BEUMER Group is continuing on its growth path and expanding its commitment in India. The global manufacturer of material handling solutions invests more than INR 2 billion in a new, state-of-the-art production city in Reliance MET City/Jhajjar. Laying of the foundation stone took place on 27 June 2024, with representatives of BEUMER Group and Reliance MET City attending the ceremony.
 The new production site will further strengthen BEUMER’s global factory footprint as well as boosting the continued success of its BEUMER India subsidiary. With an area of more than ten acres, the new plant will be placed at a highly strategic location, with Reliance MET City offering exemplary infrastructure and support. BEUMER will be the first German company to set up production in the development zone. Construction work will commence this summer, the inauguration of the new plant is scheduled for September 2025.
Ceremonial laying of the foundation stone. The new BEUMER production site in India is scheduled to start operations in September 2025. Photo: BEUMER Group
BEUMER Group has been active in India since 2003. Initially catering to the cement industry exclusively, BEUMER India has grown significantly over the years and now offers solutions for the airport industry, minerals and mining, for automated warehouses and distribution centres in the retail industry as well as in the areas of e-commerce and courier, express and parcel. In addition, BEUMER India is also providing engineering support to the group’s global network.
On the product side, BEUMER India has been a trailblazer of new bulk as well as discrete material handling technologies to India, for example: high-capacity, high-speed automatic loop sortation for passenger baggage, fully automated truck loading for cement bags, high-efficiency bulk material transport, as well as curved belt and pipe conveyors.
Over the years, BEUMER strengthened its position in India through various steps, such as diversifying to all business segments as global operations, acquisition of ENEXCO Technologies India, FAM India and the establishment of a modern manufacturing unit at Naurangpur, Haryana.
“This expansion reflects BEUMER Group’s strategic focus and commitment to long-term success in India. The new production site plays an important part in our global factory footprint, strengthening our position as a quality leader and partner of choice for our customers”, said Rudolf Hausladen, CEO BEUMER Group.
“Our new production site at Reliance MET City offers a convenient ease of business and synergy in approaching infrastructure and facilities with a vision towards sustainable development. Setting up a manufacturing unit in the context is truly ‘plug and play’, with Reliance staying true to its goal of developing a ‘Model Economic Town'”, said Nitin Vyas, Cluster Asia CEO, BEUMER Group.
How can mining companies make their operations more sustainable to reduce their environmental footprints? One element that can be perfectly adapted to match the conditions is the efficient transport of the mined material. Here overland conveyors that can move large quantities of material over long distances are required. BEUMER Group relies on modern planning and layout tools to support operators at an early stage of the project and design the ideal conveying solution together with the customer.
BEUMER Group installed the first overland conveyor with horizontal curves as early as 1969. Since then, calculation methods and components such as idlers, belts and drives have undergone constant development, resulting in the implementation of increasingly efficient conveying systems for routes that are often complex. Mine operators can use BEUMER curved troughed belt and pipe belt conveyors to transport raw materials over routes with steep inclines and narrow curve radii. âWe can exactly match our systems to the required conveying task and topography,â says Dr. Kilian Neubert, Global Head of Mining at BEUMER Group. âWe rely on state-of-the-art planning tools to provide our customers with an efficient, sustainable and cost-effective material flow.â
Sustainability in mining
Raw materials are needed to produce almost all industrial and consumer goods; however, extracting them has far-reaching effects on the environment and society. This is why mining companies constantly strive to make their extraction and processing operations even more efficient and sustainable, and such efforts are called for in the planning of a new mine.
Mine operators must ensure that the population generally approves of the planned project. This approval can be obtained through extensive approval procedures, environmental impact studies, geo-monitoring, and the implementation of suitable risk management systems. âMining companies need to build trust with the public,â Neubert explains. âFor example, they need to involve the public and key stakeholders at an early stage of projects.â This is why operators need to integrate the issue of sustainability into all aspects of planning a mine and improve the environmental compatibility of the overall system by ensuring the efficient transport of ore and waste rock over longer distances. Optimised routing and the selection of suitable methods achieve these objectives
The fundamentals and capabilities of modern conveying systems
No two conveying systems are alike, even if the primary task of transporting bulk material from A to B appears comparable. âWe must adapt the components and the system to the material to be conveyed,â says Neubert. âThe mass flow to be conveyed and height differences that need to be overcome over the length of the conveyor line are important factors that we must address when designing a system.â
The energy consumption of long, horizontal belt conveyors is primarily determined by the main resistance in the upper and return strand in stationary operating conditions. This resistance consists of the running resistance of the idlers, the indentation rolling resistance, and the flexing resistance of both the conveyed material and the belt as they run over the idlers. The forces required to overcome these resistances depend on various operational and design parameters; however, they can be determined using the âsingle resistance method.â If components with low running resistances are used, such as belts with reduced indentation rolling resistance or running-optimised idlers, the calculations of the systems nowadays show considerably lower tractive forces of the belt than those of a few years ago. This leads to lower energy costs, and smaller radii can also be selected for the horizontal curves thanks to the lower tractive forces of the conveyor belt.
The topography of the existing terrain also has a significant influence on the design of the conveying system. An in-depth analysis of various dynamic load cases and a thorough investigation of the technically feasible horizontal and vertical curve radii must be conducted to design the system in the most efficient and environmentally friendly way.
Long and difficult conveyor lines distances must be considered during the planning phase. Source: BEUMER
This is especially true for longer and more difficult conveyor lines. Potential obstacles that must be considered during the planning phase include residential areas, roads, and rivers. âToday, we can design curved overland conveyors of up to twenty kilometres or longer without the need for a transfer tower,â says Neubert. The conveying capacities of a system like this are more than 20,000 tons per hour.
The right layout
A 3D model of terrain and conveyor: the advantages of earthworks (cut & fill) or steel structures …âŠ. can be quickly and precisely assessed using graphic representations and mathematical calculations. Source: BEUMER
âWe use our BEUMER Overland Layouting Tool to ascertain the ideal layout for the system,â says Neubert. âIt generates a digital 3D model of the conveyor in the virtual landscape during project planning, more or less automatically.â The critical topography data can either be provided by customers, or drones are used to capture terrain data. âThese 3D visualisations are also ideal for supporting mining companies in their PR relations work,â explains BEUMER expert Neubert. Important factors such as âcut and fillâ volumes, i.e. the necessary excavation work, and the required steel structures for the conveyor can be evaluated and illustrated on this basis. âThis procedure considerably accelerates the project planning process and enables us to provide project-critical data to the customer at an early stage of the project,â says Neubert.
Ongoing development in conveying technology
The 1990s saw BEUMER Group start its development into one of todayâs leading suppliers of pipe conveyors. In these systems, the idlers form the belt into a closed pipe that protects the material to be transported against external influences and the environment from emissions such as dust and odours. This conveying solution is therefore ideally suited for fine bulk materials such as ore concentrates. Pipe conveyors also allow tighter curve radii and greater angles of inclination compared to conventional troughed belt conveyors.
No two conveying systems are alike, even if the primary task of transporting bulk material from A to B appears comparable. Source: BEUMER
However, what if bulk material with large grain sizes requires a larger pipe diameter? The rule of thumb here is that the pipe diameter should be about three times the maximum grain size. To solve this problem, the BEUMER Group developed the U-shape conveyor. âThis variant combines the advantages of a troughed belt conveyor with those of a pipe conveyor,â says Neubert. The idlers form the belt into a U-shape rather than a pipe. The U-shape conveyor enables tighter curve radii than a troughed belt conveyor and higher mass flows than a pipe conveyor and also protects the conveyed material from environmental influences and the environment from material loss and emissions.
BEUMER Group delivers palletiser to Indonesian cement manufacturer PT Semen Tonasa:
The cement manufacturer PT Semen Tonasa relies on a palletising solution of BEUMER Group to be able to accelerate processes and relieve the personnel from heavy physical work. Photo: BEUMER Group
PT SemenTonasa ‘s plant on the island of Bali has commissioned BEUMER Group to supply a palletising system for 40 and 50 kilogram bags. This enables the manufacturer to accelerate processes and relieve his personnel of heavy physical work. The target: installation and commissioning should take place in the third quarter of 2022.
PT Semen Tonasa is part of Semen Indonesia Group, the largest cement manufacturer in Southeast Asia. In Indonesia alone, the group has a market share of more than 50%. At its Celukan Bawang plant on the island of Bali, employees stack the 40 and 50 kg cement bags on pallets, which are then fed into the packaging system. A fork-lift truck takes the palletised and packaged stacks and loads them onto the loading spaces of the trucks. For the personnel, this is not only physically very strenuous, but also takes a lot of time. In order to accelerate this process and relieve the personnel, PT Semen Tonasa has commissioned BEUMER Group to supply a layer palletiser.
The cement manufacturer has opted for the palletiser of the system supplier, because the system exactly complies with the required technical specifications. The palletiser is characterised by its very good stack quality and its reliability. A multi-program interface includes all common packing patterns, and can be individually adjusted to the different requirements of the building materials industries.
Global influences such as delivery bottlenecks, shortages of raw materials and logistics problems continue to massively disrupt the supply chains. Nevertheless, the system provider will be able to send the machine to the customer in seven months. The target is to install and commission the machine in the third quarter of 2022.
This year, the Institute of Research & Data Aggregation GmbH honored BEUMER Maschinenfabrik for the quality and individuality of its Promotion of Young Talent scheme. This anchors the systems provider from Beckum in the top one percent of training companies in Germany. Various employers from all industries and regions were compared in an independent survey as part of the âTop Trainersâ study.
This year again, BEUMER Maschinenfabrik in Beckum showed that it was one of the best training companies in Germany. The DĂŒsseldorf Institute of Research & Data Aggregation confirmed the result in its âTop Trainersâ study, which determines the top one percent of the best training centers in Germany.
âWe are very proud that we have again won a prestigious award. We aim to inspire as many young people as possible to start an apprenticeship with us in the future,â says Michael Dilla, Head of Technical Vocational Training at BEUMER Maschinenfabrik. The company trains young adults to become industrial management assistants, IT specialists, industrial and construction mechanics and mechatronics and electronics technicians (m/f/X) . August 2022 will see twenty-two young people launch their careers at BEUMER. As part of a planned joint training program, two more trainees from partner companies will also complete part of their apprenticeships with BEUMER.
The categories in the study included the companyâs internal and external communications, former, current and potential traineesâ evaluations, exceptional auditing results, and voluntary self-reporting. Potential trainees receive orientation with the help of freely available data. The data sources include the rating portal Kununu, Capital, Ausbildung.de, Territory, Bertelsmann, Deutschlandtest, Focus and Great Place to Work.
