New Octapalant® Allows Customers to Reduce Implementation Time and Adapt to Changing Market Conditions
Advancing urbanization is driving infrastructure demands for residential and industrial space, also spurring increased demand for cement. For cement producers, flexibility and, above all, proximity to the market and speed in logistics are the keys to success and profitability. In response, Haver & Boecker developed the Octaplant, a visionary packing concept. The Octaplant, an innovative and comparatively compact system for packing and loading cement in bags, consists of a modular design incorporating high quality technology and prefabricated components to allow for quick installation and adaptability.
Octaplant sets new standards in terms of time and cost optimization as well as risk minimization – especially during the implementation phase. The concept is also impressive in terms of sustainability because it can be reassembled and used at another location and features Haver & Boecker’s cutting-edge packing technology. In addition, the Octaplant occupies a very small footprint.
Equipped for tomorrow’s requirements
Over the past 20 years, the shipping of clinker and cement has steadily increased driven by increased construction in formerly agrarian countries. In the future, plants and terminals that are currently located on the outskirts of cities may have to give way to infrastructure for trade, industry and people.
As urbanization evolves and construction grows, mobility, speed and responsiveness will be essential for success in the cement industry. Octaplant gives producers the ability to be the first at the point of sale to serve exactly where the demand exists when conditions change, creating an enormous competitive advantage.
Project implementation in the fast lane
Significant time saving is the main advantage that Octaplant offers in comparison to conventional systems. With all components on the shelf and many of the assembly tasks completed before the system ships, the construction phase of the plant is significantly reduced. Less construction needed on site translates to fewer potential errors and reduced labor demands for installation. It also comes into play at the very start of the planning phase. Engineering that is completely planned and finalized down to the last detail accelerates project implementation and ensures the best possible planning security with regard to expected costs, yields, equipping buildings and technology. Moreover, standard delivery of all the tools required for assembly avoids expensive delays that could occur due to missing or incompatible devices and systems. The simple, modular design decreases the need for crane lifts to erect the plant by 80% over the installation of conventional systems. A plug-and-play design, allows for individual elements to simply connect and be operational quickly reducing overall installation time and facilitating quick relocation of the plant based on business potential or demand.
The installation time from planning to the start of production is reduced by three and a half months compared to conventional systems, allowing for lower finance costs and a rapid return on investment.
Well thought out for all requirements
An Octaplant building consists of three segments. The heart is the eponymous octagonal “OctaTower” that houses the Haver & Boecker Roto-Packer® RVTs packing system, including a foreign body screen, pre-hopper and spillage return system. These elements are shipped in a simplified and cost-optimized manner in seven standard sea containers, from which the adjacent container building is erected after unloading. It provides space for the bag discharge line, the fully automatic Radimat® bag applicator, the system control and the compressor unit. The final section is a lightweight hall where the filled cement bags are loaded onto trucks. The HB 10 system for rear loading and the HB 17 system for loading open trucks are available here. Moreover, a photovoltaic system can be installed on the roof and thus generate sustainable electricity for the plant.
The Octaplant’s efficient design is adapted to the extreme site conditions of the target markets. The containers are reinforced and reliably withstand wind speeds of up to 200 km/h and earthquake loads. The light-colored façade reflects solar radiation in the best possible way. In addition, the air flow from the packing machine’s dust extraction system not only creates a low-dust environment, but also provides measurable temperature regulation. The OctaTower and container building can also be sufficiently insulated for colder climates.
Resource-saving concept
Thanks to its mobility and space-saving design, the Octaplant saves on resources and materials. Existing system components and high-quality technical equipment can be easily reused at another location. Space-optimized transport and a high degree of prefabrication also contribute to a reduced ecological footprint. Finally, the integration of Quat2ro® products and the PROcheck life cycle approach minimize greenhouse gas emissions, energy consumption and the use of materials during plant operation.
Fulfilling the highest standards
In order to control, monitor and optimize all processes, all the workflows are networked in the best possible way using Quat²Ro System Intelligence. With the PROcheck life cycle approach, Haver & Boecker guarantees comprehensive support: from selecting the right equipment with the right empty bags to offering spare parts and comprehensive services.
When developing the space-optimized and relocatable system, the focus was on ease of operation and maintenance. The Octaplant offers maximum efficiency not only in terms of planning and building design, but customers can also count on maximum output and high quality from the Haver & Boecker packing machines when it comes to technical equipment and efficient operation.
The engineering for the Octaplant concept was completed by Haver & Boecker so that project planning and production could take place immediately.
Customized system solutions
from Haver & Boecker and IBAU
Another Haver & Boecker system solution for special requirements that has already been put into operation by several customers is the Smart Plant. It offers a modern and customized packing solution with high-quality standard equipment and a wide range of possible applications. The compact and space-saving layout is ideal for applications in small spaces in cement plants, grinding plants and terminals. The standardized, preconfigured concept makes the Smart Plant particularly cost-effective to manufacture and operate, is quickly available and installed and is extremely flexible thanks to its modular design. Together with IBAU, Haver & Boecker also offers the Smart Plant as a complete solution with silo technology.
