Space-saving design with proven HAVER & BOECKER quality

The primary objectives for the new plant were defined quickly.

“High performance with a capacity of at least 2,800 bags per hour, intuitive and economical operation with only 1.5 operators, as well as maximum weighing accuracy and cleanliness, were of particular importance to the customer,”

summarizes Markus Horstkötter.

In addition, on-time and reliable delivery, along with straightforward commissioning, played a central role in the project. Since the certification of the existing plant was nearing expiration, the timely completion of its modern replacement was essential.

For the implementation of the project, the cement plant’s management chose the turnkey solution offered by the HAVER & BOECKER team. As part of this comprehensive approach, our specialists took responsibility for executing and coordinating all required activities, from constructing the new building, including fire protection, lightning protection, lighting, heating, automatic doors and gates, maintenance and operator platforms, to delivering a fully operational filling and packaging plant ready for production.

Following an intensive planning phase, construction of the new building began at the end of November 2020. Meanwhile, production at the soon-to-be-retired packing plant was ramped up to ensure uninterrupted supply of bagged OPTERRA cement products to professional distributors and DIY retail customers.

The old system was shut down in mid-December, with the goal of commissioning the new Smart Plant on schedule in March 2021. The new facility was installed in a compact building measuring just 12.5 meters in height, 18 meters in length, and 15 meters in width.

“It was a perfect landing under challenging conditions,”

summarizes Guido Küpper, Project Manager at HAVER & BOECKER.

“The COVID-19 pandemic complicated numerous processes and required additional, unforeseen safety measures.”

Thanks to continuous coordination with the customer, smooth project management, and the outstanding performance of all contractors involved, the ambitious timeline was successfully maintained.

The smart filling and packaging plant has also more than fulfilled expectations.

“The performance of the plant, reaching up to 3,000 bags per hour, is impressive. After fine-tuning, we consider the weighing accuracy to be excellent,”

says Dr. Frank Noack, Head of Investments at OPTERRA Zement GmbH.

In daily operation at the OPTERRA cement plant in Karsdorf, the compact Smart Plant demonstrates its full range of advantages. At the heart of the system is the high-performance ROTO-PACKER® RVT with eight filling spouts, combined with the fully automatic RADIMAT® bag applicator featuring a dual-roll system.

The new plant even exceeds the specified capacity requirements, achieving outputs of up to 3,000 bags per hour. Thanks to its high degree of automation and intuitive user interface, the desired reduction in operating personnel was also successfully achieved.

Designed in accordance with OIML Accuracy Class X(1), the system currently fills six different products to the customer's complete satisfaction.

In terms of production cleanliness, the cement plant benefits not only from the expertise and experience of HAVER & BOECKER specialists but also from innovative technology.

“The high-quality standard equipment and the integrated patented ROTO-LOCK® dosing unit minimize product loss,”

explains Guido Küpper.

“In addition, we ensure the best possible results through the individual evaluation of all relevant factors before commissioning. Depending on the customer's specific product and the type of bag used, often in close coordination with the bag manufacturer, we optimize all components of the entire packing line, including air dosing systems, to perfectly match the operating conditions.”

Precise dosing and filling reduce product loss while contributing to a healthier working environment and a cleaner, more organized plant area.

The HAVER & BOECKER Smart Plant is also ideally prepared for future challenges. In addition to extensive product- and bag-specific setting options, the system can be configured with various standard design variants and can, of course, be equipped with the product-protecting SEAL technology.

The customer’s conclusion is overwhelmingly positive. Andreas Klinger, Regional Sales Manager at OPTERRA, was impressed both by the almost seamless transition process and by the final result:

“The performance and precision of the plant are highly convincing!”

Dr. Frank Noack views the investment primarily from an economic perspective:

“The modern filling and packaging plant, together with the new control system covering the entire process from the silos to the shipment-ready palletized cement bags, provides OPTERRA with long-term operational reliability in the bagged cement sector for many years to come.”