BEMA newsletter, March 2024

At BEMA, stagnation is not in our vocabulary. We aim to keep evolving and improving. One notable trend in recent years has been the steady increase in the size and complexity of our projects, compared to our basic products. We take pride in the fact that both new and loyal customers choose us when they need solutions designed and produced, whether it is a standalone project or intergraded into larger systems.

In this newsletter, we will share a couple of these larger projects we have been working on.

To ensure efficient handling of tasks and consistently meet customer demands, we utilize the Stockmaster inventory management system. This system automatically alerts our suppliers and internal production system when inventory levels are low, ensuring that we always have the necessary supplies available. Additionally, Stockmaster will now encompass parts that have worn down in our lathe department, which helps creating a more streamlined production with complete control over all processes.

However, our focus extends beyond inventory management and production efficiency. Ensuring floor safety is equally vital for maintaining a secure workplace and meeting the high standards our customers expect. As part of our commitment to safety, we have participated in a research project focused on workplace health and safety. Following a thorough assessment, we achieved a score of 75 out of 100 points. While this is quite high, we have further improved our score by an impressive +10% throughout the duration of the project.

Many know our Sales and Product Manager, Ronny Bæk, from meetings, customer visits, and trade fairs. He has just reached a significant milestone at BEMA A/S – his 10-year anniversary, but he thankfully aims for at least ten more. We are thrilled because Ronny is not only highly competent and well-liked but also a key driver in the ongoing development of project sales and custom solutions here at BEMA A/S. We congratulate Ronny on his ten years at BEMA!

We have recently completed the production of a large pressure vessel, also known as a boiler, for one of our clients. This boiler will serve as the core component in a larger project solution. While the client provided the boiler design, we at BEMA A/S have handled the complete manufacturing process in accordance with all specifications and test requirements.

A crucial aspect of this project was third-party testing of welds and pressure equipment. Non-Destructive Testing (NDT) was conducted on all welds, and Pressure Equipment Directive (PED) tests were performed on the boiler’s pressure equipment. External certification serves as an additional assurance for the client, confirming that the work has been carried out to meet all requirements and specifications in the field. We went the extra mile by testing the boiler up to 24 bars, surpassing the minimum requirement of 18 bars.

For one of our clients abroad in the energy sector, we have produced no less than 14 conveyors with a diameter of 500 mm and 2 conveyors with a diameter of 600 mm. They are part of a large system for biogas production. The transportation screw conveyors vary in length – the shortest being 6,000 mm and the longest 13,600 mm. These conveyors transport the residual product from the biogas production across multiple levels to a final storage with six silos. From here, the farmer can retrieve the residual product, which is used as fertiliser.

The complete transportation screw system is designed to go around several pillars, along different floor levels, a staircase and in connection with walking decks, among other places. The system is divided into two parts, each with three storage silos, where our transportation also includes mixing screws, ensuring that the residual product is similar and can be immediately returned to the fields as fertiliser.

It has been a demanding design task, but the result is 16 custom-made screw conveyors that can be easily installed on site.

We have delivered screw flights to the other side of the world – 8975 km away, to be exact. Distance is not an obstacle for us, since we have recently dispatched a series of individually tailored crafted screw flight conveyors to a client in Honduras. This addition further enriches our already substantial international clientele.

The screw flights have been crafted from Hardox 450 and stainless steel 1.4301/AISI-304 and made with cut offs on the outer diameter. This requires a special design, showcasing our ability to tackle any winding challenge — even when the client is located on the opposite side of the globe.

In any BEMA transport solution, the most crucial component is the screw flights. For a screw rotor to fulfill its purpose, endure many hours of work, and require minimal maintenance, then the screw flight has to be precisely and perfectly crafted.

We have extensive experience in producing screw flights, covering all aspects from dimensioning to calculating pitch, thickness, inner diameter, and outer measurements. Our screw flights are manufactured through cold pressing, which guarantees optimal durability and strength. Even though it may sound simple, trust us, it is not that simple!

Our engineering department specialises in designing custom screw flights of any configuration, which gets tailored to fit the specific screw rotor. Precise screw flights save countless hours of adjustments during fabrication—and reduces costs! Therefore, we continuously strive to enhance our screw flight production to ensure they seamlessly fit when welded onto the core tube.

One of our specialties includes large screw flights measuring up to approximately a diameter of 2500 mm in Hardox and other abrasion resistant steel types. Here, we utilise sandwich plates that meet the demands of particularly abrasive applications. However, we also cater to smaller requirements if that is what you desire!

BEMA newsletter, December 2023

Thanks to the excellent cooperation with our numerous customers, at BEMA, we can look back on 2023 as a year where most of our business areas were in full swing. We have delivered many exciting projects in the auger transport of various materials. The rapid development of the recycling industry can also be seen at many of our customers’ sites. We are delivering increasingly more projects and transport solutions that are used for recycling customers’ materials or production waste, and we are also seeing increased demand for complete solutions for this. Thank you for the great cooperation in 2023!

This year’s trade show tour has now come to a close. Once again, many visitors stopped by our stands, and we held productive discussions about their needs and the possible solutions. In 2024, you will also see us at the most important trade fairs in the industry – it is going to be an exciting year too!

Like most companies, we have launched a number of initiatives to become a greener company and to achieve a smaller carbon footprint. We have installed solar cells on the roofs of our halls and they help cover as much of our daily electricity consumption as possible. However, now we also want to connect electric car charging stations to our solar panels. We are continuously replacing our fossil-fuelled cars with electric cars for our sales staff, and the first ones will soon be rolling out of the parking lot – charged with electricity we produce ourselves.

This summer, two apprentices passed their exams to become stainless steel mechanics. We have already signed four new apprenticeship contracts and we are in the process of signing another adult apprenticeship agreement. We would like to help train professionals for the industry and thereby help retain highly professional – not to mention exciting! – jobs.

We have delivered a true workhorse for the transport of plastic waste for use in the further processes of one of our customers. The solution consists of two 7,000 mm long rotors (Ø400) mounted in a steel housing. It is painted in the customer-specific RAL color. The auger flights are designed to pack down the transported material, thus making it more uniform for further processing.

To make the installation and maintenance as simple as possible, the rotor is made in two parts, and the solution is designed in a way to minimise ongoing service and maintenance beyond the natural replacement of wearing parts.

We have assisted the customer with capacity calculations for different rotor speeds in order to match the customer’s needs exactly. This is a great example of how we can leverage our engineering department to ensure the optimal design for a specific need. BEMA has the in-house capacity to assist with all the relevant engineering calculations when it comes to designing auger solutions and material transportation.

For one of our loyal customers, we have just installed a 9,000 mm auger, Ø350, which is mounted in a cylindrical housing that is 2/3 full of water when in working mode. The auger transports material mixed with water. In the top 1/3 of the housing, which is not water-filled, the water is drained off. The material then moves on to the processing stage. The auger system is made of 1.4404/AISI 316L stainless steel with an acid-resistant surface.

We developed the complete solution design together with the customer. They greatly benefitted from the fact that we have a full in-house engineering department and can perform all the calculations and drawings required.

Because we know our customer so well, we were able to design and manufacture all the components according to the location, making the installation work as efficient as possible.

The bottom of the auger housing has a plastic coating to provide the best possible support for the shaftless screw conveyor. In addition, we provided a walkway around the plant and equipped it with channels that guide the material to the inlet of the auger.

The end of the year is approaching, but before we start 2024, let’s enjoy Christmas and some nice days off until the New Year. At BEMA, we’re busy getting the last items finished and out the door before the holidays. We’re looking forward to keeping up the fast pace in 2024 and assisting you with exciting solutions and products that can best meet your individual needs.

We wish you all a Merry Christmas and a Happy New Year!

Holidays – closed days

BEMA A/S will be closed from 23 December 2023 to 1 January 2023, both days included. The last date for pickup is Wednesday, 20 December 2023 if the goods are meant to be shipped before the holidays.

At BEMA, we have 75 years of experience in the manufacture of all types of screw flights. It is a field that requires extensive knowledge, a sense of high quality and the utmost care in production.

Our construction department manufactures special flights which are made to fit the given auger rotor. The precision of our flights will save many hours of workshop adjustment during manufacture, thereby highly reducing costs!

That is why we are constantly working to further improve our manufacture of screw flights – to ensure an optimal fit when they are welded to the core housing.

One of our specialties is large flights of up to approx. Ø2500 in Hardox and other types of hardened steel. These are sandwich panels which are able to meet the requirements of particularly abrasive applications. At the other end of the spectrum, we sell small flights which are designed to solve specific tasks.

BEMA newsletter, June 2023

Summer vacation is approaching, but BEMA is still going strong. We just launched another exciting initiative – solar panels on the roofs of our production halls! Once they have been fully installed in mid-June, they will be able to cover our entire energy consumption when the season is right. This is yet another step along the green path we want to follow.

There are several advantages to producing our own electricity:

• We will emit less CO2
• Strengthening of our overall environmental profile
• We will become less sensitive to fluctuations in the electricity price

Furthermore, we expect that in the coming years, there will be increasing demands for industrial companies to establish green energy solutions. As a preparatory measure, it makes sense to utilize the space already at our disposal. This also makes the overall solution relatively cost-neutral over a period of five to seven years. All this is a benefit to us as well as our customers.

The solar panels are another element in our efforts concerning energy and the green transition. Previously, we replaced all our light fixtures with LED lighting, both in production and administration. This alone resulted in a significant decrease in our power consumption.

We also believe that the green transition should look good and be seen in our everyday life. It is not just about energy and savings. That is why we have planted 60 fruit trees and 70 fruit bushes in front of the administration building. Hopefully, they will attract bees and other insects, providing food for wild birds. Our employees can also get an extra dose of vitamins by grabbing an apple or a handful of berries during their lunch break. And lastly, we are sowing a variety of wildflower seeds along the production halls, which will contribute to increased biodiversity. It will also be a pretty sight, instead of the usual grass.

We have manufactured a special trough conveyor for one of our customers with special sidewalls that fit perfectly into their process plant.

As the trough conveyor is meant to transport abrasive materials, it was made of stainless steel EN1.4401 combined with 1.4462 duplex steel. The same applies to the housing, ensuring the most durable and cost-effective solution with minimal maintenance required.

The trough conveyor is yet another example of how, at BEMA, we work with our customers to develop solutions that combine design and manufacturing in the best possible way.

We have entered into an agreement with one of our customers for the series production of a large number of high-end screw rotors in stainless steel. This is a great example of how we develop projects together with our customers and tailor our production accordingly. As a result, there is a high demand for consistency and precision with these screw rotors. We have established a complete production setup for the task, including specific and precise measuring equipment to ensure high quality throughout.

The screw rotors are manufactured in stainless steel, EN1.4301, AISI-304, and are designed with double threads, requiring precise manufacturing of the screw flights.

Here at BEMA, we have 75 years of experience in the manufacture of screw flights and rotors, and we know the meaning of accuracy and precision when it comes to dimensions, pitch, thickness, inner diameter and overall measurements. We are the market leader of screw rotors for any purpose.

We are happy to take on specialized tasks because our expertise and long experience set us apart from other manufacturers.

Our setup for this particular customer is a prime example of our agile approach to customer projects. We are willing to alter parts of our organization to meet their requirements and specifications, leading to yet another satisfied and loyal customer.

Kim Jørgensen, our most experienced screw flight manufacturer, is celebrating his 40th! anniversary in August. We look forward to celebrating Kim when we return from vacation. Kim was hired on August 18, 1983, by the former owner of BEMA. He was told never to start work on a Monday, as that would just get him fired, which is why he started on August 18, which was, in fact, a Tuesday. Kim makes an average of 200 flights per day, which means that he has made no less than 1,600,000 flights over the 40 years he’s worked for BEMA – that’s quite a lot!

We are dedicated to bringing new, young people into our exciting profession! This year, we have signed four new blacksmith apprentices. Two have already started work, and the other two will start in August. We are excited to give them a solid foundation for their future careers.

In addition, we have two apprentices who will complete their training in July this year, and two more in 2024 and 2025.

It takes four years to become a qualified blacksmith. You have to complete a diverse and varied program involving theory, apprenticeships and schooling.

Everyone at BEMA would like to wish you a great summer and a wonderful vacation when the time comes. The period leading up to the holidays is often particularly busy as everything needs to be in order, but it’s all the more satisfying to be able to relax and enjoy some time off with family and friends.

We will be closed during weeks 29 and 30 (from Friday 14.07 to Monday 31.07).

If you need wear parts or anything else before the holidays, we will be taking and processing orders until Monday 10.07.

BEMA nyhedsbrev, december 2022

Vi nærmer os slutningen af 2022, og vi vil alle her hos BEMA A/S gerne ønske jer en rigtig glædelig jul og et godt nytår – og sige jer tak for et spændende år, som har været præget af høj aktivitet. Nu ser vi ind i 2023, der som alle andre nye år vil rumme mange udfordringer, glæder og nye samarbejdsmuligheder. Vi ser frem til fortsat at udvikle løsninger og projekter sammen med nye og gamle kunder.

Efteråret har været travlt med flere messer. Vi elsker denne værdifulde måde at kunne møde vores kunder på, præsentere produkter og skabe dialog. Tak til alle jer, der mødte os på Foodtech, Ajour og Elmia!

Sammen med en af vores kunder har vi skabt en løsning til transport af affald fra mineraluldsproduktion. De i alt 15 snegle med tilhørende trug er specielt designet til en større fabriksombygning. BEMA har stået for konstruktion og fremstilling på baggrund af et overordnet designlayout.

Løsningen er et godt eksempel på, at vi kan hjælpe med at udarbejde et designlayout, hvis der er udfordringer med dette. Vi har måleudstyr, så vi kan foretage præcise opmålinger og tilpasse endog store og komplicerede løsninger til afgrænset plads. Særligt vil vi fremhæve vores 3D scanningskamera, hvor vi kan skabe en komplet model af området, hvor sneglen skal opsættes. Modellen sikrer, at sneglene ikke kommer i konflikt med eksisterende udstyr i området.

BEMAs produkter indgår ofte i en længere værdikæde med vores specialkompetencer. For eksempel har vi netop designet et sæt specialvindinger i DUPLEX stål, som er monteret på en rotorstamme, som kunden har leveret til os. BEMA’s opgave har været at konstruere sneglevindingerne, således de passer til kundetegningen.

Efter at vi har fremstillet vindingerne, har vi monteret dem på rotorstammen. Herefter returneres de til kunden, som selv forestår den videre bearbejdning til slutproduktet.

BEMA A/S leverer i lige så høj grad løse vindingskomponenter, som vi leverer komplette, færdige rotorer. De indgår i kunders egne maskiner eller systemer, alt efter det behov, som den enkelte kunde har. I et tilfælde som dette er der tale om et større, fælles samarbejde med kunden, som selv har udarbejdet alle rotorstammerne. Herpå monterer vi så de specialdesignede vindinger, som vi producerer her hos BEMA A/S.

BEMA leverer totalløsninger – men er også en stærk leverandør af komponenter af alle slags. Vi har høstet lang erfaring med sneglerotorer og vindinger og forestår alle processer fra design til færdigt produkt, så vi på den måde kan sikre det endelige resultat.

Et af vore specialer er store vindinger på op til ca. Ø2500 i Hardox og andre slidstålstyper. Vi arbejder her med sandwichplader, som opfylder kravene til særligt slidende applikationer.

Vores konstruktionsafdeling konstruerer specialvindinger i enhver udformning, som tilpasses den givne sneglerotor. Præcise vindinger sparer mange timers værkstedstilpasning under fremstillingen – og mindsker dermed omkostningerne! Derfor arbejder vi hele tiden på at forbedre vores produktion af vindinger, så de passer optimalt, når de skal svejses på kernerøret.

Vi påtager os også større projekter, hvor vi bistår med at designlayoute et helt transportsystem, som kan indeholde mange transportsnegle i flere forskellige størrelser, alt efter behov. På den måde kan vi rykke tættere på kunderne som totalleverandør af transportløsninger til bulk- eller andre materialer.

Kontakt os med forespørgsler på:

• Rustfrit procesudstyr
• Sneglemaskiner
• Sneglerotorer
• Sneglevindinger

BEMA newsletter, December 2022

The end of 2022 is fast approaching, and everyone at BEMA A/S would like to take this opportunity to wish you a merry Christmas and a very happy New Year – and thank you for an interesting year marked by a high level of activity. We’re now looking to 2023 which, like all other new years, will present many challenges, delightful moments, and new opportunities for collaboration. We look forward to continuing to develop solutions and projects together with both new and long-standing customers.

The autumn has been a busy period, as we took part in several trade fairs. We value meeting our customers in this way, presenting products, and starting a dialogue. We’d like to thank everyone who came to see us at Foodtech, Ajour, and Elmia.

Our factory is busy completing the last projects for 2022. Everybody is working hard to dispatch the last customer orders, be they large or small, special solutions or standard stock components. However, no fun makes Jack a dull boy, as the saying goes, and this year, we’ve put up Christmas socks, resulting in many fine and fun presents from Father Christmas in December…

Together with a customer, we have created a solution for conveying waste from a mineralwool production line. The total of fifteen screw conveyors with accompanying troughs are specially designed for a major factory renovation. BEMA did the construction and manufacture on the basis of an overall design layout.

The solution proves that we can assist with preparing a design layout, if this presents a problem. We have measuring equipment enabling us to make exact measurements and adapting even large-scale and complex solutions to a limited space. As a special feature, we’d like to highlight our 3D scanning camera, which we use to make a full-scale model of the area where the conveyor will be installed. The model ensures that the conveyors will not clash with existing equipment in the area.

BEMA’s products often form part of a lengthy value chain along with our special competences. To give you an example, we’ve just designed a set of special screw flights in DUPLEX steel, mounted on a rotor shaft supplied by the customer. BEMA’s task was to construct the screw flights to match the customer’s specifications.

After producing the screw flights, we mounted them on the rotor shaft before returning it to the customer, who will handle the further processing required for their end product themselves.

BEMA A/S supplies separate screw flight components as often as we supply complete rotors. They form part of the customer’s own machines or systems to suit the needs of individual customers. A case like this one is based on major collaborative work with the customer, who have produced the rotor shafts themselves. We then mount the specially designed screw flights produced here at BEMA A/S.

BEMA supply total solutions – but we are also a proven supplier of all kinds of components. We have time-honoured experience of screw rotors and screw flights and we manage all the processes from design to finished product, which means that we can vouch for the final result.

One of our key competences is large screw flights measuring up to approx. Ø2500 in Hardox and other wear-resistant steel types. These are made from sandwich sheets that meet the requirements for applications sustaining heavy wear.

Our construction department makes specialised screw flights in all designs, which are then adapted to a given screw rotor. Exact flights save many workshop hours spent on adaptations during production – thus reducing costs! We are therefore constantly striving to improve our production of screw flights to ensure their correct dimension before welding them onto the shaft.

We also accept major projects where we assist with designing a layout for a complete conveyor system, which could include several screw conveyors in several different sizes according to requirements. In this way, we can match our customers’ needs as total suppliers of conveyor solutions for bulk or other materials.

Contact us for enquiries about:

• Stainless-steel process equipment
• Screw conveyors
• Screw rotors
• Screw flights

BEMA newsletter, October 2022

Hope to see you at the trade fairs this autumn!

The autumn trade fair season is here, and we’ll take part in the following three:

Foodtech in Herning
1.-3. November 2022

Elmia Subcontractor in Sweden
15.-17. November 2022

Ajour in Odense
24.-25. November 2022

These are three trade fairs covering most of our business activities, and we hope to see both new and existing customers.

Meanwhile, we’d like to mention some of the exciting projects, we’ve been working on. Covering a wide area from supplying tanks to developing a complex solution for an ACTA bale opener.

There are tough requirements for the equipment used in the drinking-water industry. The processing work must be second to none and the materials must meet the high hygiene standards essential when supplying clean drinking water to consumers.

We’ve produced four stainless-steel tanks for the water industry, and we’re proud of this total delivery of process equipment to an industry sector requiring such high-level standards. The tanks were produced to customer specifications and non-destructive testing (NDT) work was carried out by a specialist partner. This was a unique construction requiring, amongst much else, a solid work effort by our certified welders.

The recycling industry is expanding. Enormous quantities of PET bottles are being collected and converted into new plastic products, thus reducing the problems of waste in the natural environment and our consumption of natural resources. This requires specialised handling equipment, and BEMA has just supplied a full solution comprising a six-screw ACTA bale opener and a specially constructed conveyor system to continuously feed this powerful machine. The solution means that our – highly satisfied – customer has doubled their factory capacity.

The conveyor system consists of an almost fourteen-metre-long chain-driven metal-slat conveyor belt, extending upwards from floor level and dropping the compressed bales from a height of 4.2 metres into the ACTA infeed. Each bale measures 1,200 mm x 1,200 mm and weighs 450–600 kg.

The six-screw ACTA is an unbelievably powerful machine. Since the bale opener doesn’t use knives, the PET bottles are not broken or shredded in the process of opening the highly compressed bales. This is one of the prime advantages of an ACTA bale opener and means that the further sorting, washing, etc., of PET bottles will be simpler and more efficient.

It takes a powerful and sturdy machine to handle the compressed bales. The screws in an ACTA bale opener are linked via gears in a motorised set-up, which means that each screw is capable of operating with a torque level of almost 15,000 Nm to prise open the bales.

The machine is operated from a fully PLC-programmed control cabinet also constructed and supplied by BEMA.

The total solution is designed and produced by BEMA and had to be transported in two tightly packed forty-foot containers. We’re very proud of this turn key project, which significantly consolidates our reputation for efficient project management and our status as an entrusted supplier.

BEMA supplies total solutions – and is a reliable supplier of all types of components. With longstanding experience of screw rotors and flights, BEMA handles all processes from design to finished product, ensuring an optimal final result.

We supply a large assortment of flights. Moreover, our skilled technicians and production staff are always ready to produce specialised flights to suit your specific system.

Large flights of up to approx. Ø2500 in Hardox and other wear and abrasion resistant steel types are among our specialities. We use sandwich sheets which meet the requirements for applications requiring particularly tough wear resistance.

Our construction department makes specialised flights in any design adapted to specific screw rotors. Precision flights save many hours of workshop adaptation during the production process – thus reducing costs! We therefore work tirelessly to improve our flight production so that they will fit perfectly when welded onto the core barrel.

We produce rotors to order as well as stock. We supply identical rotors on a continual basis, and as all production data are updated on a current basis, you will always get a uniform product.

Contact us for enquiries about:

• Stainless-steel process equipment
• Screw conveyors
• Screw rotors
• Screw flights