» Engineering your success «

Bulk materials components made by Zeppelin Quality that pays off

Components

Engineering your success

Zeppelin Systems, the world leading plant manufacturer for high

quality bulk material handling, has remarkably grown over the past

60 years. We cover the demands of a wide range of industries and

supply all plant manufacturing services from one single source,

whether basic engineering, in-house production of components,

fi nal assembly or comprehensive after sales service. Thanks to

our fi nancial strength and our global network we have long been

a reliable partner for our customers.

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Polymer Plants Plants for plastics producers and forwarders

Plastics Processing & Rubber Plants Plants for the plastics processing and rubber industry

Reimelt Food Technology Plants for the food, confectionery and bakery industry

Henschel Mixing Technology Mixers, extruders and compounders

Liquids Processing Plants for the beverages industry

Silos & Filters Silo technology and fi lters Components Diverter valves, rotary feeders, separators … After Sales Service Assembly, maintenance and spare parts Quality Service Services in quality management

Zeppelin plant engineering – business fi elds

Every Zeppelin plant is developed according to the clients’ specifi c requirements and realized thanks to our customized innovative processes and technologies.

The knowledge we have acquired over more than 60 years of plant manufacturing and the world’s largest network for bulk material handling are the key to providing ideal solu-tions whatever the challenge. After all, your success is our goal.

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When Zeppelin pushed the development of its

components many years ago, it was clear to all

that only unconditional quality strategy would

lead to success. In the meantime, we have be-

come one of the leading components suppliers

for bulk materials. Our customers benefi t from

our innovative solutions and their numerous

advantages.

Quality prevails

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Whole grain

Inlet baffl e plates installed in housings prevent plastic pellets from being crushed but, in turn, reduce the remaining inlet cross section, the fi lling capacity of the rotor chambers and the speed range which results in low throughputs. Our engineers have analyzed the problem and found a solution: the edges inside the housing are specially designed to operate like baffl es and the down-rotating part of the housing is foreseen with by-pass chambers to avoid product damage. Thanks to this largest possible inlet cross sec-tion, a higher throughput can be achieved.

Furthermore, the smooth and shock-free opera-tion reduces the wear of the chain drive and the gear motor. Exchanging these parts then be-comes obsolete, normal product life and regular maintenance provided.

As the rotary feeder can be reliably started with vertical product columns, slide gate valves for the start-up are no longer required.

Gap-free seals

The sealing system incorporated in our high-pressure rotary feeders with operating pressures up to 3.5 bar has been specially designed to eliminate gaps through which fi ne dust or powder may penetrate. Seals in conventional sealing systems are subject to rapid wear caused by penetrating material. Our seals, however, can last at least 12 months if installed in powder plants and even several years if used in pellet systems. Lateral arrangement of the axial sealing system ensures that the seal is pressed uniformly against the sealing surface. Thanks to additional pressure compensation, the required pressure is reduced. This innovative solution contributes to energy savings: the input power for a 400 series rotary feeder is merely 1.1 kW.

Gap-free sealing system

Innovative edge design serves as pellet baffl e

Our rotary feeders are so effi cient that even a smaller design will perform

just as well. Thanks to the intelligent feeder design, product damage is

almost history!

High-tech rotary feeders

Rotary feeders

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Minimizing leakage

Differential pressure causes leakage at the gap between the housing and the rotor of the rotary feeder. For product temperatures above 60°C, larger gap widths are required due to the tempera-ture difference between the housing and the rotor. These gaps naturally result in an increased leakage. We have equipped the feeder housings with jacket heating systems which allow tempe-rature adjustment, reduction of gaps and mini-mized leakage gas rates. The heating system of a 90 tons/h throughput rotary feeder can reduce leakage of up to 500 Nm³/h of gas.

The jacket heating systems can operate with water, oil or steam. Electric heating elements tailored to the housing contour are also available.

For a long service life

Rotary shaft seals have become the standard modern sealing system for rotating shafts. Although the reliabil-ity of their function is very good for use with gases or liquids at limited pressures, diffi culties may occur if they are used with powders, e.g. when powder parti-cles penetrate between the sealing lip and the sealing surface. Then, the seal rings are often worn after a few weeks only. Therefore, rotary feeders designed by Zeppelin are equipped with a purge gas connec-tion. The purge gas fl ow reduces abrasion considerab-ly and the rotary shaft seals need no exchange before the normal yearly maintenance.

Purge gas connections for purge gas fl ow

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Maximum fl exibility

Our versatile rotary feeder program offers ideal solutions for various fi elds of application and installations. Whether fl exible speed regulation by chain transmission or fl ange-mounted or interlocked maintenance-free drive units, we customize your rotary feeder in accordance with the specifi c conditions on site and your requirements.

Jacket heating system to prevent leakage

Versatile rotary feeder program

Rotary feeders

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Infl ated for longer life

Diverter valves are used for directing the fl ow of bulk materials without losses caused by leakage. Reliable switching and perfect sealing are required for optimum performance. If used in powder conveying systems, materials which penetrate the interior of the diverter valve may cause switch malfunction and friction at the seal resulting in wear and fi nally leakage. Therefore, Zeppelin has developed an infl atable seal that prolongs the service life and prevents malfunctions. Inspection and seal exchange (if required) have only to be carried out during the annual maintenance.

The large range of Zeppelin diverter valves

offers the right solution for any application.

Our latest generation of diverter valves is

based on an especially intelligent design

principle: they can be tailored to the sim-

plest standard application or the most

complicated one.

Maximum effi ciency

diverter valves

Infl atable sealing system in operating mode

Infl atable sealing system (close-up view) –prevents the penetration of impurities

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Just replace the inserts!

Why purchase a complete new diverter valve if exchanging the insert is enough? We use specially designed inserts made of hardened tool steel or ceramic for diverter valves subject to excessive wear, e.g. for conveying glass-reinforced products. Worn inserts can be easily exchanged – without any impact on the basic components. Thanks to these special inserts, the service life of diverter valves is now four times longer and even ten times for ceramic inserts. The costs incurred for a new insert amount to approximately 20% of the cost of a new diverter valve.

Simpler is better

Often the simplest solutions require the most development work. This is the case for the static sealing system incorporated in our diverter valves. Our engineers have designed several seal edges that ensure a reliable sealing and minimize friction during switching. Special shaping ensures that the gasket is fi xed tightly in the groove bed. The effort has paid off for our customers: additional control interlocks and the actuation of additional instruments are no longer necessary; exchanging the seal has been facilitated and can be realized during the regular maintenance intervals.

Diverter valves

Static sealing system Inserts made from hardened tool steel or ceramic

ApplicationFor feeding into pneumatic dilute and dense phase conveying systems or for feeding and discharge of bulk materials in processing plants

For the metered discharge of bulk materials as well as feeding equipment for dilute phase conveying systemsFor feeding bulk materials into pneumatic dilute phase conveying systems

Bulk materials Powder, pellets Powder

Operating pressure -1.0 to +3.5 bar (g) -1.0 to +1.5 bar (g)

Temperature range -10 to +250°C

Sizes (Capacities)

200 to 8505 to 350 LTR

200 to 7507 to 270 LTR

160 to 5002.5 to 87 LTR

Materials Aluminium/stainless steel/gray cast iron

Accessories Direct drive/chain drive, leakage gas collector, feeding chutes, ATEX design, quick cleaning version, additional accessories upon request

CFH

Subject to modifi cations without notice

High pressure rotary feedersThe Zeppelin modular system of rotary feeders always offers the ideal solution for your application.

Rotary feeders from the expert

Rotary feeders

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ApplicationFor feeding into pneumatic dilute and dense phase conveying systems or for feeding and discharge of bulk materials in processing plants

For the metered discharge of bulk materials as well as feeding equipment for dilute phase conveying systemsFor feeding bulk materials into pneumatic dilute phase conveying systems

Bulk materials Powder, pellets Powder

Operating pressure -1.0 to +3.5 bar (g) -1.0 to +1.5 bar (g)

Temperature range -10 to +250°C

Sizes (Capacities)

200 to 8505 to 350 LTR

200 to 7507 to 270 LTR

160 to 5002.5 to 87 LTR

Materials Aluminium/stainless steel/gray cast iron

Accessories Direct drive/chain drive, leakage gas collector, feeding chutes, ATEX design, quick cleaning version, additional accessories upon request

A series IICFM D series II

Medium pressure rotary feeders

Blow-through rotary feederDischarge rotary feederDischarge rotary feeder

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Application Diverter valves for directing or converging the product flow in pneumatic conveying systems and gravity pipes

Special features Multi-way diverter valve Mounted on the silo without adapters Universal use for directing the product flow Symmetric piping design

Bulk materials Powder, pellets

Operating pressure -1.0 to +3.5 bar (g)

Temperature range -40 to +120°C

Diverting angle 4 x 90° 90° 45° 2 x 45° symmetric

Sizes (diameters) 150 to 350 80 to 350 80 to 300 150 to 350

Materials Aluminium/parts in contact with the product made of stainless steel

Accessories ATEX design, inflatable seal, additional accessories upon request

Subject to modifi cations without notice

Diverter valves

Setting the course for the future

Diverter valves

M-Diverter valve

Zeppelin diverter valves have been developed to guarantee reliable operation in the future as well. The patented design of the inlet, the outlet and the rotary plug channel ensures gentle transport of materials without any deposits. The active conveying direction is pressure-tight to avoid leakage or product impurities. Infl atable seals enable washing of pipes.

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Application Diverter valves for directing or converging the product flow in pneumatic conveying systems and gravity pipes

Special features Multi-way diverter valve Mounted on the silo without adapters Universal use for directing the product flow Symmetric piping design

Bulk materials Powder, pellets

Operating pressure -1.0 to +3.5 bar (g)

Temperature range -40 to +120°C

Diverting angle 4 x 90° 90° 45° 2 x 45° symmetric

Sizes (diameters) 150 to 350 80 to 350 80 to 300 150 to 350

Materials Aluminium/parts in contact with the product made of stainless steel

Accessories ATEX design, inflatable seal, additional accessories upon request

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Diverter valves

VST-Diverter valveTST-Diverter valve Y-Diverter valve

Single channel

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Application For directing or converging the product flow in pneumatic conveying systems and gravity pipes

Special features Abrasive products, exchangeable wear inserts Dilute phase conveying especially with powder Adhesive powders with poor flowability

Bulk materials Powder, pellets

Operating pressure -1.0 to +3.5 bar (g) -1.0 to +2.0 bar (g) -1.0 to +4.0 bar (g)

Temperature range -40 to +120°C

Diverting angle 35° Number of outputs 2 3

Sizes (diameters) 50 to 250 50 to 150 50 to 225

Materials Aluminium/parts in contact with the product made of stainless steel Aluminium/parts in contact with the product made of stainless steel/PU

Accessories ATEX design, additional accessories upon request

Subject to modifi cations without notice

Diverter valves

ZWV-Diverter valveZWR-Diverter valve

Diverter valves

Two-channel

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Application For directing or converging the product flow in pneumatic conveying systems and gravity pipes

Special features Abrasive products, exchangeable wear inserts Dilute phase conveying especially with powder Adhesive powders with poor flowability

Bulk materials Powder, pellets

Operating pressure -1.0 to +3.5 bar (g) -1.0 to +2.0 bar (g) -1.0 to +4.0 bar (g)

Temperature range -40 to +120°C

Diverting angle 35° Number of outputs 2 3

Sizes (diameters) 50 to 250 50 to 150 50 to 225

Materials Aluminium/parts in contact with the product made of stainless steel Aluminium/parts in contact with the product made of stainless steel/PU

Accessories ATEX design, additional accessories upon request

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Hose-type diverter valves

ZWS-Diverter valve

Two-way

DWS-Diverter valve

Three-way

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Granucheck samplerSampler type MPN

ApplicationSampling from the product stream, hoppers and gravity pipes

Sampling from conveying pipes For automatic feeding to extruders, processing machines, hoppers and storage silos

Bulk materials Powder, pellets Pellets Pelletized, powdered, and granulated products

Operating pressure -1.0 to +1.0 bar (g) Up to -0.5 bar (g)

Temperature range -20 to +80°C

Operating principle Pneumatic, manual Pneumatic

Sizes (diameters) DN 50 DN 80 DN 50 (S1) DN 100 (S2) SFG 2 SFG 3 SFG 6

Performance

Working volume [cm³]

50 200

Max. throughput [m³/h] for free-� owing pellets

0.2 5

Normal throughput [kg/h]

500 800 2000

Material Stainless steel Stainless steel/aluminium Stainless steel

Accessories ATEX design, high-temperature version, controls, additional accessories upon request ATEX design, controls, vacuum pump, conveying hose, additional accessories upon request

Subject to modifi cations without notice

Samples of our know-how

Additional components

The sampler type MPN is used for sampling powdery and pelletized products from the prod-uct stream in gravity pipes or hoppers at normal atmospheric conditions, excess pressure or vacuum (maximum 1 bar).

The automatic Granucheck sampler works with virtually any free-fl owing bulk material. The samples may be directed from stationary and/or moving bulk material column through gravity by way of the pneumatically-driven sampler probe to the connecting container or piping.

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SFG powder vacuum hopper loader

ApplicationSampling from the product stream, hoppers and gravity pipes

Sampling from conveying pipes For automatic feeding to extruders, processing machines, hoppers and storage silos

Bulk materials Powder, pellets Pellets Pelletized, powdered, and granulated products

Operating pressure -1.0 to +1.0 bar (g) Up to -0.5 bar (g)

Temperature range -20 to +80°C

Operating principle Pneumatic, manual Pneumatic

Sizes (diameters) DN 50 DN 80 DN 50 (S1) DN 100 (S2) SFG 2 SFG 3 SFG 6

Performance

Working volume [cm³]

50 200

Max. throughput [m³/h] for free-� owing pellets

0.2 5

Normal throughput [kg/h]

500 800 2000

Material Stainless steel Stainless steel/aluminium Stainless steel

Accessories ATEX design, high-temperature version, controls, additional accessories upon request ATEX design, controls, vacuum pump, conveying hose, additional accessories upon request

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Automatic feeding

The SFG powder vacuum hopper loader automat-ically feeds pelletized, powdered, and granulated products to silos, hoppers, processing machines, and extruders. Oversized surface area of fi lter designed with powdered products in mind. Use this universal unit with your existing feeding systems or as a standalone device.

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Zeppelin Technology Center

In addition to outstanding staff, you will find the world‘s largest Technology Center for handling bulk materials for the plastics, chemi-cals and rubber industries at our location in Friedrichshafen, Germany. Together with our test facilities in Rödermark and Kassel, we cover the needs of the food industry as well as the mixing and compounding sectors. We’re ready to take on nearly any challenge.

For the development of our components we naturally take advantage of all

resources available to leading plant suppliers such as ourselves.

Take advantage

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Henschel Mixing Technology, Kassel

Reimelt Food Technology, Röder

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Research and

Development

At Zeppelin we can rely on excellent spe-cialists who are masters of their trade. The requirements to each individual component are known best by those who design and build complete systems. Our employees in development, manufacturing and installation, quality assurance and other departments are all quality experts.

Quality experts at work

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com » Belgium

» Brazil

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www.zeppelin-systems.com

Global presence

Zeppelin Systems GmbH

Leutholdstr. 26

88045 Friedrichshafen

Germany

Tel.: +49 7541 202-02

Fax: +49 7541 202-491

Email: zentral.fn@zeppelin.com

© Zeppelin Systems GmbH

Edition 06/12 | 031101201

Subject to modifications without notice

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