EMDE Automation GmbH
About us
As an innovative plant manufacturer, we develop tailor-made systems and components for conveying, dosing, mixing, filling and emptying bulk materials. We see it as our task to further develop your production concept with you – to implement it economically, future-proofed and networked.
EMDE has consistently developed over its 40-year history. From component manufacturer for, for example, flexible screw conveyors to plant manufacturer for big bag filling stations. Then, from plant manufacturer to solution specialist for technologically demanding systems.
Top quality and professional competence – in a variety of fields:
Bulk materials technology
Plant and components for conveying, dosing, mixing, filling and emptying bulk materials.
Control systems
Control systems production and electrical installations for complete solutions and plant optimisation.
Products
Automatic big bag emptying station
Material handling for hazardous products or bulk goods is increasingly being handled using big bags. For this reason, we have developed the automatic emptying system for big bags. With maximum emptying performance and semi-autonomous handling of big bags, this system is an absolute novelty on the market. The process is automated: The big bag is hooked in at the pick-up point by the operating personnel, then fed fully automatically to the emptying position via a positioning system, then cut open by a circular knife and emptied. Thanks to the use of the circular blade, even bulk materials that form strong bridges or are agglomerated can be discharged from the big bag safely. Product features: - Possible integration of further peripheral components such as empty bag compressors etc. - Overall concepts with all necessary safety devices - Robot-controlled feeding of the bulk material into the processing process - Dust-free emptying of big bags with and without discharge spout - Ideal for applications in areas with hazardous substances and in multi-shift operation - Intelligent networking of machines and processes thanks to connection and monitoring in the MES system - Reliable automatic operation even in industrial environments
Fully automatically operated Big Bag Filling station
Material handling for hazardous products or bulk materials is increasingly being handled with big bags. For this reason, we have developed the fully automatic filling system for big bags. With the highest filling capacities and the completely self-sufficient handling of 4-loop big bags, this system is an absolute novelty on the market. The process is fully automated: Picking up the big bag from a pick-up station, feeding it into the filling position via a robot-controlled handling system, connecting the filling spout to the filling head and closing it after filling. Product features: - Ideal for applications in areas with hazardous substances and for systems in multi-shift operation - Intelligent networking of machines and processes thanks to connection and monitoring in the manufacturing execution system (MES) - Reliable automatic operation even in industrial environments - Robot-controlled feeding and hooking of the 4-loop big bags (loops in the load hooks) - Dust-tight filling nozzle connection via inflation hose - Hanging filling, making complete expansion of the big bag possible - Automatic big bag closure through self-sufficient clip closure system - Problem-free filling of FIBC with inliner through prior inflation of the big bag by inflation devices - Effective compaction of the products during the filling process and vibration decoupling - Automatic feeding systems of pallets with pallet magazines – integrated conveyor technology for pallets - Possible integration of further peripheral components such as paper feeders, label printers, etc. - Complete concepts with all necessary protective devices
Automation
Your system only achieves the maximum of efficiency with a perfectly synchronised control system. With its own department for control and automation technology, EMDE offers you a full service for your system solutions. For this, we work with renowned manufacturers on the basis of our in-house standard or in accordance with customer specifications. We support your projects during: conceptual design, circuit diagram creation, control cabinet construction, programming, electrical installation and commissioning. In combination with our service via remote maintenance, you also receive an full service package with your perfectly controlled complete system, including a CE declaration of conformity. Our services: - PLC controls with integration into an existing control system - Modernization and expansion of existing controls - Control planning using EPLAN - Electrical installation and commissioning of the system from a single source to avoid interfaces in project handling - Short response times in the event of a standstill thanks to optional remote accesses - So that you always have everything in view: Visualisation and system operation via HMI panels - Tuning and parameterization of the weighing system to the respective application - Use of various weighing electronics from different manufacturers with standard programmes or customised solutions - Coordination of the weighing systems with our or existing dosing systems - Use of calibratable load cells and weighing terminals
Loading system
With the EMDE Bulk Batch System, the products are transported to the required point of use via different transport systems with feeding containers. The docking of the shuttle at the site of operation is fully automated and dust-free. The entire feeding technology as well as product and recipe management is controlled by a higher-level data management system. Product features: - The intelligent solution for formulating, feeding and dosing - Supply of several production lines simultaneously through adapted system solutions - Systems planning in 3 dimensions; thus optimum space utilisation of the existing production area - High system utilisation due to simultaneous dosing of different formulations - Batch tracking according to Industry 4.0 through integrated IT / automation solutions - Dust-tight shuttle docking system for clean and hygienic production - Expandable system design for maximum flexibility for future market requirements - Variety-pure product handling due to the expanded number of shuttles - Shuttle identification via chip identifier - Freely selectable shuttle distribution on mixed and finished product lines - Possible expansion with all available Emde emptying, conveying and filling systems - Complete batch tracking even during the ongoing production process - Design of the feeding systems with roller conveyors or driverless transport system
Big bag filling stations
The packaging material par excellence for bulk goods is the big bag, which is used for various products in all industries. The different properties of bulk materials often require specially adapted solutions to ensure clean and accurate filling of the big bags. The applications, the desired filling capacities, and the requirements for the degree of automation of the systems are correspondingly individual. Product features: - Volumetrically or gravimetrically controlled filling - Dust-tight filling nozzle docking via inflation hose - Filling of different big bag sizes by lifting devices for the filling head or by lifting the big bag - Safety assured by optional fall protection devices on the lifting devices - Design for hazardous dust areas: Filling of all explosive dust products - Effective compaction of the products during the filling process by vibration decoupling of the vibration frame from the weighing frame - Problem-free filling of FIBC with inliner through prior inflation of the big bag by inflation devices - Simplified operation due to automatic and extendible safety folding hooks - Best ease of use due to automatic closing apparatus with a clip device - Automatic, airtight closure of inliners by integrated welding systems - Ergonomically designed workstations and operating platforms, optionally with an extendible step for hooking on carrying loops or docking the filling spout - Piece goods handling with pallet magazine, integrated conveyor technology for pallets - Possible integration of further peripheral components such as paper feeders, label printers, etc. - Complete concepts with all necessary protective devices - Mobile versions: whether by hand, with a forklift truck, on rails, or freely movable with its own drive
Big bag emptying stations
Use of big bags in the bulk materials sector is constantly increasing. Dust-free emptying, fast and secure handling and an ergonomically ideal design for the emptying stations have priority for this application. EMDE big bag emptiers are produced in four different basic variants. Each variant offers the customer optimum benefits for the respective application. Your specific requirements are the basis for the design of the emptying system. The type-defining selection criteria include product-specific flow properties, such as grain size, flow properties, bulk material weight and consistency. Four different basic variants: BE 1000 – simple feed hopper with safety support frame BE 1400 – docking connection with bag clamp BE 1500 – feed hopper with sealing membrane and operating opening for tying up big bags BE 1600 – double ring docking system with sealing plate; inflatable hose and retightening device optional Further important dimensioning criteria are the number of containers to be emptied per hour, local circumstances and finally the customer’s concrete needs. Various additional accessories are necessary to always configure the ideal solution for the customer due to the varied configuration of big bags (FIBCs), starting with the dimensions, the material, the emptying nozzle dimensions and the number of loops. Handling: The emptying stations can be fed either with integrated hoisting gear and crane crossbeam, with forklift truck and forklift crossbeam or with a crane provided by the customer. Various docking systems are available for dust-free emptying, such as double ring docking systems with inflation hose and re-tensioning device, docking nozzles with bag clamps or feed hoppers with rubber membranes.
Big bag compactor
Due to its compactness the EMDE BSV 800 big bag compactor can be set up directly next to the work area. This eliminates otherwise unavoidable dust formation when the empty big bags are transported within the company. Empty big bags are effectively and efficiently compacted. The container is disposed of via a generously sized filling opening with a gas strut-supported hinged lid. The sacks are pressed into an empty disposable big bag by a robust, cantilevered compacting screw with progressive reduction. The big bag compactor is also available as a mobile version. The big bag compactor can be connected to external dust extraction via an aspiration nozzle so that dust discharge is avoided and the big bags can be disposed of with a minimum of dust.
Empty sack compactor
With the help of the EMDE LSV 400 empty sack compactor, empty paper and plastics sacks can be effectively and efficiently compacted to some 10-15% of their original volume. Loading is performed either via a safety-compliant collection chute or via a connecting chute to the sack emptier. The sacks are pressed into a continuous polyethylene hose by a robust, cantilevered compacting screw with progressive reduction. For better compaction the empty sack compactor is equipped with an adjustable brake slider. As a mobile version the empty sack compactor is mounted with a brake slider on a base frame. To remove the compacted sacks the polyethylene sack is tied up and detached. An electrically conductive polyethylene hose covering is used when deployed in Atex zones.
Single screw mixers
At the heart of many industrial plants is a mixer for producing homogeneous mixtures. Short mixing times, gentle handling of the product, and optimum accessibility are important here in order to clean the batch mixer efficiently. The Emde single-shaft screw mixer combines these properties and ensures fast and uniform mixing of the batches thanks to the special geometry of the mixing tool. The mixing equipment mixes batches quickly and evenly using an external mixer which brings the material towards the centre of the mixing trough and a small concentric helix. Product features: - Batch mixer design adaptable for different industries (chemical, food, building materials, or plastics industries) - The single-shaft mixer in steel or stainless steel for batch sizes from 80 to 5,000 L - Mixes different bulk materials, from granulate to powder - Version for gas or dust hazardous areas (zone 1/2 or 21/22) is possible - Version with polished surfaces that come into contact with the product: particularly hygienic for food applications - Double-speed mixing screw for fast and homogeneous mixing - Different sealing systems: stuffing box, shaft sealing, or special sealing systems for food or chemical applications - Integration of washing nozzles for the safe removal of product residues - Installation of a cutter head for breaking up agglomerates - Easy cleaning due to a pull-out mixing tool - Possible additional devices for heating and moistening the mixture
Sack emptiers
The classic container for storing and transporting bulk materials is still the sack. For product quantities of 1 to 100 sacks per batch, the manually operated sack emptying system is still the most economic variant. EMDE sack emptiers offer ergonomically optimised, manual handling of the container by four different basic types: 1. EMDE sack emptiers 2. EMDE sack chutes 3. EMDE sack emptying cabins 4. Combined EMDE sack / big bag emptiers Product properties: - Manually operated bag handling - Ergonomically optimised bag handling - Integrated filter systems, designed specifically for each product - Optimum extraction performance with the emptying opening open - Handling of very dusty or low-toxicity substances via a closed emptying cabin with a ‘glove box’ - Low-dust empty bag disposal via empty bag spout or empty bag compactor - Combined bag and big bag emptying station for flexible container selection and emptying of various products via one station
Mixing/Breaking up
First-class products can only be manufactured if the raw material and the product mixture are homogenous. With various mixing variants: 1. Single screw mixer as batch mixers - Highest mixing quality within the shortest mixing time - Charging and mixing in a single process step - Very gentle mixing - Mixing trough with virtually no dead space - Energy-efficient mixing - Batch mixing with simultaneous additional processes such as: heating/cooling, drying, moistening, deagglomeration/crushing 2. Continuous mixers: - Continuous and, if desired, gas-tight closed mixing process - Mixing, transporting and moistening in a single process step - Separate drives for inner and outer mixing spirals ensure an optimal mixing process - Maximum throughput capacity - Low space requirement 3. Double paddle mixing screws: - Continuous mixing and increasing conveying - Overlapping mixing paddles ensure highly effective mixing results - Simultaneous mixing, heating, cooling or drying - Easily accessible and cleanable mixing trough
Container, octabin and barrel filling/emptying stations
Bulk goods are not only stored and transported in big bags and sacks. They often have to be filled into other containers, such as drums, octabins or containers. However, not all systems are designed for this. On the contrary: Filling usually requires customised filling and emptying stations. EMDE emptying systems consist of the following basic components: - Base frame in sturdy square tube welded construction with the necessary centring devices - Drum and octabin emptying stations with electrically or hydraulically driven swivel frames - Docking with spring-mounted sealing plate The following additional equipment is also available: - Discharge aids such as vibration frames - Discharge screws or pneumatic conveyor systems - Dosing devices with agitator for uniform product discharge - EMDE frame scale for recording the product quantities to be discharged - Compressed air piston vibrator for emptying the containers completely - Feeding can be carried out by forklift, chain hoist or roller conveyor
Volumetric and gravimetric dosing screws
The manufacture of quality products requires even dosing within extremely narrow tolerances. Leave it to us to achieve this, even with materials with the most problematic bulk properties. Free-flowing powders and granulates are dosed very precisely and purely volumetrically. The desired flow volume is set or changed by the screw speed. Gravimetrically controlled dosing is, however, essential for documenting dosing quantities. Product properties: - Dosing screw troughs optimally designed for flow characteristics - Product-specific dosing spirals and screws - Separately driven loosening agitator to ensure a uniform filling level - Dosing capacity adjustment via frequency converter or servo-controlled drives - Gravimetrically controlled dosing for the following applications: Dosing of batches, withdrawal according to setpoint specification, differential dosing according to fixed setpoint specification, differential dosing according to variable and continuous setpoint specification - Control components with standard PLC modules - Process adjustment via continuous controller adjustment - Complex process control via several PID controllers connected in series - Complete process documentation
Vacuum conveying systems
The EMDE vacuum conveyer is available in two different variants as a Type VFS-G granulate conveyor or a Type VFS-P suction conveying system for powder. The Type VFS-G granulate conveyer Has a sintered metal filter disc built into thehead which is very easy to clean and replace. The device cover, into which the dedusting nozzle holder is also integrated, is secured with a quick-release clamp. This can be quickly removed for cleaning purposes. The VFS-P suction conveying system The VFS-P suction conveying system designed for powder and flow-resistant products is disassembled just as quickly. The product container is simultaneously the conical strainer protruding downwards which can be completely fluidised and thus guarantee reliable product discharge.
Dust extraction systems
EMDE dust suction systems in mobile and stationary designs are the ideal solution for the effective cleaning of complex industrial plant. These offer safe, environmentally friendly technology, high-quality manufacture and problem-free, impeccable quality. Large systems and buildings are ideally provided with a central piping network. By using EMDE dust extraction systems, you can be assured thatdust deposits are picked up and disposed of dust-free in even the smallest cracks and corners. To extract explosive dusts, the filter system can be provided in a10 bar shock pressure-resistant design in accordance with VDI 2263 DIN EN 1127-1, or alternatively in a reduced-pressure variant (1.5 bar) with a relief valve. The piping network and the roots blower are decoupled by means of corresponding protective equipment.
Pressure and suction conveying
Pneumatic conveying is the most economical way of gently transporting powders and granulates over long distances, both horizontally and vertically. The transport speeds are adapted to the technical requirements and the product characteristics. Whether dilute phase conveying or dense-phase conveying: we offer you all technical solutions. We also offer various dust extraction systems in mobile and stationary versions. They ensure the effective cleaning of complex industrial plants and impress our customers with their safe, environmentally friendly technology, high-quality workmanship, and long-lasting quality. Since longer conveyor distances can often only be achieved with pneumatic pressure or suction conveyor systems, we offer the following pneumatic conveyor systems: 1. Pneumatic container conveying systems as dense flow or slug conveyors, partly with bypass pipe for blowing in conveying air along the conveying pipe. 2. Low and medium pressure conveying systems with feed locks or injectors 3. Conventional suction conveyor systems with feed locks or injectors
System components
Clean workplaces and reproducible product quality are of the greatest importance, and are a prerequisite for long-term employee and customer retention. A small component such as the EMKOM compensator, can play an absolutely decisive role in attaining these goals when handling dusty bulk materials. Many so-called compensators are much too stiff or even permeable; they certainly do not compensate for oscillations or external forces. Especially with materials which are a hazard to health, this leads to safety-relevant aspects which urgently require attention. The EMKOM silicone compensator permanently and reliably eliminates these weak spots. The many benefits with regard to permanent elasticity, aging resistance, suitability for use with foodstuffs, temperature resistance and the highest flexibility, make it an essential weighing technology component. In addition, it is a popular choice as vibration decoupling for dosing channels,and as a connecting element between system components. The bellow-shaped compensator possesses excellent mechanical properties for decoupling vertical oscillations. The level compensator has the advantage that two different pipe diameters can be connected together. For Ex-protected gas and dust areas we offer electrically conductive compensators with the corresponding manufacturer’s declaration. Due to the extremely flexible tensioning strap it is possible to connect different pipe diameters of the nominal size by means of a tensioning strap. The single-hand bag clamp is used to secure big bags, sacks or inliners. It is made entirely of stainless steel and can be operated with one hand. Thanks to the various interchangeable sealing inserts, the single-hand bag clamp can be used directly in food applications with FDA approval or as an optional electrically conductive version.
