Report on Summer Training

in

BEUMER INDIA LIMITED, GURGAON

BACHELOR OF TECHNOLOGY
DEGREE
Session 2017-21
in
MECHANICAL ENGINEERING
By

Ishaan Kharbanda
Roll Number –UE179039

Submitted to : MR. AMIT THAKUR

MS. ANJALI GUPTA

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 Student’s Declaration
I hereby declare that the work and experience being presented in this report on

summer training in “BEUMER India Limited, Gurgaon

(Haryana)” is an authentic record of my own work and experience carried out

under the supervision of Mr. ANSHUMAN MISHRA

The matter embodied in this report has not been submitted from any other source.

This is to certify that the above statement made by the candidate is correct to the
best of my knowledge.

Signature of Faculty

(Mechanical Engineering)

Date............................

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 ACKNOWLEDGEMENT

I express my sincere thanks and gratitude to Mr. Amit Thakur and Ms. Anjali
Gupta for providing me an opportunity to undergo summer training at BEUMER INDIA
LIMITED, GURGAON ( HARYANA) .

The successful completion of project work requires efforts of several

intellectual minds. Working with BEUMER India Limited has been a great learning
experience for which I would like to thank everybody who has been instrumental in the
completion of my training.

I wish to express my deep sense of gratitude to my Guide, Mr. Anshuman

Mishra (Manager Production), for his able and uninterrupted guidance and useful
suggestions, which helped me in completing the summer training, in time.

I would also like to give a special thanks to Mr. Manish Kaushik ( Head
Manufacturing) and Mr. Deepak Batra ( Head HR & Admin.) for providing me the
opportunity to do summer training at" BEUMER INDIA LIMITED"..

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COMPANY PROFILE

BEUMER India Limited is an amalgamated company of M/S BEUMER

Technologies India Pvt. Limited. and M/s Enexco Teknologies India Limited. These

companies have been amalgamated with a view to have Synergies in operations to

optimize utilization of resources. BEUMER India Ltd. is a 100% subsidiary of

BEUMER Group in Germany, which was established in 1935.

BEUMER Technologies India Pvt. Limited was incorporated in 2003 and Enexco

Teknologies India Limited was incorporated in the year 1985.

Envisioned with the objective of leadership in intralogistics; in the fields of

conveying; loading; palletizing; packaging; sortation and distribution technology,

serving core sectors of Airports, Logistics, Cement, Petro-Chem, Mining, Power

Plant etc. With an array of engineering products and services , BEUMER India

Limited has emerged as a successful business enterprise serving India as well as

other parts of the world. Over the years, the company has grown significantly in

size and volume and equipped itself with necessary resources to meet the growing

demands of the industry.

BEUMER Group offers the right solution for almost every logistic and end of line

packaging challenge.

BEUMER India Limited is located in Gurgaon near New Delhi; the company has its

focus on all the business segments BEUMER Germany is active in:

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Its rigorous and ethical business practices coupled with a streamlined

manufacturing procedure has enabled it to earn an ISO 9001:2008 certification

from ROYAL CERT International Registrars, Germany.

The company relates its success to its highly motivated workforce comprising of

skilled experienced engineers and trained workers led by a professional

management with proven track records.

Capitalizing on the vast growth potential that India has on offer and riding on its

technological brilliance, BEUMER India Limited is constantly delivering cost

effective performance oriented solutions in its focused sectors of Airports,

Logistics, Cement, Petro-Chemical, Mining, Power Plant etc..

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INFRASTRUCTURE

BEUMER India Limited delivers value-added solutions that are acknowledged

globally. To achieve perfection in its manufacturing operations, it has a dedicated

design engineering centre and a well laid out production facility at Naurangpur in

Gurgaon.

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Completely technology driven, BEUMER's designing centre is manned by expert

design engineers capable of translating complex customer demands into high

value products engineered to optimization. Proficiency in designing and drawing is

achieved using the latest software platforms like solid works, emulation, simulation,

etc..

Spread across an area of more than 22,000 sq metres BEUMER is an organized

set up capable of manufacturing supply of complete Cement Plant, grinding units,

packing plant and Material Handling equipment apart from regular processing

equipment.

Equipped with latest technology in plant machinery, the facility undertakes

specialized manufacturing operations like: Fabrication, Machining, Shot Blasting

and Painting.
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QUALITY

BEUMER is known for the impeccable quality it infuses in all its operations right

from initial stages of production till final delivery.

To ensure consistency in manufacturing and regular increment in quality levels, a

Quality Assurance department is in place for adherence to various quality

standards. An in-house test lab with necessary resources for validation and testing

supports the company's initiative for serving its customers with best quality

products.

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 Products
BUCKET ELEVATOR

Purpose: used to lift the cement or the clinker to a certain height.

Parts: Boot casing, Head casing, Bar drum, Standard casing, Assembly Casing,

Inspection whole cover casing, proxy casings, Steel cord belt, Buckets etc.,

Boot casing is the resting area of bar drum and contains the inlet area. In general a

boot casing may

contain two inlets

one for the main

feed and another

for the auxiliary

feed. The main

feed goes directly

into the elevator

while the auxiliary feed goes at the bottom of the elevator.

The bar drum is attached to the boot casing via a cylindrical tapered bearing. A

tension adjusting screw is provided on both the ends of bar drum which contains a

rack and pinion arrangement for the proper positioning of the bar drum to provide

sufficient tension to the belt.

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The head casing contains the top bar drum which is connected to a motor and a

gear box via. shaft which rests on the plummer block. Cylindrical tapered bearing

is used here for the shaft positioning.

Between the head casing and the boot casing are two types of casings, standard

casing, with a standard length of 20-25 meters and proxy casings that contains

different proxies.

The bar drum used at the bottom of the elevator is perforated so as to avoid any

material to get stuck within. The drive pulley at the top is of smooth surface and is

covered with rubber sheet to give proper rolling friction to the belt.

The belt used in the bucket elevator is a steel cord belt and contains steel wires

inside the original rubber coating. This is done to provide more strength to the belt.

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The bucket elevator contains three proxy switches. Two are called belt sway proxy

and are attached at the opposite ends in standard casing. Their purpose is to

detect the disposition of the belt. They have a working range of 25 mm i.e. when

the belt reaches this distance to the proxy it cuts off the motor supply thus alarming

any problems. The third proxy is called zero speed proxy. It is located at the boot

casing opposite of belt sway proxy and serves the purpose of detecting any

problems related to belt damage, i.e. if the belt breaks the proxy stops sensing the

movement of the buckets across its field and cuts off the main motor supply.

A counter weight is used at the center of the elevator above the boot casing. The

weight used for the purpose may vary depending on the length of the belt used.

The purpose of counter weight is to keep the bucket elevator down during the

startup of the system.

Bucket elevators are of two types chain type and belt type. Although belt type are

more preferred because of their quite operation but chain type have their own

advantages over the former one in its life span and less maintenance problems.

HIGH CAPACITY
BUCKET ELEVATOR

Bucket elevators have proven themselves for vertical transport of many and

diverse bulk materials for decades. As a market leader, BEUMER Group

successfully established the belt bucket elevator technology in the market decades

ago. Belt bucket elevators were consistently developed in the past and enable the
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 highest possible conveying capacities

with maximum centre distances today.

Chain bucket elevators are the preferred

conveying systems for the transport of

hot bulk materials and coarse-grained

materials. With its central chain bucket

elevators, BEUMER Group offers

efficient and proven solutions even for

the highest conveying capacities.

High-capacity belt bucket elevators are used for all floury and small-sized bulk

materials, e.g. raw meal, cement, grits, sand, concentrated ores, etc. Conveying

heights of up to 175 metres have been realised .

Bucket widths of 160 to 2,000 mm are available for a finely graduated adaptation

to the conveying capacity. A special bucket design is used for particularly light-

weight materials, making the construction as efficient as possible.

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HEAVY DUTY
BUCKET ELEVATOR

Heavy-duty bucket elevators have been developed from belt bucket elevators and

are specially designed for coarse, highly abrasive bulk materials. HD bucket

elevators can transport piece sizes up to 120 mm.

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By using a specifically designed BEUMER Group steel wire belt, HD bucket

elevators enable maximum conveying heights and conveying capacities. They are

particularly suitable as recirculation units behind high-pressure roller mills, which

are increasingly used for pre-grinding in the cement and ore sector.

Furthermore, the special design of the HD bucket elevator enables the highest

conveying capacities for coal and similar products. For this sector, the HD bucket

elevators can also be offered in an explosion-proof version.

CHAIN BUCKET
ELEVATOR

The traditional chain bucket elevator is designed with a double-strand round steel

link chain .This type is mainly used as an efficient solution for coarse, highly

abrasive materials in the low to medium capacity range. It is also suitable for

conveying hot bulk material.

HIGH CAPACITY
CENTRAL
CHAIN BUCKET
ELEVATOR

Central chain bucket

elevators have been

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developed from the traditional bucket elevators and enable high conveying

capacities with large centre distances.

High-capacity chain bucket elevators with central chain are particularly suitable for

the transport of hot, granular and abrasive bulk material. In the cement industry

BEUMER central chain bucket elevators are used, among others, for the vertical

transport of hot, abrasive clinker, silo feed and in clinker milling systems.

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FILLPAC

Purpose: To pack cement bags at high speed and efficiency.

Parts: Main drive assembly, Material Inlet, Dedusting chamber, Packer Bin,

Packing spout.

Main drive assembly consists of a hollow shaft that runs through the entire length

of the packer. It is connected to the gear assembly and main motor via

intermediate support which intern is connected to the main support that holds the

packer structure. A slip ring assembly is used to provide the power the packer unit.

The material inlet part is form where the cement is fed to the system from the inlet

chute coming form the storage bin.

A dedusting chamber is provided to the packer to allow the outlet of the dust to

allow the proper functioning. All the spouts are connected to the same through

their supporting frame of filling module. The dust collected is then vented out

through the ducts which are connected to the auxiliary inlet of the bucket elevator.

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Packer bin is used to store the cement temporarily before it goes through the

impeller structure. A flow control gate is attached at the top of the inlet chamber

which adjusts the inlet rate of the cement using a level indicator. The level indicator

is fixed to the stationary cover with a moving lever. A proxy is attached to the

indicator stationary part, when the bin gets fill the lever rises and when it reaches

the range of proxy the flow control gate is turned off.

Packing Spout: A packing spout is made of three main parts i.e. a spout controller

that is connected to the PLC and controls the spout, a saddle assembly and a

packing stool assembly. A saddle assembly and packing stool assembly combined

contains the following:

Impeller: it is a 6 blade circular structure which drives the cement out towards the

nozzle.

Impeller motor: It is a 5.5kwatt motor which is used to drive the impeller blades for

the proper flow of the cement. It is connected to the impeller shaft via wedge belt

to a V-pulley.

Filling module: It consists of spout control panel, load cell assembly, filling nozzle

assembly, and bag chair.

Saddle plate: A pair of plates located directly below the nozzle that is used to keep

the bags while filling.

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Load cell assembly: located behind the spout control panel it is made up of two

parts a load cell and a load cell rod & is used to measure the weight of the bag

while filling.

Spout control panel is used to control the filling rate of the spout. This is done

using a touch screen control panel EFS 100TS which is windows programmed

capacitive type touch screen and can measure upto 100 tonnes. Filling nozzle

assembly consists of a filling nozzle and three position system and is connected to

the filling port of the impeller box.

A spout contains 3 different cylinders; a bag holding cylinder lies on top of the

discharge nozzle holds the bag during filling. Three position cylinder adjusts the

output of the cement and lies between the nozzle inlet and the filling port of

impeller box. It works in 3 different positions viz. full or coarse flow, fine flow and no

flow. The bag discharge cylinder is connected to the tipper frame and discharges

the bag once it is filled.

The weight of cement bags can be varied by adjusting the bag stool to fit a bag of

desired size.

All the cylinders work at a pressure of 5bar which is fed through the compressor. A

solenoid valve is used to distribute the pressure according to the requirements. In

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all 5 solenoid valves are used per spout, three for each cylinder and one each for

impeller and nozzle aeration.

The main driving motor is a three phase 2.5kwatt motor which is connected to a

variable frequency drive to adjust the motor rpm. The packer rotation rate varies

between 2-2.5 rpm.

Two proxies per spout is attached, one for bag holding and another one for

discharge.

There are 3 different models available for the roto packer viz. 8 spout packer, 12

spout packer and 16 spout packer.

Working.

The cement stored inside the main bin is fed to the packer via ducts going through

the FCG. From there the cement goes inside the packer bin. The bin has openings

towards the impeller. The impeller blades continuously rotate thus throwing the

cement towards the nozzle area. For the filling purpose the bag is inserted

covering the nozzle completely and while doing so a lever attached at the top of

the nozzle is pushed back. This lever is continuously being sensed by the proxy

and as soon as it goes back the proxy gets active and commands the bag holding

cylinder to move down and bag stays in position. This proxy also instructs the three

position cylinder to go from full close to full open and the flow is started. A limit is

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predefined using the control panel to set the coarse flow. The load switch

continuously detects the change in weight of the bag and as soon as the limit is

reached it orders the 3 position cylinder to the switch to fine flow mode. The

purpose of doing so is the get maximum accuracy while filling. As the bag reaches

its desired weight which is fed on the Weighing Unit, the load cell cuts off the

supply to the nozzle. For discharge purpose the operator when desired extends

the discharge cylinder on the top which is detected by the discharge proxy. This

activates the discharge cylinder and the bag is dropped at the desired position.

Radial collector. It is located at the discharge end of the roto packer and serves

the purpose of collecting the discharged bags and transporting them further to the

other conveyors. It consists of a drum motor and a drum pulley which are

connected via endless belt. Bag cleaners are located on the top of the collector

from where compressed air is discharged to the bags and the dust arising from it is

collected using the suction duct at the top which goes into the auxiliary feed of the

bucket elevator via ducts. These are called radial packers because they transport

bad in the radial direction wrt the packer.

Tangential collector: they are similar to the radial collectors except foe that they

are positioned tangentially and transport bags in tangential direction wrt packer.

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Spiral Chute: it is used to transport the cement bags. These are used at places

where the height of discharge is very high and cannot support incline chutes.

These chutes can be designed to move bags in any direction and from any height.

DIRECT PACKING

BEUMER FILLPAC RC

Equipped with up to 20 filling modules and

with a compact design, the BEUMER fillpac

RC can fill up to 300 tons of free-flowing

material per hour, e.g. cement or various

types of plaster, into a range of bag types.

The bag weight correction function, which

automatically adjusts the weight of the next

bag in sequence, ensures filling results are

always accurate. The motor-driven bucket wheels on the impeller packers maintain

especially high filling pressure and thus achieve the best possible compaction of

the

free-flowing materials being bagged. At the end of the process, the filled bags are

both compact and stable, and no additional de-airing is required.

BEUMER FILLPAC IC

In addition to the rotary impeller filling machines, BEUMER Group also supplies

inline versions: the BEUMER fillpac IC with up to four modules and a capacity of

1,200 bags per hour. The filling modules are arranged next to each other to save

space and maximise access, making them very easy to maintain. BEUMER inline
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packers score particularly well in terms of efficiency in production environments

with low product throughput

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OUTER PACKAGING
PROTECTION UNDER THE HOOD

STRETCH HOOD

Practical, efficient and space-saving packaging technology. How do you find an

even more economical way of hooding palletised goods? By using the

highly efficient and compact BEUMER Stretch Hood A from the high-

capacity BEUMER stretch hood packaging system model range. It

impresses with improved system performance, ergonomic operation and a

space-saving format. This is BEUMER's new response to the increasing

demand for machine safety and economic efficiency in the packaging

industry.

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Packaging for optimum final results

The BEUMER Stretch Hood A uses an improved mode of operation to package

palletised load units quickly, safely and sustainably in water-proof film hoods. This

provides reliable protection for the goods against all environmental stress ensuring

excellent load stability. The palletised goods are clearly visible due to the smooth

surface of the transparent film. This offers excellent display characteristics for

presenting goods.

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 Improved unwinding Behavior

The modified crimping bows on the BEUMER OptiStretch system dispense the

film to the palletised stack in a way that is even more precise. The method

optimises the expansion of the film in all directions, which improves both system

availability and the packaging results. The special shape of the crimping bows

allows for close lowering towards the stack contour, while at the same time

ensuring clean and smooth pulling over of the film hood to boost the stability of the

palletised stack.

Defined film positioning

Thanks to the use of the BEUMER Multistretch system, a method for implementing

a variety of packaging types, the system positions the film on the palletised load

units with the greatest degree of accuracy.

Biaxial film tensioning forces

The BEUMER Stretch Hood A uses

biaxial stretching to combine

horizontal and vertical film

tensioning forces. This ensures

excellent load stability, even for

irregular packages and sensitive

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unit loads such as beverage pallets, and they keep this stability, even through

multiple transhipment.

A new dimension in personal protection

With its innovative film transport system, the BEUMER Stretch Hood A removes

the need for a platform - or a lower able film feed device. This ensures a low

overall height and improves safety in operations and maintenance work. For

instance, the blades or the sealing bars are replaced from the floor without the

person needing to climb into or onto the system. There is no need to lower

subassemblies into maintenance position, thus reducing the risk of accidents and

malfunctions. After positioning the film roll with a fork-lift truck or lifting equipment,

the film is inserted with a few easy actions and completely without tools.

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 For more economic efficiency

Low-maintenance, excellent packaging capacity and short downtimes mean that

the machine pays dividends in the shortest possible time. Film rolls are easily

changed using a fork-lift truck and thanks to easy film feeding without time-

consuming threading of the film. There is no need for a film sealing seam cooling

time.

The optimised sequences of movements also contribute to improve the machine's

availability. Powerful suction units combined with mechanical grippers guarantee

functionally safe film handling. Energy-efficient technology sustainably saves

energy costs for the drive system.

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 Easy handling

In terms of handling, the system impresses with a sustainably optimised work

environment and system control. The system is easy to operate by the modular,

space-saving BEUMER Group HMI with a soft-touch panel, a graphical user

interface and pictograms. The panel also gives the operator access to all the

required training programs. Some of them are video-supported to achieve the best

possible training effect.

LOADING MACHINES

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Purpose: To load the packed cement bags on trucks more quickly and efficiently

than manual labor.

Parts: Feed conveyor, discharge conveyor, luffing gear box, loader moving

assembly.

The feed conveyor is the main part of the truck loader and consists of drum motor,

drum pulley, rollers and endless belt, these parts are attached on a structure called

stringer which is bolted to the main body. The feed conveyor is fixed and can only

move forward or backward along with the whole assembly.

The discharge conveyor is attached to the free end of the main conveyor and lies

below the discharge plate of feed conveyor. It is fixed on a bearing and can move

180 degrees in either direction and can move up and down motion. While the

sideways motion is done manually the up/down motion is controlled using either a

luffing gear box or pneumatic jack.

Working: The packed cement bags are discharged from the spiral chute conveyor

they land at the feed conveyor of the truck loader. The drum motor constantly

drives the belt which moves the bag in forward

direction towards the discharge conveyor. This

conveyor also has the same assembly and so the

bag moves to the required position. Once the bags

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are filled to a certain height the telescopic conveyor can be lifted up using the

motor and gear arrangement.