600 filtration system met this
requirement, too, offering a highly flexible
filter area from 0.66 to 69.30 m² (7.10 to
745.94 ft²), which allows for customisable
solutions for individual applications.
Ease-of-maintenance was also placed high
on the specification list. An automatic
re-tightening function monitors the actual
tightening pressure during operation, because
once the depth filter sheets become
wet, their thickness deviates, so the system
needs to re-press to ensure leak-tight performance.
The Compact Plate A600 filtration
system can detect changes immediately and
automatically adjusts the hydraulic pressure
if it falls below a threshold value. Meanwhile,
ease of handling and excellent cleanability
is achieved thanks to ergonomic design
and use of smooth surfaces. At the same
time, a wide range of accessories such as fittings
and riser pipes meant the system was
ready for quick and secure connection.
Production efficiency enhanced
With the combination of the KD 7 depth
filter sheets and the Compact Plate A600
multi-sheet filter system solids, water residues
and gel particles can be reliably removed
in a much shorter space of time than
was previously achievable with the twostage
process. For Eaton, the project represented
a highly successful collaboration. The
laboratory screening tests showed that the
KD 7 depth filter sheets offered just the
right level of filtration, meaning that effective
removal of water residues and solids
could be achieved at specific volume and
flow rates. Meanwhile, the flexibility of the
Compact Plate system meant that the size of
the frames could be adapted to meet the
specified dimensions of the production line.
Looking to the future, Eaton believes that
the specific properties of the KD 7 depth
filter sheet mean it is sure to find further
application in the silicone manufacturing
industry.
www.cpp-net.com
Online search: Eaton
Hall 12.0, Booth D22
AUTHOR:
JÖRG THIEMANN
Product Manager Filter
Media,
Eaton Technologies
cpp 02-2022 45

cpp ACHEMA PHARMACEUTICAL ENGINEERING, PACKAGING
A modular direct compression line
Continuous tablet
production
Continuous direct compression offers numerous process advantages. Nevertheless,
it has not yet become a reality for many manufacturers. Pharmaceutical and food
producers sometimes associate high investment and conversion costs with the
changeover from the batch process. But there is another way, as Fette Compacting’s
new process line with integrated process analysis shows.
Continuous manufacturing has been making
its way into pharmaceutical and nutritional
production for almost 20 years. It is
associated with a wide range of advantages:
integrated processes increase both process
reliability and efficiency; process times are
reduced compared to batch processes, while
the specific production output increases;
market launches can be realised more
quickly, and production becomes more flexible
overall.
In tablet production, continuous direct
compression is meeting with growing acceptance,
as it appears attractive in terms of
process technology and enables a leaner
plant design compared to batch-to-batch
production. The reasons for the still dominant
role of batch production are manifold
and lie, among other things, in well-known
reservations.
Overcoming economic reservations
One central concern can be traced back to
observations of existing continuous facilities:
these often take up a lot of floor space and
room height, which usually requires prior
modifications to existing buildings or even
new builds. In addition, there are concerns
about long lead times for design and manufacturing
and the tendency for high investments
as plants have to be customised. The
complexity also makes many manufacturers
shy away, as scientific personnel are required
for setup and specially-trained users for operation.
During operation, interested parties
also fear long downtimes due to the timeconsuming
cleaning and retooling processes.
Conversely, conclusions for economic continuous
manufacturing can also be derived
from these “pain points”. This involves less
complex and easier-to-adapt systems based
on a simplified process chain. The direct
compression process creates optimal conditions
for this.
Compact and flexible overall system
Building on these conclusions, Fette Compacting
has rethought continuous manufac-
Pictures: Fette Compacting
The FE CPS enables continuous direct injection with a slim plant design and closed process unit
46 cpp 02-2022

Ultrasound enables a uniform powder flow even with different formulations
A new user interface provides an overview
of the parameters of the entire continuous
process
turing for tablet production from the ground
up. The result is the continuous direct compression
system. It comprises a closed dosing-mixing
unit FE CPS including powder
transport system, an FE 55 tablet press, and
an operator terminal. The entire system can
be integrated into existing production areas
on a single level. Structural investments are
thus reduced to a minimum.
The FE CPS processes a wide range of formulations
with throughputs from about five to
200 kg per hour. It thus offers a high degree
of process flexibility: from product development
to smaller batches and large-volume
production. The FE 55 tablet press has three
compression stations instead of two, enabling
longer pressure holding times at
lower pressure. This results in gentler processing
and an even more flexible tableting
process. Such a setup is also suitable for a
multiple unit pellet system (MUPS), as segregation
processes can be effectively reduced.
Focus on safety and simplicity
During development of the FE CPS, the
focus was on operator safety. The process
area was designed to be dust-tight. Additional
protection is provided by the enclosed
design, which is also supported by
sealed glass panels and a vacuum in the process
area.
Until now, cleaning and retooling were considered
critical work steps in continuous
systems, as they consist of much more than
a hundred individual parts. The new dosingmixing
unit, on the other hand, features
significantly fewer parts and interfaces and
has separate process and technical areas
which are easily accessible. For this purpose,
it was divided in such a way that the
process parts of the refilling stations, the
dosing stations and the specially-developed
mixer are located in the process area. The
technical area, which is dust-tight and separate
from the process area, houses the
drives, the electronics and the cabling,
among other things. All components can be
easily removed from the process area for
cleaning.
Furthermore, the system follows a design
principle that consistently focuses on simplicity
in terms of operation, changeover
and maintenance. At its heart is the humanmachine
interface (HMI), which provides
the operator with an overview of all para -
meters for dosing, mixing, tableting, and
process analysis. In future, a single terminal
will be sufficient to record the entire continuous
process, including recipes, protocols,
events and diagnostics. Handling of the
HMI is learned in a short time, so that the
qualification threshold for operation in continuous
operation is significantly lowered.
Fully-integrated process analysis
The material properties and the machine
and process design have a major influence
on the stability of the continuous process.
This is where the continuous direct compression
system sets new standards. To
monitor the decisive quality attributes, it
has a new type of technology for inline process
analysis (embedded Process Analytical
Technology, ePAT), in which sophisticated
sensors are integrated into the process units.
They can be positioned at four points to
continuously monitor relevant production
parameters: at the outlet of the mixer, at the
inlet of the tablet press, at the Fill-O-Matic
and in the process chamber of the tablet
press. For example, the sensor at the mixer
checks mixing homogeneity. Such inline
measurements, which take place directly in
the production flow, allow swift reactions in
the case of quality deviations and direct adjustment
of the production process.
With data acquisition and analysis in real
time, the FE CPS also sets new standards in
terms of measurement and reaction speed.
When it comes to measurement methods,
near-infrared spectroscopy (NIRS) has proven
to be particularly efficient. Its advantage
lies in the fact that it is good at detecting
many active substances in this spectral
range. The infrared rays penetrate deep into
the tablet without damaging it. NIRS enables
ultra-fast quality checks on larger
sample quantities, making it ideal for highperformance
tablet presses such as the FE 55
and the upstream mixer. Depending on
requirements, Fette Compacting works with
users to determine an individual PAT solu -
tion to exploit the full efficiency potential
of continuous tableting.
www.cpp-net.com
Online search: Fette Compacting
Hall 3.0, Booth F25
AUTHOR:
DR. MARTEN
KLUKKERT
Manager Technology Center,
Fette Compacting
cpp 02-2022 47

cpp ACHEMA PHARMACEUTICAL ENGINEERING, PACKAGING
Paper-based solutions without quality loss
Sustainability in
pharmaceutical packaging
Since packaging offers an important lever to act in an eco-friendly way, pharmaceuticals
manufacturers have been eager to seek alternatives to traditional packaging
materials and styles. Recyclable mono-laminates or even paper can pave the way to
a more sustainable future. Syntegon developed a solution to produce paper-based
push-through blister packaging for tablets and capsules.
Sustainability is far more than a buzzword.
Companies around the globe share a common
goal: to reduce their environmental
impact and save resources. Sustainability in
the pharmaceuticals industry, for instance,
includes many facets, from decarbonising
operations by using renewable energies, to
reducing or changing packaging materials.
In this respect, recyclable and/or biodegradable
solutions are pushing to the fore.
At the same time, they pose a challenge for
pharmaceuticals manufacturers: how can
they replace existing materials, like traditional
plastics, without compromising on
efficiency and product quality, two pillars of
pharmaceuticals production?
The need for flexibility
Besides packaging quality and rigorous hygienic
standards, efficiency has always been
a key requirement in the pharmaceuticals
industry. On the one hand, life-saving medicines
call for efficient processes and often
high outputs to ensure steady market
supply. Therefore, in recent times, the industry
has seen strong demand for highly flexible
operations. Pharmaceuticals manufacturers
need equipment that allows them to
quickly change between products, filling
methods and packaging formats. In addition,
fast and easy cleaning plays a major
role to ensure high product quality and ultimately,
patient safety.
On the other hand, technological, regulatory
and market changes make flexibility essential:
packaging machines must be easily
adaptable to new packaging materials or
formats. While polyvinyl chloride (PVC)
may be the packaging material of choice for
e. g. standard blister packs, changing regulations
and market demands may lead to
recyclable polypropylene (PP) or even paper
taking over that role.
Any changes to packaging materials call for
equipment that can easily process a wide
range of options while ensuring smooth
and efficient operations. As a trend-conscious
packaging solution provider, Syntegon
has been actively monitoring these developments
and devised technologies that
help pharmaceuticals manufacturers meet
their efficiency, flexibility, and sustainability
goals at the same time.
The “Blister meets Paper” packaging has a barrier and a heat-sealable layer, which makes
its barrier properties comparable to those of classic mono-PVC or aluminum blisters
Pictures: Syntegon
Focus on mono-laminates and paper
Syntegon began investing in the development
of equipment solutions at an early
stage to support sustainable pharmaceutical
production. This includes applying its
know-how in processing sustainable pack-
48 cpp 02-2022

Versioned catalog
production
Paper forming technology makes it possible to produce a wide range of innovative packaging
styles that can be used outside the pharmaceuticals industry
aging materials to demanding pharmaceutical
tasks where non-recyclable plastics have
been the norm. The company recently developed
a solution called “Blister meets Paper,”
which sparked an impressive response on
the market and received the German Packaging
Award in 2021.
The paper-based push-through blister packaging
for tablets and capsules is particularly
suitable for nutraceuticals. It comes with a
barrier and a heat-sealable layer, which
makes the paper blister’s barrier properties
comparable to those of classic mono-PVC or
aluminum blisters. Both the base and lidding
material can be recycled. Thanks to the
combination of the TPU 1000 form, fill and
seal machine for paper packaging, the 3D
formable FibreForm paper from paper
manufacturer Billerudkorsnäs, and the sealable
barrier coating from partner Huhtamaki,
paper with the geometry required for
many conventional tablets can be formed.
With a double-cavity clamshell design, Syntegon
even offers a paper-based solution for
capsules.
Alternatives to plastics
Paper blisters can be readily processed on
Syntegon machines and represent a sustainable
alternative to the non-recyclable
plastics and aluminum that are widely used.
The paper forming technology also meets
the industry’s need for flexibility, as it
makes it possible to create different shapes
and package styles for tablets and capsules.
Available machine designs target a mid-output
range. The TPU 1000 form, fill and seal
system, for instance, mechanically produces
paper pods and blisters at rates of up to
15,000 packages per hour while ensuring
tight seals. Paper pods can be sealed with
any heat-sealable lidding materials; barriers
can be perfectly tailored to customer needs
to ensure the necessary protection and high
quality of the packaged product. For additional
shelf appeal, paper forming allows
the use of personalised high-quality packaging
designs and embossing.
It all starts with questions
Changing a running system, however, poses
various challenges that pharmaceuticals
companies and equipment providers need
to address before any sustainably packaged
tablet or capsule can go to market. While
switching from plastic to paper may sound
simple, it often involves several questions
that all parties involved need to consider.
Will the barrier be sufficient for a specific
product? What opening feature should the
package have? What type of product can the
paper-formed cavity hold? How many cavities
can a blister sheet offer? Answering
these questions and validating the packaging’s
use and performance calls for a Proofof-Concept
procedure. Syntegon has devised
such an approach, which covers everything
from designing the package to producing
filled samples or small batches on a laboratory
scale. Confirming these parameters is
important and needs to be considered when
exploring go-to-market concepts. The company
is confident that we will see the first
paper-based blisters on store shelves in
2023.
www.cpp-net.com
Online search: Syntegon
Hall 3.1, Booth C71
AUTHOR:
TORSTEN SAUER,
Director Sustainability,
Syntegon Technology
We are well-equipped for
the production of your
multilingual or multi-version
catalogs – especially when
it comes to managing your
highly complex jobs.
Individual tools, perfectly
adapted for your project,
accelerate and simplify the
entire process.
We can do much for you,
please contact us.
producing
media
intelligently
www.konradindruck.de
cpp 02-2022 49
katalog_V2_44x270_4c_en.indd 1 22.10.20 16:16

cpp
CONTACT THE EDITORS
LUKAS LEHMANN
Editor V.i.S.d.P.
Phone +49 711 7594-290
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Editor
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Editorial Assistant
Phone +49 711 7594-415
barbara.diviggiano@konradin.de
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Publisher:
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Publishing House:
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Ernst-Mey-Straße 8, 70771 Leinfelden Echterdingen,
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Publishing Director:
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Editor V.i.S.d.P.
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Ernst-Mey-Straße 8,
70771 Leinfelden-Echterdingen, Germany
Phone +49 711 7594-290
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Printed by Konradin Druck GmbH,
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Printed in Germany
© 2022 by Konradin-Verlag
Robert Kohlhammer GmbH,
Leinfelden-Echterdingen
cpp
LIST OF ADVERTISERS
Aerzener Maschinenfabrik GmbH,
Aerzen 21
AFRISO-EURO-INDEX GmbH,
Güglingen 24
AZO GmbH & Co. KG, Osterburken 13
Beumer Group GmbH & Co.KG, Beckum 5
Paul Bungartz GmbH & Co. KG,
Düsseldorf 3
C. Otto Gehrckens GmbH & Co. KG,
Pinneberg 25
Maschinenfabrik Gustav Eirich
GmbH & Co. KG, Hardheim 27
ElringKlinger Kunststofftechnik GmbH,
Bietigheim-Bissingen 2
ENEXIO Water Technologies GmbH,
Hürth 15
Fette Compacting GmbH, Schwarzenbek 52
GATHER INDUSTRIE GmbH, Wülfrath 43
H2O GmbH process water engineering,
Steinen 26
Pepperl+Fuchs SE, Mannheim 39
REMBE GmbH Safety + Control, Brilon 26
Dr. Thiedig & Co., Berlin 11
50 cpp 02-2022

Industrie
The
network of
expertise
for industry
17 media brands for all major sectors
of industry
Information, inspiration and networking
for professionals and industry executives
Practical knowledge spanning all media
channels: Trade journals, websites, newsletters,
whitepapers, webinars, events
Your qualified partner for future topics
of industry
Discover the appropriate media for
you and your specific industry sector:
konradin.de/industrie
media.industrie.de
cpp 02-2022 51

THE NEW FE CPS
CONTINUOUS
MANUFACTURING
REINVENTED
Discover how Continuous Manufacturing
can be compact, fast, flexible, easy
to use and efficient. The FE CPS offers
standardized and widely applicable
Continuous Manufacturing technology.
Visit our website for more information:
fette-compacting.com
52 cpp 02-2022