ROBUST TECHNOLOGY TO SIZE - Charging Technology & Glass Level Controlling - ZIPPE
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ROBUST TECHNOLOGY
TO SIZE.
Charging Technology & Glass Level Controlling
ZIPPE has extensive experience in planning, constructing and building batch chargers.
These, virtually, belong to the DNA of the company.
1953, Alfred Zippe senior developed the first fully automatic batch charger for the
glass industry. Herewith, it all began and we are still building our batch chargers in
our company in Wertheim. Our long-time experience and our high manufacturing
quality is retrieved in many details of our machines.
BATCH CHARGER –
TYPE V I B R O T U B E ®
GOOD VIBRATIONS.
C U R R E N T L Y P R O B A B L Y THE
M O S T M O D E R N , A D V A N CED AND
E F F I C I E N T C H A R G E R ON THE
MARKET.
The VIBROTUBE®-Charger was especial-
ly developed for feeding container glass
furnaces. This modern, patented batch
charger ensures a completely closed
doghouse and also shows considerably
lower wearing compared to alternative
systems. Due to the closed doghouse
and the optimized charing pattern valua-
ble meting energy is saved.
The VIBROTUBE® stresses impressively
our experiences for decades in the field
of batch charging.
E u rop ean Patent
Patended by 4131
no. EP289
2
N O e m is s i on
Low X onsumption
Low energy c
01 SEALED DOGHO U S E
The heat protection shield is executable in a round and straight
design and seals the doghouse completely. Therefore, the heat
protection shield adapts perfectly to the furnace conditions.
The two pushers in front of the vibrating tubes as well as their
movements are executed in a way that there is no opening in
the outlet area. Thus, in fact a dust free encapsulation of the
doghouse is effected. As an uncontrolled inflow of air is elimi-
nated, a significant reduction of NOx emission is the result.
02 VIBRATING TUBES
The batch is transported to the melting furnace through
vibrating tubes. Compared with alternative solutions, e.g. screw
chargers, this conveying technology has a big advantage: The
material is transported through vibrations nearly without con-
tact, which reduces wearing significantly. The results are longer
lifetimes and significantly lower operating costs. Furthermore,
the front part of the vibrating tubes being situated in the melting
furnace is water-cooled in order to avoid any batch caking.
03 LINEAR DRIVE
The two pushers divide the batch conveyed into the melting
furnace into small portions. This leads to optimal batch melting
due to the larger heat contact surface of the batch. The push-
ers are driven by a servo gear motor which is infinitely variable.
Thereby, stroke length and lifting speed can be individually
adjusted to the desired requirements.
TECHNICAL DATA
Conveying capacity: 50–500 t / 24 h
Machine width: 1,940 mm
Doghouse depth: min. 600 mm
Adjustable swivel angle: ± 4°
Stroke: up to 280 mm
Connection control cabinet: 32 A
Water connections: 2x1½
Total water consumption: 10–15 l / min
per water cycle
Pusher width: 140–340 mm
3
BATCH CHARGER –
TYPE E V P
MANYFOLD TRIED AND
T E S T E D , S O P H I S T I C A T ED
N O N - D E S T R U C T I B L E – OUR
EVP BATCH CHARGER
Due to the special construction of the
EVP charger and the use of a heat
protection shield a charging at relatively
small doghouse openings is possible
while at the same time sealing the dog-
house. Heat loss is reduced.
The capacity of the batch charger can be
continuously or discontinuously regu-
lated by a command signal of the glass
level controller.
By dividing the batch into small portions
by means of the pusher a bigger contact
surface and herewith faster melting is
possible.
ZIPPE batch chargers type EVP rank among the most uncom- TECHNICAL
plicated and most reliable batch chargers on the market. For DATA
example, they can be applied for all container glass doghouse
types. Conveying capacity: 50–500 t / 24 h
max. 1 t
Weight:
Due to a very big outlet opening the amount of cullet can add up Machine width without
to 100 % without leading to blockades. EVP batch chargers are heat protection shield: 1,000 mm
situated in front of the melting furnace. By this all areas are well Doghouse depth: min. 600 mm
accessible. For maintenance work (e.g. exchange of pusher) Swiveling angle: ± 10°
the batch charger can easily be pulled away from the furnace. Stroke: up to 350 mm
This reduces production downtimes and maintenance costs Water connection: 1x1½
tremendously. Total water consumption: 10–15 l / min
4
BATCH CHARGER –
TYPE ECD
THE ECD, A CLAS S O F I T S O W N The charging capacity will be determined automatically by the
glass level controller due to change of the motor speed.
This batch charger makes it possible to charge batch onto the
melting surface while avoiding a fall and thus also avoiding Intermediate pusher and hopper are fixed on a swivel unit
dust generation. which can be swiveled by 35° / 44° by means of an electrically
operated cylinder. This guarantees an optimal batch charging.
The pusher pivots from side to side allowing good directional Three positions can be chosen. The stroke length of the pusher
control of the material flow and an even addition of batch onto can be adjusted manually.
the melting surface. The design of the batch charger allows the
doghouse to be sealed. Thus, energy is saved.
DESIG N
The batch charger consist of a feeding hopper with heat
protection shield, water-cooled pusher, swivel device and
supporting part.
FUNCT ION
From an intermediate hopper batch flows into the doghouse
which is pushed into the glass melting furnace by means of a
pusher which is driven by a frequency control gear motor.
TE CHNICAL DA T A
Type Approx. charging Connected Size of gate mm Approx. cooling water Approx. weight kg
capacity t / 24 h load kW consumption l / min
ECD 20 40–80 1.1 80 / 100 x 250 20–30* 880
ECD 30 40–160 1.1 80 / 100 x 350 20–30* 950
ECD 40 120–240 1.1 80 / 100 x 450 30–40* 1,020
ECD 50 200–340 1.1 80 / 100 x 550 30–40* 1,070
ECD 60 280–500 1.1 80 / 100 x 650 30–40* 1,120
* depending on input temperature
5
B A T C H C H A R G E R F O R
E L E C T R I C F U R N A C E S
THE COLD-TOP CH A R G E R –
A TRU E PIECE OF G E N U I N E “ H I G H - T E C H ”
The batch is moved from an intermediate silo into the feeding
hopper of the batch charger. The batch is fed into the furnace
via a vibrating chute driven by an air piston vibrator. The vibrating
chute can be replaced by a conveyor belt for specific applica-
tions. Furthermore, beside rectangular furnaces also hexagonal
furnaces can be fed.
The charger moves both from left to right and from front
to back during the charging process. The charging rate
is adjusted optimally by a glass level control unit to meet
the furnace conditions.
Each Cold-Top charger is customized and multiply
tested and proven.
6
BATCH CHARGER FOR
FLAT GLASS FURNACES
THE FLOAT GLASS C H A R G E R –
BIG, ROBUST, EF F I C I E N T
The use of several machines in one doghouse allows the
stream of glass batch to be directed individually both in terms
of direction and volume, thus making optimum charging of the
furnace surface possible.
ZIPPE flat glass chargers can be configured for all doghouse
widths. The chute is air-cooled on standard. If requested, we
can deliver in water-cooled design, as well.
The filling volume of the furnace pre-silo can be chosen in in-
dependence of the existing heights. Every single machine can Delivery and installation of dust cover is possible upon
be moved fast backwards in an emergency case. Trained staff request. Depending on the requirements, these can be
need only 20 minutes time. pulled out at each site (two-part).
Also upon request, an automatic central lubrication unit
The stroke length of 0–250 mm is continuously adjustable. The can be integrated.
speed of the chute can be adjusted individually.
7
THE EXPERTS FOR
S P E C I A L T A S K S
BATCH CHARGER T Y P E E SCREW CONVEYOR CHARGER POT FURNACE CHARGER
The standard batch charger features Screw conveyor chargers are suitable for The traditional manual charging of a pot
a particularly sophisticated and robust charging all types of furnaces; a dog- furnace had been mechanized already
design combined with easy maintenance. house is no longer necessary. Several several years ago by the proven pot fur-
Parts in contact with the glass are wa- batch chargers are arranged parallel or nace charger. The batch charger can be
ter-cooled but, if particularly required, can opposite to each other in the case of large easily moved by hand and has been well
be supplied in heat-resisting special steel furnaces or high furnace outputs. designed for its task. The charging chute
without water-cooling. In case of furnaces has a pneumatic drive. The advantages of
with wide dogholes, for example in flat A particular advantage is that the furnace the pot furnace charger are a significant
glass furnaces, several chargers can be is completely sealed on the side used by reduction in dust generation and poison-
used in parallel to each other across the the charger; this is a pre-requisite for fur- ing hazards, no spillage of the molten
entire width of the doghouse. naces where oxygen is used in the heat- glass, a consistent level in the pot furnace
ing process. But it is also an advantage and a reduction in physical work for the
in conventionally heated furnaces due to furnace crew.
energy conservation, dust avoidance and
a constant hearth pressure.
TECHNICAL DATA TECHNICAL DATA TECHNICAL DATA
Capacity: 20–200 t / h Capacity: Compressed air
Chute width: customized Typ SF 150 1 t/h requirements: 2 Nm3 / min
Typ SF 200 2 t/h Operating pressure: 5–6 bar
Typ SF 250 3 t/h Weight: approx. 270 kg
Typ SF 300 4,5 t / h Cooling water-
consumption: approx. 80 l / min
Further data on request.
8
MECHANICAL GLASS LEVEL
CONTROLLER BZ 24 FOR
CONTAINERGLASS FURNACES
TRUST IS GOOD – C O N T R O L I S B E T T E R . ADVANTAGES OF A MECHANICAL
OUR G LASS LEVEL C O N T R O L L E R B Z 2 4 GLASS LEVEL CONTROL
The glass level controller is available in two versions: As BZ 24 S/H 1. Fully digital processing of measured values.
with water-cooled electrode for being installed directly at the 2. Parameterization of the controller in dialogue via
furnace for scanning through the side wall or as BZ 24 S/V with control unit or web interface.
ceramic electrode for being installed at the feeder for scanning 3. Text display of controller status.
through the feeder. 4. Integrated proportional regulator usable for
feeding control. Optional bus connection to higher-
GLASS LEVEL CON T R O L L E R C O M P O N E N T S level control possible.
5. The operation and display part as well as the
· scanning mechanism with the platinum electrode line recorder can be installed in a control
· electronic evaluation unit for measuring the glass level and cabinet located in the furnace control room
the set values calculation (independently from the controller).
· optional line recorder 6. Reliable mechanical equipment, low maintenance.
· optional system for cutting the glass string pulled by the
electrode tip TECHNICAL DATA
NEW F EATURES BZ 2 4 Measuring range: ± 10 mm of calibrated glass level
height
· Parameter settings can be modified via keyboard or Measuring
alternatively via web interface accuracy: ± 0.01 mm
· Visualization of glass level trend in the Internet Browser. Output signal: non voltage contact by a two
Backup of current settings on the PC position controller
· Optional network interfaces to enable data exchange with Analogue signal: 0–10 V, 4–20 mA
different PLC systems (Profibus, Profinet, Ethernet/IP
and Modbus/TCP)
Type BZ 24 S/V Type BZ 24 S/H
9
OPTICAL GLASS LEVEL
CONTROLLER BZ 31 FOR
FLOATGLASS FURNACES
IT SEES EVERYTH I N G ! ADVANTAGES OF THE OPTICAL
GLASS LEVEL CONTROL
A halogen light source (projector) sends a light beam onto
the glass surface in the melting furnace where this beam 1. No operational license required as necessary
will be reflected, collected by a receiver and evaluated in for radiometric glass level controlling.
an electronic unit. 2. No mechanical wear, because touchless
measuring system.
Alterations of glass level height will cause parallel displace- 3. Water cooling is not necessary.
ment of the reflected light beam, which can be used as 4. Easy installation, also for refurbishing.
evaluation signals. 5. No point measurement, but an area
measurement across approx. 30 cm2 in order to
relativize uneven surface.
TECHN ICAL DATA 6. Wide light spectrum – independent
from glass colours.
Measuring range: ± 5 mm of
calibrated glass Condition for a trouble-free operation is a smooth, blank
level height and reflective glass surface.
Angle of declination: 7°–30°
Projection distance: 3–20 m
Measuring accuracy: ± 0.01 mm
Light source: halogen lamp
24 V / 150 W
Receiver Evaluation unit Projector
10T H E A D D I T I O N A L E X T R A
WHICH MAKES
THE DIFFERENCE
HIGH LEVELS OF A V A I L A B I L I T Y
AND STANDBY REA D I N E S S
Faults must be eliminated in the daily production process.
When faults occur however, our service specialists ensure
speedy, targeted problem analysis and then immediately take
the actions necessary. Customers can use the ZIPPE-24-hour
hotline and our teleservice. This way we are able to guarantee
availability and standby service at all times - across the globe.
CONTINUAL QUALI T Y I S M A N D A T O R Y IN-HOUSE PRODUCTION
We want to offer you, our customers, the best The production area is over 4,000 m² in size and every
possible quality in all aspects of our busi- day sees the manufacture of batch chargers, scraping
ness relationship. And to also make this conveyors, crushers and other key system components.
clear in our outward image, we have in Most of the 55 production employees have been at
use a modern quality management system ZIPPE for the highest levels of quality and reliability.
complying to DIN EN ISO 9001 this is TÜV
CERT certified. This is also where our service engineers and supervisors
learn their skills for deployment across the globe.
11IN TH E HEART OF G E R M A N Y
Just 50 minutes from the airport Frankfurt
am Main away Wertheim is located in a
unique place on the banks of two rivers,
surrounded by a beautiful landscape with
rich vineyards.
The historic old town is full of history with
elaborately decorated half-timbered hou-
ses, winding alleyways and small, char- Hamburg
ming spots. And above all, the Wertheim
Berlin
Castle reigns from the top with pride.
An environment with a long glass
tradition in which we feel at home and
we as well as our company are strongly
connected with.
Köln
We are looking forward to your visit.
A3 Wertheim
A3
Frankfurt Würzburg
Nürnberg
A9
Stuttgart
A81 München
Batch Plants · Cullet Plants · Automation · Modernization ·
Engineering · Factory Cullet Recycling · Glass Recycling · Batch Charging ·
Glass Level Controlling · Preheating · Maintenance & Service
ZIPPE INDUSTRIEANLAGEN GMBH
Alfred-ZIPPE-Straße 11 · D-97877 Wertheim · Germany
Tel: +49 9342 804-0 · Fax: +49 9342 804-138
E-Mail: zippe@zippe.de · www.zippe.de
Technical alterations reserved · © by ZIPPE Industrieanlagen GmbH 2017 · All rights reserved · 02-2021You can also read
