Rail Car

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Telestack Limited continues to excel in providing innovative mobile bulk material handling systems to its worldwide customer base. This has been emphasised in the manufacturing and development of a fully mobile systems for loading barges and rail wagons directly from trucks. Telestack’s mobile truck unloaders are designed for a range of applications, with operators greatly benefiting from eliminating the double handling of the bulk material by unloading directly from trucks to barges / rail wagons. These mobile solutions offer the performance both in loading rates and environmental qualities of a fixed installation with the added bonus of greater flexibility and mobility on existing berths, to eliminate the need for dedicated port/berth infrastructure or civil requirements.

Telestack’s complete range of truck unloaders

The range of Telestack truck unloaders is extensive, taking into consideration varying truck sizes, payloads, materials, cycle times, unloading rates etc, all customized to the needs of the particular client and operation. As with all Telestack products the mobility and flexibility of the units are the key features. The advantages of mobile systems are being recognized more and more in the industry, with port operators identifying the flexible mobile system as a viable option replacing expensive fixed installation which require civil work, planning permission and and (in some cases) an ineffective loading procedure for both barges and rail wagons. The advantage of moving the mobile truck unloader off the site when it is not required is of great importance, especially when the port is not owned by the operator or it is a multi-cargo berth.

Telestack’s mobile truck unloaders offer a range of mobility options for each individual requirement. The tracked mounted option, gives the operator unrivalled flexibility when moving around site, as this unit is completely independent of all other systems. There is a diesel engine to drive all functions, with an optional dual-power upgrade available which means the unit can be tracked into position and plug in the three-phase electrical supply to power the conveyor belts, this limits the diesel consumption of the units.

There is also an option of rubber track pads available which ensures the concrete / asphalt surfaces are not damaged from the tracks. The greater mobility of these units also ensures they can be used in other applications within in stockyards, mines and quarries if required, important for possible re-sale value if contracts are finished. There are also wheeled options available for a more basic unit which allow the operator or shipper to tow the unit around the site into each position. Telestack can also offer static version, depending on the specific needs of the client.

Typically, the range of truck unloaders can handle trucks up to 50 tonne payload (Tipping or Dump truck), the large hopper capacity increases cycle times which increases production rates. As there is such a wide range of trucks available in the market, Telestack can custom-design the hopper area to facilitate the most effective and efficient unloading area, including extended hopper sides, folding sides, flared design, dual access (increased cycle times), integrated fall break and many more. This ensures that the flow rate of each specific material and truck can be defined and taken into consideration during the design procedure. Also, the unloaders can be easily fed from wheel loaders and grab cranes for added flexibility. When handling dry bulk material, the dust suppression measures installed on the units ensure minimal dust emissions when unloading. Dust covers and telescopic discharge chute minimise dust emissions in the unloading area and discharge point.

All of the truck unloaders incorporate a heavy duty apron chain belt feeder, which ensures the surge of material discharging from the truck can be transferred and controlled onto the incline conveyor and barge / rail wagon or auxiliary equipment. Unlike other feeder conveyors which use rollers which would slip under the intense load in the hopper, the chain and sprocket driven belt, ensures there is no slippage and stalling of the feeder conveyor.

Mobile truck unloaders as part of mobile system

Telestack’s range of truck unloaders can also be used with Telestack range of radial telescopic ship / barge loading conveyors. The combination of the mobile truck unloader and the mobile radial telescopic shiploaders offer the ‘perfect’ loading operation directly from trucks to ship / barge. As seen in the picture below, the radial telescopic technology offers unrivalled trimming capabilities without moving the truck unloading equipment.

Rail wagon loading – the mobile option

The flexibility and mobility of the range of truck unloaders and hopper feeders allow for different perspective for loading rail wagons. For loading directly from trucks, the mobile truck unloaders ensure an efficient loading method while completely filling the wagons without moving the train. The radial boom conveyor of the TU 515R mobile truck unloader allows for the wagons to be loaded easily while moving the truck unloader parallel to the rail line. The radial feature enhances flexibility for the operator and allows for radial travel 60° left / right, so the unit can be used in range of applications, including bargeloading, stockpiling, feeding other Telestack equipment and many more. This unit can also be easily fed from wheel loaders, which allows for direct feeding from stockpiles on site, especially when trucks are not available or in between the truck cycle time for increased production capacities.

When loading rail wagons directly from wheel loaders, Telestack offer a range of mobile hopper feeders to allow the operator to feed and load the wagon at a controlled and safe manner. The tracked mounted mobile hopper has a 180° swivel boom conveyor which allows the unit to track parallel to the rail line while loading directly into the centre of the rail wagon. This is a much safer way to load the rail wagons, as typically the wagons can be loaded with wheel loaders, however, this can lead to damage to the wagons and possible accidents.

Telestack units fully built and tested in factory before dispatch

Telestack products are fully designed and manufactured in the state-of-the-art manufacturing facility in UK. All products are custom designed to each specific application, material, loading rate etc. The equipment is fully built and tested in the factory before dispatch, with extensive testing of all operations, including electrics, hydraulics, functions etc, before been packed for transport (either containers or ro/ro). This ensures high-quality design and manufacturing throughout the process and ensures there are no issues with the equipment on site. In terms of installation and commissioning, all units are bolted together (no welding), minimal hydraulics and electric (plug and socket system), which ensures the units are operational within one week or less.

Telestack Limited continues to excel in providing customised mobile bulk material handling solutions to its wide customer base. The company offers the Ship and Barge loading/unloading industry the most innovative and customised mobile conveying systems on the world market today. Telestack Limited have recently designed and manufactured a customised Hopper feeder and Radial Telescopic Ship-loader to load Woodchips to Handymax / Panamax Vessels in Africa for a company who are shipping the material to Powerstations throughout Europe.

The Telestack System!

The TS 650 Radial Telescopic Ship-loader (51.4 metre - 170ft) and Hopper feeder offers a unique system which ensures complete flexibility and efficiency during the loading process at rates up to 600TPH @ 0.35t/m3 (2000TPH+ @ 1.6 t/m3). The customer was previously using a 120ft top fold single belt conveyor for his loading process, however, as the customer intends to load Handy- max / Panamax vessels, their current conveyor was not able to load this type of vessel. The customer identified the Telestack equipment as the perfect solution as it has the ability to reach 2 - 3 to 4 hatches from one single feed-in point at a 12 metre free-board height, which greatly reduces production downtime. Also, with the telescopic

feature of the shiploader it allows the customer to trim all parts of hatch with ease, via the optional all function remote control, which ensures maximum flexibility during the loading operation. The shiploader also includes an integrated wheeled dolly unit which allows the customer to move the equipment around the site via the loading shovel on site.

The CF 615 Hopper feeder has an 18m3 hopper capacity for direct loading from a front end loading shovel, with an integrated variable speed drive on the belt feeder so loading rates can be controlled. As with the shiploader, the hopper feeder can be moved around the site via an integrated toe hitch to the rear of the unit, which again allows for enhanced manoeuvrability. This unit also has an integrated 230Kva genset which is used to drive conveyor belts on the CF 615 hopper feeder and TS 650 shiploader, which allows for a fully independent system. The customer also availed of Telestacks’ customised options by installing an over-band magnet to remove any tramp metal which may contaminate the woodchips.

The design and manufacture of these units highlights Telestacks’ drive to provide a complete Shiploading systems within the Ports / Inland terminals Industries which identify the needs of the customer and to provide an efficient, flexible and reliable shiploading system to its global customer base. For these units the customer intends to have the equipment operational by December 2009.