HAVER & BOECKER

PREFABRICATED – QUICKLY INSTALLED – RELOCATABLE

Over the past 20 years, shipping of clinker and cement has steadily increased, driven by booming construction in developing regions. As urbanization increases in such markets, mobility, speed and responsiveness will be essential for the success of the cement producers that supply them. In response, we have developed an innovative and comparatively compact system for packing and loading cement into bags: the OCTAPLANT^®.

Your advantages at a glance:

Fast to market: you have a short period of time between your purchase decision and entry into the market.
Transparent and reliable costs: reduce your risks regarding construction time and construction cost.
Reliable output: your upscale your costs adapted to market needs and maximized output.
Fit for future: you have the possibility of relocating the plant as market conditions change.
Proven quality: you can rely on our expertise.

The system consists of a modular design that incorporates high-quality technology and prefabricated components to allow for quick installation and adaptability. This allows it to set new standards in terms of time and cost optimization while reducing risks - especially during the implementation phase. The concept is also a sustainable option, as it can be reassembled and used at another location, while occupying a very small footprint. Overall, the OCTAPLANT^® gives producers the ability to be the first to serve new markets exactly where demand arises, leading to an enormous competitive advantage.

Here you can see different views, variants and the essential elements of our OCTAPLANT®

OCTAPLANT® cement packing plant container building — OCTAPLANT® container building

The heart of the OCTAPLANT® cement packing plant — The heart of the OCTAPLANT®

Cement packing plant OctaTower — The octagonal tower “OctaTower”

The OCTAPLANT® concept features:

Detailed 3D model
Detail engineering 100 % finished
High degree of prefabrication
Modular concept
Small foundations
Scalable concept
Supported by PROCHECK

OCTAPLANT® HB10 portable cement packing plant

Frequently Asked Questions

Here you can learn, how the new concept for efficient, mobile packing and loading of cement, overcomes the challenges of tomorrow.

OCTAPLANT^® is a fully developed concept for a modern, comparatively compact system for filling and loading cement. What is essentially new is the unprecedented level of risk reduction, time and cost optimization. This plant is not only particularly quick to plan, implement and commission, but it can also be dismantled just as quickly if required so that it can be reused at another location. Space-saving, pre-configured systems such as Smart Plant and numerous traditional pre-planned layouts have long been established at HAVER & BOECKER. OCTAPLANT^® relies on very special features and advantages that redefine future viability.

One of the megatrends is increasing urbanization. This is currently in full swing and is an essential part of the future worldwide, especially in emerging countries in Asia, Africa and South America. Urbanization and rapid changes in the markets mean that speed and mobility are becoming increasingly important. On the one hand, the demand for living space, infrastructure and industry is increasing. Where cement is produced or ground, stored, packaged and loaded today, the use of dwindling space for residential areas could soon be a priority. On the other hand, the shipping of clinker and finished, loose cement has increased over the last 20 years. Building is underway in many formerly agrarian countries and the demand for cement is growing. This means being the first to enter the market at the point of sale if possible - and moving on again just as quickly if required!

One of the most striking features of OCTAPLANT^® is the exceptionally high degree of prefabrication. Right from the planning phase, customers benefit from engineering that has been completed down to the last detail. This guarantees the best possible planning security in terms of equipment and expected costs. It also leads to significant time savings, which are maximized later in the project through a significantly accelerated construction phase. All system elements are designed for fast and resource-optimized production. All the production steps that can already be carried out in the manufacturing plant are completed before delivery. This not only means a shorter construction time during on-site assembly, but also a reduction in the sources of error and personnel requirements. All of this leads to minimized costs, fewer problems and uncertainties, and faster revenue generation. OCTAPLANT^® only requires around 20 percent of the number of crane lifts needed to erect a traditional system. Through our close contact with our customers, we know that the planning and erection of buildings for new plants often causes more headaches than the planning and installation of the equipment itself. With OCTAPLANT^®, such difficulties and uncertainties are a thing of the past.

The OCTAPLANT^® building consists of three segments. The centerpiece is the octagonal tower “OctaTower”, which gives the building its name and houses the HAVER ROTO-PACKER^® RVTs packing system, and includes the foreign body screening machine, pre-hopper, spillage return system, etc. The adjacent container building provides space for the bag discharge line, the fully automatic RADIMAT^® bag applicator, the system control and the compressor unit. The final segment is a lightweight building in which the cement bags are loaded onto trucks in two possible variants. The HB 10 system for rear loading and the HB 17 system for loading open trucks are available here. As to the motto “form follows function”, these three separate segments were designed so that they can be manufactured, delivered and assembled equally cost-effectively and quickly - without compromising on ease of use, safety and productivity.

The OCTAPLANT^® objectives actually determine the structure and appearance of the entire facility. The octagonal tower arose from the idea of using existing elements directly for the required building. The basic cylindrical shape is already the basis for the pre-hopper, ROTO-PACKER^® and its protective housing, etc. in many packing plants today. The shell of the OctaTower consists mainly of a total of 2 x 8 wall modules in classic steel construction, which are manufactured without screw connections. Where possible, trapezoidal sheets, windows, vents and other components are also fitted directly in our factory. These modules only need to be screwed together on site.

That's right. When stacked, these wall modules fit perfectly into a standard sea container, which enables simple and cost-optimized shipping. Rental containers with the equipment and the components of the tent hall are shipped from Germany and a European manufacturer. All elements for the tower are delivered directly from the manufacturer in seven containers. These are the other special features of OCTAPLANT^® - after unloading the OctaTower, they then become the aforementioned container building of the plant. The containers are reinforced from the inside at the tower's manufacturing plant so that they can reliably withstand wind speeds of up to 200 km/h and earthquake loads. These are important basic requirements for the generally coastal locations of the main target markets. Window, wall and door openings are also marked at our factory. In order to maintain the approval of the containers for particularly economical standard shipping, these openings must be cut out later on site.

The delivery of the system includes all the tools required for assembly as standard. In this way, we avoid expensive delays caused by missing or incompatible equipment and systems. In addition, the container building's seams are rainproof and its exterior painted on site.

The tent hall for shipping is erected in a very short time. This even allows the installation of a photovoltaic system. The equipment is then installed. Thanks to the “plug and play” design, numerous elements only need to be connected and can be put into operation immediately.

Essentially, the same features that enable fast production, economical shipping and reduced set-up time ensure that the system can be dismantled and reassembled easily. In addition to the high degree of prefabrication, ots compact design is particularly important. Once the machines have been secured, the OctaTower can simply be laid on its side and loaded onto a heavy-duty transporter or shipped by barge. This is made possible by the extremely small tower diameter of less than five meters. For example, we have moved the bucket elevators and filter systems to the outside. Even the foundations could be reused if the soil load-bearing conditions are right. We are also considering supplying prefabricated foundations in the near future and offering suitable steel formwork.

The “typical” location for OCTAPLANT^® is windy due to its practical proximity to the coast. In addition, earthquakes can occur under certain circumstances. Moreover, possible high temperatures must be taken into account. The light-colored outer shell should reflect the sun's rays as well as possible. In addition, we not only achieve the desired low-dust environment with the air flow from the packing machine's dust extraction system, which is guided through the container building in a controlled manner, but also measurable temperature regulation. The OctaTower and container building can also be sufficiently insulated for operation in colder climatic conditions.

The factors that ensure savings are actually multifaceted. It starts with the lower financing costs due to the minimized time to commissioning. Then there is the reduced need for steel and concrete and the extremely economical shipping.

Here’s a concrete example calculation: With a conventional plant, we assume around seven months from the start of construction to market launch. With OCTAPLANT^® this time is reduced to a good three and a half months. Next we assume a realistic operating time of eight hours a day, six days a week, an output of 100 tons per hour and a profit of around ten euros per ton. This results in a profit of around 672,000 euros. The plant mobility also allows new business to be generated with the existing resources at a new location in the event of serious market changes, and that turnover can be quickly generated again.

Despite the savings potential of OCTAPLANT^®, customers can rely on maximum output with high efficiency, as with all systems and equipment from HAVER & BOECKER. Particularly with regard to the space-optimized, relocatable design of OCTAPLANT^®, ease of operation and maintenance were at the forefront of development.

The packing machine level, for example, is optimally accessible. For access to the less frequented area of the screening machine, it made sense to move the stairs leading to it to the outside in order to save space. Thanks to our QUAT²RO^® SYSTEM INTELLIGENCE for controlling, monitoring and optimizing all processes, all workflows are networked and designed in the best possible way. Last but not least, HAVER & BOECKER guarantees effective support with its PROcheck life-cycle approach: from selecting the right equipment with exactly the right empty bags, to diagnosing and rectifying faults or inefficient processes, to offering original spare parts and a wide range of services.

OCTAPLANT^® is also impressive in terms of sustainability. First and foremost, it is reusable and equipped with high-quality, durable systems. Moreover, its space-saving design means less land and fewer resources are required. The space-optimized transport and its high degree of prefabrication also contribute to a reduced ecological footprint. Finally, the integration of our QUAT2RO^® products and the PROcheck life cycle approach also minimizes greenhouse gas emissions, energy consumption and the use of raw materials and materials during plant operation. This in turn improves the work conditions for people. HAVER & BOECKER takes its ecological and social responsibility very seriously - and OCTAPLANT^® meets the high standards in every respect.

A broad target group benefits from the many features and advantages of this new concept. Investors who want to exploit the growing cement industry potential are addressed just as much as cement manufacturers who want to open up new, attractive locations. In particular, companies that already operate grinding plants and want to further expand their business will find OCTAPLANT^® to be a flexible solution that can be implemented quickly and efficiently.

The engineering is complete and everything is ready. We can get straight to consulting and project planning and start production without any delays. This means that potential OCTAPLANT^® customers can benefit immediately from the special advantages and benefits of the new concept!

Please contact us if you would like to talk to us about this new concept. Our expert Guido Neu (+49 (0) 2522 / 30339 – g.neu@haverboecker.com ) will take the time to talk to you about your questions and plans.