Time:2025-12-22 17:48:04 Number of Clicks:
An open-air port overseas required transferring palm kernel shells and palm kernel meal from stockyards to ocean-going cargo ships. Previously, it adopted a transportation method combining fixed shiploaders with manual auxiliary feeding via grab buckets. This method had problems such as uneven feeding leading to equipment blockages, lack of enclosed dust removal structures resulting in excessive dust emissions, and poor flexibility and adaptability of fixed equipment. The operating efficiency was far below the requirement of 3,000 tons per hour. To address these pain points, ZOOMRY customized a collaborative solution of mobile shiploader and hopper feeder, achieving efficient and compliant transportation.
Targeting the core needs of the open-air port, ZOOMRY built an integrated bulk material handling system of "hopper feeder + mobile shiploader" based on the design concept of "precise connection, efficient conveying, environmental compliance, stability, and reliability." Through seamless collaboration between precise feeding at the front end and efficient loading at the back end, the whole-process optimized transportation of palm kernel shells/palm kernel meal is realized.
For the hopper feeder selection, ZOOMRY chose a heavy-duty crawler-type hopper feeder specially designed for high-capacity bulk material handling. The hopper capacity is customized to 24m³, perfectly matching the feeding efficiency of front-end loaders and grab bucket cranes to avoid frequent feeding interruptions. The conveying system adopts a wear-resistant chain plate structure. Aiming at the caking tendency of palm kernel meal, a dedicated material agitator and 60° inclined anti-blocking side walls are installed inside the hopper, effectively preventing material bridging and caking blockages, and ensuring uniform and continuous material conveying. Meanwhile, the hopper is equipped with a closed dust cover and pulse dust collector, combined with rubber sealing skirts at the bottom, controlling dust emission within the limits allowed by international environmental standards and solving the pain point of lightweight palm kernel shell dust from the source.
The power system adopts a hybrid mode, which not only meets the flexible operation needs in scenarios without power supply but also complies with EU Stage V international emission standards. The energy consumption is 20%-25% lower than that of traditional diesel models, showing significant advantages in long-term operating costs. The chassis adopts a crawler-type design with a large ground contact area, which can easily adapt to the soft or uneven ground environment of open-air ports. It also has a hydraulic leveling function to ensure the equipment maintains a stable operating posture under complex terrain. The electrical system is equipped with a PLC intelligent control system, supporting frequency conversion and speed regulation. It can accurately match the conveying volume according to the operating rhythm of the back-end shiploader, achieving a stable output of 3,500 tons per hour. At the same time, it has functions such as blockage alarm, emergency stop protection, and remote control, supporting unattended operation and greatly reducing manual intervention.
The mobile shiploader selects ZOOMRY's ZRSL series high-capacity model, which is specially designed for port bulk material loading. The belt width reaches 1600mm, and the maximum conveying speed is 4.0m/s, forming a perfect capacity match with the hopper feeder to ensure a continuous loading efficiency of 3,500 tons per hour. The equipment adopts a fully hydraulically driven wheeled chassis, with multiple functions such as radial rotation, telescoping, and luffing. The maximum radial rotation angle can reach 110°, which is more flexible than the 70° rotation angle of traditional belt conveyors. It can adapt to the loading needs of various tonnage ships such as barges, handy-size ships, and Panamax ships, without the need for frequent ship position adjustments, greatly improving operating efficiency.
The telescopic boom design allows the effective operating length of the equipment to be flexibly adjusted within the range of 30-60 meters. Combined with the optimized design of +28% super large stacking capacity, it realizes efficient material stacking and loading in the limited port space. Meanwhile, the equipment adopts a closed conveying structure, combined with a head scraper cleaning device and a tail dust cover, further reducing dust pollution and material loss during palm kernel shell transportation and ensuring the material quality is not affected. To adapt to the salt spray erosion environment of open-air ports, the main structure of the equipment is made of high-grade carbon steel, with anti-corrosion coating on the surface. Key components such as idlers and rollers have undergone special anti-corrosion treatment, with a service life of more than 50,000 hours, greatly reducing the maintenance frequency in open-air environments.
The core advantage of the entire solution lies in the seamless collaboration between the hopper feeder and the mobile shiploader, forming a full-process closed loop of "feeding - conveying - loading." The front-end hopper feeder directly accepts palm kernel shells/palm kernel meal unloaded by grab bucket cranes from ships or stockyards. After crushing and homogenizing the materials through the agitator and anti-blocking device, they are smoothly conveyed to the feed inlet of the mobile shiploader. According to the distribution of ship holds, the mobile shiploader accurately conveys materials to each cabin of the ship through radial rotation and telescopic adjustment of the operating position, realizing uniform loading.
The PLC centralized control system equipped with the system can realize the linked operation of the two devices. The conveying speed of the hopper feeder is automatically adjusted according to the loading progress of the mobile shiploader, avoiding material accumulation or insufficient supply. Meanwhile, the remote control function of the mobile shiploader allows operators to complete all operating actions in the safe area on the shore, including emergency shutdown, telescopic boom adjustment, radial movement, inclination adjustment, etc., which not only improves operational safety but also reduces labor intensity.
The modular design of the equipment makes on-site installation extremely convenient. Most components are pre-assembled in the factory, and on-site commissioning can be completed in 10-20 days for put into use, greatly shortening the project commissioning cycle. At the same time, the equipment can be disassembled and transported in 40"HQ containers, reducing international transportation costs and perfectly adapting to the deployment needs of overseas projects.
The wear-resistant chain plate conveying structure of ZOOMRY's heavy-duty crawler-type hopper feeder adopts 6mm hardened steel liners, with wear resistance 30% higher than that of ordinary equipment, which can effectively resist the wear of conveying components by impurities in palm kernel shells. The material agitator adopts an elastic drive design, which crushes caked materials while avoiding material deterioration caused by excessive extrusion, ensuring the product integrity of palm kernel shells/palm kernel meal.
The electrical system of the equipment reaches IP65 protection level, with excellent dust and water resistance, fully adapting to the harsh environment of open-air ports. The centralized lubrication system and large-size access door design enable equipment maintenance without complex disassembly, reducing maintenance time by 40% and further improving the effective operating time of the equipment. In addition, this model complies with international industry standards such as CEMA and AS, and has passed international certifications such as CE and EAC, which can seamlessly adapt to the industrial compliance requirements of different regions around the world, providing a reliable guarantee for the port's cross-border transportation business.
The grid frame structure adopted by the ZRSL series mobile shiploader greatly reduces the self-weight while ensuring the strength of the fuselage, with a strength-to-weight ratio reaching the industry-leading level. Combined with the chassis made of high-grade carbon steel, it can resist wind loads and vibrations in open-air environments, ensuring long-term stable operation.
The hydraulic winch system is equipped with an automatic locking mechanism. Even in the event of sudden power failure or steel rope breakage, the telescopic boom can achieve self-locking within 0.01 seconds, avoiding equipment damage or material scattering. The safety performance meets international industrial safety standards. The design of inspection walkways on both sides makes equipment maintenance operations more convenient and safe, further reducing operation and maintenance risks. In addition, the optional crawler-type tail structure of the equipment greatly improves its mobility in the limited space of the port, enabling it to easily meet the loading needs of different berths and ships, with adaptability far exceeding that of traditional fixed loading equipment.
The idlers equipped on ZOOMRY's bulk material conveying equipment adopt high-precision processing technology. The idler runout is ≤0.4mm (better than the Chinese GB standard of 0.5mm), the axial displacement is <0.4mm, the rotational resistance is ≤2N, and the operating noise is as low as 40-45dB, which not only improves conveying efficiency but also reduces noise pollution in the open-air operating environment. The sealing performance meets the water seepage standard of less than 100g (better than the GB standard of 150g), effectively resisting port salt spray erosion, with a service life of more than 50,000 hours.
The rollers are made of 40Cr forged steel, with a shaft diameter of ≥159mm. They undergo CNC four-roll rounding processing and ultrasonic flaw detection. The ovality is <1.5mm. After welding, they are tempered to eliminate stress, ensuring no deformation or fracture risk under the high-load working condition of 3,500 tons per hour. The surface adopts a diamond rubber wrapping design to enhance friction with the belt and avoid slipping during material conveying.
After the solution was put into actual operation, it completely solved the core pain points of palm kernel shell/palm kernel meal transportation at the open-air port, achieving a triple breakthrough in efficiency, environmental protection, and cost, and winning high recognition from the customer.
In terms of operating efficiency, the entire system stably achieves the designed handling capacity of 3,500 tons per hour, operating continuously for 24 hours without failure. The maximum daily transportation volume can reach 72,000 tons, which is more than 50% higher than the port's original transportation mode. This greatly shortens the ship's stay time at the port and improves the port's berth turnover rate. The high mobility and flexible adjustment capability of the mobile shiploader reduce the average loading time of a single ship by 30%, and the operating efficiency far exceeds the customer's expectations.
In terms of environmental performance, through the collaborative effect of the closed design of the hopper feeder, the sealed conveying structure of the mobile shiploader, and the pulse dust collector, the dust emission concentration at the operating site is lower than the limit of international environmental standards, and the noise level is controlled within 45dB. This not only avoids material loss caused by lightweight palm kernel shell dust (the loss rate is reduced from the original 5% to less than 0.5%) but also meets the strict requirements of local environmental protection departments, realizing green port operations.
In terms of cost control, the automatic control system reduces on-site operators by 60%, significantly lowering labor costs. The equipment energy consumption is 20%-25% lower than that of traditional solutions, showing obvious advantages in long-term operating energy consumption costs. The long-life design of core components and the convenient maintenance structure reduce the annual equipment maintenance cost by 30%, and the maintenance cycle is extended to once every 6 months, greatly reducing operation and maintenance investment. In addition, the high mobility and adaptability of the equipment eliminate the need for large-scale civil engineering transformation of the port, saving huge infrastructure investment, and the investment payback period is 15% shorter than expected.
In terms of compliance and reliability, the entire set of equipment fully complies with international standards such as CE, EAC, and EU Stage V, successfully passing various inspections and certifications by local regulatory authorities, clearing the compliance obstacles for the port's cross-border bulk material transportation business. The equipment has withstood complex climatic tests such as wind, rain, and salt spray in open-air environments, still maintaining an equipment integrity rate of over 99% and continuous operation without major failures, fully verifying the international quality and environmental adaptability of ZOOMRY's products.
"ZOOMRY's mobile shiploader and hopper feeder solution has completely exceeded our expectations. The stable handling capacity of 3,500 tons per hour has achieved a qualitative leap in the efficiency of our port transportation. The ship turnover speed has been greatly improved, directly driving the growth of port throughput," said the port operation director. "More importantly, the equipment's performance in environmental protection is very outstanding. The dust and noise control fully comply with international standards, helping us successfully pass the strict review of local environmental protection departments."
Talking about the user experience of the equipment, the on-site operation and maintenance supervisor commented: "The equipment has a high degree of automation. The remote control and PLC automatic adjustment functions make the operation simple and efficient, greatly reducing manual input. The modular design and convenient maintenance structure make our daily operation and maintenance work much easier, and the downtime due to failures is almost negligible. ZOOMRY's technical support team responds quickly, providing full professional guidance from installation and commissioning to later operation and maintenance, fully reflecting the service strength of an international brand."
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