ZIPPE: The future of batch plant technology – today

With its incredible company history, and the fourth generation of the Zippe family running the business, ZIPPE Industrieanlagen can certainly say that it knows its way around handling raw materials and cullet for the glass industry. In this article we take a look at some of the skills of the company, and how its name is used as a synonym for different technologies in the batch and cullet processing sector.

100 YEARS OF PASSION AND FASCINATION FOR GLASS
ZIPPE Industrieanlagen, an independent family owned- and run company, has been serving the International Glass Industry for 100 years. Right from the beginning, the company has always been dedicated to the design and manufacture of plants and machinery that help to create optimal melting material for fascinating glass products.
Many changes and improvements have taken place in the glass industry over the years, such as the first batch chargers, the first fully-automatic batch plants for the glass industry, the first internal cullet return systems, the first batch preheating systems and most modern process control systems including plant-wide automation concepts nowadays.
ZIPPE’s aim is to continue to provide innovative, outstanding and economic solutions for customers to help to secure their success and sustainability.
ZIPPE’s core business is the development and construction of batch and cullet systems. As pioneers in its branch of industry, the company has been involved in key developments in the glass industry from the very outset. And this is why the company’s name is being used in many countries as a synonym for different technologies in the batch and cullet processing sector: ‘It’s a ZIPPE’.

 

PARTNER TO THE INDUSTRY
“We regard ourselves as a reliable partner to our customers and have at our disposal the expertise and capabilities to deliver projects of any magnitude. At the same time, our customers hold in high regard our flexibility with which we are able to respond quickly to different requirements and current trends with the appropriate portion of creativity and innovation spirit. This has made us a preferred supplier for industry leaders.”
“As one of the few full-service providers in our industry, our spectrum covers all service ranges within plant construction – engineering, planning, design, production, automation technology, installation, site management for all disciplines, commissioning, training for your personnel, and services for ongoing operation.”

EVERYTHING FROM A SINGLE SOURCE
High quality batch produces high quality glass
ZIPPE batch plants ensure that the batch for every glass type is fed fully automatically into the furnace with the exact consistency and homogeneity needed, at the required amount and at the right point in time – 24 hours a day, every day.

Systems exactly to size
ZIPPE teams of experts ensure smooth and on-schedule realisation of every order – also as turnkey solutions if required, channelling all efforts into continual development, innovation and safety so that this remains the case in the future.

Powerful software and hardware systems
State-of-the-art control technology is a key part of the optimal operation of a batch plant. After all, it is responsible for the efficient, reliable and reproducible operation of a system.
It is for this reason that ZIPPE gives very special significance to the development of powerful software and hardware systems. Nearly 50 of company employees are realising next generation automation and control systems, allowing the company to carry out complete control development and realisation in-house.
This, in turn, enables ZIPPE to guarantee customers tailor-made and flexible solutions, and subsequently to provide the speedy and effective support expected of production companies today.
A 24-hour support service enables customers to phone or email an expert around the clock, who is granted access to control systems online once a secure connection has been established.

RECYCLING REPLACES VALUABLE RAW MATERIALS
Scraping conveyors – factory cullet processing 24/7
Glass production always generates a certain fraction of glass waste. Scraping conveyors are used to deliver the still hot glass drops or filaments back to production. They are positioned under the moulding machine and guarantee continual hot glass recycling around the clock almost without any deployment of personnel.
ZIPPE scraping conveyors are aligned exactly to the requirements of customers. Their length and design is based on the drop points of the hot glass waste. Nowadays scraping conveyors represent the foundation for automatic factory cullet processing plants.

GLOBAL DEPLOYMENT
ZIPPE supervisors and project engineers are realising projects across the globe. For steel structures and buildings, the company works closely with local providers and engineering consultants. Core components are installed on site by ZIPPE experts who have undergone specialist in-house training. Customers benefit from their many years’ experience on most diverse construction sites across the globe. In parallel, our software specialists provide support for the control systems providing smooth interaction between mechanics and electrics.

Capacity increase and new recycling plant for Sotuver
Tunisian company Sotuver is a manufacturer of hollow glass containers for the food industry, active since 1967. The listed company produces bottles and glassware in two melting furnaces for flint and green glass at its site in Djebel Oust (30 km south of Tunis, Tunisia) for the North African market, Western and Central African countries, as well as the South European market. Up to now, the production capacity of the two furnaces was 120,000 tons per year in total. Sotuver produces three colours: flint, emerald green and antic green.
ZIPPE was already involved in the building of the first batch house, back then at the old plant site within Tunis.
In view of the ever increasing demand, Sotuver approached ZIPPE in June 2019 with the new project ‘batch preparation of new furnace 3’. The new furnace should have a total production capacity of 110,000 tons per year (300 t/d), with a cullet portion of about 15%. Production is to be carried out on four IS-lines. The new furnace will be built directly next to the two existing melting furnaces.
In March 2020, ZIPPE received the order to supply the batch house, batch transport, and cullet return system. Moreover, ZIPPE also received the order for the planning and supply of a recycling plant for post-consumer glass cullet with a capacity of 360 t/d. Both plants are expected to be commissioned in July 2021. ZIPPE is in charge of the overall planning of the plants, supplying the equipment, the electrical control system, as well as providing support during the installation and commissioning period. The steel works and installation works will be provided locally.
The new batch house consists of 17 silos in total. For one part these silos are fed by mechanical transport and for the other part they are fed pneumatically by silo trucks or a pneumatic sender system. ZIPPE is paying special attention to a high redundancy for the charging possibilities with regards to this project. Raw materials are weighed through an additive weighing process and are conveyed into a mixer by a discharge belt. The mixer has a volume of 1,875 litres and is supplied by ZIPPE. Batch transport is carried out by a conveying belt system into both dog houses of the regenerative U-flame furnace.
For the cullet return system, ZIPPE is supplying a scraping conveyor for the charging of hot cullet, as well as a main crushing station, among other equipment.
Sotuver already has a cullet post-consumer recycling plant in operation which, however, does not have sufficient capacity for the future. As an essential component of the new post-consumer glass recycling plant, ZIPPE is installing two roller crushers, a magnet drum, and an eddy current separator, as well as a screen tray with CSP sorting level.

 


Zippe Industrieanlagen GmbH
www.zippe.de