Modern packaging systems must be cost effective, safe and reliable, as well as provide high quality packaging. Lyondellbasell Industries, one of the world's largest polymers, petrochemicals and fuels companies, understands these requirements. The company, which operates a plant that produces polypropylene pellets in Clyde, a suburb of Sydney, commissioned Beumer Australia to update its packaging operations.

Lyondellbasell Australia, a Lyondellbasell company that produces polypropylene in Australia, focuses on innovation and operational excellence to address customer needs. Polypropylene is a polymer that is used to produce numerous consumer and industrial applications - from packaging and automotive components to pipes and appliances.

After the polypropylene is produced at the plant, the product is pelletized and loaded into sacks; the sacks are placed directly onto a container or truck, or the sacks are temporarily stored in block storage. Lyondellbasell in Australia works together with the CRT Group as its logistics partner during these operations.

Tough Demands on Packaging Department
After 15 years service, Clyde's packaging equipment required updating. The aim was to increase throughput and increasing bag output from 800 to 1,800 sacks per hour, combined with an improvement in packaging quality. The Clyde plant also required improved reliability, enhanced operational safety and adherence to environmental noise regulations.

Two-Stage Modernization
Packaging specialist Beumer Australia, a subsidiary of the Beumer Group which is based in Beckum, Germany, was contracted to modernize the system. The retrofit was performed in two stages. In 2006, Beumer Australia installed a new sack filling machine, type FFS Delta, from the company Haver & Boecker. This machine brings the empty sacks into shape, fills them with polypropylene pellets and then seals the sacks. The powerful Beumer paletpac with the latest S7 control system then palletizes the sacks at a rate of up to 1,800 per hour. The palletizer is characterized by the excellent quality of the stacks it produces and by its reliability and flexibility.

Commissioning of a High-Performance Packaging Machine
Once the palletization systems had been successfully upgraded as part of the project, Lyondellbasell Australia concentrated on selecting a new packaging machine for its Clyde plant. Beumer was able to demonstrate the effectiveness of its Beumer stretch hood high-performance packaging system, which boasts a capacity of 100 pallets per hour. This system was integrated into the existing layout of the plant and connected to the existing control platform. The Beumer stretch hood packs the palletized stacks of sacks into a stretch hood made of film, which protects the product against the elements as well as against dust and moisture. After this step, the stack of sacks is fully packaged and can be transported to the loading area. The stacks are very stable because the film is kept under continuous tension in the horizontal and vertical direction - even if the pellet material in the sacks settles, causing the sack volume to reduce.

The modernization work took place during a break in production. This meant that Beumer's staff had just ten days to successfully assemble the packaging machine and put it into operation. They also trained the operating staff to use the new system components.

Reliable Operation, Higher Throughput
Since the modernization work was performed, the Clyde plant's packaging department has improved the reliability and efficiency of its packaging operations. The plant has been able to achieve significantly higher throughput rates and meet the 80 dBA noise level specified in local environmental regulations. As well as improving packaging performance, the stretch hood technology also improves the visibility of the product on the pallet. In addition, the BEUMER stretch hood and the Beumer paletpac have enabled the Clyde plant to reduce its power consumption. The modernization has also improved the safety of forklift operations.