AZO GmbH + Co. KG

Flexible bulk materials receptacles such as big bags have become firmly established for handling powders in a variety of branches. They have clear advantages over sacks when it comes to transporting and storing bulk materials. They are environmentally friendly, require less operating staff and storage space and reduce costs for transport and processes.

AZO big bag discharge stations make it possible to discharge big bags without generating excess dust and to feed products reliably into the closed production plant. To improve efficiency and reduce costs even further, AZO has developed a modular concept for a big bag discharge station. The required components such as frame, support beams, chain hoist, discharging aids, big bag docking system, buffer bin and discharging unit can be chosen from a “construction set”, depending on the requirements. The entire discharge station can be configured to suit needs without outlay for design, which has a very positive effect on the price and delivery time. They are comparable with equipment from series production, however the modular station covers a much broader range of uses than a standard model, which makes it very flexible. Modular technology makes it possible to adapt the stations in use to changing production conditions with minimum outlay.

As part of a process for managing complexity, AZO will be optimising further equipment lines and meeting demand from customers for reductions in investment costs and shorter delivery times.

AZO Cyclone screener type DA Vario Containment for screening Active Pharmaceutical Ingredients (API)

Preferred application

The DA Vario Containment screener is suitable for use in the bulk materials handling industry where there are very stringent requirements regarding the amount of residual dust released. This means the machine is suitable for screening toxic materials both in the pharmaceuticals field and also in other industrial applications. A risk to machine operators from dust that is harmful to their health can be ruled out, both in normal operation and in the event of a service job.

Special advantages

• Replacing the screen basket and dosing screw under containment conditions

• Inspection of the screen basket by opening the inspection hatch under containment conditions

• Outlay for operations wearing full body protection can be reduced

• Easy to exchange the dosing module for different performance ranges

• Technology for cyclone screener type DA proven over years of use

• No additional dosing unit is required thanks to self-dosing, resulting in low overall height

• The drive with rotor and screen basket can be pulled out and pivoted with quick-release fasteners

• The drive with dosing screw can be pulled out using quick-release fasteners

• Suitable for CIP

• Chromium-nickel steel design

How it works

Based on the DA screener, tried and tested for years in actual practice, and on the widespread practice in the pharmaceuticals industry of using flexible containment systems, it is now feasible to open the inspection hatch without any dust escaping. It is possible to inspect the screen in use through the film thanks to the built-in lamp. Once the inspection has been completed, the inspection hatch can be closed again using a gauntlet integrated into the flexible liner. The machine operator has no contact with the high-risk substance in the machine at any time whatsoever. If damage to the screen fabric is found, the screen must be replaced. This procedure is also carried out using liner technology. Once the machine has stopped, the drive unit for the screen rotor is removed from the housing lengthwise. The installed plastic film system is unfolded in this process. It forms a hose-like working space, in which the screen basket and the screener rotor are located. By using appropriate locking and cutting techniques, it is then possible for the machine operator to remove the old screen within the liner and to fit the new screen by using another liner, also within a protected environment. The fitting of the new liner prepares the machine for the next screen replacement.

Features of the Vario Containment cyclone screener

The design of this machine is based on the tried and tested type DA cyclone screener with two drives and extraction devices. There are different dosing modules available in addition to the cover for various ranges of performance.

The screener is fitted with film liners. This make it possible to replace both the contaminated screen basket with a cleaned one and also the screw feeder in the dosing module under containment conditions.

AZO COMPONENTER® Step – automatic weighing of minor and micro components

Until now, minor and micro components had to be weighed manually, thus entailing risks and potential errors. These grow with the number of components and batches, and with the required weighing and metering accuracy. This has an adverse effect on product safety and quality overall.

Manual operations may under certain circumstances require a large number of staff and demands a high degree of concentration from them during weighing processes. They are to some extent exposed to relatively high amounts of dust. Occasionally automatic dosing units are also employed, which meter the ingredients onto a weigh belt feeder. However these require substantial outlay for cleaning; neither can they prevent cross-contamination.

In order to resolve the problems described above, AZO is expanding its already extensive portfolio for automation of minor and micro quantities with the AZO COMPONENTER® Step. This system makes it possible to weigh minor and micro components automatically with gram accuracy, such as flavourings, baking agents, emulsifiers, colourings and other ingredients. It improves product safety while simultaneously boosting production efficiency by reducing individual manual production steps to a minimum.

Especially when it comes to sectors with stringent requirements for hygiene, batch purity and product separation, the AZO COMPONENTER® Step enables adherence to the strict regulations and requirements of specific branches.

Fully automated filling and transport within the plant result in high throughput rates while achieving considerable levels of accuracy. Tracking and tracing of all raw materials used guarantee maximum product safety. All process steps and weighing results are reproducible, which ensures consistent, strict adherence to recipes. Strict separation of batches prevents cross-contamination, e.g. between allergens and non-allergens. What is more, the AZO COMPONENTER® Step is extremely flexible when it comes to changing products over thanks to its modular design.

The system was especially designed to satisfy the high requirements for hygiene in the food industry. This is primarily achieved by having the products filled into receptacles and keeping exposure to dust to a minimum by using aspiration. The outlay for cleaning can be kept low by using storage and target containers for the specific product groups. If necessary, target containers can be provided with liners.

Apart from customized solutions for automating raw materials and processes, AZO also offers the possibility to support the customer in planning production logistics by conducting concept studies.

This service is performed by the engineering & services division (AZO®e&s) as part of the pre-engineering process, tailored to the customer's existing or planned new system. Parallel to the plant design, additional process equipment is harmonized and planned with potential vendors. Apart from systems and process engineering, the logistics, media supply and staff rooms also play an important part. They can, if necessary, also be taken into consideration early on during this phase in order to create an ideal basis for further procedures (architecture, planning of budgets etc).

Regardless of whether it concerns an existing brownfield plant, where the aim is to refurbish existing buildings and/or equipment in accordance with the latest state-of-the-art technology (retrofit) and include possible expansion, or whether the project is at the greenfield stage where the priority is on dimensioning and ensuring investment for the entire facility. This independent planning service combines systems expertise with process-oriented layout design, thus ensuring a comprehensive engineering phase.

Logistics and layout are adapted to suit the (core) process engineering so constraints and bottlenecks can be averted or kept to a minimum. Planning is carried out entirely in-house, this simplifies communication and organisation.

Various planning and digitalization tools allow us to additionally support specific planning processes whilst including this service in our portfolio. In addition to the usual 3D design, there is the option of preparing systems and components designed using CAD so that they are available for the virtual environment (VR technology). Models are given a realistic, tangible character. This helps to make things more understandable for people not directly involved in the project and offers the advantage of not having to wait for the unit to be completed. This means, for instance, that operator training courses can be held in advance, saving the customer time and money.

In particular, VR technology can be integrated into the planning for future equipment. However, then questions are raised; “Is the existing space large enough?”, “Where is the best position” and so on. Limits are often reached in existing plants, especially when making adaptations or expansion. In order to counteract such problems, 3D scanning is becoming increasingly important as an as-built documentation. Here too AZO offers you this service, either as a service provider or by integrating it in ongoing projects. A simple  3D scan which offers a range of potential options for creating added value through the data collected, allowing a digital transformation and so providing the customer with maximum assistance in the planning process.

The main output of this technology is a point cloud, which depicts the collected data in the form of thousands of three-dimensional point coordinates. Preparing this file makes it possible to directly plan the current situation. In addition to documentation of the current state of the plant, collision-free planning with 3D CAD is possible. The time saved by control, reference and interface procedures can be invested in more detailed and accurate planning. In addition to the point cloud, a 360° photographic view is an additional benefit resulting from this service.

AZO LIQUIDS’ customers in the food, cosmetics and pharmaceuticals industries rely above all on the dependable and reproducible production processes of our plants. Maximum flexibility, efficient use of energy, fully automatic controls and consistent quality features are what set products from AZO LIQUIDS apart. Added to these advantages is our comprehensive industry expertise in all aspects of raw materials handling, from deliveries of raw materials to output and metering, mixing and controlling. AZO covers all areas of production and develops bespoke solutions for its customers.

Above and beyond this, you can expect AZO LIQUIDS to provide professional plant engineering, taking full account of your particular requirements, and to collaborate closely with you in developing solutions for your process.

Batch vacuum processing plants type zoatec® BG:

mixing, dispersing and homogenising – Fresh power for your liquid processes

The modular vacuum processing plants type zoatec® BG structured in assembly groups can be used everywhere that dry powders and liquids, or liquids and liquids, have to be mixed, dispersed and emulsified. As a result, they cover a wide product spectrum for liquid to semi-solid applications in the food industries. In addition, they are characterized in particular by short batch times.

AZO LIQUIDS processing plants stand out from all conventional plants with their ingenious design. Complete processing plants are assembled from standardized modules. The modules are independent from the process parameters, and can be adapted to your requirements with great flexibility. The entire series is designed according to similar geometrical principles, thereby making scale-up considerations much more precise. As a result, it is possible to concentrate on the actual process parameters in the planning phase, in order to make realistic predictions. Furthermore, the design offers major advantages in the areas of production, cleaning and maintenance.

The vacuum processing plants in our portfolio range from 10 l pilot plants through to 12,000 l production plants; and from 100 l/h up to 5000 l/h in the case of plants for continuous production processes.

Ingenious modularity provides the flexibility to satisfy every requirement

•Modular, consistent machine design – scale-up from lab operation to large-scale production. Separation between production and technical area.

•The agitator/s modular design allows a combination of stationary and moving vortex breakers. Other agitator elements can be integrated on a custom basis (e.g. dissolvers, jet mixers, propeller agitators, etc.).

•All components at the process hopper are easily accessible from outside for simple operation, cleaning and maintenance. The dispersing and pump mode for adding and mixing lumpy materials is available as an option.

•All plants can be adapted to meet process requirements. AZO LIQUIDS designs their system according to hygienic standards as HACCP, EHEDG and 3ASSI.

Logistics for precise dosing of solid – Solids meets Liquids

Agitator vessel (stirred-tank), vacuum mixers, coating lines, reactors, horizontal mixers, dough kneading machines, extruders, etc. are the core apparatuses in the production of food, cosmetics, pharmaceuticals and chemicals. Crucial for the quality of the end products, which are taken from these core apparatuses, is the highly precise and reliable dosing of liquids with different properties.

AZO LIQUIDS supplies the entire logistical systems for storage, dosing and temperature control of bulk liquids from large storage tanks, standard containers such as IBCs, drums and canisters down to the metering of very small quantities.

AZO combines the know-how of solid and liquid material handling and supplies customers with an "all-round care package" – without having troublemaking interfaces with third parties.