With the delivery of seven automatic Process Cranes, Demag Cranes & Components has supplied the systems used to serve a shipping store for rolls of paper operated by the Turkish paper manufacturer Modern Karton. The newly built store in the north-west of Turkey accommodates the production output of a new paper machine. The cranes are used in high cycle operation to store and retrieve the rolls of paper. With a storage capacity of more than 70,000 t of paper, it is the largest newly built shipping store in the world. The further scope of delivery, which Demag Cranes & Components supplied with its long-standing agency Genel Makina, includes the entire store management system and control of the roll transport system. In addition, the newly installed paper machine was equipped with Demag crane systems.
With this major project, Demag Cranes & Components has strengthened its presence in Turkey and also underlines its leading position as a specialist for materials handling solutions in a dedicated industry.
Modern Karton Sanayi Ticaret produces paper used for the manufacture of liner and test liner in Corlu, 180 km west of Istanbul.
Within Eren Holding, which also operates in the textiles, cement and energy sectors, the company is the division with the highest sales.
With its PM 4 paper machine, the fourth investment of its kind in 30 years, Modern Karton has boosted its annual capacity by 400,000 t to more than 700,000 t.
In the production area of the PM 4 paper machine, Demag Cranes & Components installed two Process Cranes that have a span of 28.9 m, which were already used for assembly of the paper machine They are each equipped with two MPW hoist units with load capacities of 120/60 t at the wet end and 60/60 t at the dry end, as well as further auxiliary hoist units.
The automatic store has to accommodate high handling rates. At peak periods, up to 206 rolls of paper have to be moved per hour. Demag Cranes & Components meets these demanding requirements with seven identical automatic cranes, which - operating 24 hours per day - achieve lifting speeds of 70 m/min and long-travel speeds of 120 m/min under load.
Besides delivery of the crane installations, Demag Cranes & Components was also responsible for installation of the entire store management system, including coordination of the transport system. The store management system is integrated direct with the in-house facility director and the production management system. The Demag store management computer receives all data relevant for production from this system.
When they have been measured and labelled, the rolls of paper are transported to the neighbouring storage complex. This consists of three bays arranged next to each other and each measuring 127 m in length and 35 m wide. The store management software specifies the storage location and guides the rolls of paper along conveyor lines to the transfer points.
Here, the rolls are picked up by double-girder overhead travelling cranes (ZKKW), which are installed in the three bays of the store. The cranes each have a span of 32.63 m and are fitted with MPW open winch units and vacuum lifting devices.
The Process Cranes transport the various paper rolls, which have diameters of up to 1,500 mm, a width of 3,300 mm and a maximum weight of 4,900 kg, and deposit them vertically in stacks measuring up to 15 metres in height.
By picking up the rolls from above using vacuum lifting devices, which is also gentle on the load, the rolls can be stored in a space-saving arrangement. Optimum utilisation of the storage surface is achieved by means of a triangular storage pattern. The entire store, which measures almost 13,000 m² in size, is rated for 4887 stacks of rolls and offers a storage capacity of up to 77,850 t when filled to a theoretical capacity of 100%.
The Demag store management system features installation-specific storage strategies, which can be configured by the customer by means of visualisation screens. These strategies include order-specific storage operations, optimised travel paths and handling to prepare for shipping on the following day.
Demag Cranes & Components
Mr Christoph Kreutzenbeck
Tel. 49 (0) 2335 / 92-7333