Thorsten Koth, Sales Director at ScrapeTec Trading GmbH, discusses his company’s dust mitigation and conveyor control systems with Global Gypsum.
Global Gypsum (GG): Please could you introduce ScrapeTec?
Thorsten Koth (TK): ScrapeTec Trading was founded in 2016 by Wilfried Dünnwald and myself. My background is in sales, with 15-plus years in paper industry engineering. Wilfried had been involved in the mining sector for more than 30 years and, while he has formally retired, he remains ‘addicted’ to improving conveying technology. He has always looked for ‘smart ways to avoid stupid work.’ I convinced him that we should start a company together, rather than license his patents to other manufacturers, as he had done in the past.
GG: What are the company’s main products for the global cement sector?
TK: Since its founding, ScrapeTec has acted as the development base for Wilfried’s ideas, most notably the AirScrape. This is a system to reduce dust emissions at transfer points between conveyors. Traditional systems and covers mitigate dust emissions at transfer points by use of physical means, i.e.: they actually touch the belt.
However, belts run quickly and wear down, even if they are in contact with a relatively soft material like rubber. The wear soon leads to a gap between the belt and the cover. Dust can then escape once more, sometimes within a couple of weeks or even a few days after installation. At this point, gypsum producers will often simply accept the waste and health and safety effects as a ‘business as usual’ feature. Stopping the plant for maintenance or cleaning is just too costly.
The AirScrape, in contrast, is a dust mitigation technology for transfer points that does not touch the belt. It prevents dust formation, reduces material spill and enables thorough belt-cleaning at critical sections along the conveyor route and at transfer points. It does this via a highly-effective side seal that lies over the conveyor belt, without contact. It creates negative pressure on the belt due to its specially-designed lamellar structure. As the system hovers freely above the conveyor belt, skirt friction and belt damage are eliminated and the service life of every component of the conveyor is extended. Unlike conventional systems, it also works well with moist and sticky materials, like flue-gas desulphurisation (FGD) gypsum.
GG: How does ScrapeTec manufacture the AirScrape?
TK: The key components for all of our machines are designed and engineered by ScrapeTec, with a number of manufacturing partners that look after fabrication. They are located in Germany and the Czech Republic. There is some variation in design, with three main sizes: small, medium or large. If the belt overhang is small we use a smaller design, if the overhang is larger, we use a larger design. We ask the customer for the trough angle (0 - 45°) and the belt overhang (>60mm). The speed of the belt or the mass it is carrying are not important factors. As long as the air is flowing into the AirScrape from outside, there will be no emission of dust.
GG: How is the AirScrape system installed?
TK: ScrapeTec’s team will arrive on site and can typically install the AirScrape in around six hours. It is fitted above the belt and then turned on, along with the conveyor belt itself. After a period of operation, it is usually the case that the client is satisfied with the system. The AirScrape then remains in operation, with almost no attention required from the operator - It really does look after itself. Occasionally, there are queries from clients in the early stages once ScrapeTec’s staff have left the plant. These are usually easy to resolve and we are always happy to help, often via video call.
GG: Where are ScrapeTec’s main markets?
TK: As a German company, we began in the German market in the early days. However, we now have references around the rest of Europe, in North and South America, Africa, Asia and elsewhere, across a range of industries. Quite a lot of the growth actually took place during the first two years of the Covid-19 pandemic. We have made a lot of contacts from presenting at virtual conferences and seminars, including those of Global Gypsum. Today, we have references all over the global gypsum sector, from big players like Knauf to individual wallboard plants.
Other sectors that we serve include large mines, particularly in Chile, Peru, Brazil and Indonesia. These are particularly lucrative because of the sheer size of the installation. In a gypsum plant, we might be looking to use the AirScrape system over an 8m section of conveyor belt. In the large mines the distance could be 120m or more.
We are also active in many other sectors: anywhere that powders are transported on conveyor belts, there is an opportunity to use our technology, from cement to coffee, salt and sugar to fertilisers, paints and pharmaceuticals.
GG: So is gypsum becoming a smaller piece of the overall sales pie for ScrapeTec?
TK: That’s not really the case, as we are growing rapidly in a number of sectors. They are growing roughly in proportion to each other.
GG: What kind of return on investment does the AirScrape system offer?
TK: The initial outlay for the AirScrape system is higher than traditional approaches. It costs around Euro400 to cover a 1m section, compared to Euro80/m. Despite this, the payback, in terms of material kept in the process and reduced downtime and cleaning, ensures that most systems pay themselves back within 5 - 6 months. We’ve even had reports of payback times less than a month in some cases. There are numerous advantages aside from this. There is no more dust, no more spillage. This means that there is no need for cleaning and maintenance, allowing more time and money to be spent on other projects. The lifetime of the equipment is prolonged. For all of these reasons, AirScrape is a sustainable solution.
GG: What is the next thing in line for ScrapeTec?
TK: We have launched our PrimeTracker system, which is a system to ensure the correct position of belts. This one works totally differently to conventional trackers and is completely flexible. It reacts directly, without friction and wear. It is easy to install and works in both directions. We are also about to launch a monitoring system that reports the condition of the belt to the user. If the belt is, for example, off-centre, there may be something wrong with the rollers, the vulcanisation of the belt, or the position of material on the belt. The PrimeTracker monitoring system will alert the operator to such events and allow them to take appropriate action, before any damage can be done.
ScrapeTec also manufactures the DustScrape and TailScrape systems, both of which complement the AirScrape system. The DustScrape is used in production areas that have particularly high dust generation. Support arches can easily be mounted to an existing AirScrape installation. A close-meshed, anti-static and resistant plastic fabric is then applied to it, retaining the dust in the belt area. This significantly reduces health and safety risks from dust.
The TailScrape acts as an extension to the AirScrape at the end of the conveyor. It is shortened to the distance between the two AirScrapes mounted on the side and tailored to fit the trough. The TailScrape is fixed and adjusted to the sheet by means of slotted holes and lifting elements, with a gap and no contact with the belt.
GG: What are ScrapeTec’s overall growth aims for the next five years?
TK: The most important aim for ScrapeTec, as in the past, is to identify and work with the right installation partners in overseas markets. This will be the fastest way to expand. After success of remote installations during the pandemic, we are developing the capability to advise installers via video link in real time, while also developing a range of ‘how to’ videos for installation and trouble-shooting.
In terms of markets for the coming years, there are two main areas for us; the big mines in South America, the US, Canada, China and so on, remain lucrative. However, there are other markets that we need to look at. Gypsum remains a high priority as a highly visible sector and one that presents a lot of challenges.
Overall, we are at an important point for the company. Growth will come with the right partnerships, with those that are committed to the technology. We have a range of very effective solutions to improve conveyor belt efficiency and safety across a range of industries. ScrapeTec looks forward to continuing its work in this area.
GG: Thank you for your time today Thorsten.
TK: Thank you too - It was great to chat!
