In the course of growth and expansion to four different locations, Bropack Bronner Packmittel GmbH decided to build a new headquarters. Together with WEIMA Maschinenbau GmbH (WLK 1500), Steiner GmbH, Nolting Holzfeuerungstechnik GmbH and Mühlböck Holztrocknungsanlagen, an innovative system was designed for an in-house drying and heating system. The new building brought Bropack considerable progress in terms of climate impact and heat self-sufficiency.
History
Bropack Bronner Packmittel GmbH (founded in 1863 by Matthias Bronner) is now managed by the sixth generation of the Bronner family, Andreas Bronner. In 1963, the company expanded into the production of crates and pallets. This marked the beginning of its activities in the packaging industry, with the materials coming from the remains of sawn timber production. In 1993, Klaus Bronner established the wooden packaging production as an independent division, known as Bropack Bronner Packmittel.
Bropack Bronner Packmittel GmbH
The product portfolio includes transport bases, folding crates, crates for shipping, reusable packaging and individual special packaging. The company is focusing more strongly on specialized markets. Bropack relies on in-depth specialist knowledge, the skills of its employees, modern IT systems and high-performance machines to maintain its position in the market. The materials are cut automatically and, depending on requirements, either to maximize output or yield.
Existing and cost-effective fuel resources
In order to be able to design as many processes as possible autonomously, the company has its own drying plant at the new site in addition to a photovoltaic system. The sawn timber delivered is first taken to the drying chamber to be dried to a moisture content of 18 to 21% before being stored and further processed. The decision to dry the timber in-house was made not only because of the flexibility and greater independence, but also because of the available, cost-effective fuel resources (disposable pallets, packaging and waste wood from production).
Wood pallets and waste wood shredding with WEIMA shredder @Bropack
Reliable shredding technology from WEIMA for smart fuel handling
Damaged disposable pallets, packaging and residual wood from production are shredded by a WEIMA shredder. To empty the containers filled with wood waste, Bropack uses a special tipping device. This makes it possible to load the waste wood directly into the hopper of the shredder using a conventional forklift truck.
The WLK 1500 single-shaft shredder from WEIMA is designed for large quantities and a wide variety of wood waste, from small offcuts to entire disposable pallets. Its rotor, with a length of 1,500 mm, a diameter of 370 mm and 123 reversible cutting blades, works against a counter blade, whereby the cutting gap can be adjusted according to wear. The shredder has a maximum output of 90 kW, but adapts to the current power requirement, which is continuously monitored. At Bropack, the chip sizes are determined based on the requirements of the smaller Nolting boiler. The current edge length is between 20 and 25 mm.
"For complicated wood materials, such as bulky pieces, the chipper can reverse its direction to reposition the wood above the rotor. The size of the wood chips produced can be varied by simply changing screens."
Fred Haller, Sales Director at WEIMA
Learn more:
The WLK 1500
Individually designed support system
The transport system to the storage bunker was designed and provided by Steiner GmbH. At Bropack, the wood chips are picked up from the shredder by a horizontal screw conveyor. A vertical spiral then transports the material to a magnetic separator with a capacity of 60 m3/h to safely remove metallic components. These are collected in a separate container and sold on as scrap metal. The screw conveyor can change direction, which means that the wood chips are either stored in the bunker or diverted into a container for sale. The wood chips reach the bunker, which can be filled up to a height of 5 m, via another vertical conveyor spiral.
The transport system to the storage bunker
In total, Steiner's transport system extends over more than 30 m. Due to the high filling capacity and the resulting load, particularly stable bunker discharge systems were selected, one for each boiler, with reinforced drives. These systems are supplied by the boiler manufacturer Nolting and have a diameter of 5.5 meters. They are installed horizontally on a raised floor and lead directly to the boiler sluice.
Boiler technology boosts heat self-sufficiency at Bropack
The Nolting “LCS-RU 400/450” boiler has a rated output of 450 kW and, thanks to a 38,000 liter buffer storage tank, can meet the variable heat requirements of a double drying chamber. It has an “NWT 350” flue gas heat exchanger, which meets the efficiency requirements of the Bata subsidy program. The reference fuel consists of approximately 50% solid wood and 50% plywood/OSB, with specified water contents and grain sizes. Both boilers have automatic ignition, modulating control and remote access. The boiler supplies the heat for the drying chambers and also heats the new offices in the administration building.
The Nolting "LCS-RU 400/450" boiler
Recovering heat with Mühlböck wood dryers
The choice for wood drying fell on double chambers for more efficient drying, whereby the need for thermal energy is highest in the initial phase and decreases as drying progresses. The two drying chambers are equipped with heat recovery for fuel-saving operation. An installed dryer (1306 Pro) is suitable for different types of wood and also enables IPPC treatment. To ensure uniform drying, the flow direction of the drying air is changed regularly, which reduces heat losses.
Open drying chamber
The implementation of the new headquarters together with the respective specialists shows how sustainable and efficient processes can be successfully realized through innovative approaches and good cooperation. WEIMA is proud to have made a valuable contribution to the success of this project with the WLK 1500 shredder.
The success story was created in friendly cooperation with the Holz-Zentrallblatt.
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