Demag process cranes: reliable storage of high production volume
Modern Karton Sanayi ve Ticaret once again relies on Demag crane technology. The Turkish cardboard and packaging manufacturer has commissioned Terex Material Handling with the installation of an automated paper store with six Demag process cranes at its Corlu location. The task of the double-girder overhead travelling cranes, which are equipped with vacuum lifting devices, is to gently place the finished paper rolls into storage in a space-saving fashion and to stage them ready for shipping as required. The scope of delivery also includes a warehouse management system that will provide for optimised process steps thanks to configurable storage strategies. The project, including installation and commissioning of the crane systems, is being implemented in co-operation with the Turkish Demag agency Genel Makina from Istanbul. Production is scheduled to begin at the first quarter of 2015.
As early as 2008, Modern Karton commissioned a paper roll store with Demag crane systems. The paper roll shipping store, which is currently the largest in the world, channels the production output of the PM 4 paper machine. The Turkish paper manufacturer’s paper machine 5, which is currently under development, is designed for an annual production capacity of 400 000 tonnes of liner and fluting paper, which is made from 100%recycled paper. After the PM 5 is commissioned, Modern Karton will achieve an annual production volume at its Corlu location of one million tonnes of paper, which will be stored and staged ready for delivery by Demag crane systems.
Dr Lars Brzoska, Vice President & Managing Director Terex Material Handling, explains: “We are pleased with this renewed vote of confidence by our customer Modern Karton in our Demag brand crane technology. With this project, we are continuing to expand our presence in this economically significant region and consolidate our position as a specialist for intralogistic solutions for specific industries.”
Hamdullah Eren, Member of the Board of Eren Holding A.S., underlines: “For us it was important from the beginning to work in close co-operation with an international company that has extensive references. A decisive factor in the award of the new contract was also that for more than five years, Demag crane systems have demonstrated their outstanding efficiency and reliability in our first paper roll shipping store. Moreover, by implementing appropriate storage strategies, Terex Material Handling has again been able to offer an integrated solution that fully meets our requirements with respect to high installation performance.”
Maximum performance and availability in 24/7 operation
When the new PM 5 paper machine in Corlu is operated at full capacity, up to 1,450 tonnes of paper will have to be loaded every day in future. The rolls, which are configured to customer requirements, have a diameter of between 900 and 1,550 mm and weigh up to 6,000 kg. Coming from production, the paper rolls are placed in intermediate storage in the automated store. They are stored vertically, thus saving space. The shipping store is divided into two blocks in which, depending on the respective diameter, the paper rolls can be stacked on top of each other up to a height of 15.5 metres. The entire store will accommodate a volume of approximately 53,000 tonnes of paper.
The six ZKKW double-girder overhead travelling cranes each have a lifting capacity of six tonnes and feature a span of 32 metres. They travel on two 143-metre-long crane runways installed parallel to each other and reach travel speeds of up to 120 m/min and lifting speeds of up to 70 m/min at full load. The process cranes are equipped with Demag 6 tMPW open winches and vacuum lifting devices, which are used to gently pick up and safely transport the rolls of paper.
In addition to high operating speeds, the crane control system employs dynamically overlapping travel paths of the three cranes travelling on each track to provide the required high handling rates.
About Modern Karton
The Turkish company Modern Karton Sanayi ve Ticaret belongs to Eren Holding S.A. and is one of the largest cardboard and packaging paper manufacturers in Europe. In 2008, its PM 4 paper machine started operation at the Corlu location 120 km west of Istanbul. Modern Karton was thus able to expand its annual capacity by 400,000 tonnes to more than 700,000 tonnes, which represents approximately 36 per cent of the entire Turkish production capacity. With the commissioning of its new PM 5 production machine, the one million mark will be exceeded.