AZO GmbH + Co. KG

AZO CleanDock® is a system for docking containers at upstream dosing units. Apart from dust-free transfer between dosing units and mobile containers and decoupling from scales, it provides further functions.

This contrasts with the situation when mobile containers are used. The use of this type of system means that there are transfer points between dosing units and the relevant bulk materials container. These transfer points have to satisfy several requirements simultaneously: First, the target receptacle needs to have a cover lid that prevents foreign matter from getting into the inside of the container during storage time. Residual quantities, which typically stick to the outlet of the dosing unit after dosing operations, should be prevented from falling into the plant. Use of special docking systems rules out potential contamination of the plant. A sealed connection between the dosing units and the target receptacle while it is docked is critical to avoid dust from accumulating. A flexible connection with minimum force shunt is absolutely necessary. De-aeration of the bulk materials container being filled should be considered as an add-on.

The AZO CleanDock® is a system for docking containers at upstream dosing units

AZO provides container docking to satisfy these requirements with its CleanDock® system. This is a double-cone system, consisting of a passive part on the container and an active part on the dosing unit. The passive part on the container seals the opening with a spring-loaded lock. The drop tube, which is below the dosing unit and which feeds the product, is sealed with a cone in the active part of the AZO CleanDock®. When the container is docked, both housing parts (active and passive) are first joined and then locked. Thanks to the flexible connection built into the passive part, a dust-tight join is formed between the dosing unit and the container. The flexible connection is formed of air-permeable filter media. This ensures de-aeration of the container in the filling process and a reliable air supply flow during discharge. Typical of the AZO CleanDock® design is the line contact of the four components: active part of housing, passive part of housing, passive part of cone and active part of cone. This principle allows various containers to be docked below several different dosing points without this causing cross-contamination of products. This is a particular advantage when handling allergens. In the food sector, products with a strong flavour may also necessitate using strict isolation like this. In firms from the paints and lacquers sector, isolating systems are used to ensure the strict differences in shades.

The AZO CleanDock® allows mass flow rates of up to 25 t/h. Its design is characterised by simple, time-tested components and it affords robust operating performance with emergency running properties. Several tens of thousands of operating cycles have already been implemented in continuous operation without need for maintenance measures.

The AZO CleanDock® double-cone system surpasses conventional docking systems as regards emissions of dust. It effectively prevents generation of dust from the partially or full container. The AZO CleanDock® reliably holds back any product residue, which, in conventional plants, would adhere to the dosing unit after dosing and fall on the floor or into the plant. The connection between the dosing unit and container is secure at all times during dosing thanks to the frictional and form-fitting connection. The AZO CleanDock® keeps accumulation of dust below the minimum dust concentration as regards dust explosion. Any adverse effect on the weighing result due to force shunts is kept to a minimum thanks to the flexible connection. The AZO CleanDock® cannot be classed as a containment system. However, where automation and subsequent operating cycles are concerned, the AZO CleanDock® compared with the familiar split valve system is far superior.

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.

Highly precise batch and minor quantity automation from the market leader
During the manufacture of food, pharmaceuticals, chemical and plastic products, precise adherence to the recipes is decisive for the product quality. As the producer, you must have absolute confidence in the exact supply of your raw materials. Each ingredient must be meticulously documented.

With around 7,500 vacuum weighing systems already delivered, AZO has been Number One in mixer feeding of main components for quite some time. Over 650 installed systems, from ManDos through AZO COMPONENTER® in various designs and DosiBox® up to ShuttleDos® solutions, now also make AZO market leader in small and minor quantity automation throughout the world.  

Your advatages:
• Sustainable, economic solutions with high energy efficiency
• Safety thanks to experience and fully developed technology
• Great flexibility, meaning weighing various weights from 10 grams up to several 100 kilograms
• Variable design possible, simple to expand, easy to change recipes
• High precision for small and large weight units
• Minimised non-productive times, e.g. through process-optimised collection of components results in high speed
• Product and operator protection through contamination-free solutions
• User-friendly control and visualisation
• Reliable batch traceability and permanent documentation

AZO®MULTIAIR dense phase transport for short on degradation and dehomogenization over long distances and with high conveying capacity

• Gentle on the product
• Low wear
• Low level of dehomogenization
• High conveying capacity
• Long transport distances
• Energy saving due to targeted transport air supply

Preferred applications
AZO®MULTIAIR dense phase transport is a system that operates in the positive pressure range. The transport pressure range is between 1 and 4 bar positive pressure. The optimum transport pressure setting is based on the product and performance. This transport system is particularly dedicated for abrasive products such as PVC Dryblend and fiberglass-reinforced granulates as well as for pneumatic transport of foodstuffs such as breakfast cereals, instant products or milk powder with low levels of dehomogenization.

Special advantages
The extremely low transport speed is gentle on the product and transports it with low levels of dehomogenization. In addition, the wear on the system is reduced at the same time. The wide transport pressure range means that this system is particularly suited to high transport rates at the same time as for covering long transport distances. The control system is optimized for the product in question, while the targeted input of secondary air allows this system to operate with great energy efficiency.

AZO®VacuumPlus dense phase conveying gentle, segregation-free and extremely energy efficient

• Segregation and destruction free
• Low air and energy consumption
• Conveying of critical bulk materials
• Optimized controls
• Efficient usage of conditioned air

Preferred applications
The AZO®VacuumPlus dense phase conveying system is a new conveying system, intelligently combining the advantages of pressure and vacuum systems. Whenever fragile and/or temperature sensitive bulk materials need to be gently conveyed without segregation, this new materials handling technology is the solution – especially for applications with medium throughputs and conveying distances of up to 100 m.

Special advantages
The low product speed achieves a dense phase conveying with very little product segregation. This also means the conveyed product is handled very gently, with very little attrition, and therefore extremely low wear rates within the conveying pipes. It is easy to engineer such a system with many different product feeding points. Due to the low air and energy consumptions this system is very efficient, especially advantageous if conditioned air is required for conveying the product

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.