ZOOMRY
In the transoceanic shipping of marine sand and construction aggregates, 80,000-120,000 DWT Capesize bulk carriers have become the core capacity carrier for intercontinental sand and gravel trade. For a long time, however, heavy-duty ship loading equipment compatible with Capesize vessels has always been a core pain point in the industry. Conventional shiploaders have insufficient operating radius and poor adaptability, resulting in high demurrage charges due to frequent ship shifting. The high abrasiveness and dust-prone characteristics of marine sand and aggregates impose stringent requirements on the wear resistance and environmental performance of the equipment. Meanwhile, the increasingly tightened environmental and safety compliance standards of ports around the world have continuously raised the access threshold for equipment.
ZOOMRY Heavy Duty Mobile Shiploader directly addresses the core pain points of the industry. It provides efficient, eco-friendly, compliant ship loading solutions with low total lifecycle cost for global port operators, sand and gravel production and trading enterprises, and bulk material shipping companies, fulfilling our brand philosophy and development mission of "Craft Premium Conveying Equipment, Build a Century-old Foundation".
1. Core Industry Pain Points
For practitioners in the global sand, gravel and marine sand trade, the ship loading process of Capesize vessels directly determines the efficiency and profitability of the entire supply chain. The industry generally faces four core challenges, which are also the core decision-making demands of users searching for this product.
First, Capesize bulk carriers have a deadweight tonnage ranging from 80,000 to 120,000 DWT, with a wide beam, large span of hatch distribution, and wide fluctuation range of draft depth. Conventional shiploaders have insufficient operating radius and pitch adjustment capability, and can only cover 1-2 hatches with single positioning, requiring frequent ship shifting during loading, which greatly extends the port stay time of a single vessel. In the international shipping market, the daily demurrage charge for Capesize vessels can reach tens of thousands of US dollars, and the demurrage risk caused by frequent ship shifting has become one of the biggest cost black holes in the industry. At the same time, the shipping of aggregates and marine sand is characterized by large batch size and high timeliness requirements, and the hourly conveying capacity of conventional equipment is insufficient to match the rapid loading demand of large-tonnage vessels.
Second, marine sand contains chloride ions and quartz components, while construction aggregates have high hardness and large particle size fluctuation, both of which have extremely strong abrasiveness. The core components of conventional shiploaders, such as idlers, pulleys and belts, wear quickly and have a high replacement frequency, which not only drives up operation and maintenance costs, but also easily leads to unplanned shutdowns and affects the loading schedule. Meanwhile, marine sand has large fluctuations in moisture content, which is prone to material sticking and blockage in the rainy season and dust generation in the dry season, putting forward exclusive design requirements for the hopper, chute and sealing structure of the equipment.
Third, at present, all major trading regions in the world, including the European Union, North America, Southeast Asia and the Middle East, have issued stringent port environmental regulations, setting clear limits on dust emission, noise control and carbon emission level of bulk material operations, as well as mandatory requirements for equipment safety certification and quality standards. Equipment from most small and medium-sized manufacturers cannot meet international standards and certification requirements such as CE, EAC and CEMA, making it impossible to operate in mainstream markets. The open operation mode of conventional equipment is also very easy to face environmental penalties or even suspension of operation qualification due to dust and material scattering.
Finally, most sand and gravel export ports around the world are small and medium-sized berths or temporary berths, with insufficient foundation bearing capacity and limited operating space. Fixed shiploaders require large-scale civil construction, which not only has high input cost, but also faces a long approval cycle, making it impossible to quickly respond to market demand. At the same time, for ports with multi-berth operation, fixed equipment cannot realize flexible site transfer, requiring separate equipment configuration for each berth, which greatly increases asset investment and results in extremely low capital utilization rate.
2. ZOOMRY Heavy Duty Mobile Shiploader Solution
ZOOMRY Heavy Duty Mobile Shiploader is an exclusive heavy-duty loading equipment developed by ZOOMRY based on more than 20 years of technical accumulation in bulk material conveying, targeting the material characteristics of marine sand and aggregates, the operation requirements of Capesize vessels, and the working conditions and compliance requirements of global ports. Centered on the ZRSL series, the equipment covers full models from ZRSL-40 to ZRSL-60, which is perfectly compatible with 80,000-120,000 DWT Capesize bulk carriers, and can also be downward compatible with Panamax and other full series of vessel types, realizing "one machine for multiple purposes" and providing global customers with ship loading solutions covering full vessel types and full working conditions.
2.1 Full-dimensional Adaptation to Capesize Vessels, Maximizing Loading Efficiency and Completely Eliminating Demurrage Risks
In response to the operation pain points of Capesize vessels, ZOOMRY has carried out full-chain optimization of the boom structure, operating range and automation system of the shiploader. The equipment has a maximum operating radius of up to 60 meters and a pitch height adjustment range of 0-16 meters, which can fully cover the full hatch distribution of Capesize vessels. It can complete the loading operation of most hatches of the vessel with single positioning without frequent ship shifting, fundamentally eliminating the risk of demurrage charges. For the large flow conveying demand of aggregates and marine sand, the maximum conveying capacity of the equipment can reach 3500tph. A single unit can complete the full loading of a 100,000 DWT vessel within 3 days, and the loading efficiency is increased by more than 30% compared with conventional equipment in the industry.
The equipment is equipped with ZOOMRY's self-developed PLC fully automatic ship loading control system and HMI touch human-machine interface panel, supporting three operation modes: fully automatic PLC, remote control and manual operation. In the fully automatic mode, the equipment can automatically complete boom telescoping, radial rotation, pitch adjustment and belt conveying start and stop according to the hatch position and material accumulation height, realizing unmanned continuous loading, greatly reducing manual intervention and lowering the safety and efficiency risks caused by human operation errors. At the same time, the equipment is equipped with a full-function remote control system, which can remotely complete all core operations such as emergency stop, boom telescoping, belt start and stop, radial movement and inclination adjustment. Operators can complete the operation at the position with the best vision, adapting to the complex operating environment of the port and further improving the operation safety and efficiency.
2.2 Ultra-long Service Life and Extremely Low Total Lifecycle Cost
In view of the high abrasiveness, easy blockage and dust-prone material characteristics of marine sand and aggregates, ZOOMRY has carried out full-process exclusive optimization of the equipment relying on the self-developed and self-produced core component system. The performance of core components fully exceeds Chinese national standards and international mainstream standards, greatly extending the service life of the equipment and reducing operation and maintenance costs.
The core idlers and pulleys of the equipment are all produced in ZOOMRY's own factories. For more than 20 years, all long-distance belt conveyor EPC projects of ZOOMRY have adopted self-developed high-performance idlers, which have passed long-term verification in various complex working conditions such as large inclination angles, cross-river and cross-sea projects, and underground mines. The performance of the idlers is fully better than the national standard requirements: radial runout ≤0.4mm (national standard limit 0.5mm), axial displacement ≤0.4mm (national standard limit 0.7mm), rotational resistance ≤2N (national standard limit 3N), water inflow in immersion test ≤100g (national standard limit 150g), noise of silent idlers ≤45dB (national standard limit 55dB), with a service life of more than 50,000 hours. For the high abrasion characteristics of aggregates, various models such as wear-resistant steel idlers, HDPE idlers and buffer idlers can be customized to perfectly adapt to high-abrasion working conditions. For the chloride ion corrosion problem of marine sand, anti-corrosion coating and stainless steel material components can be customized to fundamentally solve the corrosion loss problem.
The equipment pulleys adopt exclusive wear-resistant design. The shaft body is made of 40Cr rolled material and 40Cr forged material respectively according to different diameters. The pulley shell is processed by CNC four-roller rolling machine with ovality ≤1.5mm. After welding, ultrasonic flaw detection and tempering stress relief treatment are completed, with a service life of more than 50,000 hours as well. The surface adopts diamond-shaped rubber lagging design, which greatly improves the anti-slip and wear resistance, and the wear resistance is increased by more than 40% compared with conventional flat pulleys. At the same time, the equipment is equipped with a three-stage polyurethane scraper + brush cleaning system, which can completely remove the residual marine sand and aggregate particles on the belt, reduce belt wear and extend the service life of the belt. The optimized large-opening hopper and unpowered dust removal chute can adapt to the continuous feeding of front-end truck unloaders and belt conveyors, and the anti-blocking structure is optimized for the fluctuation of marine sand moisture content, ensuring continuous and stable operation under different working conditions.
2.3 Full-process Environmental Protection Design
In terms of environmental performance, the equipment adopts a fully enclosed material conveying structure, with an optional tubular belt conveying system. The material is in a sealed state from feeding to ship loading, completely eliminating the scattering and dust of aggregates and marine sand, and the dust emission is far lower than the limit requirements of international organizations such as the European Union and IMO. The self-developed silent idlers equipped on the equipment control the operation noise within 45dB, meeting the noise control requirements of global ports. Compared with the traditional forklift + dump truck transfer loading mode, this loading system can reduce carbon emissions by more than 60%, greatly reducing the carbon footprint of the operation, and perfectly adapting to the global carbon neutrality trend and sustainable development regulations such as the EU CSRD. At the same time, the equipment can be equipped with diesel generator sets and new energy power systems according to customer needs, which can realize flexible operation in remote ports without power grid, and also meet the zero-emission operation requirements of low-carbon ports.
In terms of compliance certification, ZOOMRY has established a complete international quality and environmental management system, passed ISO 9001 Quality Management System and ISO 14001 Environmental Management System certification. The equipment has obtained EU CE certification, Eurasian Economic Union EAC certification, and Korea KCS certification. The design and manufacturing are compatible with global mainstream industry standards such as CEMA, AS and GB, which can meet the equipment access requirements of all major trading regions in the world, including Europe, Russia, Southeast Asia, the Middle East, Africa and South America, and completely solve the cross-border operation compliance problems of customers.
2.4 Adaptation to All Types of Port Working Conditions
In response to the diverse working condition requirements of global ports, ZOOMRY heavy-duty shiploader adopts a modular and mobile design, providing multiple models including wheeled, crawler, full hydraulic wheeled and fixed types, which are perfectly compatible with various operation scenarios such as fixed deep-water berths, temporary berths and multi-berth site transfer.
The mobile models do not require large-scale civil construction, and can be put into production only with simple ground leveling and foundation treatment, which greatly reduces the civil construction investment, and shortens the project approval and construction cycle. The fastest assembly and commissioning can be completed within 20 days after the equipment arrives at the site. The equipment can quickly complete site transfer operation, and one unit can cover the loading demand of multiple berths, greatly improving asset utilization rate and reducing equipment investment cost. For temporary berths with uneven ground and insufficient foundation bearing capacity, crawler travel mechanism can be optionally equipped to ensure the stable walking and operation of the equipment under complex terrain.
At the same time, the equipment adopts a global transportation-friendly modular design. The whole machine can be disassembled and loaded into 40-foot high cube containers, which greatly reduces the international shipping cost. All modules are pre-assembled, pre-wired and pre-commissioned in the factory, and adopt plug-and-play socket connection design. No complex electrical and hydraulic construction is required on site, and the assembly and commissioning of the whole machine can be completed in only 10-20 days, helping customers achieve rapid commissioning and rapid return on investment.
3. Full Lifecycle EPC+M+O Services
As a professional bulk material conveying equipment manufacturer and EPC general contractor, ZOOMRY not only provides customers with high-performance equipment products, but also relies on more than 20 years of industry experience to provide global customers with one-stop EPC+M+O services covering the full lifecycle of the project, completely solving customers' worries.
ZOOMRY has a number of engineer teams with rich design experience and on-site service capabilities, especially specializing in the design, manufacturing and installation of bulk material conveying systems under complex terrain and complex working conditions. For global customers, we provide one-to-one customized design services, and complete exclusive equipment design and system matching according to the customer's port working conditions, vessel parameters, material characteristics and capacity requirements, ensuring that the equipment perfectly adapts to the customer's actual operation needs. At the same time, we can provide full-link bulk material conveying solutions from truck unloaders, belt conveyors, stackers to shiploaders. All series of equipment are self-developed and self-manufactured, with full system compatibility, avoiding the failure risk of multi-brand equipment linkage, and maximizing the efficiency of the whole system.
In the project implementation phase, ZOOMRY can provide global on-site installation and commissioning services. Engineers can go to sites around the world to guide installation, complete equipment commissioning, and provide systematic training for customers' operation and maintenance personnel, ensuring that the customer's team can independently, safely and efficiently complete equipment operation and daily maintenance. After the equipment is put into production, we provide customers with full lifecycle operation and maintenance services, including rapid supply of global spare parts, equipment overhaul, upgrading and transformation, project operation management, etc. We also provide 7×24 hours remote technical support to quickly respond to various customer needs and solve the core pain points of overseas project operation and maintenance.
For more than 20 years, ZOOMRY has provided EPC general contracting services for dozens of long-distance onshore conveying system projects in China, and provided thousands of technical consulting, operation management and project upgrading services for nearly 200 customers around the world. Our products are widely used in mining, ports, thermal power, cement, iron and steel, chemical and other industries, and have been widely recognized by global customers. For the marine sand and aggregate industry, we have provided Capesize shiploader solutions for many large-scale sand and gravel export ports in Southeast Asia, the Middle East, Africa and other regions, helping customers achieve the core goals of improving loading efficiency, reducing operation and maintenance costs, and meeting environmental compliance requirements, and becoming a trusted partner in the global marine sand and gravel shipping industry.
With the continuous development of the global sand, gravel and marine sand trade, the efficient and compliant loading of Capesize bulk carriers has become a key link that determines the core competitiveness of enterprises. ZOOMRY Heavy Duty Mobile Shiploader directly addresses the four core industry pain points of efficiency, cost, environmental protection and compliance. Relying on more than 20 years of technical accumulation, self-developed and self-manufactured capabilities of the whole industrial chain, globally recognized certification system and full lifecycle service guarantee, we provide global customers with a more adaptable, more efficient and more reliable bulk material ship loading solution.
