Machinery, Steel Belts,Installation & Maintenance

5 + 1 = 1All from one group !

Steel Belt Systems Korea NBC

KSBS

BSBSSBS

BBS NBC

BBG

Editorial

Steel Belt Systems S.r.l., Italy

Kaiser Steel Belt Systems GmbH, Germany

Berndorf Belt Systems INC., USA

Nippon Belting Co., Ltd., Japan

Berndorf Steel Belt Systems Ltd., Co., Korea

Berndorf Band GmbH & Co, Austria

How do customers befefit from the Berndorf MCM Group

Impressions

Contacts, Impressum

Contents

3

4

5

6

7

8

9

10

11

12

2

What does it mean? Are the editors of this brochure unable to

do a simple calculation?

No, not at all. In fact this is not a calculation, but a

concept which brings many of the benefits to customers within

the chemical, pharmaceutical, rubber, plastics and food

industry - not only locally, but world-wide as well.

5 + 1 = 1 indicates that five excellent companies, specialized

in steel belt machinery along with Berndorf Band, well known

manufacturer of high quality steel belts, are all working

together as one close group and world-wide organization.

Each company made huge investments in research and

development thus their customers benefit from the latest

technologies. All applications using steel belt machines are

designed to meet a variety of customers� special needs.

Efficient solutions for new materials have been found. Due to

the close co-operation among Berndorf Belt Systems (USA),

Berndorf Steel Belt Systems (Korea), Kaiser SBS (Germany),

Nippon Belting Company (Japan), Steel Belt Systems (Italy)

and Berndorf Band (Austria), new developments and patented

machines of each company are available world-wide. There is

a wide range of different applications including

pastillators, flakers, single and double belt coolers, belt

reactors, film and sheet casters, steel belt dryers and curers,

polymerizers, double-belt presses, belt tracking units and other

equipment.

These global advantages are not limited to machines only - the

machinery group together with Berndorf Band are able to do

installations, maintenance, repairs and spare belts. This group

is known throughout the world as the �so called� Berndorf MCM

Group which maintains and can provide well trained service

engineers at a moments� notice.

On the following pages we will introduce you to the six

members of the group as well as to some of their special

products and services.

5+1 = 1

3

Steel Belt Systems S.r.l., Italy

Established in 1984, SBS designs and produces continuousprocess conveyors for a wide range of applications within thechemical, petrochemical, plastic, food and rubber industries.Typical continuous process systems using endless steel beltsare coolers-flakers, coolers-pastillators, double belt coolers,belt reactors, continuous driers with perforated belts or beltfreezers.

SBS maintains its own test facility near to Milano. Based on theresults of customers� trials it is possible to scale up steel beltcoolers for industrial production. Continuous research anddevelopment have been leading to new and patentedmachines, such as the ROLLDROP® pastillator and the DoubleMixed Effect cooling conveyor.

The pastillating device ROLLDROP® represents the new generation of dropformers. It transforms molten products ofdifferent viscosities into disk shaped pastilles with diametersranging from 3 to 10 mm, with feed temperatures up to 280°C.The ROLLDROP® system is very simple: the liquid product comes out of the feeding and distribution device,deposits itself on the whole feeding surface and fills in thespaces in between the teeth of the rotor. Due to the influenceof gravity and centrifugal force the product gathers at the topof the teeth and, as a result of that, drops are formed anddeposited on the steel belt.

Its main components are the rotor - which has teeth on its outside surface (shape and size of teeth determine the size ofthe pastilles) - and the feeding and distribution device,designed according to the characteristics of the product, inorder to obtain a homogeneous distribution on the feeding surface. All the main components in contact with product areheated by using thermal oil.

The Double Mixed Effect cooling conveyor is used for cooling down liquid or doughy products like powder coatings,resins, masterbatches, etc. This type of equipment uses boththe advantages of chilled calander rolls and high quality stainless steel belts from Berndorf Band. It reduces the cooling time especially for products with low thermal conductivity. A further benefit are the space saving dimensionsof this machine.

For more information please visit us at: www.steelbeltsystems.it

4

Belt

Productpre-distribution

comb

Level controlledjacketed product

chamberToothed rotor segments

Shaft

Heatingchamber

KAISER Steel Belt Systems GmbH,

experts in Melt Solidification, is the successor company ofGebr. Kaiser, and has accrued more than 50 years experiencein the solidification and granulation of molten products usingBerndorf endless steel belts.KAISER SBS was the first company to develop and patent thepastillation process and today offers four different types ofpastillators to the chemical and food industry worldwide.KAISER SBS also offers strip granulators, flakers, double beltcoolers, belt reactors, bag-filling units, special batch mixersand turnkey plants. KAISER SBS has a back-catalogue of morethan 8,000 samples of products tested in its Technical Centre

and more than 1,000 units delivered.

ZN system (A) was designed by KAISER SBS in1970 to produce pastilles with low viscosities from 0 - 500mPas. With an out put range of up to 1,000Kgs/hr this simple needle type system will producepastilles from the most difficult of products

GS system (B) by KAISER SBS was introduced forproducts of medium range viscosities 300 - 5,000mPaswith out puts up to 1,500 Kgs/hr.

Rollomat® system - Patented and designed byKAISER SBS for melt viscosities ranging from 15 -30,000mPas and out puts up to 6,000 Kgs/hr. This�internal� rotor system has advantages over othersimilar systems in the wide range of products it cancomfortably process. The product is pushed throughthe holes along the length of the rotor under pressure from the pressing roll. Free flowing, regular sized / shaped pastilles can be continuouslyproduced giving a product that is simple to handleand transport.

5

For more information please visit us at: www.kaiser-sbs.de

Major Benefits

● Continuous production of regular, uniform sized pastilles without dust or fines.

● Creates a quality end product that is simple and easy to handle.

● Low product retention time in heated areas to avoid procuct degradation.

Berndorf Belt Systems, INC, USA

Berndorf Belt Systems (BBS) is recognized as a leader in thesupply, design and manufacturing of solid steel belt conveyorsand supporting systems. BBS has over twenty-five years ofexperience in the USA supplying individual units, along withtotal steel belt systems for the most demanding of applications.

Each unit is engineered from scratch and manufactured in theUSA to exacting quality standards using the highest qualitymaterials and parts. As a customized, application-driven, solutions provider BBS has the capability to run tests on customers� product(s) in their state of the art test centre in Elgin, IL.

BBS has the ability to manufacture and design steel belt conveyors for various applications.Shown here is a conveyor completely submerged under waterincluding the steel belts and all drive components.

The machine is used to produce a sheet product for the manufacturing and use as high strength fishing line. Due toBBS� high standards in manufacturing and its ISO 9000 certification the machine was able to produce products to thecustomer�s specs. No testing or pre-evaluation was needed.Materials of construction including the bath assembly are all ofstainless steel.

Based on another customer requirement to process highly sensitive pharmaceutical products in a sterile environmentwithout extreme changes in temperature, moisture or physicalstate BBS developed the system as shown here.

Due to limited space, Berndorf Belt Systems designed a self-contained processing system on casters made completelyout of stainless steel to guarantee product purity. The productis manufactured from an extruder in paste form. All the cooling water is held in the drums. Two steel belts sandwichthe product to the exact thickness required. Product is cooledon the continuously cooled belt surface as it passes over thedrums. The output is a product manufactured to guaranteezero contamination.

For more information please visit us at: www.berndorf-usa.com

6

Nippon Belting Co., Ltd. , Japan

was established in 1980 as a joint venture between Berndorf AGand Mitsubishi Rayon Engineering Co., Ltd. The target of thisco-operation was to provide customers in Japan, Taiwan andother Asian countries with various steel belt machines andrelated services in the chemical, rubber, plastics and foodindustry.

Besides various types of belt coolers/flakers, NBC also designsand fabricates special belt machines like double belt presses aswell as film and sheet casters, belt type laminators, steel beltdryers and curers, polymerizers and various types of pastillators.

NBC is specialized on cooling conveyors, e.g. the NR type double belt cooler, patented in 1992.Until today more than 100 units have been installed successfully. Due to the special design of this machine, thefeed material is pressed into sheet form by press rolls at theentrance via steel belts and then cooled in close contact withboth upper and lower belt. Compared with other types of coolers, the NR double belt cooler proves a lot of advantageswhen processing high viscosity materials like epoxy, phenol orpolyester resin. Because of its special design at the feedingsection, this cooler can be used even for products with viscosityover 100,000mPas.

NBC also provides its customers with all types of steel beltsfrom Berndorf Band. Besides installation and start up at site,full technical service for belt machines and steel belts (e.g.repairs in case of cracks or deformations, shot peening, dry icecleaning, endless welding at site, repairs of mirror polishedsteel belts) are also available.

Besides the office in Osaka, NBC is running its own test centrein order to find optimal design conditions. In close co-operationwith customers, applicable solutions will be found even fornewly developed material.

The picture at the left shows NBC�s pilot-scale pastillationmachine presented at the Inchem, Tokyo (international exhibition of chemical machinery).

Customers benefit from NBC�s long term experience, comprehensive technical know-how and NBC�s lived corporate philosophy �to contribute to society through our expertise insteel belts and belt machineries�.

For further information please visit us at:www.nippon-belting.com

BAND

NIPPON BELTING Co., Ltd.

NBC

7

Berndorf Steel Belt Systems Ltd., Co., South Korea

This member of the Berndorf group designs and manufacturesmachines for a wide range of applications within the chemicaland food industry. Besides steel belts, process systems likesingle belt coolers, double belt coolers, casters and dryers aresupplied and serviced. Founded in 1991, BSBS is in charge ofthe domestic Korean market and has also internationally wonhigh reputation with their exported steel belt systems!

In the chemical and food industry many customers rely on theexpertise of BSBS when producing various kinds of resins(epoxy, polyester, phenolic, petroleum), waxes and paraffin,hot melt adhesives, epoxy moulding compound (EME), powderpaint, sulphur, anti-oxidant, aluminium sulphate, maleic anhydrite, pitch, rubber, peg, and other 200 kinds of chemicalproducts. In the food industry the main products are: caramel,gum-base, candy, agar-agar, chocolate, biscuits, artificial crabmeat (Surimi), frozen coffee and many other more.

BSBS serves also other industries:

Especially in manufacturing of casters for acrylic resin basedartificial marble panels Berndorf Steel Belt Systems prove a lotof experience. Such decorative panels can be found as countertops in offices, restaurants and hospitals as well as wall coverings in kitchens and bathrooms in many homes due tothe huge possible diversity in colours. Customers benefit fromcompetent engineering advice and design know-how. As aresult many BSBS production lines have been installedthroughout South Korea and put in operation successfully.

For more information please visit us at:www.berndorf.co.kr

Steel Belt Systems Korea

BSBS Powder Coating cooling conveyor and/or Epoxy MouldingCompound (EME) cooling conveyor

General layout drawing of 100 % Acrylic based Artificial Marble Production Line

8

Berndorf Band GmbH & Co, Austria

Berndorf Band is one of the world�s leading manufacturers ofhigh quality steel belts for various applications. Berndorf Bandsteel belts are used as high precision machine components forprocessing purposes.

In order to guarantee perfect tracking and optimal flatness,each Berndorf Band special steel belt runs as an endless unitduring production. Most of our own belt production lines weredeveloped and produced in-house. By running and maintainingthese machines for decades, we have gathered extensiveexpertise in this field. Today, many of our customers benefitfrom this experience in developing customized solutions.

In order to meet our customers� individual requirements,we additionally offer

● steel belt machines● steel belt tracking

systems (bernmatic®)● engineering support for

new developments and improvements to existing steel belt machinery

Unlike many other systems,the bernmatic® belt trackingsystem works according tothe principle of positionjustment. Only the exactposition adjustment canguarantee ideal belt tracking as track-keeping basically depends on geometric properties. This

makes the difference between bernmatic® and other systems,mainly functioning by the principle of pressure adjustment.

The bernmatic® software recognizes tracking trends and thusforces the guiding drum to turn proportional to the deviation ofthe steel belt. This control device guarantees absolute straighttracking. Successful installations world-wide and for many different applications, like double-belt presses, film castingmachines, bake oven terminals or the Berndorf Band steel beltproduction, are the best proof of this systems� reliability.

For more information please visit us at: www.berndorf-band.at

bernmatic®

safeprecisereliable

control panel

bernmatic® position measurement unit

belt edge sensor

valve assembly

pressure sensor

hydraulic cylinder

hydraulic unit

rotation sensor

▲

Principle Sketch

Finite elements analysis of a steeldrum

Double-belt press for the productionof foamed plates

9

The Berndorf MCM Group

10

The Berndorf Machinery Group comprises of fiveindependent machinery companies, strategically locatedaround the world, who interact together and collaboratewith Berndorf Band to react and serve as

one global company.

The Berndorf MCM Group has more than five decades ofexperience in the field of melt solidification, belt reaction,dryers and curers, double-belt presses, etc. Due to theclose co-operation we are able to select the best technicaland economically viable solution to meet our customers´needs. No other company or group can match this uniqueexpertise. We do not try to fit your process to a standardoff-the-shelf model but rather design our systems tomeet the stringent requirements of your process. Thisapproach gives you the most economical and energy efficient system to meet your processing goals.

Each customer, no mater where they are geographicallylocated can receive the same complete, tailor-made processing systems, including installation, maintenanceand spare belts from a local member of the BerndorfMachinery Group.

A further important fact is, that all processing systemsdesigned by the Berndorf MCM group are equipped withsteel belts from Berndorf Band, Austria. These steel beltsare produced to meet exactly customers� requirements onspecific applications. Know-how, long-term experience inbelt production and innovative manufacturing methodsare demonstrated in every single belt. A world-wide operating service centre in Berndorf, steady developmentof new maintenance and repair tools as well as work techniques plus a broad training offer prove the outstanding care Berndorf Band takes about their customers.

Customers� benefits are expressed best in the sloganbelow:

Multiple Solutions - One Group!

Are you ready to put the responsibility for your productionin the hands of the Berndorf Machinery Group?

11

CONTACTS (in alphabetical order)

Berndorf Band GmbH & CoLeobersdorfer Straße 26A-2560 BerndorfAUSTRIATel.: (+43)2672/800-0Fax: (+43)2672/84176band@berndorf.co.atwww.berndorf-band.at

BERNDORF BELT SYSTEMS INC.850 Commerce ParkwayIL 60110 ElginUSATel.: (+1)847/649-0200Fax: (+1)847/649-0223mauricef@berndorf-usa.comwww.berndorf-usa.com

BERNDORF STEEL BELT SYSTEMS LTD., CO.47B-9L, Namdong Complex, #436-8, Nonhyun-Dong, Namdong-Ku405-300 IncheonKOREATel.: (+82)32/816 0432Fax: (+82)32/816 0435bsbs@berndorf.co.krwww.berndorf.co.kr

KAISER Steel Belt Systems GmbHMagdeburger Straße 17D-47800 KrefeldDEUTSCHLANDTel.: (+49)2151/4934-0Fax: (+49)2151/4934-56info@kaiser-sbs.dewww.kaiser-sbs.de

NIPPON BELTING CO. LTD.Uchikanda DNK Bldg., 8th floor No.15-2, 2-chome, Uchikanda, Chiyoda-kuTokyo 101JAPANTel.: (+81)3/32573050Fax: (+81)3/32579050yoshida_ma.nbc@mrg.mrc.co.jpwww.nippon-belting.com

S.B.S. Steel Belt Systems S.R.L.Via Enrico Mattei, 3I-21040 Venegono InferioreITALYTel.: (+39)0331/864841Fax: (+39)0331/864959info@steelbeltsystems.itwww.steelbeltsystems.it

Impressum:Berndorf Band GmbH & CoA-2560 Berndorf, Austria

Printed 05-2003