Report on Summer Training

in

BEUMER INDIA LIMITED, GURGAON

Submitted as partial fulfillment for the 3rd Year of

BACHELOR OF TECHNOLOGY
DEGREE
Session 2016-17
in

MECHANICAL ENGINEERING
By

VISHAL SINGH
Roll Number -1403240918
Submitted to
.

MR. NEERAJ SHARMA

(ASST PROF.)
MR. CHETAN RAJORIA (ASST PROF.)
MR. MAYANK KUSHWAHA (ASST PROF.)

ABES ENGINEERING COLLEGE, GHAZIABAD

AFFILIATED TO

UTTAR PRADESH TECHNICAL UNIVERSITY, LUCKNOW

36

Students Declaration
I hereby declare that the work and experience being presented in this report on
summer

training

(Haryana)

in

BEUMER

India

Limited,

Gurgaon

is an authentic record of my own work and experience carried out

under the supervision of Mr.

ANSHUMAN MISHRA (If there was your any

supervisor in the company).

The matter embodied in this report has not been submitted from any other source.

Dated :

Signature of student
VISHAL SINGH
Department : Mechanical Engineering

This is to certify that the above statement made by the candidate(s) is correct to
the best of my knowledge.
Signature of Faculty

(Mechanical Engineering)

Date............................

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ACKNOWLEDGEMENT
I express my sincere thanks and gratitude to Mr. Apoorva Anand, HOD, ME
Department for providing me an opportunity to undergo summer training at BEUMER
INDIA LIMITED, GURGAON ( HARYANA) .
The successful completion of project work requires efforts of several
intellectual minds. Working with BEUMER India Limited has been a great learning
experience for which I would like to thank everybody who has been instrumental in the
completion of my training.
I wish to express my deep sense of gratitude to my Guide, Mr. Anshuman
Mishra (Manager Production), for his able and uninterrupted guidance and useful
suggestions, which helped me in completing the summer training, in time.
I would also like to give a special thanks to Mr. Manish Kaushik ( Head
Manufacturing) and Mr. Deepak Batra ( Head HR & Admin.) for providing me the
opportunity to do summer training at" BEUMER INDIA LIMITED"..

Signature of Student
(Vishal Singh)

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Table of contents

SL. NO.

TOPIC

PAGE ON.

COMPANY PROFILE (BEUMER INDIA LTD)

5-11

SUMMARY OF REPORT (PRODUCTS DETAILS)

12-36

a.

BUCKET ELEVATOR

13-18

b.

FILLPAC

19-26

c.

STRETCH HOOD

27-34

d.

LOADING MACHINES

35-36

COMPANY PROFILE - BEUMER Group

37-44

BROCHURE BUCKET ELEVATORS

45-56

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COMPANY PROFILE

BEUMER India Limited is an amalgamated company of M/S BEUMER

Technologies India Pvt. Limited. and M/s Enexco Teknologies India Limited. These
companies have been amalgamated with a view to have Synergies in operations to
optimize utilization of resources. BEUMER India Ltd. is a 100% subsidiary of
BEUMER Group in Germany, which was established in 1935.
BEUMER Technologies India Pvt. Limited (located with head office in Mumbai) was
incorporated in 2003 and Enexco Teknologies India Limited was incorporated in
the year 1985.
Envisioned with the objective of leadership in intralogistics; in the fields of
conveying; loading; palletizing; packaging; sortation and distribution technology,
serving core sectors of Airports, Logistics, Cement, Petro-Chem, Mining, Power
Plant etc. With an array of engineering products and services , BEUMER India
Limited has emerged as a successful business enterprise serving India as well as
other parts of the world. Over the years, the company has grown significantly in
size and volume and equipped itself with necessary resources to meet the growing
demands of the industry.

36

BEUMER Group offers the right solution for almost every logistic and end of line
packaging challenge.
BEUMER India Limited is located in Gurgaon near New Delhi; the company has its
focus on all the business segments BEUMER Germany is active in:
Its rigorous and ethical business practices coupled with a streamlined
manufacturing procedure has enabled it to earn an ISO 9001:2008 certification
from ROYAL CERT International Registrars, Germany.
The company relates its success to its highly motivated workforce comprising of
skilled experienced engineers and trained workers led by a professional
management with proven track records.

Capitalizing on the vast growth potential that India has on offer and riding on its
technological brilliance, BEUMER India Limited is constantly delivering cost
effective performance oriented solutions in its focused sectors of Airports,
Logistics, Cement, Petro-Chem, Mining, Power Plant etc..

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INFRASTRUCTURE

BEUMER India Limited delivers value-added solutions that are acknowledged

globally. To achieve perfection in its manufacturing operations, it has a dedicated
design engineering centre and a well laid out production facility at Naurangpur in
Gurgaon.

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Completely technology driven, BEUMER's designing centre is manned by expert

design engineers capable of translating complex customer demands into high
value products engineered to optimization. Proficiency in designing and drawing is
achieved using the latest software platforms like solid works, emulation, simulation,
etc..
Spread across an area of more than 22,000 sq mtrs BEUMER is an organized set
up capable of manufacturing supply of complete Cement Plant, grinding units,
packing plant and Material Handling equipment apart from regular processing
equipment.

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Equipped with latest technology in plant machinery, the facility undertakes

specialized manufacturing operations like: Fabrication, Machining, Shot Blasting
and Painting.

QUALITY

BEUMER is known for the impeccable quality it infuses in all its operations right
from initial stages of production till final delivery.
To ensure consistency in manufacturing and regular increment in quality levels, a
Quality Assurance department is in place for adherence to various quality
standards. An in-house test lab with necessary resources for validation and testing
supports the company's initiative for serving its customers with best quality
products.

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CSR POLICY OFBEUMER INDIA LIMITED

BEUMER believe that the Corporate Social Responsibility (CSR) is an integral part
of the way we have been doing our business. The Company's CSR initiatives play
pivotal role in improving the lives of the communities and society at large, with an
objective to energize, involve and enable them to realize their potential. This shall
also enable us to fulfil our commitment to be a socially responsible corporate
citizen.
I. OBJECTIVE
The main objective of BEUMER CSR policy is:
1. To lay down guidelines to make CSR a key business process for sustainable
development of the society.
2. To directly/indirectly undertake projects/programs this will enhance the quality of
life and economic well-being of the communities in and around our plant and
society at large.
3. To generate goodwill and recognition among all stake holders of the company.

II. BEUMER RESPONSIBILITIES

A) Towards our communities
We shall involve communities surrounding our operations to bring about a positive
change in their lives through holistic, sustainable and integrated development.

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B) As a Corporate Citizen
We reaffirm our commitment to conduct our business with environmental
accountability. We will endeavour to adopt environment-friendly technologies and
energy efficiency in our operations while continuously monitoring and reducing
emissions.
C) Responsibilities toward our Employees
We will foster a work culture with high ethical principles and standards and
encourage our employees to perform with utmost integrity, commitment, ownership
and complying with OHS standards guidelines.

III. GUIDING PRINCIPLES

A) Community Support
1. Select underprivileged communities that we want to work with using a consistent
and objective assessment framework
2. Work independently and in partnership with NGOs on the selected
underprivileged communities
3. Have a singular focus of making them self-sufficient through innovative and
sustained long-term intervention programs
4. Assess the performance of communities objectively on a periodic basis
B) Environment Support

36

Spread awareness and adoption of environment friendly practices within the offices
and in the communities we operate in.
C) Disaster Support
Provide aid and relief measures in the event of major calamities affecting the
region or nation we operate in.

Summary Report

36

BUCKET ELEVATOR:

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Purpose: used to lift the cement or the clinker to a certain height.

Parts: Boot casing, Head casing, Bar drum, Standard casing, Assembly Casing,
Inspection whole cover casing, proxy casings, Steel cord belt, Buckets etc.,

36

Boot casing is the resting area of bar drum and contains the inlet area. In general a
boot casing may contain two inlets one for the main feed and another for the
auxiliary feed. The main feed goes directly into the elevator while the auxiliary feed
goes at the bottom of the elevator.

The bar drum is attached to the boot casing via a cylindrical tapered bearing. A
tension adjusting screw is provided on both the ends of bar drum which contains a
rack and pinion arrangement for the proper positioning of the bar drum to provide
sufficient tension to the belt.

The head casing contains the top bar drum which is connected to a motor and a
gear box via. Shaft which rests on the plummer block. Cylindrical tapered bearing
is used here for the shaft positioning.
Between the head casing and the boot casing are two types of casings, standard
casing, with a standard length of 20-25 mts and proxy casings that contains
different proxies.

The bar drum used at the bottom of the elevator is perforated so as to avoid any
material to get stuck within. The drive pulley at the top is of smooth surface and is
covered with rubber sheet to give proper rolling friction to the belt.
The belt used in the bucket elevator is a steel cord belt and contains steel wires
inside the original rubber coating. This is done to provide more strength to the belt.

36

The bucket elevator contains three proxy switches. Two are called belt sway proxy
and are attached at the opposite ends in standard casing. Their purpose is to
detect the disposition of the belt. They have a working range of 25 mm i.e. when
the belt reaches this distance to the proxy it cuts off the motor supply thus alarming
any problems. The third proxy is called zero speed proxy. It is located at the boot
casing opposite of belt sway proxy and serves the purpose of detecting any
problems related to belt damage, i.e. if the belt breaks the proxy stops sensing the
movement of the buckets across its field and cuts off the main motor supply.

A counter weight is used at the center of the elevator above the boot casing. The
weight used for the purpose may vary depending on the length of the belt used.
The purpose of counter weight is to keep the bucket elevator down during the
startup of the system.
Bucket elevators are of two types chain type and belt type. Although belt type are
more preferred because of their quite operation but chain type have their own
advantages over the former one in its life span and less maintenance problems.

HIGH CAPACITY BUCKET ELEVATOR

Bucket elevators have proven themselves for vertical transport of many and
diverse bulk materials for decades. As a market leader, BEUMER Group

36

successfully established the belt bucket elevator technology in the market decades
ago. Belt bucket elevators were consistently developed in the past and enable the
highest possible conveying capacities with maximum centre distances today.

Chain bucket elevators are the preferred conveying systems for the transport of
hot bulk materials and coarse-grained materials. With its central chain bucket
elevators, BEUMER Group offers efficient and proven solutions even for the
highest conveying capacities.

High-capacity belt bucket elevators are used for all floury and small-sized bulk
materials, e.g. raw meal, cement, grits, sand, concentrated ores, etc. Conveying
heights of up to 175 metres have been realised (for information: ACC, India).

36

Bucket widths of 160 to 2,000 mm are available for a finely graduated adaptation
to the conveying capacity. A special bucket design is used for particularly lightweight materials, making the construction as efficient as possible.

HD BUCKET ELEVATOR

Heavy-duty bucket elevators have been developed from belt bucket elevators and
are specially designed for coarse, highly abrasive bulk materials. HD bucket
elevators can transport piece sizes up to 120 mm.

36

By using a specifically designed BEUMER Group steel wire belt, HD bucket

elevators enable maximum conveying heights and conveying capacities. They are
particularly suitable as recirculation units behind high-pressure roller mills, which
are increasingly used for pre-grinding in the cement and ore sector.

Furthermore, the special design of the HD bucket elevator enables the highest
conveying capacities for coal and similar products. For this sector, the HD bucket
elevators can also be offered in an explosion-proof version.

CHAIN BUCKET ELEVATOR

The traditional chain bucket elevator is designed with a double-strand round steel
link chain (marine chain). This type is mainly used as an efficient solution for
coarse, highly abrasive materials in the low to medium capacity range. It is also
suitable for conveying hot bulk material.
Special versions, as for example central discharge bucket elevators, can be
designed according to customers' requirements.

HIGH CAPACITY CENTRAIL CHAIN BUCKET ELEVATOR

36

Central chain bucket elevators have been developed from the traditional bucket
elevators and enable high conveying capacities with large centre distances.
High-capacity chain bucket elevators with central chain are particularly suitable for
the transport of hot, granular and abrasive bulk material. In the cement industry
BEUMER central chain bucket elevators are used, among others, for the vertical
transport of hot, abrasive clinker, silo feed and in clinker milling systems.
Their reliability and long service life mean economic benefits for our customers,
resulting from the use of BEUMER Group technology.

FILLPAC

36

Purpose: to pack cement bags at high speed and efficiency.

36

Parts: Main drive assembly, Material Inlet, Dedusting chamber, Packer Bin,
Packing spout.

Main drive assembly consists of a hollow shaft that runs through the entire length
of the packer. It is connected to the gear assembly and main motor via
intermediate support which intern is connected to the main support that holds the
packer structure. A slip ring assembly is used to provide the power the packer unit.

The material inlet part is form where the cement is fed to the system from the inlet
chute coming form the storage bin.

A dedusting chamber is provided to the packer to allow the outlet of the dust to
allow the proper functioning. All the spouts are connected to the same through
their supporting frame of filling module. The dust collected is then vented out
through the ducts which are connected to the auxiliary inlet of the bucket elevator.

Packer bin is used to store the cement temporarily before it goes through the
impeller structure. A flow control gate is attached at the top of the inlet chamber
which adjusts the inlet rate of the cement using a level indicator. The level indicator
is fixed to the stationary cover with a moving lever. A proxy is attached to the
indicator stationary part, when the bin gets fill the lever rises and when it reaches
the range of proxy the flow control gate is turned off.

36

Packing Spout: A packing spout is made of three main parts i.e. a spout controller
that is connected to the PLC and controls the spout, a saddle assembly and a
packing stool assembly. A saddle assembly and packing stool assembly combined
contains the following:
Impeller: it is a 6 blade circular structure which drives the cement out towards the
nozzle.

Impeller motor: It is a 5.5kwatt motor which is used to drive the impeller blades for
the proper flow of the cement. It is connected to the impeller shaft via wedge belt
to a V-pulley.

Filling module: It consists of spout control panel, load cell assembly, filling nozzle
assembly, and bag chair.
Saddle plate: A pair of plates located directly below the nozzle that is used to keep
the bags while filling.

Load cell assembly: located behind the spout control panel it is made up of two
parts a load cell and a load cell rod & is used to measure the weight of the bag
while filling.

Spout control panel is used to control the filling rate of the spout. This is done
using a touch screen control panel EFS 100TS which is windows programmed
capacitive type touch screen and can measure upto 100 tonnes. Filling nozzle

36

assembly consists of a filling nozzle and three position system and is connected to
the filling port of the impeller box.

A spout contains 3 different cylinders; a bag holding cylinder lies on top of the
discharge nozzle holds the bag during filling. Three position cylinder adjusts the
output of the cement and lies between the nozzle inlet and the filling port of
impeller box. It works in 3 different positions viz. full or coarse flow, fine flow and no
flow. The bag discharge cylinder is connected to the tipper frame and discharges
the bag once it is filled.

The weight of cement bags can be varied by adjusting the bag stool to fit a bag of
desired size.

All the cylinders work at a pressure of 5bar which is fed through the compressor. A
solenoid valve is used to distribute the pressure according to the requirements. In
all 5 solenoid valves are used per spout, three for each cylinder and one each for
impeller and nozzle aeration.

The main driving motor is a three phase 2.5kwatt motor which is connected to a
variable frequency drive to adjust the motor rpm. The packer rotation rate varies
between 2-2.5 rpm.

36

Two proxies per spout is attached, one for bag holding and another one for
discharge.

There are 3 different models available for the roto packer viz. 8 spout packer, 12
spout packer and 16 spout packer.

Working.
The cement stored inside the main bin is fed to the packer via ducts going through
the FCG. From there the cement goes inside the packer bin. The bin has openings
towards the impellor. The impellor blades continuously rotate thus throwing the
cement towards the nozzle area. For the filling purpose the bag is inserted
covering the nozzle completely and while doing so a lever attached at the top of
the nozzle is pushed back. This lever is continuously being sensed by the proxy
and as soon as it goes back the proxy gets active and commands the bag holding
cylinder to move down and bag stays in position. This proxy also instructs the three
position cylinder to go from full close to full open and the flow is started. A limit is
predefined using the control panel to set the coarse flow. The load switch
continuously detects the change in weight of the bag and as soon as the limit is
reached it orders the 3 position cylinder to the switch to fine flow mode. The
purpose of doing so is the get maximum accuracy while filling. As the bag reaches
its desired weight which is being feeded on the Weighing Unit, the load cell cuts off
the supply to the nozzle. For discharge purpose the operator when desired
extends the discharge cylinder on the top which is detected by the discharge proxy.

36

This activates the discharge cylinder and the bag is dropped at the desired
position.

Radial collector. It is located at the discharge end of the roto packer and serves
the purpose of collecting the discharged bags and transporting them further to the
other conveyors. It consists of a drum motor and a drum pulley which are
connected via endless belt. Bag cleaners are located on the top of the collector
from where compressed air is discharged to the bags and the dust arising from it is
collected using the suction duct at the top which goes into the auxiliary feed of the
bucket elevator via ducts. These are called radial packers because they transport
bad in the radial direction wrt the packer.

Tangential collector: they are similar to the radial collectors except foe that they
are positioned tangentially and transport bags in tangential direction wrt packer.

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Spiral Chute: it is used to transport the cement bags. These are used at places
where the height of discharge is very high and cannot support incline chutes.
These chutes can be designed to move bags in any direction and from any height.

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STRETCH HOOD

Practical, efficient and space-saving packaging technology. How do you find an

even more economical way of hooding palletised goods? By using the
highly efficient and compact BEUMER stretch hood A from the highcapacity BEUMER stretch hood packaging system model range. It
impresses with improved system performance, ergonomic operation and a
space-saving format. This is BEUMER's new response to the increasing
demand for machine safety and economic efficiency in the packaging
industry.

36

Packaging for optimum final results

The BEUMER stretch hood A uses an improved mode of operation to package

palletised load units quickly, safely and sustainably in water-proof film hoods. This
provides reliable protection for the goods against all environmental stress ensuring
excellent load stability. The palletised goods are clearly visible due to the smooth
surface of the transparent film. This offers excellent display characteristics for
presenting goods.

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Improved unwinding behaviour

The modified crimping bows on the BEUMER OptiStretch system dispense the
film to the palletised stack in a way that is even more precise. The method
optimises the expansion of the film in all directions, which improves both system
availability and the packaging results. The special shape of the crimping bows
allows for close lowering towards the stack contour, while at the same time
ensuring clean and smooth pulling over of the film hood to boost the stability of the
palletised stack.

Defined film positioning

36

Thanks to the use of the BEUMER multistretch system, a method for implementing
a variety of packaging types, the system positions the film on the palletised load
units with the greatest degree of accuracy.
Biaxial film tensioning forces
The BEUMER stretch hood A uses biaxial stretching to combine horizontal and
vertical film tensioning forces. This ensures excellent load stability, even for
irregular packages and sensitive unit loads such as beverage pallets, and they
keep this stability, even through multiple transshipment.

A new dimension in personal protection

With its innovative film transport system, the BEUMER stretch hood A removes
the need for a platform - or a lowerable film feed device. This ensures a low overall
height and improves safety in operations and maintenance work: For instance, the

36

blades or the sealing bars are replaced from the floor without the person needing
to climb into or onto the system. There is no need to lower subassemblies into
maintenance position, thus reducing the risk of accidents and malfunctions. After
positioning the film roll with a fork-lift truck or lifting equipment, the film is inserted
with a few easy actions and completely without tools.

For more economic efficiency

Low-maintenance, excellent packaging capacity and short downtimes mean that
the machine pays dividends in the shortest possible time. Film rolls are easily
changed using a fork-lift truck and thanks to easy film feeding without timeconsuming threading of the film. There is no need for a film sealing seam cooling
time.

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The optimised sequences of movements also contribute to improve the machine's

availability. Powerful suction units combined with mechanical grippers guarantee
functionally safe film handling. Energy-efficient technology sustainably saves
energy costs for the drive system.

Easy handling

In terms of handling, the system impresses with a sustainably optimised work

environment and system control. The system is easy to operate by the modular,
space-saving BEUMER Group HMI (human machine interface) with a soft-touch
panel, a graphical user interface and pictograms. The panel also gives the
operator access to all the required training programs. Some of them are videosupported to achieve the best possible training effect.

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Highlights

Space-saving design, without a maintenance platform or stairs

Operator workplace at floor level featuring optimum ergonomic design

Easy and direct insertion of the film with a film transport system that is
gentle on the film

No cooling time required for the film sealing seam

Energy-saving drive technology

Intuitive operation via a soft-touch panel

Stretch hooding benefits at a glance compared with stretch wrapping:

Increased load stability due to vertical film forces

Reduction of product loss due to theft

Product ventilation and printing of film possible

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Well suited for AGV or automated high-rack systems

First class weather protection from 5 or 6 sides

Up to 10 times fewer film replacements increase system availability and

minimize operator interaction

Absolutely clear film improves product presentation and brand recognition at

point-of-sale or in transit and positively impacts consumer buying behavior

High capacities of up to 200 pallets per hour possible

Outstanding bar code readability due to no overlaying film bands

Precise budgeting due to exact film consumption

Fully recyclable film Stretch hooding benefits at a glance compared with

shrink hooding:

Increased load stability due to vertical film forces

No heating of film - reduces the risk of fire and potentially minimizes

insurance rates

Reduction of environmental stress due to over 30% less film and >90%
energy savings

Higher flexibility of handling various product sizes

Sound level < 75 db (A)

Reduced maintenance

High capacities of up to 200 pallets per hour possible

Choice of operating with 5- or 6-sided protection against external impacts

No sprinkler system or additional cooling system for ambient temperature

required

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LOADING MACHINES

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Purpose: to load the packed cement bags on trucks more quickly and efficiently
than manual labour.

Parts: Feed conveyor, discharge conveyor, luffing gear box, loader moving
assembly.

The feed conveyor is the main part of the truck loader and consists of drum motor,
drum pulley, rollers and endless belt, these parts are attached on a structure called
stringer which is bolted to the main body. The feed conveyor is fixed and can only
move forward or backward along with the whole assembly.
The discharge conveyor is attached to the free end of the main conveyor and lies
below the discharge plate of feed conveyor. It is fixed on a bearing and can move
180 degrees in either direction and can move up and down motion. While the
sideways motion is done manually the up/down motion is controlled using either a
luffing gear box or pneumatic jack.

Working: the packed cement bags are discharged from the spiral chute/belt
conveyor they land at the feed conveyor of the truck loader. The drum motor
constantly drives the belt which moves the bag in forward direction towards the
discharge conveyor. This conveyor also has the same assembly and so the bag

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moves to the required position. Once the bags are filled to a certain height the
telescopic conveyor can be lifted up using the motor and gear arrangement.

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