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All specialists under one roof

Systems for the Rubber and Tire Industry: Innovative technologies for economic raw material handling.

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The industry sector of the Zeppelin group is among the leading

manufacturers of plants for the storage, conveying, blending,

and proportioning of high-quality bulk solids. Thanks to our

world-wide activities and locations in all important industrial

centres we can always provide our clients with the latest, most

innovative and secure process technology – to ensure maximum

economic success.

As the direct successor of Earl Ferdinand von Zeppelin who,

more than 100 years ago, turned the human dream of flying into

reality by building his legendary air ships we are used to looking

ahead. Constantly innovating, striving for perfection and maximum

functionality in our products has turned us into the company

that Zeppelin is known as today: the technological leader for

handling high-quality bulk solids.

100 years of meeting your tasks has helped us gain strength – through experience.

On site world-wide – always near our customers. Production plants in Germany, Belgium, Brazil, and China as well as partners and representations all over the world enable Zeppelin to serve our customers with speed, flexibility and the utmost closeness to our customers. More than 200 engineers – including specialists in chemical engineering – guarantee innovative and economic design of plants.

The Zeppelin group

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The industrial Zeppelin group and the number of divisions belong-

ing to it orient themselves strictly to the requirements of their

different groups of clients – all activities have, however, one thing

in common: the economic handling of high-quality bulk solids.

Silogistic: turn-key plants for plastics producers, engineering com-

panies, and forwarders from the world-wide leader in the planning

and construction of logistic centers and manufacturing plants.

Silo plants for the plastic, food, and chemical industry integrated in

the general logistics concept – starting with consultation and design

up to manufacture, assembly, and after-sales service.

Turn-key plants for the plastics processing and chemical industry

as well as for rubber producers and tiremakers.

Conveying components for any application: for powders or pellets,

for high or low pressures, for products with good or poor flowability,

for standard or special applications.

Competence in bulk solids handling – you can rely on Zeppelin.

Zeppelin has been the leader in the international market for decades. Thanks to our own modern manu-facturing plant and the international experience of our assembly staff and service engineers we guarantee quality of the highest level.

Pulling all the strings: the central office for the industry sector is located in Friedrichshafen, Germany. Here, in the largest Test Center in the world for pellets and powders tests are carried out on an industrial scale – the results of which are available to the subsidiaries. On this basis our clients are always on the safe side – no matter where their plant is located.

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Systems for the Rubber and Tire Industry

Innovative technologies for first class mixing results.

The operating success of companies in the

rubber and tire industry rises and falls with

the exact mixing of the raw materials and

the reliable and highly accurate weighing

and dosing. The quality of the mixture is a

decisive factor – one that requires purpose

designed technologies, specialist know-

how and in particular experience.

Zeppelin as technology leader in this de-

manding area not only provides the rubber

and tire industry with more than 20 years

experience but also with expert knowledge

that was gained through the realization of

more than 500 systems.

For Raw Material Intake, Storage and Con-

veying Technologies, Polymer Feed, Weig-

hing & Dosing of Carbon Black/Silica/Oils &

Additives and Minor Chemical Ingredients

Zeppelin delivers everything from individual

components to complete mixing room

systems from a Single Source.

Technical innovations such as our patented

dense phase conveying process for beaded

Carbon Black and Silica, point the way for

the rubber industry and stand as testaments

to Zeppelin’s commitment and outstanding

reputation worldwide.

Skilled staff: For such complex systems we

rely on in house capabilities for all the

Key Functions - Development, Production,

Quality Management, Installation and

Commissioning are executed by our own

Experienced Zeppelin specialists.

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Turn-key systems:

As the Technical Leader in the field of Raw

Material Handling, over the years Zeppelin

has become accustomed to meeting the

exacting standards of our customers in the

Rubber Mixing Room.

If required we can take over the responsibi-

lity for the Complete Batch Preparation Pro-

cesses – and Guarantee the Batch Weights

and product Quality by using specially deve-

loped techniques and components.

Turn-key Systems from the Mixing Room Specialists.

The Control of the whole Spectrum of

Material Handling is the base for a com-

plete system that is Cost Effective and an

operation that is Accurate, Reliable and

Repeatable. Zeppelin as a system supplier

will provide Sound Advice, show Alternatives

and guide you to the Optimal Arrangement

tailored to your Individual Requirements.

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Profit from the Experience and Know-How

of the Market Leader by involving our Project

Engineers in the very early phases of the

system conception. As the technology

leader we see ourselves as in Partnership

with our customers – consulting with a focus

on both the current and long-term view.

The Decision about which System Con-

cept is the most suitable depends on what

Products you make, what Batch Recipes

you use, Quality Assurance requirements

and Cycle Times. These frame conditions

influence directly the arrangement of your

system.

From advise on the Preliminary Arrange-

ment and Building Requirements to the

Final Design and Layout of the system, at

Zeppelin you are looked after by competent

specialists who set great store in one parti-

cular concept: the Profitability and Opera-

tional Security of Your System

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For 40 years Zeppelin has been the market

leader in silo manufacturing, World-Wide.

Profit from our experience in handling

demanding products like Carbon Black, Silica,

Kaolin, Zinc Oxide, Sulphur and other

cohesive and non free-flowing powders.

Whether at the bulk silos or the smaller day-bins

and receiving hoppers – special designs & tech-

nologies for Mass Flow, Filtration, Discharge Aids

and Dosing guarantee reliable storage of the raw

materials for your Rubber Compounds as well as

a Dependable Discharge, Accurate Dosing and a

working environment free from Dust Emissions.

Right from the Product Intake you will profit

from Zeppelins System Competence. Delive-

ries of material in many variations of Bulk or

FIBC transport must be managed and unloaded

flexibly, quickly, reliably and free of emission.

It must be transported by special conveying

methods Optimized and Adapted to accom-

modate the Material Characteristics.

Always on the Safe Side – with the Technology Leader in Silos.

Product Intake and Storage

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Pneumatic Conveying

To ensure an absolutely Dust Free System

and Workplace, the powdery raw materi-

als have to be conveyed pneumatically in

closed systems. Depending on the Charac-

teristics of the Product, QA requirements

and Equipment Configuration we can offer

vacuum or pressure systems and Dilute,

Dune or Dense Phase Conveying Processes.

For conveying with Minimum Fines generation

the Conveying Velocity is critical. For Sensitive

Products like beaded Carbon Black or Silica

we target the lowest possible velocities

(< 10 m/s). For less sensitive products (i.e.

zinc oxide) or less stringent fines (< 125µ)

limitations we can utilise simpler high speed

technologies.

Dust Free, Reliable, Low Fines Generation.

In modern Rubber Compounds in the tire in-

dustry very different qualities of Carbon Black

and Silica are used. Despite the very different

characteristics and flow properties of these

raw materials the conveying system must ope-

rate reliably, dust free and with the specified

performance at all times.

For Dense Phase conveying we use our pa-

tented by-pass conveying systems (Overflow)

where a controlled quantity of secondary air is

put into the pipe at defined intervals, prevent-

ing material plugs from blocking the line.

For the air regulation we can utilise our pa-

tented intelligent air management systems

(AQU) which regulate the airflow automatical-

ly. These optimize the system to suit the flow

characteristics of the carbon black and silica

grades for Minimum Fines.

The AQU (Air Quantity Unit) is a key element of the system as it Regulates the airflow according to the Product, Conveying Distance and Pipe route. Stored data allows the operator to select the product and target hopper and the Velocity is Automatically Controlled independent of line pressure.

Carbon Black with High Fines Content after conveying with too high a velocity. Below: Carbon Black with a Minimum Fines Content after optimized conveying.

Secondary Air Injection with Overflow Valve.

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Feeding / Dosing and Weighing

Dosing screws can only work effec-tively if the product characteristics, product intake and cycle time are considered and matched to the screw size, geometry and design. The system must also be able to isolate the influence of pressure variation and in-flight material.

A Prerequisite for short Cycle Times and High

Productivity is the exact and quick Dosing of

the formula Components (Polymers, Powders

and Liquids) as well as the Reliable & Complete

Discharge of the scale contents into the mixer.

Of course the system must also avoid dust

emissions into the workplace while minimizing

product losses.

Feeding / Dosing are affected by Dosing Screws,

Rotary Valves, or Conveying Lines which are

adapted to the products and work with adjust-

able frequency controllers. Our Weighing Sys-

tems, including the down-stream mixer feeding

chutes, guarantee accurate batches and rapid,

complete emptying into the mixer.

This is Ensured by use of suitable Weigh Hopper

designs, Discharge Aids, Fluidisation, Venting

techniques and Non-Stick materials. This makes

it possible to empty the scales in a very short

time without the risk of residual material stic-

king in hoppers, drop chutes and mixer feed

chutes. This in turn ensures the Accuracy of

the Batch Formula right to the mixer.

High Precision Mixer Feeding

Weigh Hopper with fully fluidised cone

Mixer Feed Chute with Off-Spec Discharge

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The decision of which system is used to feed

the scale is the starting point for the design

of your system. In principle 3 methods are at

your disposal.

· intake by Vacuum conveying

· intake by Pressure conveying

· intake by Gravity (from day-bins

via dosing screws)

Independent of which method, or combina-

tion of methods, is the most economical for

individual requirements – Zeppelin guarantees

the highest levels of accuracy and operational

security in each case. We are always at your

disposal, to advise and guide you to the most

Cost Effective Solution for You.

High Spec Weighing: Flexible Hopper with pneumatic rappers wind barriers and auto calibration.

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For Liquids and Minor Chemical Additives

we have our own specially designed pro-

ducts that we can Manufacture, Deliver,

Install and Commission on a Turn-Key

basis.

Bulk Storage, Day-Tanks, Drum Heating /

Discharge Stations, Plasticizer Scales and

Pumps – each component for handling Liquid

Additives – is specially developed or selected

by Zeppelin with years of experience.

A Core Component of a system for liquid

dosing is the liquid scale especially develo-

ped by Zeppelin for use with i.e. Plasticizers,

Systems with Maximum Reliability.

Oil and Small Components

Oils, Melted Waxes, Stearic Acid and other

liquid additives. Heated, Easy to Access,

with Coarse and Fine Dosing Valves for exact

weighing, Over-Charge Safety device and Au-

tomatic Calibration options. Available as field

proven standard solutions – or individually

adapted to your special requirements.

Our Small Component Systems are designed

to limit operator error and provide material

traceability. Manual, Semi-Auto and Fully

Automatic arrangements customized to suit

the Number & Type of Additives, Storage

Capacity requirements, Batch Weights,

Cycle Times and your Manpower needs.

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The Controls Package is the central ner-

vous system of a Modern Automated

Mixing Room. We can provide everything

you need: Power Distribution, Weigh

Controllers, Central Servers, Material &

Formula Database, Archiving, Local Ope-

rator Stations and Remote Visualisation /

Programming Stations and Modem Fault

Finding facilities. Whether you simply

require a Functional Description or a

Complete System we work to your

specifications and actively support you

to achieve the control system you need.

We think Long Term – and advise you with

this in mind. In the end the control system

must be Operator Friendly and Serviceab-

le as this bears directly on your operating

results. Our comprehensive Batch Reports

will also allow you to easily identify how you

can Improve your Products in future and arm

yourself for the Markets of Tomorrow.

Everything in View and Under Control.

Controls

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Test Center

Your investments, both in individual

components and complete systems, must

be profitable, with the right product for

each specific job – readily available and at

a fair price. Being the technological leader

Zeppelin provides a powerful Develop-

ment and Test Center supporting different

technologies for handling bulk solids.

Our Test Center, encompassing the entire

Zeppelin product range, is yet another factor

which we place at your disposal to contrib-

ute to your success. Ensuring that you ob-

tain sound information on your product and,

therefore, the best possible component or

plant design.

Our Test Center is built on an industrial scale

to meet the wide range of demands of our

customers. For this reason we are geared to

provide tailored answers to your individual

tasks, with trials on an industrial scale and

special configurations that can be quickly

installed.

Leading edge technology is not accidental, but earned.

Two Test Centers – one specially designed

for pellets as well as the requirements of

the large scale chemical industry and one

for powders and additives (for the rubber

and plastics processing industry) form

the hub of our research and development

activities.

Whether commercial sized installation or

processing plant – whenever possible we

conduct full scale tests to avoid the uncer-

tainties of scale-up. The Zeppelin Test Center

offers an impressive range of options. As our

customer you naturally expect maximum

performance reliability – Zeppelin provides

results with no “ifs and buts” as a sound

basis for investment decisions.

For this reason the results that Zeppelin

provides leave nothing unexplained.

· competent result analysis by our specialists

· conclusive test reports and documentation

· determination of relevant design

parameters

Powders or pellets – nothing is left unexplained.

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Test Center

Your investments, both in individual

components and complete systems, must

be profitable, with the right product for

each specific job – readily available and at

a fair price. Being the technological leader

Zeppelin provides a powerful Develop-

ment and Test Center supporting different

technologies for handling bulk solids.

Our Test Center, encompassing the entire

Zeppelin product range, is yet another factor

which we place at your disposal to contrib-

ute to your success. Ensuring that you ob-

tain sound information on your product and,

therefore, the best possible component or

plant design.

Our Test Center is built on an industrial scale

to meet the wide range of demands of our

customers. For this reason we are geared to

provide tailored answers to your individual

tasks, with trials on an industrial scale and

special configurations that can be quickly

installed.

Leading edge technology is not accidental, but earned.

Two Test Centers – one specially designed

for pellets as well as the requirements of

the large scale chemical industry and one

for powders and additives (for the rubber

and plastics processing industry) form

the hub of our research and development

activities.

Whether commercial sized installation or

processing plant – whenever possible we

conduct full scale tests to avoid the uncer-

tainties of scale-up. The Zeppelin Test Center

offers an impressive range of options. As our

customer you naturally expect maximum

performance reliability – Zeppelin provides

results with no “ifs and buts” as a sound

basis for investment decisions.

For this reason the results that Zeppelin

provides leave nothing unexplained.

· competent result analysis by our specialists

· conclusive test reports and documentation

· determination of relevant design

parameters

Powders or pellets – nothing is left unexplained.

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The Zeppelin group of companies:All specialists under one roof.

Zeppelin Silos & Systems GmbHLeutholdstr. 10888045 Friedrichshafen, GermanyPhone: (+49) 75 41 20 2-02Fax: (+49) 75 41 20 2-491E-mail: zentral.fn@zeppelin.com

Zeppelin Materials Handling GmbHLeutholdstr. 10888045 Friedrichshafen, GermanyPhone: (+49) 75 41 20 2-02Fax: (+49) 75 41 20 2-581E-mail: info.fn@zeppelin.com

Zeppelin Belgium N.V.Munsterenstraat 93600 Genk, BelgiumPhone: (+32) 89 62 94 00Fax: (+32) 89 61 18 31E-mail: zeppelin.belgium@zeppelin.be

Zeppelin Technolgy Far East Pte, Ltd.#18-06 Odeon Towers331 North Bridge RoadSingapore 188720, SingaporePhone: (+65) 63 36 33 20Fax: (+65) 63 39 99 29E-mail: buero@zeppelin-zfe.com.sg

Zeppelin Systems USA, Inc.P.O. Box 40501Houston TX 77240-0501, USAPhone: (+1) 71 38 49 56 66Fax: (+1) 71 38 49 56 55E-mail: zeppelin-usa@zeppelin-usa.com

JMB Zeppelin Equipamentos Industriais Ltda.Rua João XXIII, N° 650CEP 09851-630 Jardim NazarethSão Bernardo do Campo, SPSão Paulo, BrazilPhone: (+55) 11 43 93 94 00Fax: (+55) 11 43 92 23 33E-mail: diretoria@jmbzeppelin.com.br

Zeppelin Systems India Pvt Ltd.F411-414, Kailas Industrial ComplexGodrej Park Site Off L.B.S. MargVikhroll (West), Mumbay – 400 079, IndiaPhone: (+91) 22 25 18 16 14 Fax: (+91) 22 55 97 49 05E-mail: zeppelin@mtnl.net.in

Zeppelin Solid Technology (Beijing) Co., Ltd.111#, Parkview CenterNo. 5, Fangyuan West RoadChaoyang DistrictBeijing 100016, ChinaPhone: (+86) 10 64 32 48 59 (+86) 10 64 32 48 69Fax: (+86) 10 64 32 48 29E-mail: office@zeppelin-china.com

Zeppelin Plast Tech S.r.l.Centro Direzionale „Summit“Palazzo „C“/Via Brescia20063 Cernusco sul Naviglio, ItalyPhone: (+39) 02 92 10 69 05Fax: (+39) 02 92 10 42 19E-mail: info@zeppelin-zi.it

Please visit our web site: http://www.zeppelin-industry.com© Zeppelin Silos & Systems GmbH, SD 03/06. Any changes are reserved.

All specialists under one roof

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