Rotary Batch Mixers, Tumble Mixer, Tumble Blender, Drum Mixer

Rotary Batch Mixers

Blend dry bulk solids with or without liquid additions quickly, uniformly, and gently, achieving total discharge and zero cross-contamination.

The Rotary Batch Mixer (also known in the industry as a Tumble Mixer, Tumble Blender, Drum Mixer, or Drum Blender) is a highly advanced mixing solution engineered to deliver flawless uniformity in exceptionally short cycle times. Capable of producing homogeneous blends in under 3 minutes, this mixer offers the lowest energy consumption in its class, complete discharge without segregation, and an extraordinarily gentle tumbling action. Its highly accessible, seal-free interior ensures that it can be cleaned and sanitized rapidly, preventing any risk of cross-contamination.

Proprietary 4-Way Mixing Action & Supreme Uniformity

At the core of the Rotary Batch Mixer is a unique, four-way mixing action that simultaneously folds, tumbles, cuts, and turns the material. As the drum rotates, proprietary internal mixing flights create a dynamic flow pattern that provides free space between particles, causing them to recombine up to 288 times per minute.

Because there is no forced agitation or free-fall of materials, the mixing process is incredibly gentle. Light, fluffy materials are blended without densification, and dense, fragile materials are mixed without degradation. Despite this gentle handling, the mixer distributes particles with astonishing precision, achieving batch uniformity to one-tenth of one percent (0.1%), even when blending ingredients of widely disparate sizes, shapes, and bulk densities.

Precision Liquid Additions and Coatings

The continuous, dynamic flow pattern creates an ideal “fluid bed” condition for introducing liquid additions, flavorings, colors, and impregnations. Unlike conventional mixers that spray liquids onto a narrow “waterfall” of material, Rotary Batch Mixers spray liquids onto a wide, deep bed of continuously moving material. This ensures every particle is uniformly coated, rapidly achieving distribution ratios down to 1 part per million of liquid to solids.

Unmatched Purity, Total Discharge, and Fast Cleaning

Unlike stationary mixers that rely on internal agitators, the Rotary Batch Mixer completely eliminates internal shafts and shaft seals that contact the material. The rotating vessel is supported entirely by oversized external trunnion rings riding on heavy-duty alloy roller assemblies.

This seal-free interior is paired with an exclusive plug gate discharge valve. When opened, the valve plug pivots inward, and the internal mixing flights continuously direct material through the opening until the vessel is 100% empty, effectively eliminating residual waste. Because the drum rotates continuously during loading, mixing, and discharging, it totally prevents material segregation and stratification upon discharge.

Cleaning is ultra-fast thanks to:

Unrestricted Interior Access: Large, safety-interlocked access doors allow complete visibility and reach to all internal surfaces.
No Dead Spots: There are no hidden chutes, recesses, or internal bearings to harbor contamination.
Automated Sanitizing Options: Available with Clean-In-Place (CIP) multi-directional spray nozzles and convenient drain plugs for rapid wash-down and cross-ventilation drying.

High Flexibility for Any Industry

With capacities ranging from 5 to 600 cubic feet (142 liters to 17 cubic meters), this mixer provides unsurpassed processing flexibility. A single machine provides equal mixing efficiency whether filled at 100% of its rated capacity or operating as low as 5% (or 33% when making liquid additions).

The stationary inlet and outlet chutes allow for seamless hard-piping into automated, dust-tight systems, meaning the machine loads, mixes, and discharges on the same floor level without needing multi-level structures or tilting mechanisms.

Available Configurations & Options:

Sanitary Models: Built to stringent USDA, FDA, and pharmaceutical standards. These feature #304 or #316 stainless steel product contact surfaces, continuously welded flights, and internal welds radiused to 0.25 inches and polished up to 240 grit to prevent material entrapment.
Industrial & Abrasion-Resistant Models: Heavy-duty models are constructed with abrasion-resistant steel and replaceable wear plates. They are engineered to handle extremely heavy, poor-flowing materials like concrete premix, ceramics, glass cullet, and metal powders with bulk densities exceeding 200 lbs/cu ft.
Heating & Cooling: Mixing drums can be equipped with low-pressure or ASME-coded high-pressure jackets to handle steam, hot oil, or refrigerants for precise temperature control during exothermic/endothermic reactions.
Intensifier Bars: For non-free-flowing materials or soft agglomerates, an optional internal intensifier bar can be installed to impart necessary shear and promote rapid dispersion.

Key Benefits Summary

1 to 3 minute cycle times
Uniform dry blends and liquid additions (down to 0.1% uniformity)
Gentle mixing with no particle degradation or densification
Total discharge with zero segregation
Ultra-fast cleaning and full interior access
Lowest energy costs per volume of material mixed
Stationary inlet and outlet for automated, dust-tight operation
Operates efficiently from 5% to 100% capacity

For small production, laboratory, or pilot plant applications, Rotary Batch Mini Mixers are also available with capacities ranging from 0.25 to 15 cubic feet (7 to 425 liters).

Mixing, Blending and Size Reduction Systems

Munson Mixing Blending Size Reduction Separation Systems

Founded in 1823, Munson Machinery has established itself as a world-leading manufacturer of industrial mixers, blenders, and size reduction equipment for bulk materials.

As the official EU representative, Polimak is proud to bring Munson’s unparalleled engineering, robust construction, and high-performance solutions directly to European manufacturers. Whether your facility processes fine powders, coarse aggregates, highly abrasive minerals, heavy industrial waste, or sensitive pharmaceutical and food products, our extensive equipment portfolio is engineered to meet your most demanding specifications. From small laboratory mini-mixers to massive continuous production lines, Polimak provides the EU market with Munson’s custom-built machinery, helping you optimize cycle times, reduce energy consumption, and guarantee perfect uniformity in every batch.

Overview of Munson Machinery Products

Munson Machinery provides an incredibly broad and highly specialized range of equipment, uniquely positioning them as the only manufacturer to offer all eight types of mixing and blending machines The product lines are separated into distinct categories: Mixing & Blending Equipment (both batch and continuous), Size Reduction Equipment (for large bulk, coarse, and fine reduction), and Separation Equipment (for liquid/solid and solid/solid separation)

Munson equipment is available in carbon steel, abrasion-resistant steel, and AISI 304/316 stainless steel constructed to strict food-grade and pharmaceutical sanitary standard. With Polimak’s representation, European industries – ranging from nutraceuticals, spices, and cosmetics to cement, plastics, and sludge recovery – can leverage Munson’s durability and superior engineering for decades of low-maintenance operation.

1. Mixing & Blending Equipment (Batch)

Rotary Batch Mixers The Rotary Batch Mixer utilizes a proprietary four-way mixing action that gently tumbles, turns, cuts, and folds bulk materials to produce highly uniform blends in just 1 to 3 minutes. The constant motion during loading, blending, and discharging prevents any material segregation. Because the drum rotates on external trunnion rings, it eliminates the need for internal shafts or seals that contact the material.

Capacities: 5 to 600 cubic feet. Operates efficiently at fill volumes from 100% down to 5%.
Variations: Rotary Batch Mini Mixers are available for small production and laboratory applications (0.25 to 15 cu ft). Rotary Glass Batchers are built with replaceable wear plates for extremely abrasive materials like refractories and glass.

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Ribbon, Paddle, and Plow Blenders These heavy-duty horizontal blenders feature a stationary U-shaped vessel and a central flanged shaft supporting ribbon, paddle, or plow agitators. They force agitators through stationary material, making them incredibly effective for blending dry solids with other solids, or with liquids to produce pastes and slurries in 5 to 10 minutes.

Capacities: 1 to 1,150 cubic feet.
Variations: The CROSSLEY ECONOMY™ line features standard, non-customized stainless steel ribbon blenders in capacities from 3.53 to 105.94 cu ft for fast shipment. Cylindrical Plow Blenders are also offered for high-intensity batch blending, rotating three to five times faster than trough-style blenders to intersperse difficult materials.

Vee Cone Blenders Comprised of two inclined cylinders, the Vee Cone Blender relies on gravity to cause materials to fall, converge, and divide. This gentle tumbling action achieves uniform blends in 5 to 15 minutes while consuming significantly less power than agitated machines. They feature smooth internal surfaces with no baffles for 100% complete discharge and rapid sanitizing.

Capacities: 0.25 to 200 cubic feet. Optional liquid dispersion intensifier bars can be added to reduce soft agglomerates or distribute liquids.

Fluidized Bed Mixers Engineered for speed, these mixers use twin, counter-rotating shafts with paddles to sweep low- to medium-density bulk materials upward into a fluidized, airborne zone. They achieve highly uniform blends in 10 seconds to two minutes with insignificant heat generation and zero degradation of fragile particles.

Capacities: 0.21 to 280 cubic feet. They discharge rapidly through full-length, pneumatically actuated drop-bottom gates.

2. Mixing & Blending Equipment (Continuous)

Rotary Continuous Mixers For long product runs, these mixers blend primary bulk ingredients and minor additives gently, rapidly, and dust-free. They feature fixed internal mixing flights within a rotating drum and stationary inlet/outlet ports. Typical residence times are just one to two minutes, making them ideal for high-volume mixing and liquid coating applications.

Variable-Intensity Continuous Blenders Based on a horizontal cylindrical vessel with an infinitely adjustable single agitator, this blender provides versatile continuous mixing. It can operate at low speeds for gentle homogenizing and coating, or at high speeds for high-shear mixing and lump-breaking of dry materials, dense pastes, and slurries. High throughput is achieved with typical residence times of 20 to 30 seconds.

3. Size Reduction Equipment

Centrifugal Impact Mills (Pin Mills) Pin Mills pulverize friable materials into tight size ranges down to fine 400 mesh powders without using screens, hammers, or knives. Material travels from the center to the periphery between an outer stationary disc and an inner rotating disc, where centrifugal force causes particles to alternately impact alternating rows of pins thousands of times.

Attrition Mills Ideally suited for grinding fibrous and friable materials from coarse sizes down to 100 mesh. Material travels radially between a stationary disc and a rotating runner disc. The gap between these discs is adjustable via a hand wheel, providing extremely precise control over the final particle size.

De-Clumper™ Lump Breakers Placed inline or standalone, these compact machines reduce compacted or agglomerated materials back to their original flowability. They utilize rotating breaking heads to force lumpy materials through curved classifying bed screens with perforations from 1/32 inch to 2.5 inches.

SCC™ Screen Classifying Cutters Combining the shear of a knife cutter with the impact of a hammer mill, the SCC reduces hard, semi-hard, and fibrous materials down to 20 mesh. It utilizes a solid-mass rotor with a staggered, helical array of interconnected parallelogram cutters that shear materials against twin stationary bed knives with minimal heat and fines.

Variations: Ultra-high capacity Magnum™ Cutters are available for massive-scale applications, and Laboratory Mini Cutters are offered for small-volume production.

Rotary Knife Cutters Operating with high shear and low impact, this cutter uses five rotating blades cutting against four stationary bed knives. It yields exceptionally clean-cut particles for spices, corn, roots, and plastics, cleanly cutting materials with little to no dust. Screens provide a 320-degree exposure area for high throughput.

HammerHead™ Hammer Mills Designed to smash heavy volumes of friable and fibrous materials, these industrial-duty mills utilize hardened steel hammers rotating at speeds up to 270 MPH. Centrifugal force causes the pivoting hammers to strike material in mid-air and crush it against breaker plates until particles pass through a lower bed screen.

Titan™ Shredders & CX Heavy Duty Cutters For primary size reduction of massive, bulky scrap:

Titan™ Shredders utilize dual, low-speed, high-torque rotors with extended cutter teeth to shear large volumes of industrial waste, plastics, fiberglass, and cardboard with minimal power consumption.
CX Heavy Duty Cutters act as single-rotor, high-torque hogs designed to chew through exceptionally tough materials like synthetic rubber, wood, and solid detergent blocks.

Security Destructors Specialized high-velocity cutters engineered to confidently and securely destroy sensitive products, including circuit boards, photographic materials, bank notes, and pharmaceutical vials.

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4. Separation Equipment

Rotating Drum Screens Engineered for high-capacity liquid/solid separation, this machine efficiently removes solids from industrial and municipal wastewater or recovers solid product from process streams at rates up to 4,650 gallons per minute. It utilizes a horizontal wedgewire screen cylinder. Because the rotating drum is the only moving part, it prevents blinding and clogging while keeping maintenance costs low.

MUNSIFTER™ Centrifugal Sifters Designed for high-throughput solid/solid separation, this sifter can scalp, sift, and de-agglomerate dry materials quietly and without vibration. Material is fed into a stationary horizontal screen cylinder while rotating internal paddles reliably propel on-size particles through the screen apertures, ejecting oversize materials out the discharge port.

Ready to upgrade your processing line? As the official EU representative for Munson Machinery, Polimak is ready to help you select, customize, and install the perfect equipment for your facility. Contact Polimak today to request a quote or learn more!

For further information send email to [email protected]

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Screw Jacks Applications

Polimak linear motion technologies provide a wide range of lifting and positioning solutions for numerous industries. Some of these industries include defence, manufacturing, construction, entertainment, communication, energy and many others. We provide robust and durable screw jacks that guarantee quality and reliable performance. Our experienced and innovative engineering team works with our clients to help them meet their application demands.

Solar Tracker application

In response to the rapidly growing Global Solar Photovoltaic (PV) market – with regard to solar panel tracking systems, Polimak produces linear motion control systems with state-of-the-art components that can be utilised in solar energy systems. A solar tracker must be highly robust so that it may be able to withstand different environmental conditions such as wind forces. We produce screw jack systems that render efficiency, reliability and environmental value to various applications in the energy industry. Our screw jack solutions are ideal for heavy-duty solar trackers as they require little to no maintenance, thereby reducing downtime and making them the best option for solar tracking systems.

Stage Lifting application

The entertainment industry benefits a great deal from our jack screw solutions. Theatre, orchestra, dance and other forms of performed arts typically utilise elevated stages during performances. Because of the high force capabilities and reliable functioning, Polimak linear motion solutions are an excellent choice for stage lifting in the aforementioned performed arts. For improved safety, our power screw jacks are equipped with gear reduction boxes to cease movement in the event of a complete power cut.

Barrier application

Cylindrical wedge barriers, commonly known as bollards, are typically used in a variety of different applications as a security method of preventing vehicular access. For heavy-duty robust bollards like the ones used as vehicle impact barriers which may consist of hefty steel components collectively weighing on the order of a hundred kilograms, the use of translation screw assemblies is ideal. Hydraulic or pneumatic rams are not the best option because they are expensive, consume a lot of power supply and require regular expert maintenance. Our screw jack solutions provide greater advantages for raising and lowering bollards because of their limited maintenance, reduced noise levels, environmentally friendly designs (no contaminants) and reliable functioning in extreme conditions.

Satellite Antenna application

The communication industry and other industries benefit from satellite antennas which are typically used for coverage (signal) purposes. Regardless of the environmental conditions, satellite antennas must perform quick, smooth, precise and efficient movements during operation. Our jack screw systems render the high torque control needed to effectively and efficiently handle rapid movements of satellite antennas. We design and manufacture screw jacks with varying capacities, a number of clevis and optional accessories like boots.
The application of screw jacks in satellite antennas is similar to that used in the military industry in their radar systems.

Manufacturing Machinery application

Our screw jack solutions enable machining and metal fabrication clients across the manufacturing industry to attain optimal productivity and high-end quality in tough and demanding industrial setups. Manufacturing machineries have to be able to operate with a high degree of accuracy, precision and dependability in the most demanding conditions. Polimak linear motion solutions have been trusted to address a wide range of machine tool equipment design challenges. Our screw jacks can be integrated with manufacturing machines like rolling machines.

Aerospace Systems application

The aerospace industry involves the manufacturing and assembling of large and sensitive parts for flight vehicles such as aircraft, satellites, spacecraft and other related crafts for manned or unmanned flight. Assembly and maintenance platforms are some of the systems used to handle various flight vehicle parts (e.g., engines). Linear motion products are commonly utilised on platforms to enhance safety and increase productivity. Polimak produces innovative worm gear screw jacks with integral safety that can be incorporated into platforms. Our screw jacks can also be used in different Ground Support Equipment (GSE) like airport pallet loaders. Ease and accurate controlled movements without safety risk can be accomplished with our screw jack solutions.

Other possible applications

Screw jacks provide robust and quality support in numerous systems used in various industries. Other possible applications of jack screws include the following:

The opening and closing of penstocks.
Food processing machineries (e.g., palletizing machines).
Crank tables height adjustments.
Missile launching platforms.
Vehicle ramp and vehicle lifts.
Scissor lifts.
Airport passenger walkway (passenger boarding ramp).
Bath lifts.
Patient transfer trolleys.
Construction works.

Bulk Material Handling Systems

Bulk solids handling systems pneumatic conveying batching loading discharging

A bulk material handling system is required in any process that necessitates bulk material processing. Bulk material handling systems produced by Polimak are designed to the specific requirements of each industrial application. This ensures the deliverance of state of art solutions for the toughest challenges. Our bulk material handling systems’ fundamental role is to efficiently store, transport, feed and supply bulk solids to processing units whenever needed.

The ability to provide expert solutions to a wide range of industries derives from a team of experts who have many years of experience in the design, production and installation of bulk material handling systems. Each phase of a bulk material handling project is critical to achieving desired performance and required safety. Our team of highly experienced engineers provide industrial solutions designed for safety and reliable performance. There exist several aspects that affect system design and each of these aspects should be considered carefully to achieve an efficient bulk material handling solution. Physical and chemical properties of bulk materials (bulk density, particle size, angle of repose, flowability, moisture, corrosivity, minimum ignition temperature etc.), conveying capacities, storage, process limitations, and connected equipment are some of the important factors in system design. Process and occupational safety considerations are also key elements in engineering design. Being a solution provider in the bulk solids handling industry with over 40 years of experience, our strength comes from R&D, custom design and production capabilities for each application. Our operational organizations are flexible enough to supply problem free solutions for our customers from a single equipment production to complete turnkey system installation in a short time.

Bulk material conveying systems

Raw dry bulk materials which are in powdered or granular forms are typically received from trucks, ships, or even trains and they are processed using bulk material handling systems like bulk solids conveying systems. Bulk solids handling systems utilise screw conveyors, pneumatic conveyors, belt conveyors and other related bulk material conveying systems to transfer dry solids from one point to another within a process line. Polimak bulk solids conveying systems allow smooth, fast and reliable transfer of bulk materials for numerous applications. Some of these applications may include; the transfer of bulk solids from sack or bag to storage silos, the conveying of dry bulk solids from bulk bag unloading stations to storage containers, the feeding of production lines from silos or hoppers and many other applications.

Bulk material loading systems

These are systems used to load dry bulk solids into bulk trucks, ships, storage silos and other related storage or containment objects. Dry bulk solids are frequently loaded at a production site using bulk material loading systems and they are transported to their site of use by means of suitable bulk vehicles. Bulk loading systems produced by Polimak include mobile bulk truck loading systems, ship loading systems, stockpile loading systems, big bag loading systems, tanker loading systems, hopper loading systems and many more.

Bulk Material Storage Systems

Powdered and granular dry bulk materials used in a broad range of industrial handling processes require safe and compacted storage systems. It is necessary for a bulk material handling system to have storage systems where dry solids are stored until they are required for usage. Polimak bulk material storage systems (silos, hoppers, bins) give dry bulk solids processors the ability to store large and small volumes of their dry solids. Our bulk solid storage systems ensure minimum ground space consumption, bulk material contamination prevention and optimal flow into downstream systems.

Bulk material discharge systems

Bulk solids are usually stored prior to being used, even if it is just for a relatively brief period of time. Their flow, dry bulk solids, varies when being discharged from storage systems. Bulk material handling systems utilise bulk material discharge systems to help stimulate or improve dry solids flow from bulk containers. In some operations, the downstream equipment is significantly influenced by the design of bulk solids discharging systems. Silo discharge systems, mixer discharge systems, tank discharge systems, big bag discharge systems, octabin discharge systems, bag dump systems, bulk truck unloading systems, tanker unloading systems, liner bag container unloading systems, and storage hopper discharge systems are among Polimak’s bulk material discharge systems.

Bulk material dosing systems

In several productive applications, it is necessary to develop formulations (based on bulk solids properties) required for dosing various products being processed. Bulk material dosing systems are used in bulk material handling systems to provide precise and accurate dosing. Dosing accuracy is critical for achieving an accurate bulk solids handling process when a consistent output is required. A combination of gravimetric or volumetric dosing systems and pneumatic conveying systems are used to feed bulk material mixers. Polimak provides a wide range of configurations depending on the process requirements.

Turnkey bulk material handling systems

We provide turnkey bulk solid handling systems from raw material input to its output. Equipment for bulk solids loading, filling, discharging, conveying, mixing, dosing, feeding and weighing are combined to have a complete production line. Design, production, installation and commissioning services for production lines of a wide range of industries are available from one supplier.

Bulk material handling industries and applications

Bulk material handling is an essential aspect of any industry that processes dry bulk solids. Our experience within the industry of producing bulk handling systems allows us to design and produce cutting-edge bulk material handling systems used in various industries like cement, food, chemical, mining, plastics, agriculture etc., for numerous applications. We have the experience to design and supply our customers with the right bulk material handling systems to meet their requirements.

Agricultural Industry

The agriculture industry benefits from the use of bulk material handling systems when processing bulk materials like soybeans, corn, wheat, rice and many other related products. Bulk solid conveying systems such as pneumatic conveyors, screw conveyors, belt conveyors are utilised to transfer bulk materials within process lines. Bulk solids storage systems, with storage silos being the most prevalent equipment, are used to store dry grains.
Wheat, flour, semolina, barley, oat, rye, bran, chaff, feed, seed, corn, chickpea, bean, lentil, pea, soybean, sesame, rice, pice flour, dried fruit, hazelnut, peanut, almond, sunflower seed, cottonseed, grain cereals, chestnut are some of the bulk materials that can be handled by bulk solids handling equipment and systems.

Food Industry

Food processing and manufacturing for both human and animal consumption is a huge industry that is still growing. Corn milling, sugar refining, coffee processing are some of the ways in which bulk material handling systems are utilised in the food industry. Polimak’s food-grade bulk material handling systems constructed from stainless steel having no crevices are ideal for handling food products.
Grains and powders like coffee grain, coffee powder, sugar, salt, flour, milk powder, corn, starch and spice can be conveyed, stored, loaded and fed by bulk solid handling systems. Food grade equipment are used in food industries.

Mining Industry

Raw materials such as limestone, quartz etc., mined from the Earth’s crust have to be processed before consumer use. In mining industries including cement, calcium carbonate (also known as calcite having a chemical formula CaCO3), lime etc. grinders are used to reduce feed material size in order to liberate minerals from barren rock. Ball mills are currently the most commonly used grinding machines in the mining industry. Ball mill operations make use of feeding systems like screw feeders to gradually feed raw material (e.g., ores) to a mill at consistent rates. The material size (part of it) is reduced and discharged via the mill’s outlet. Steady material discharge is very crucial throughout the process, hence bulk material discharge systems can be used at the outlet port to promote efficient and controlled bulk material discharge.

Power Industry

Internal combustion or combustion turbine conventional steam technologies are commonly used to generate electricity from fossil fuels such as coal, oil, or gas. A by-product of coal combustion, fly ash, is transported from baghouse filters and ESP systems to bulk material storage systems like silos. Using bulk material discharging systems, fly ash is discharged from storage and loaded into appropriate bulk vehicles or conveyed using conveying systems to plants for manufacturing (e.g, cement manufacturing).

Plastics Industry

In the plastics industry, storage, discharging, loading, and feeding of plastics such as polyvinyl chloride (PVC), polyethylene, polypropylene (PP), acrylonitrile butadiene styrene (ABS) and many other related plastics are done by using bulk material handling systems. Bulk solids (powdered and granular) are transferred between silos, mixers, and batching units by using conveying systems and fed into injection and extrusion machines by means of feeding systems.

Chemical Industry

Bulk solids handling systems are required to convey and process bulk materials in the chemical industry. Dry bulk solids like aluminium oxide, Titanium Dioxide (TiO2), urea, paint additives, and other related products are pneumatically conveyed on ship unloaders and barges by using conveying systems like roots blowers. Polimak designs and manufactures bulk solids systems for metering and conveying purposes.

Bulk Material Handling Systems FAQ

What is bulk material?

Also referred to as dry bulk solids or simply bulk solids, bulk materials are loose commodities usually found in powdered or granular forms. Some examples of bulk solids are sugar, salt, starch, flour, coffee beans, beans, rice, wheat, plastic pellets, sand, cement, coal, chemicals and many others.

What is bulk material handling?

Bulk material handling refers to the engineering process of designing mechanical systems for transporting and processing bulk materials. Bulk material handling is critical in a variety of industrial operations including mining, food, agriculture, plastics etc.

What is a bulk material handling system?

A bulk material handling system is a collective term used to refer to all the machinery used in processing bulk materials. Bulk material handling systems are essential in several industries for handling and storing dry bulk solids. Handling can be accomplished mechanically with the use of conveying systems like screws, belts etc., or pneumatically with the use of conveying air (pressure or vacuum). Other bulk handling systems include weighing, batching, dosing, dust collection, milling, and mixing.

Brochure of Bulk Solids Handling Systems

Bin Activator Technical Document

Downloadable bin activator datasheets and a catalogue are accessible below.

Download Bin Activator Catalogue

Download PTK600 Bin Activator Datasheet

Download PTK900 Bin Activator Datasheet

Download PTK1500 Bin Activator Datasheet

Download PTK1800 Bin Activator Datasheet

Download PTK2350 Bin Activator Datasheet

Download PTK2500 Bin Activator Datasheet

Download PTK2600 Bin Activator Datasheet

Bin Activator

A vibrating bin discharger is a conical-shaped equipment that allows dry bulk materials to flow continuously by gravity. It is used to feed downstream equipment such as conveyors, hoppers, rotary feeders etc., installed to its outlet port.

Bin Activator Models

Our vibrating bin dischargers come in a broad variety to meet the economic demands and the diverse industrial application requirements. We deliver our equipment with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel.

Industrial Applications

The vibrating bin discharger is used in most industries that process dry bulk solids to discharge storage silos, bins etc., and feed downstream equipment such as conveyors, hoppers, rotary feeders etc. It helps prevent bridging, ratholing, or arching during bulk material processing. It is mounted to the upstream equipment’s outlet and the downstream equipment’s inlet.

Options And Accessories

We provide a wide selection of industrial production vibrating bin dischargers (or bin activators) with innovative options and accessories. These options and accessories ensure smooth and efficient operations as well as safe function over time.

Technical Documents

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Bin Activator Industrial Applications

Companies have been storing finished products or dry bulk raw materials in storage equipment such as silos since the industrial revolution. The extraction of cereals has not possed much of a problem. However, the extraction of other bulk materials such as flour, metal oxides etc., causes problems during extraction from the silo without manual intervention. Bin Activators also known as vibro dischargers are the perfect solution when dealing with such problems. Vibro dischargers impart vibrations to the dry bulk material directly and the vibrations are isolated from affecting the upstream or downstream equipment through the use of flexible seals. Bin activators are used in industries such as mining, food, cement, plastics etc.

Bin Activator for Silo Discharge

Vibrating silo dischargers can be used to facilitate the extraction of dry bulk materials from silos. A flange is welded to the silo cone and the silo discharger is bolted to this flange. During the bulk material discharge from the silo, the bin activator generates vibrations that are transmitted to the bulk material inside the silo, which in turn promotes uniform bulk material flow.

Bin Activator for Hopper Discharge

Similar to the way the bin activator is utilised in extracting dry bulk materials from silos, the bin activator is used in the same way with hoppers. It is installed under the hopper. The vibrating bin discharger ensures a continual flow of the bulk material from the hopper to the downstream equipment by using controlled vibrations.

Bin Activator

Bin Activator Models

Industrial Applications

Options And Accessories

Technical Documents

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Bin Activator Models

Polimak’s bin activators come in different models to meet the economic needs and the diverse industrial application requirements. Our vibrating bin dischargers are delivered with a mounting flange that can be welded to the upstream equipment. These vibrating bin dischargers are available in ST37 carbon steel, hardox steel and AISI304 stainless steel. Some of the models that we produce include the following:

Standard Bin Activators

Polimak’s standard bin activators are the equipment of tapered-conical shapes that regulate dry bulk material flow from upstream equipment such as silos or bins due to the generated vibrations. The standard vibrating bin discharger consists of a seamless carbon steel cone formed on sheet metal, a polyurethane seal, spring suspensions as well as a single electric vibrator.

Features

Material: ST37 Carbon Steel
A polyurethane seal.
An inlet skirt.
A broad range of intern baffles with respect to the application.
A compact design.
Durable suspensions and flexible seal.

Food Grade Bin Activators

Our food grade bin activators incorporate the same durable features as those found in the standard bin activators. However, they are particularly designed to meet the requirements of the food industry and other related processing industries. They are mainly produced from stainless steel with high-grade surface finishing. The mating parts are properly welded on both sides, thereby acquiring a perfectly smooth surface that reduces bulk material residue.
The food grade vibrating bin dischargers are an ideal choice where minimal dry bulk residue is required and contamination of the bulk material has to be strictly avoided.

Features

Material: AISI304 Stainless Steel
A silicone flexible seal.
An inlet skirt.
A broad range of intern baffles with respect to the application.
A hygienic design.
High-grade surface finishing.
Durable suspensions and flexible seal.

Wear Resistant Bin Activators

Our wear resistance bin activators incorporate the same durable features as those found in our standard bin activators. The wear resistance bin discharger consists of a seamless hardox steel cone, a polymer engineered seal, spring suspensions and a single electric vibrator. Manufactured from hardox steel, the wear resistance bin dischargers are an ideal choice for handling abrasive bulk materials like clinker, silicon carbide, fly ash, alumina etc. Due to the nature of the handled bulk materials, the inlet skirt plays a crucial role in prolonging the usable life span of the seal. This model is primarily used in industries such as mining, aggregate, cement, foundry etc.

Features

Material: Hardox Steel
An inlet skirt.
A polymer engineered seal.
A wide selection of interns baffles with respect to the application.
A robust and compact design.
Wear resistant surface.
Durable suspensions and flexible seal.

Bin Activator Dimensions Table

MODEL	A (mm)	ØDI (mm)	ØDO (mm)	H (mm)	No of Suspensions	No of Motors
PTK600	500	580	168	400	4	1
PTK900	685	880	219	520	4	1
PTK1500	1115	1480	323	760	12	1
PTK1800	1190	1780	323	910	12	2
PTK2350	1595	2330	406	1150	16	2
PTK2500	1720	2480	406	1290	16	2
PTK2600	1820	2580	406	1350	16	2

Bin Activator

Bin Activator Models

Industrial Applications

Options And Accessories

Technical Documents

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Bin Activator Options and Accessories

Polimak offers a broad selection of industrial production bin activators (or vibrating dischargers) with innovative options and accessories. These options and accessories ensure smooth and efficient functions as well as safe operation over time. Some of the options and accessories that allow enhanced material handling by our bin activators include:

Secondary Baffle

For efficient and smooth discharging of the dry bulk material from the lower portion of the vibrating discharger, an additional baffle plate commonly known as a secondary baffle can be installed in the system. It prevents the jamming and compacting of the bulk material at the bin activator’s outlet, thereby allowing the dry solids to flow steadily through the outlet.

Slide Gate Valves

Slide gate valves are designed to render efficient flow control of the free-flowing dry bulk material. They are designed to fit the circular or rectangular/square flange of the equipment they are mounted to. The slide gate is installed to the outlet of a vibrating discharger, where it is used for opening and closing the dry bulk material discharge to downstream equipment. It also makes easier the maintenance operations of the mounted downstream equipment. It can be configured to be operated automatically or manually.

Butterfly Valves

Similar to the slide gate valves, the butterfly valves are also designed to offer efficient flow control of the free-flowing dry solids. The butterfly valve consists of a rotating (up to 90 degrees) disc installed in a hollow body. The valve is mounted to the exit port of a vibrating discharger. It is used to regulate the bulk solid’s flow from a bin activator to installed downstream equipment. This is achieved by the rotating disc. When fully opened, it becomes parallel to the dry solid’s flow permitting minimum resistance. As it gets closed, it gradually becomes perpendicular to the dry solid’s flow, thereby, reducing its flow. It also functions as a shutoff valve and completely prevents the dry bulk material flow.

Diverter Valves

Flap type diverter valves are connected to the outlet port(s) of a vibrating discharger and are utilised for the redirection of the bulk material flow to two or more downstream equipment. A diverter valve consists of a hinged flap, hence the name ‘flap type diverter valve’. The hinged flap is responsible for diverting the flow of the dry bulk material inside the valve.

Vibration Sensor

A vibration sensor is used to detect the bin activator functionality throughout the operation. The sensor is equipped to the system and it is responsible for perceiving the bin activator’s vibrations. In the case where the system’s operation is started and the vibrations are faulty, the sensor alerts the user and the necessary precautions are taken.

Flexible Connector Sleeve

Flexible Connector Sleeve A flexible sleeve is used to cover the gap between a bin activator and upstream or downstream equipment. Typically, a polyurethane sleeve is used as a flexible sleeve connector. Instead of the polyurethane seal, Polimak offers another option which is the use of a silicone connector seal.

Multiple Outlets

This option promotes the flow of the dry bulk material from a single upstream equipment into several separate downstream systems. The multiple outlets design eliminates the demand for using a downstream diverter valve, hence, reducing the overall system cost.

Custom Designed Internal Baffles

Custom Design Internal Baffles Custom designed internal baffles are available in a wide range of configurations in accordance with industrial applications. They are mainly utilised for damaging bridges, segregation or rathole formation. Our bin dischargers incorporate various internal baffle designs (convex deflector, conical deflector or compound deflector), that promote a continuous flow of the dry bulk material through the system without bridging or jamming.

Bin Activator

Bin Activator Models

Industrial Applications

Options And Accessories

Technical Documents

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Bin Activator

Bin Activators are equipment conically shaped that aid dry bulk material flow from storage silos, or hoppers. Polimak Bin Activators are used in several industrial applications to efficiently discharge dry solid materials in powder or granular form from upstream equipment, thereby, reducing bulk material bridging or ratholing while promoting mass flow.

The fluidity of some dry bulk materials is at times so flawed that material discharge from the upstream equipment (silos, bins, etc.,) with flow aids such as pneumatic hammers, air cannons or even fluidised pads is not possible. The lack of fluidity introduces bulk material processing difficulties such as bridging, arching, or ratholing during the discharge of the material from upstream equipment. Shaking or hammering the bulk container to allow bulk material discharge might seem like something to consider but instead, this is a difficult and sometimes dangerous approach, especially when handling containers with large capacities. However, the bin activator also known as a vibrating bin discharger is one of the best flow aid and discharging equipment for such bulk materials because it renders the possibility of shaking the bulk material through vibrations without agitating the upstream equipment. This possibility is achieved with the help of an engineered polymer seal that forms a flexible connection between the bin activator and the respective upstream unit.

Bin Activator Features

Polimak’s engineering and production teams provide a vast range of industrially manufactured bin activators having different innovative features. Some of the significant design components of the equipment include the following:

Baffle Plate

An internal tapered-conical shaped baffle plate is positioned at the diameter centre of the bin activator. The baffle is rigidly attached to the body of the equipment using structural steel parts. It facilitates bulk material flow from an upstream equipment by inducing vibrations directly to the material. A secondary deflector plate eases the weight of the bulk material from the lower portion of the bin activator by acting as a wedge below the material and thrusts it around the areas adjacent to the surface of the cone. Our baffle plates come in various configurations (convex plates and cone plates) and angles (15°, 30°, 45°, or even 60°) depending on the flow characteristics of the handled bulk material and type of application.

Engineered Polymer Seal and Suspensions

Engineered Polymer Seal and Suspensions Special spring suspension links and an engineered polymer seal collectively form a flexible connection between a vibrating bin discharger and an equipment configured above it.
Proper design and installation of the polyurethane seal, prevents the seal from slipping off and the leakage of the dry bulk material. In addition, high-stress resistance and durability over time are guaranteed. These stresses are caused by motor vibrations, pressure conditions etc.

Spring suspensions externally installed to the system offer full resilience to the vibrations of the cone head. They ensure that generated vibrations do not agitate the upstream equipment structure rather than the cone itself.

Flange

In order to fit a bin activator, a silo’s cone has to be shorter than usual. This leaves a wide outlet portion. A flange that is provided together with the bin activator is separately welded to an outlet (slightly above the outlet) of the silo on the production site. The vibrating bin discharger is bolted to the flange when installed to the silo.

Vibration Motor

A vibratory motor is externally mounted to the bin activator. When powered, the electric vibrator causes the bin activator to vibrate which results in a steady flow of dry bulk materials within the system. One or two vibratory motors can be externally installed to the system.

Inlet Skirt

This is an option that we offer to help enhance the life span of the flexible connector sleeve. The skirt’s upper portion is attached to the outlet port of the upstream equipment and dangles down into and through a bin activator’s inlet port. The main purpose of the skirt is to act as a shield and render protection to the flexible connector seal.

Bulk materials handled by bin activators

Depending on the handled dry bulk material, our vibrating bin dischargers are manufactured from carbon steel, stainless steel or other types of steel. Some of the bulk materials processed using our bin activators include starch, milk powder, wheat flour, sugar, salt, bran, coffee powder, spices, rubber powder, calcium sulphate, cement, aluminium hydrate, carbon black, soot, sodium sulphate, sand, calcium carbonate, dolomite, titanium dioxide, limestone, talcum powder, copper oxide, alumina etc.

Benefits of bin activators

Polimak’s bin activators are available in a vast range for handling various types of dry bulk materials stored in different vessels of different capacities. They render many advantages to the user industries. Some of the significant benefits our bin activators offer are:

Complete resilience to the vibrating dish head provided by special spring suspensions.
Flexible seal connections at the inlet and outlet to ensure safe connections.
Excellent performance with low energy consumption.
Easy to fit and low maintenance.
High functioning efficiency.
A housed motor in a single seal enclosure.
Smooth discharge assurance.

Bin Activator FAQ

What is a bin activator?

A bin activator is an equipment with a tapered conical design that induces motion via generated vibrations to promote bulk material flow from storage silos or hoppers. During operation, the bin activator characterises a gyratory motion which is transmitted to the dry bulk material in the silo which results in smooth bulk material flow into downstream equipment.

How does a bin activator work?

The bin activator functions on the principle of convergence in relation to its shape – cone. The bulk solid material moves from a larger diameter inlet to a smaller diameter outlet of the bin activator when discharging the bulk material from upstream equipment (silo, bin etc.,) to downstream equipment (feeder, container etc.). During operation, mild vibrations of the bin activator generated by the synchronised vibrator and motor are transmitted to the dry solid material inside the silo resulting in fluent material flow through the bin activator into the connected unit. The system’s vibration levels can be easily adjusted. The motor is housed in a single seal enclosure with no belts to slip or break. The single seal enclosure ensures that there is no oil leakage, hence, preventing material contamination. Positive discharge is attained if the outlet is large enough and there is no downstream equipment to impede the flow of the bulk material. In addition to the outlet being large enough, a secondary baffle can be utilised. The secondary baffle helps prevent the jamming and compacting of the bulk material at the outlet.

What are the flow problems of stored bulk materials?

Flowability is the term that refers to the property of a bulk material which determines how well a bulk material flows from storage containers like silos or bins. It helps measure a particle’s movement freedom when subjected to a force, gravity in such a case. Dry bulk solids flow characteristics vary and can be classified according to their flowability – free-flowing, average-flowing or sluggish dry bulk solids. Free-flowing bulk solids are those in which their constituent particles possess low strength, that is, they possess low resistance to movement in relation to each other and have maximum freedom to manoeuvre independently when set in motion. Particles’ increased resistance to movement increases affects the bulk material flow, hence the terms; average-flowing dry bulk solids and sluggish dry bulk solids.

Loss of material flow from storage containers is generally due to common bulk material flow problems, namely, bridging or arching and ratholing.

What is material bridging and ratholing?

Bridging :

Bridging and arching are terms that are used interchangeably to describe an arch-shaped profile formed above the outlet of a storage container such that the flow of the dry bulk solid is stopped. Bridging in fine-grained bulk materials occurs due to the strength of the bulk solid which is caused by adhesion forces acting between the particles. In coarse-grained bulk solids, arching occurs because of particles interlocking and wedging.

Ratholing :

Ratholing is a term used to describe a funnel-shaped contour formed by bulk materials inside storage containers. It occurs when bulk solids discharge happens only in the flow channel situated right above the outlet of a silo or bin. It is caused because of the strength of the bulk material.

How can bulk material bridging and ratholing be prevented?

There are several ways used to alleviate bulk material flow difficulties from storage containers. A wide selection of flow aids for new or existing containers may be custom-made to address almost any bin flow issue. Bin activators, storage containers design and air fluidising nozzles are all options to aid condition bulk material flow and prevent arching and ratholing problems.

Bin Activator Photo Gallery

Bin Activator

Bin Activator Models

Industrial Applications

Options And Accessories

Technical Documents

Technical catalogues, product brochures, installation, operation and maintenance manuals of bin activators.

Handled Bulk Materials by a Rotary Valve

Food

The processing of most food products is fairly easy hence the basic valve design can be used without compromising the product. Foods such as salt, sugar, baking soda, wheat, rolled oats, rice, dry beans, dried corn etc. that contain preserving or sterilizing agents and do not pose any corrosion risks can be processed by a standard constructed valve. On the other hand, foods such as fatty milk powder, and infant food products have a high degree of sensitivity and require the use of a properly configured valve. The configurations include stainless-steel with a polished internal surface. The dairy sector also makes use of the properly configured rotor valve significantly. The valve is responsible for material movement whilst maintaining sanitary surroundings. The valve is designed to keep away from bacteriological contamination.

Biomass

This industry needs a valve that can simultaneously withstand the material’s hostility and maintain proper functionality. The valve serves two main purposes, (i) to behave like a lock – prevention of fire and gas reflux. (ii) to behave as a feeder – feeding the biomass to the pneumatic conveying line that conveys the biomass to the burning chamber. Thanks to the advanced geometry of the valve, large sized biomass particles of up to 50mm can be fed to the conveying line. The valves can be manufactured from carbon steel or cast iron. Further enhancements for durability are possible by means of coating.

Foundry

Steel, aluminum, cast iron, bronze, and brass are some of the common raw materials used in many industries. Foundries are places that generate a high amount of dust. Metal melting and casting are the primary sources of dust emission. Dust collection systems are used to provide a safer environment. The dust is carried from the source by a suction tube attached to the dust collector with the hooper at the bottom. The hooper is fitted at the bottom with a rotary valve for continued release of dust. The dust enters the dust collector, and the heavy particles fall down to the hooper due to the baffle plates used in the system, then exits via the rotary valve into the bin.

Chemical

Similar to the processing of infant foods in the food industry, the valve used in the chemical industry must be corrosion resistant, easy to clean, and able to withstand harsh environments. This industry involves the movement of delicate and pure chemicals whose purity cannot be imperiled. Hiccups must be avoided at all costs because of the nature of the industry.

Aggregate and Mining

Just as the name ‘aggregate’ entails, this industry is responsible for the manufacturing of building materials such as materials driven from the Earth’s core (sand, asphalt, cement, sandstone, garnet, ceramic, silicon carbide, slag etc.). Due to the nature of the industry, the valve must be solid to put up with the materials roughness and toughness. The prime function is to convey the material from an inlet down through its desired point of work. The valve must have the following characteristics; abrasion resistant, Hardox rotor and housing, and coated internal surface with tungsten carbide or hard chrome. This particular valve is not only used in this industry, but also in asphalt, cement, coal, and mining industries just to mention a few.

Agriculture

This is one of the industries that immensely makes use of the rotary feeder. The rotary valve is used mostly for handling grains. The grains are supplied to the valve, then the valve discharges the grains to the conveying pipeline. Properly selected rotary valves provide good service without harming handled product.

Other bulk materials handled include cement, calcite, ash, glass powder, marble powder, plastic pellets, sawdust, fly ash, coal, coal dust, wheat, flour, barley, feed, seed, corn, chickpea, bean, soybean, sesame, rice, rice flour, dried fruit, nuts, peanut, almond, sunflower seed, cotton seed, grain cereals, chestnut, coffee grain, coffee powder, sugar, salt, spice.

ATEX Certified Rotary Valve

Atex certified rotary valves play an important role in bulk material handling industries that process combustible dry bulk materials. They are used to help reduce or isolate explosion propagation in instances where a combustible cloud ignites. Polimak’s ATEX rotary valves are certified with 10 bar explosion tests.

An ATEX certified rotary valve does not cause a risk for explosion, hence it is an ideal choice for explosive zones. All rotary valve components such as rotary valve rotors, rotary valve endplates etc., comply with ATEX regulations and provide ex-proof characteristics. An ATEX certified airlock valve can be used in the food industry and many other industries that handle combustible dry bulk solids.

Explosion isolation and flame proof

In a case where a dust cloud ignite during material handling, there are various ways of stopping a flame from spreading throughout a production line. One of the way to do so is by using isolation the flame by using ATEX certified equipment – rotary valves. They designed in such a way that they can stop a flame wave and resist or reduce the explosion pressure impact. This is commonly referred to as flame resistance and explosion isolation. Coal powder, sugar powder and flour are some examples of combustible bulk materials. For a rotary valve to be used in industrial sectors that handle inflammable bulk materials, the rotary valve must be ATEX certified.

ATEX zone classification

Industries are to classify the areas of the explosive atmospheres into zones according to the ATEX directive. The probability of the explosion developing and how long it will persist if developed, determines the location, size, and classification of the zone. The zone classification for hazardous clouds of dust and fibres are;

ATEX zone classification

ZONE 20

This is an explosive atmosphere with a combustible dust cloud that is likely to ignite frequently and extensively.

ZONE 21

This is an explosive atmosphere containing a combustible cloud that ignites less frequently and less extensively compared to that of Zone 20.

ZONE 22

In this zone, the explosive atmosphere contains a combustible dust cloud that ignites less frequently than in the aforementioned zones and occurs for a short period.

For the ones that involve hazardous gas, mist or vapour, the zones can be classified as follows.

ZONE 0

This comprises areas where an explosive atmosphere containing dangerous gas, vapour or mist may combust frequently for an extended period.

ZONE 1

This includes areas where the explosive atmosphere with hazardous vapour, mist or gas is likely to combust less frequently and less extensive compared to the effects in Zone 0.

ZONE 2

An explosive atmosphere containing gas, vapour or mist that ignites less frequently and occurs for a short period compared to Zones 0 and 1.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Atex rotary airlock valve explosion isolation dust flame preventation

Because an ATEX certified valve does not pose an explosion risk, it is frequently utilized with explosive materials. All ATEX certified devices are utilized with atmospheres having the possibility of explosion occurrence because of materials that are likely to ignite.

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Accessories And Options

Polimak renders a wide range of industrial production rotary valves (or airlock valves) with innovative options and accessories. Options and accessories ensure smooth and efficient functions as well as safe operation over time. Rotary valve endplates, housings and drive connections/systems are some of the valve’s parts where these features can be installed. Some of the options and accessories that allow enhanced material handling by our rotary valves include:

Pneumatic Conveying Line Connection Adapter

Also referred to as a discharge blow-through adapter, a pneumatic conveying line connection adapter is used in pneumatic conveying systems to efficiently introduce dry bulk materials into a conveying stream in a preferably low turbulence manner. The flange can either have a circular, square or rectangular shape and can be used with both flow-through and offset rotary valves.

Pneumatic coveying line connection adaptor

Slide Gate Valve

Slide gate valves are engineered to offer efficient flow control of free-falling bulk materials. They are able to close off the material flow, hence they are sometimes referred to as close off valves or maintenance slide gate valves. Slide gates are designed with circular, square or rectangular flanges and can be fitted above a rotary valve.

Shaft Air Purge

A shaft air purge (SAP) is an essential feature to add to rotary valves, especially the ones used for handling fine bulk material. It is used to blow air past a shaft seal and bearings by introducing minimal amounts of compressed air through a valve’s cover plates to prevent contamination. A shaft air purge is also known as a shaft seal purge.

Rotor Pocket Purge

A rotor pocket purge is used for dry bulk materials with the tendency of filling up inside the rotor pockets, especially in the V-shaped rotor pockets. Compressed air is passed through the rotor area and prevents material build-up inside the pockets. Cavity air purge (CAP) is commonly used for closed-end rotor types handling abrasive, chip or flake dry bulk solids. A cavity air purge is typically used for abrasion reduction of rotor shrouds and cover plates. Abrasion reduction is achieved by blowing off bulk materials that try to settle between shrouds and end-plates.

Zero Speed Switch

Also known as a rotational sensor, a zero speed switch is a safe option that can be used with any rotary valve model. It is mounted on the valve’s shaft guard on the non-drive end and is connected to a control system. It alerts a programmable logic controller (PLC) system when the rotation of the rotor shaft stops. This option comes in handy with regard to monitoring the valve.

Shear Protector

Some dry bulk materials such as plastic pellets, wood pellets, plastic flakes, nuts etc., are susceptible to breaking easily during handling. A shear protector is used to reduce breakage occurrences during operations. Its configuration includes a bent wiper with a flexible polyurethane tip at the end. This configuration helps prevent bulk materials from jamming as they flow into a functioning rotary valve. As the bulk material flows in via the entry port, any material overflow is swept into the next rotor pocket.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Drive System

Rotary valve drive connections designed and manufactured by Polimak come in three different variations, the worm gear reducer connection, direct coupling connection and the chain drive connection. These drive connections are implemented to a rotary valve through a rotary valve rotor.

Worm Gear Reducer Drive Connection

A worm gear is the fundamental component of a worm gear reducer direct connection. It is a compact gearing equipment used for high motor speed reduction to produce low-speed output with high torque – hence the term ‘worm gear reducer’. The low-speed output is determined by the thread number on a worn and the number of teeth on a worm wheel. In other words, the output speed is based on the reduction ratio. Worm gears are used in various equipment including rotary valves. An electric drive motor and a worm gear reducer form a drive system (worm gear reducer drive) that is directly connected to a valve rotor shaft. This connection ensures reduced rotation of the rotor shaft inside the valve housing, thereby allowing smooth and controlled bulk material flow with the system.

Direct Coupling Drive Connection

The main component in a direct coupling drive connection is a coupling, also referred to as a shaft coupling. Shaft couplings are designed to transmit torque between a driving shaft and a driven shaft. They consist of two hubs, one fixed at the end of each rotating shaft. Torque is transmitted through these hubs. An electric drive motor and a driven machine (rotary valve) are directly connected using a shaft coupling. The coupling cannot reduce the motor’s rotating speed and for this reason, a worm gear reducer is used to ensure low-speed output. A direct coupling drive connection offers some of the following benefits; the absorption of mounting errors (shaft misalignment), vibration absorption during operation etc.

Chain Drive Connection

A chain drive is used for transmitting mechanical power from an electric drive motor to a driven shaft. It consists of a chain and two or more sprockets (two sprockets are typically used with rotary valves). The sprockets are attached to the drive motor shaft and the driven shaft (valve rotor shaft). The chain holes (pitches) fit over the sprocket teeth. Power is transmitted through the chain during operation. A worm gear reducer is used with chain drive connections because they cannot reduce the output rotating speed of a motor.

DRIVE CONNECTIONS FAQ

What is a drive system?

A drive system or sometimes called drive connection refers to a type of system or connection driving a machine during its operational duration.

What is Coupling?

A shaft coupling is a mechanical device that connects two rotating shafts for torque transmission from a driving shaft to a driven shaft.

How does a worm gear reducer work?

A worm gear consists of a shaft with spiral threads known as a worm and a toothed wheel known as a worm wheel (spur gear). A worm gear reducer is formed when the threads of a worm perpendicularly align to fit the teeth of a worm wheel. Torque is applied to the gear assembly via a worm pinion. As an electric motor applies a rotation force to the assembly, the worm’s threads push against the teeth of the worm wheel causing it to rotate. The rotation of the worm wheel applies a torque to the driven which turns at a speed related to the reduction ratio of the gear assembly.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Endplates

Endplates are precisely designed and manufactured to properly fit both ends of a valve housing, thereby acting as side covers of a housing. Endplates contain and prevent dry bulk solid leakage in the longitudinal direction of a rotary valve. A rotary valve endplate has a circular opening (hole) at its center that acts as a pathway for a rotor shaft which allows the rotation of a rotary valve rotor during operation. These plates fall into two categories based on their design configuration; inboard and outboard mounted bearings. They are sometimes referred to as housing cover plates. It is on these cover plates where bearings and seals are installed to allow smooth and leakage-free bulk solids handling.

ROTARY VALVE ENDPLATES CONFIGURATIONS

Inboard bearings

Inboard bearings allow smooth rotation of the rotor shaft through the housing cover plates. The bearings are fitted directly on the endplate. Inboard mounted bearings use is typically confined to low duty rotary valves where process handling characteristics are not complex. Due to their orientation, the bearings are at risk of getting contaminated and may not be suitable for use in higher temperatures.

Outboard Bearings

Outboard bearings also allow smooth rotation of the rotor shaft through the end-plates. These bearings are outboard fitted to the cover plates. Because of their orientation, outboard mounted bearings are not exposed to product contamination and may be suitable for use in heavy-duty rotary valves. They can accommodate a wide range of process handling characteristics and provide bearing protection.

Outboard bearing (rotary valve endplate)

Gland Packing Seals

Gland packing seals are utilised to form an airtight seal around a rotor shaft. This seal prevents bulk materials from escaping/leaking as the rotor shaft rotates. The seal is inserted manually into the stuffing box and compressed using a gland follower. Multiple rows can be used depending on the application and handled material. It is the commonly used seal.

Gland packing seal (rotary valve endplate)

Lip Seals

The primary function of lip seals is to keep away contaminants and retain lubricants. They also confine pressure. The nature of a seal is to function by maintaining proper contact with the rotating counterpart (rotor shaft). The sealing edge diameter is slightly lesser than the shaft diameter. The sealing lip (front face) is angled at the point of contact with the shaft to reduce friction. The garter spring helps maintain the pressure on the shaft.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Seals

A variety of sealing options with different properties are available to operate in different conditions. A seal is fitted inside the stuffing box situated on the end plates. It prevents the material outflow from the rotor pockets into the bearing region. It also prevents impurities from entering the rotor housing. Failure of the seal compromises the rotary valve system. When compromised, the bearings are put at risk and if combustible materials are processed, the entire valve system becomes dangerous because of the increased risk for material buildup and ignition. Some of the commonly used seals include; gland packing and lip seals. The operating environment affects the lifespan of these seals.

Gland Packing

Whenever a gland packing seal is utilized, a gland follower is commonly used to compress the packing. The seal is manually into the stuffing box. It is the most commonly used seal even though it is not necessarily easy to replace. Multiple rows can be depending on the valve model. When several rows are used, they are stacked together to prevent leakages in most valve systems. The seal is made from a mixture of different materials.

Lip Seal

The lip seal uses a similar working approach to that of a gland packing seal. The primary function of a lip seal is simply to keep away contaminants and retain lubricants. It also confines pressure. The nature of the seal is to function by maintaining proper contact with the rotating counterpart. The sealing edge diameter is slightly lesser than that of the shaft that is to go through it. The sealing lip (front face) is angled at the point of contact with the shaft in order to reduce friction. The garter spring helps maintain the pressure on the shaft.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Applications

Rotary Valve Models

Handled Bulk Materials

Rotary Valve Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Valve Housing Types

Rotary valves are essential for most of the industrial systems including the pneumatic conveying systems. The design, and composition are both solely dependent on its function. Some of the most commonly used models include; flow through (FT) series, blow through (BT) series, and offset (OS) series.

Flow Through (FT) Series

This is the most basic and common valve. It is also known as the drop-through rotary valve. The bulk material is supplied to the valve through the inlet port to the pockets, then transported through blades and exits right through the outlet port to the conveying line. This model is widely used for non-cohesive and free-falling materials like sand, wheat, rice, coffee beans etc. The cleaning of the valve is easier because the inside can be reached without the conveying line being dismantled.

Blow through (BT) Series

Unlike the drop-through valve, the blow-through valve has a sealed bottom. It does not contain an exit flange like that of the FT valve, instead it has a trough where the pneumatic conveying line connects. The feed is supplied to the valve via the inlet port, then the rotor turns and drops the feed into the trough where it is blown out into the conveying line. It is suitable for more cohesive materials like flour, milk powder, custard etc.

Offset Series

The offset rotary valve is designed to make sure that the filling efficiency is never 100%. This configuration is set to minimize product shearing. It is used for materials like sunflower seeds and peanuts.

CUSTOM DESIGNED ROTARY VALVE MODELS

Unique customer demands call for uniquely designed rotary valves. Custom designed products answer this call. Polimak makes possible the production of customized rotary valves aside from the standard rotary valves. Custom engineered rotary feeders are available in blow through, flow through and offset housing configurations. Our engineering team is capable of discussing the feed rates and the material’s characteristics to help select ideal housing size, rotor, drive system and seals that will ensure effective operations. Polimak is able to design and manufacture rotary feeders for customized applications in a short period of time.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Applications

Rotary Valve Models

Handled Bulk Materials

Rotary Valve Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Rotors

A rotary valve rotor is a rotating component of a rotary valve and is primarily used for controlling the bulk material flow from upstream equipment to downstream equipment. The rotation of the valve rotor is powered by a drive motor connected to it – various rotary valve drive connection are available.

Polimak offers two fundamental designs of rotary valve rotors (open end rotor and closed end rotor) commonly used in most industrial applications.We also render various rotary valve rotor types with modified features to help improve the performance during operation. The optimal rotor design is determined by the application, bulk material characteristics and feed rate. Proper selection of a valve rotor is crucial as it helps prevent premature wear, downtime, reduced efficiency and increased maintenance.

Rotary Valves Rotor Types

Open End Rotors

Open-end rotors are among the commonly used rotors in rotary valve configurations. Rotor pockets are open at each end hence the name open-end rotor. Dry bulk materials are contained on each end of the pocket by the valve housing. Open-end rotors are an ideal option for lighter bulk materials and are comonly used to handle dry bulk solids in food, pharmaceutical, ped food and chemical industries.

Closed End Rotors

Closed-end rotors have discs also know as shrouds welded to each end of the rotor pockets. This prevents the blades from coming in direct contact with the endplates and helps reduce bearing contamination by offereing better sealing in comparison to open-end rotors. Industries such as chemical, construction, plastic and other related bulk material handling industries.

Adjustable Tips Rotors

These rotor types are commonly used to handle abrasive dry bulk solids. The end of the blades have tips attached to them. Due to the characteristics of the handled bulk materials, the tips may wear out prematurely. Wearing out of the tips compromises the clearance between the valve housing and the rotor. The tips can be replaced easily to maintain optimal clearance between the housing and the blades. These rotors can be used in many industries including the construction industries.

Reduced Volume Rotors

Reduced volume rotors have reduced rotor pocket volume. The volumetric capacity of a rotary valve is decreased to match required throughput with a good degree of accuracy. If bulk materials flow too easily through a rotary valve, a downstream system may encounter challenges such as material clogging. Reduced volume rotors provide controlled bulk material flow in such instances. Pharmaceutical, chemical, food, construction and pet food are some of the industries where such rotors can be utilised.

Adjustable Polyurethane Tip Rotors

Similar to adjustable rotors, adjustable polyurethane rotors have replaceable tips. Flexible tip designs are used to handle large-sized and moderate abrasive dry bulk solids. These rotors are used to handle bulk solids such as plastic flakes, wood pellets, plastic pellets, plastic regrind etc.

Staggered Pocket Rotors

Staggered pocket rotors have rotor pockets arranged in an alternating manner (the pockets are not directly aligned). They offer continous and smooth bulk material flow into downstream equipment. The name staggered is derived from the pocket misalignement. Staggered pocket rotors are widely used in construction, pharmaceutical, plastic and pet food industries.

Scalloped Rotors

Instead of the V-shaped pockets, scalloped rotors have smooth U-shaped pockets that help with the discharge of sticky dry bulk materials and minimize material packing. Scalloped rotors are commonly utilised in food, chemical and pharmaceutical industries.

Metering Rotors

Metering rotors provide controlled bulk material feeding with high precision. They are commonly used for metering small quantities of dry bulk solids. Metering rotors are frequently used in food, chemical and pharmaceutical industries.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Vacuum Conveying and Octabin Filling System

In this video, grains vacuumed by vacuum blower with the help of the flexible suction hose are conveyed to the cyclone which is the vacuum receiver of the system. The material inside the cyclone is then discharged into the octabins through the rotary valve. The dust created during application is filtered by the dust collector which is connected to the system. The dust particles separated from the air and the air is exhausted from the filter system. The dust particles are again discharged into the cyclone.

Your application might require a faster system or a system with higher capacity. In addition to standard packaged handling systems, Polimak produces tailor made designs for most demanding applications.

Liner Bag Filling And Unloading Systems

Polimak provides all-round solutions to help bulk producers in logistics and warehouse management, covering the three main steps of the process: loading, main carriage, and unloading.

Liner Bag Unloading System Container Emptying Bulk Material Discharge Material Conveying Underground Application Pressure Tank

Different components may be used in each application to meet requirements however screw feeders, pump and motor group, rotary feeders, loading hoppers are some of the key components in filling and unloading systems.

Liner Bag Unloading System Container Emptying Bulk Material Discharge

When unloading, the output spout of liner bag is connected to loading hopper of the system. The material fallen down into the hopper are then transffered to the storage medium like silos by pneumatic conveying line. Whole system is able to be controlled by installed control panel.

Liner Bag Filling System Container Filling Screw Feeder Loading System

1. Loading

You can utilize the loading method according to your needs:

Loading from the plant;
Direct loading from a silo to a container;
Loading from a stockpile to a container;
Loading from bulk bags to a bulk truck.

Our innovative solutions offer a range of loading alternatives tailored to handle even the most challenging bulk materials.

Whether it’s through vacuum technology, conveyors, or specialized equipment, Polimak provides versatile solutions that ensure efficient and reliable bulk solid transfer.

2. Main-Carriage

The product is then transported via container shipping, short-sea shipping, train, or standard container chassis, by choosing the most efficient mode of transport.

Transport your bulk solid material in standard ISO containers.

3. Unloading

After arriving at the final destination, the product is unloaded safely using mechanical, horizontal conveying. According to the customer’s needs, the unloading can be carried out in the following ways:

Discharging the container directly to a silo;
Discharging the container to a further production process;
Discharging the container to a bulk truck.

The Critical Importance of Containerized Transport for Bulk Solids

Transporting bulk solids in containers provides significant advantages in modern logistics.

Standardized and Flexible Solution: Containers enable smooth intermodal transfers between different transportation modes, such as ships, trains, and trucks, ensuring a seamless and efficient flow throughout the supply chain.
Improved Product Protection: Containers help reduce the risk of contamination and material loss, ensuring the safe transport of bulk solids.
Minimized Handling: By reducing handling, containers speed up loading and unloading processes, leading to lower costs and increased productivity.

As a result, containers prove to be a smart choice for industries seeking cost-effective, safe, and well-organized transportation of bulk solids.

Mobile Bulk Truck Loading Systems Technical Documents

Brochure of Mobile Bulk Truck Loading Systems

Links

Mobile big bag discharge silo truck loading system sack discharge jumbo bag discharge

Big Bag Discharge and Loading System

Efficient discharging of big bags and dust-free loading of bulk trucks. The mobile system consists of a mobile platform, big bag discharger, loading screw, telescopic loading chute, and dust collector.

Mobile truck loading with front end wheel loader big hopper loading system

Mobile Truck Loading System with Front End Loader Hopper

Efficient dumping of materials to built-in loader hopper by wheel loaders. This system consists of a mobile platform, front end loader hopper, loading screw, telescopic loading chute, and dust collector.

Mobile silo truck loading system with vacuum sucking hose

Mobile Truck Loading System with Vacuum System

Efficient conveying of materials by vacuum system to trucks. The system consists of a mobile platform, flexible suction hose, vacuum receiver, pump, motor, loading screw, telescopic loading chute, and dust collector.

Mobile truck loading system mobile discharge system mobile bulk material handling system

Mobile Bulk Truck Loading Systems

Mobile systems with bigbag discharge, vacuum and large hopper are used for rapid and efficient loading of bulk solids into trucks or other bulk carriers. Our system’s excellent design and robust construction ensures easy management of loading and discharging of free flowing bulk solids.

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of mobile bulk truck loading systems.

Mobile Truck Loading System with Vacuum System

In this system the product that is to be loaded is pumped in by a vacuum system. The product inlet is the beginning of the pipeline, and then there is a mini vacuum silo / cyclone that pull in the product. Once the product is in the hopper then it is conveyed up by screw conveyor and finally loaded to by the bellow on to the truck.

Description

Mobile bulk material vacuum and truck loading systems are used for efficient conveying of materials to trucks. The system consists of a mobile platform, flexible suction hose, vacuum receiver, pump, motor, loading screw, telescopic loading chute, and dust collector. The screw conveyor can be brought to a horizontal position for easier and safe transport.

Operation

Mobile system is placed near the bulk truck to be loaded and the screw conveyor is lifted to 45 º angle with the help of automatic screw jacks.

Materials vacuumed by vacuum blower with a flexible suction hose are conveyed to the cyclone (vacuum receiver) of the system. Material inside the cyclone is then transferred by inclined screw conveyor to the top of the truck and discharged into the bulk truck through the telescopic chute. Dust emission is prevented by a dust collector which is connected to the telescopic chute.

Material coming from the screw conveyor is discharged through the telescopic chute. At the beginning of truck loading, the chute is lowered and stops automatically when it reaches to tanker inlet. Polyurethane coated discharge cone fits vessel inlet to prevent any dust emission during truck loading. Material falls freely through the inner side of the bellow. After bulk tanker truck filling is started, a built-in dust collector evacuates the air trapped in the vessel to increase the product flow rate. Dust content in the air is trapped by filter units and sent back to the hopper with the help of automatically operated pulse jet valves. The level sensor placed at the bottom monitors the product level in the tanker truck and stops loading when the truck is full. Telescopic chute retracts to the top position automatically.

Telescopic chute is used for safe and dust-free loading of the bulk truck. The dust collection system captures the dust created during the emptying of big bags and the loading of the tanker truck. Once the dusty air is filtered, the clean air is thrown out and the dust collected inside the filter is transferred to the loader hopper. The whole system is connected to this wheeled mobile chassis that allows the transportation of the system to the desired location by tow-bar, forklift, or vehicle.

When loading is finished, the screw jack lowers the screw conveyor automatically to the horizontal position when the system is to be moved to another location.

Various Parts of the System

Vacuum Receiver/ Cyclone

The material vacuumed by the flexible suction hose is conveyed to the vacuum receiver. Then the material is transferred from the cyclone to the screw conveyor. Its volume is 1 m3 and is made of ST-37 Carbon Steel.

Flexible Suction Hose

The flexible suction hose is used for vacuuming materials from any desired point or medium to the screw feeder. Its length is 12 meters and is made of Rubber (Antistatic rubber is available upon request). It has a suction/nozzle.

Screw Conveyor

The screw conveyor enables the transfer of the material conveyed from cyclone to tanker loading bellow. It can be brought to a horizontal position when the system is to be moved to another location. It is made of ST-37 Carbon Steel. It is driven by an electrical motor with a gearbox. The inclination Control is by screw jacks.

Screw Jack

It enables the movement of the screw conveyor and telescopic chute upwards and downwards. When the system is installed in the area, the screw conveyor is lifted to 45 º angle with the help of automatic screw jacks. When loading is over, the screw jack lowers the screw conveyor automatically to the horizontal position. 2 units work in parallel.

Telescopic Chute

The telescopic chute used for safe and dust-free loading of the bulk truck. It has a capacity of 250 m³/h. It is made of carbon steel and driven by an electrical motor with a gearbox.

Dust Collection System

The dust collection system captures the dust created during the loading of the tanker truck. Once the dusty air is filtered, the clean air is thrown out and the dust collected inside the filter is transferred to the screw feeder. It is a cartridge type jet pulse filter with a fan made of carbon steel. It has 8 cartridges. The operating pressure is 4-6 bars.

Air Compressor

It is used to supply pressurized air needed to operate a dust collector. It has a maximum pressure of 6 bars.

Electrical Control Panel

There is an electrical panel to control the equipment in the system. It has both cabled and wireless remote controls and is based on Siemens S7 1200 PLCs.

The Mobile Chassis

The whole system is connected to this wheeled mobile chassis that allows the transportation of the system to the desired location by tow-bar, forklift, or vehicle. It is made of carbon steel. It has 4 wheels and has swivel jacks to provide rigidity during truck loading.

Advantages of Using a Vacuum System

Quick loading
Efficient
Less manpower is used.
Environment friendly as there is less dust in the environment
No loss of material

Different Applications of the Vacuum System

Different applications of vacuum system different methods discharge places with suction hose loading discharge

Links

Big Bag Discharge and Loading System

Mobile Truck Loading System with Front End Loader Hopper

Mobile Truck Loading System with Vacuum System

Mobile Bulk Truck Loading Systems

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of mobile bulk truck loading systems.

Mobile Truck Loading System with Front End Loader Hopper

Mobile truck loading with front end wheel loader large hopper loading system

Description

Mobile truck loading systems with built-in loader hopper are used for efficient dumping of materials by wheel loaders and filling bulk trucks. The system consists of a mobile platform, front end loader hopper, loading screw, telescopic loading chute, and dust collector. Screw conveyor can be brought to a horizontal position for easier and safe transport.

Operation

When mobile system placed near the desired bulk truck to be loaded, the screw conveyor is lifted to 45 º angle with the help of automatic screw jacks.

A bucket of wheel loader dumps material to the hopper of the system. Rugged enough to withstand incidental contact with the front end loader, the heavy-gauge hopper provides an ample supply of material for the high capacity screw conveyor to run continually as a front end loader replenishes the material.

Optional air jets are available to aid product flow inside the hopper and vibrator to ensure complete and quick flow of the material.

Material inside the hopper is then transferred by inclined screw conveyor to the top of the truck and discharged into the bulk truck through a loading bellow.

The dust created during the process is prevented by a dust collector which is connected to the loading bellow and front end loader hopper. Dust content in the air is trapped by filter units and resent to the hopper with the help of automatically operated pulse jet valves.

Material coming from the screw conveyor is discharged through the loading bellow. At the beginning of truck loading process, the chute is lowered and stops automatically when it reaches to the tanker inlet. Polyurethane coated discharge cone fits vessel inlet to prevent any dust emission during bulk truck loading. Material falls freely through the inner side of the bellow.

After bulk tanker filling is started, a built-in dust collector evacuates the air trapped in the vessel to increase the flow rate of the product . Dust content in the air is trapped by filter units and sent back to the hopper with the help of automatically operated pulse jet valves. The level sensor placed at the bottom monitors the product level in the tanker truck and stops loading when the truck is full. Loading bellow retracts to the top position automatically.

Loading bellow is used for safe and dust-free loading of bulk trucks.
The dust collection system captures the dust created during the emptying of big bags and the loading of tanker trucks. Once the dusty air is filtered, the clean air is thrown out and the dust collected inside the filter is transferred to the loader hopper. The whole system is connected to the wheeled mobile chassis that allows the transportation of the system to the desired location by a tow-bar, forklift, or vehicle.

When loading is completed, the screw jack lowers the screw conveyor automatically to the horizontal position when the system is to be moved to any other desired location.

Various Parts of the System:

Front End Loader Hopper

The material brought by a bucket of a wheel loader is discharged into the loader hopper. Then it is transferred to the screw conveyor. It has a capacity of 5 m3 and is made of ST-37 Carbon Steel. There is the option of having fluidizing air jets to aid product flow inside the hopper and also the optional vibrating engine to ensure the fluidity of the product.

Screw Conveyor

The screw conveyor enables the transfer of the material conveyed from cyclone to tanker loading bellow. It can be brought to a horizontal position when the system is to be moved to another location.

Screw Jack

Loading Bellow

It is used for safe and dust-free loading of the bulk truck. Material coming from the screw conveyor is discharged through the loading bellow.

Air Compressor

It is used to supply pressurized air needed to operate a dust collector. It has a max pressure of 6 bars.

Electrical Control Panel

There is an electrical panel to control the equipment in the system. The following components can be controlled from the electrical panel.

The Mobile Chassis

The whole system is connected to this wheeled mobile chassis that allows the transportation of the system to the desired location by towbar, forklift, or vehicle. It is made of carbon steel. It has 4 wheels and has swivel jacks to provide rigidity during truck loading.

Links

Big Bag Discharge and Loading System

Mobile Truck Loading System with Front End Loader Hopper

Mobile Truck Loading System with Vacuum System

Mobile Bulk Truck Loading Systems

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of mobile bulk truck loading systems.

Big Bag Discharge and Loading System

Mobile big bag discharge silo truck loading system

System Description

The mobile big bag discharge and loading systems are used for efficiently discharging big bags and dust-free loading of bulk tanker trucks. The system consists of a mobile platform, big bag discharger, screw conveyor, telescopic chute, and dust collector. The system can be towed by a forklift or by a towbar for easier and safe transportation.

Functional Description

At the loading site, the mobile system is placed near the bulk truck which has to be loaded. The screw conveyor is elevated to an appropriate height such that the telescopic chute is connected to the tanker via an inlet port. The screw conveyor’s elevation is accomplished with the help of the screw jacks. After the successful setup of the system, the big bag is brought to the loading site by a forklift. The big bags with flat bases are placed on the discharging hooper (hooper with an inbuilt knife), the knife creates an opening below the bag for bulk material release and the bag is emptied in this manner. In the case of big bags with emptying spouts, an operator unties the spout for material release. When the material is released to the hooper, it is passed to the screw conveyor where it is conveyed to fill the truck. The bulk material is supplied to the truck from the screw conveyor via a telescopic chute.
At the beginning of loading process, the telescopic chute (also known as the loading bellow) is lowered and stops automatically when it reaches to the tanker’s inlet. A polyurethane coated discharge cone fits the vessel inlet to prevent any dust emission during the loading process. The material falls freely through the inner side of the chute.

During the loading process, emitted dust is captured by a dust collector which is connected to the telescopic chute and big bag discharging hopper. The floating dust content inside the system is trapped by the filter units and sent back to the hopper with the help of automatically operated pulse jet valves.

The level sensor located at the chute’s outlet monitors the material level inside the tanker and stops loading when it is full. The loading bellow retracts to its initial position automatically. When loading is over, using the control panel, an operator can bring the srew conveyor to its initail position by means of the screw jacks. The loading bellow is used for safe and dust-free loading of the bulk truck. All the components of the system are customized to accommodate its application requirements.

Components of the system

Big Bag Discharge Hopper

This is used for discharging big bags and transfers the material to the screw conveyor. It has metal grating for simpler handling of big bags.

The following options are available:

Cutting knife to cut the big bags instantly when placed on the hopper.
Fluidizing air jets to aid product flow inside the hopper.
Vibrating engine to ensure a good flow of the product.

Screw Conveyor

The screw conveyor enables the transfer of the material conveyed from cyclone to tanker loading bellow. It can be brought to its initial position when the system is to be moved to another location and It is driven by an electrical motor with a gearbox. The elevation is controlled by the screw jacks.

Screw Jacks

They enable the movement of the screw conveyor and telescopic chute upwards and downwards. When the system is installed on site, the screw conveyor is elevated with the help of automatic screw jacks. When loading is over, the screw jacks lower the screw conveyor to its initial position.

Loading Bellow

The loading bellow or the telescopic chute is used for safe and dust-free loading of the bulk tanker truck. It driven by an electrical motor with a gearbox.

Dust Collection System

The dust collection system captures the dust created during the loading of the tanker truck. Once the dusty air is filtered, the clean air is passed out and the dust collected inside the filter is transferred to the screw feeder.

Air Compressor

It is used to supply pressurized air needed to operate a dust collector. It has a maximum pressure of 6 bars.

Electrical Control Panel

There is an electrical panel to control the components in the system. A cabled remote control and a wireless remote control maybe used for control purposes. All the components can be controlled from the electrical panel.

The Mobile Chassis

The whole system is connected to a chassis that allows the transportation of the system to the desired location by a towbar, a forklift, or a vehicle. It has 4 wheels and has swivel jacks to provide rigidity during truck loading.

Other available options are the air jets. They help with the product flow inside the hopper and the vibrator ensures complete and quick flow of the material.

Advantages of the Big Bag Discharge and Loading System

It is the ideal system when the product is in large bags
Efficient (Efficient for nearly every throughput capacities)
Offers high standards for material, plant and operators protection.
Low dust emission
Economical
Robust

Links

Big Bag Discharge and Loading System

Mobile Truck Loading System with Front End Loader Hopper

Mobile Truck Loading System with Vacuum System

Mobile Bulk Truck Loading Systems

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of mobile bulk truck loading systems.

Pneumatic Conveying of Baghouse & ESP Filter Dusts

Dust collection systems, baghouse filters and ESP systems are used to remove dust from production lines. Collected dust is discharged from the bottom hopper of dust collectors and sent to containers, trucks and / or silos. Dust discharge and conveying is handled by different types of conveyors. Pneumatic conveying systems provide reliable and safe handling of filter dusts. Mechanical malfunctions caused by screw conveyors, scrapers, bucket elevators, chain gears and similar mechanical conveying equipment are prevented.

Features of Pneumatic Dust Conveying Systems

Pneumatic conveying system transfers the collected dust from filter or cyclone hopper to silo. Rotary valves are installed below each bag filter hopper. A pneumatic conveying pipeline is installed below rotary valves and collects the dust coming from hoppers. Pressurized supplied from roots type blower is used to transport the dust to the silo through the pipeline. A reverse jet pulse filter is installed above the silo to discharge the pressurized air and keep the conveyed dust inside the silo. Depending on configuration several bag filters, dust collectors can be connected to same pneumatic transport line. System can be designed to run by pressurized air or vacuum air.

Roots Blowers for fly ash handling in power plant

Components of Dust Conveying System

Roots Blower:
Used to supply pressurized or vacuum air needed for pneumatic conveying system.

Rotary Valve / Rotary Airlock:
Used to discharge the dust from filter hopper to conveying line. It also prevents some amount of pressurized air to move inside the filter hopper.

Electrical Panel:
Used for controlling whole system. PLC , relays, frequency inverters etc are included in electrical control panel of pneumatic filter dust conveying system

Pneumatic Conveying Pipeline:
Used to transfer the filter dust. Depending on the conveying capacity, pipeline diameter varies generally between 3” -5”.

Silo Top Jet Filter:
Jet filter is used to vent pneumatically filled silo, keeps the dust inside of the silo and lets the pneumatic conveying air to leave it.

Telescopic Truck Loading Spout:
Telescopic loading spout also known as loading chutes are used to automatically discharge the contents of silo into open trucks or tanker trucks without any dust emmission.

Pneumatic Conveying of Baghouse & ESP Filter Dusts

Advantages of Pneumatic Dust Conveying Systems

Pipeline can pass through anywhere, it is easier to install the system in tight spaces.
Filter dust can be conveyed to long distances.
Pneumatic transport system takes less space with respect to mechanical conveying systems inside the plant.
AS the filter dust is conveyed within the pipeline, there is no risk for dust emmission through moving mechanical parts.
There exist low number of rotating or moving equipment. Low risk of malfunctions, unintended stops.
Maintenance cost of pneumatic conveying systems is generally less than mechanical conveying systems.

Tanker / Truck Loading Spout

Tanker and open truck loading bellows are also known as loading chute and loading spout. Open truck and tanker loading bellows are used for safe and efficient dust free loading of dry bulk solids to tankers and open trucks. As baghouse filter and ESP filter dust have very small particle size, silo discahrging and truck loading should be done by loading bellows to prevent any dust emmission to the environment.

Application Examples of Filter Dust Conveying Systems

Iron and steel plants, blast furnace dedusting systems
Electrostatic Precipitators (ESP) of coal-fired power plants
Baghouse filters of iron foundries
Dust collectors of the food industry
Dust collectors of chemical industry

Industrial IOT Based Silo Level Monitoring and Inventory System

Storage Silo monitoring inventory management tank level monitoring industrial iot

Bulk material storage silos and tanks are crucial inventory storage units used in wide range of industries. Businesses must maintain their raw material reserves at a level that ensures efficient operation without using unnecessary additional storage. Plant operators are generally aware of what is going on and they have full control over storage facilities. But, there still remains an important challenge: having the right stock volumes at the right times. As storage vessels generally process both inbound and outbound deliveries, it is essential to have both enough available storage volume to accommodate inbound shipments, as well as to have sufficient stock levels to fulfill outbound orders. When one of those criteria are not met, either production will stop due to shortage of stock or extra costs will accumulate due to inadequate storage volume.

Altough checking and maintaining the stock level is the most important concern in bulk material handling, several other aspects should also be considered. Pressure and temperature inside the silo or tank, leaks, dust emmission, health of process equipment, vibration of fan or pump motors, outside weather conditions are some of the important parameters to be monitored for process, plant and operator safety. Condition monitoring of all connected equipment such as pumps, fans and valves provides extra functionality to keep the storage facility running all time without unintended interruptions.

Due to the stated concerns, digital monitoring and automation are quickly becoming essential for maintaining appropriate stock levels and safe operation in wide ranges of industries. Industry 4.0 concept and recent developments in industrial IoT (industrial internet of things) technology have made it possible to achieve efficient management of storage facilities with maximum safety and minimum cost. By integrating intelligent sensors that measure fill levels, process data and environment conditions, silo managers are now able to make better and faster decisions on their operations.

Polimak industrial Iot based silo monitoring system provides one of the most sophisticated solution for bulk material storage challenges using the power of the IoT, wireless connectivity, and smart devices. It provides a 360 degree solution for all storage vessels such as silos, bins, hoppers and tanks used to store powdered or granular bulk solids and liquids. This solution includes remote monitoring of product level, weight, pressure, temperature, moisture, vibration, weather conditions, dust emmission and similar process related variables. Combining and synchronising of all these measuring and monitoring systems and bringing a complete solution from a single source provides 3 important benefits:

– Efficient stock and inventory control (read more : what is silo monitoring?)

– Uninterrupted storage service (read more : what is condition monitoring?)

– Safety of plant and employees (read more : what is silo protection?)

Inventory Monitoring System

Silo and tank inventory monitoring system is developed specifically for tracing the level or weight of liquids and bulk solids in storage vessels and providing meaningful insights to plant operators for managing raw material storage efficiently. Amount of a material inside a storage vessel could be measured by using volumetric or gravimetric measurement methods. Level sensors provide volumetric readings and loadcells provide weight information. These sensors are connected to inventory monitoring platform on the cloud. Sensor values are sent through industrial Iot gateways with increased security. Using the web based user interface, users can keep an eye on their inventories at all times locally and globally. The automated flow of inventory information within the company or between partner companies creates transparency for the supplier and security of supply for the purchaser.

Which Data Are Available ?

Depending on the application and handled material, some or all of the followig data are available:

– Name of the stored raw material

– Material level

– Net weight

– Filling rate

– Discharging rate

– Filling time and dates

– Discharging time and dates

– Name of involved operators

– Health of connected equipment

– Alarms whenever certain thresholds are reached (high level, low level etc.)

– Alarms such as over pressure, high temperature, side winds, leaks, dust emmission etc.

– Maps showing geographic location of monitored silos and tanks together with storage levels

– Current values and historical data

– IoT dashboard providing actionable information

Inventory Monitoring Scenarios , Who is it for ?

Inventory Monitoring for the Enterprises

Polimak industrial Iot enabled silo level monitoring systems let the plant owners monitor and manage their own stocks at one or more locations locally or globally. System provides needfull information to have optimal coordination of raw material deliveries between suppliers, storage facilities, manufacturing sites and processing lines.

Advantages for Plant Owners

– Quick access to current and historical consumption data

– Higher efficiency and confidence in stock levels

– Prediction of run out and consumption prevents costly panic orders

– Security of supply, avoidance of production stoppages

– Cost-effective production and inventory planning in own company

– Information enables plants to deliver more product less often

– Tracing the health of storage vessels ensures process safety

Inventory Monitoring for Suppliers

Raw material suppliers can acquire the responsibility for inventory monitoring and replenishing from customers. Current and historical consumption data is collected by supplier’s system automatically and logistics operations are arranged accordingly. Customers are ensure that enough stock will be available all the time and they can focus on their core business. By using data coming from different customers across geographically dispersed locations, suppliers can optimize production, inventory management, distribution, route planning and logistics operations.

Advantages for Suppliers

– Quick access to current and historical consumption data of all customers worldwide

– Cost-effective production and supply planning

– Cost savings through optimized logistics and route planning

– Reduced delivery cost per tonne by lowering number of trucks on the road

– Improved relationships and long term customer loyalty

Inventory Monitoring for Logistics Companies

Wide range of raw materials are to be used together in same production process. Plant owners have to manage multiple supply chains and make each raw material available at site to prevent production stoppage. Similarly raw material suppliers generally produce different types of bulk products and have to deliver them at the right time to the customer. This brings a complicated problem to solve: managing logistics of multiple suppliers and customers. By monitoring inventories of suppliers and consumers, logistics companies can make a huge impact on their business model. Load consolidation could become a price efficient option, optimized logistics and route planning could bring substantial cost savings.Improved customer relationships and long-term customer loyalty could be achieved by providing security of supply chain.

Advantages for Logistics Companies

– Substantional cost savings through optimized logistics and route planning

– Reduced delivery cost per tonne by lowering number of trucks on the road

– Improved relationships and long term customer loyalty

– Cost savings due to reduced administrative work

Technology and Infrastructure Behind The Platform

Combining long years of experience on bulk solids industry and recent developments in big data technologies, Polimak offers a sophisticated inventory system based on a powerful cloud big data architecture providing insight for process manufacturers to act on. This platform enables following services to achieve complete solution from a single source:

1. Measurement of process values

2. Data collection through secure networks

3. Cloud data storage

4. Visualization of collected data

5. Data analytics

6. Business intelligence

Silo Equipment Health Monitoring System

The ability to operate a reliable system requires early and continuous testing from the system level down to the components that make up the system and the ability to deal with failure and malfunction. Bulk solids silos are storage vessels with several equipment running together to ensure safe and dependable raw material storage. Silo Equipment Health Monitoring System is a condition monitoring system that detects the failures of equipment installed on storage silos. Consequently it prevents any damages or losses due to malfunctioning equipment.

Pressure Relief Valve Condition Monitoring

Pressure relief valves are mechanical valves open at a pre-set pressure level to allow air to vent from the silo during silo filling with pneumatic conveying systems. During air vent, some amount of fine dust also escapes together with air and solidifies on moving surfaces of pressure relief valve. Accumulated and solidified dust on the pressure relief valve prevents it from functioning or reduces its function and completely blocks it up over time. As it is a small equipment installed at the top of the silo, any problem regarding the pressure relief valve can not be noticed on time. Consequently if the pressure relief valve does not operate when needed, the over-pressure could easily rupture the silo or blow the filter housing off the top. If the silo is located in a designated ex-hazardous area (due to ATEX reguklations), the over-pressure encountered during silo loading could be sufficient to stimulate an explosion resulting in costly damage and loss of product. Similar to over-pressure, under-pressure (vacuum) is also imposes a danger during silo discharge. When the product in the silo is unloaded rapidly without enough venting, silo may implode and collapse like a soda can.

Pressure Relief Valve Health and Condition Monitoring System makes tests on PRV periodically and just before silo filling or discharging to ensure it is operational whenever needed. A definite amount of air pressure or vacuum is applied on the internal side of PRV. Pressure level is continuously measured and valve position is checked. If the valve does not operate at the defined pressure level, system gives alarm and prevents the silo filling or discharging. The pressure level that the valve starts to open is also another indication of valves health. If this level increases at each consequent test, this means that valve is becoming clogged in the foreseenable future.

Jet Filter (Dust Collector) Condition Monitoring

Silo top jet filter is a dedusting system used to evacuate pneumatic conveying air in bulk solid silos while keeping dust inside. The smooth operation of silo jet filter is imperative for safe and efficient silo filling. For this reason, automatic filter cleaning systems are used to keep filter elements (bag or cartridge type) clean and maintain filter efficiency. In general, this is achieved either by reverse pulse jet cleaning or mechanical shaking. Depending on application and type of handled material jet filter design and capacity changes. In some applications a dust collection fan is used to provide additional vacuum to collect dust efficiently.

Dust collector condition monitoring system collects the process data from dust collector to detect problems before happening. Differential pressure, pulse valve pressure, dust emmision and fan motor vibration are some of the important process values that show current health of the fan and possible failures before happening. Following data is collected from dedusting equipment depending on type of dust collector:

Differential pressure (also known as pressure drop) between clean and dirty air sides.
Pressure of process air supply
Pressure in pulse valve header (compressed air tank)
Pulse valve operating signals
Air flow rate
Dust collector fan motor vibration
Fan motor casing temperature
Fan motor electric current
Dust emmission at jet filter outlet

These information are used to identify location and cause of failures related to dust collector. Such failures could be clogged filters, damaged filter bags or cartridges, insufficient process air supply, leakage in valve header, damage on fan bearing, leaking pulse valves, inoperative pulse valves, wrong adjustment in pulse timing.

Pinch Valve Condition Monitoring

A pinch valve functions as a shut-off valve and prevents the product flow completely with the aid of proper sealing. Actuation of the valve, the pinching action is accomplished by air pressure applied on the sleeve. The flexible sleeve tightly closes the line with the help of actuation pressure. When the pinch valve is in open position, bulk material flows freely through the full bore of the valve. Since there is no change in cross sectional area through the pinch valve, pressure drop is kept minimum. In silo applications pinch valve is used to protect silo from over-pressurizing and over-filling by blocking product flow through silo filling pipeline.

Pinch valve condition monitoring system monitors the health of pinch valve by monitoring supplied pressure and it’s opening and closing action. Recorded data is used to detect any failure on the valve and provides safe silo operation.

Silo Safety and Protection System

When filling and discharging bulk solids storage silos, several risks that may arise such as overfilling, overpressure and combustable dust explosion. By processing the signals coming from several sensors and taking necessary safety measures, silo control system automatically protects the silo from these risks. Health of critical components are monitored continuously and plant operators are warned if there exist any malfunctuining equipment. System provides a complete silo protection solution for safety of silo, workers and plant.

Silo Overpressure Protection

When bulk material storage silos are being filled by bulk tanker trucks or pneumatic conveying systems, pressurized air is used to fill the silos and it is vented from the top of the silo through jet filters (also named as dust collectors or silo vent filters). If the pressurized air entering the silo is not vented adequately, delivery in this manner may result in pressure build up and consequent rupture of the silo or connected equipment such as filter systems.

Potential Sources of Silo Over Pressurization are:

– Inadequate flow through the silo top jet filter due to wrong filter selection

– Inadequate flow through the silo top jet filter due to clogged filter elements

– Failure of pressure relief valve to vent excessive air inside the silo

– Sudden increase in air flow rate at the end of bulk tanker discharge

– Uncontrolled discharge of residual air from the bulk truck

– Inadequate maintenance of silo protection and safety equipment

Silo overpressure protection systems are used to ensure that storage silos and silo equipment have adequate safety measures to prevent over pressurization. In case of any lack of protection, these systems prevent filling the material to silos. This is achieved by making self tests for the silo equipment before filling and continuous monitoring of silo pressure during filling. Following safety systems are available in silo protection units:

– Silo inner pressure monitoring

– Jet filter clogging monitoring

– Pressure relief valve self test

– Jet filter self test

– Automatic closing of silo inlet in case of over pressure

– Cutting power of bulk truck or cutting signal of pneumatic conveying system in case of over pressure

Silo Underpressure Protection

During silo emptying, powdered material moves downwards and density of air above the material decreases as the empty volume increases if there is no air entrance from outside. This leads to a decrease in pressure and creates vacuum. If the vacuum level is high enough, the silo may collapse inside (implosion).

Main reason of a silo implosion is discharing material in the silo rapidly wihout providing adequate air ventilation.

Silo underpressure protection systems monitor pressure inside the silo and discharge speed of material. If the underpressure safety limit is exceeded, system automatically closes the silo discharge valve or stops the discharging conveyor.

Silo Overfilling Protection

Silo overfilling protection systems are suitable for preventing overfilling of silos and consequential damages or losses. Monitoring the product level continuosly inside the storage silos is the key for successful protection. Silo loading can be done by pneumatic or mechanical conveying systems. Rotating paddle sensors and radar sensors are widely used in storage silos to detect level of powdered and granular bulk solids. Main functions of silo overfilling protection system are as follows:

– Does not allow to start silo filling if it is already full.

– Gives alarm when it becomes full.

– Stops silo filling when it becomes full.

– Operates silo top jet filter (dust collector) during silo loading.

Explosion Protection for Ex-Hazardous Areas

If the handled material has a risk of explosion due to static charge build or the area is an Ex-hazardous area, grounding the truck is imperative. Electrostatic grounding testers are used to check whether the truck is grounded properly or not. Silo protection systems have a signal connection to truck grounding and bonding testers. Silo filling can only start if the safety permission signal is received from grounding and bonding tester.

Explosion vent panels are used to protect the silo, ensure worker and plant safety during handling of combustible dusts such as starch, sugar, coal and chemicals. An explosion vent or rupture panel is a safety device against excessive internal, explosion-incurred pressures, by means of pressure relief. It is designed to open at a predetermined pressure, to allow the fireball and explosive pressure to vent to a safe area. Burst sensors are used to detect if the explosion panels are ruptured due to an internal explosion. The sensors signal the opening of the bursting disc or panel so that equipment such as fans, screw feeders or rotary valves can be switched off and inform the plant operators to take relevant safety measures.

Operator Safety Warning System For Adverse Weather Conditions

Cold weather poses hazards to anybody working outdoors, but the conditions become more intense at higher places in the plants. Workers on the silo top facing different hazards than workers on the ground. What seems like a normal winter day on the ground could be high winds and extreme temperatures at heights. Companies and their workforces must understand what they could encounter to properly prepare for winter conditions.

Air temperature, humidity and wind speeds are measured by sensors at the top of the silo to give warning to workers before climbing to top, preventing any health problems or accidents caused by slippery surfaces, high winds, extreme cold and hot weathers.

Silo Discharge Control System

Bulk material silos have several types of discharge equipment such as screw feeders, rotary valves, butterfly valves, slide gate valves, chain conveyors, bulk truck loading bellows and pneumatic conveying systems. Depending on application, there are wide range of receiving points like bins, processing lines, weighing and batching systems, trucks, mixers etc. Silo discharge control systems provide full control over silo discharging equipment for efficient handling.

System is connected to level and pressure sensors, vibrating bin activators, dischaarging equipment, DCS or SCADA system and downstream equipment. Product discharge is controlled with respect to process requirements. If a truck is to be loaded, system is connected to truck loading bellow and stops when the truck is full. If a mixer is to be filled with the help of weighing unit, system stops when the desired filling amount is reached. If a pneumatic conveying system is connected to another bin, system stops when the bin is full.

Silo discharge control system also monitors the pressure inside the silo. If the silo unloading speed is high,powdered material inside the silo moves down rapidly and creates negative pressure (vacuum) above itself. If the level of negative pressure is high enough, it may cause the silo to collapse inwards. Silo control system can also monitor the silo inner pressure level and stops discharging if when the vacuum level is critical.

	A start signal comes from plant’s main electrical control unit to start silo discharging.
	Silo control system automatically checks silo for safety. A self test is applied on pressure relief valve (for vacuum) , process air supply and silo level. If any problem is detected (low level, malfunction in jet filter), system does not allow unloading, does not send confirmation signal to main electrical control unit and keeps discharging equipment closed.
	If product level inside the silo is enough and self tests are passed, system starts operation. and sends confirmation signal.
	Silo discharging equipment is operated.
	Silo pressure is continuously measured during silo discharging.
	If the pressure inside the silo decreases below the limits (underpressure), silo pressure relief valve opens to increase the silo pressure , a signal is sent to electrical panel to stop discharging. Built in pressure sensor is also available for double protection if the pressure relief valve malfunctions. In this case the signal coming from pressure sensor is used to stop silo discharging.
	Product level in the silo is continuously measured during silo unloading.
	If the powdered product in the silo reaches low level, or a remote stop signal is received, system stops silo unloading.
	Process values are recorded for future use

Silo Filling Control System For Silos Filled By Mechanical Conveyors

When silos are filled by mechanical conveyors, there is no pressure build up in silo. Though the system becomes simpler. Mechanical conveying systems such as bucket elevators and screw conveyors that fill silos in industrial plants generally have their own electrical controls with SCADA, DCS or similar systems. Implementing new silo equipment or several safety devices may require substantial effort. Depending on mechanical and electrical configuration of conveying system, a local control panel handling all silo functions might be much more convenient. Polimak silo filling control system panels have the capability of connecting to DCS or SCADA units. Start, stop, level and alarm signals can easily be transmitted between both units, providing cost efficient and practical way of implementation.

	A start signal comes from plant’s main electrical control unit to inform the silo filling control system that conveying system will start filling the silo.
	Silo control system automatically checks silo for safety. A self test is applied on dust collector (silo top jet filter) , process air supply and silo level. If any problem is detected (high level, malfunction in jet filter), system does not allow filling, does not send confirmation signal to main electrical control unit and keeps pinch valve closed.
	If silo is not full and jet filter self test is passed, system starts operation. and sends confirmation signal.
	Silo top jet filter (dust collector) is operated.
	Confirmation signal is sent to main electrical control unit to start filling.
	Product level in the silo is continuously measured during silo filling.
	If the powdered product in the silo reaches top level, system sends signal to stop pneumatic conveying. After a definite time dust collector is stopped.
	Process values are recorded for future use

Silo Filling Control System For Silos Filled By Dense or Dilute Phase Pneumatic Conveying Systems

Pneumatic conveying systems that fill silos in industrial plants generally have their own electrical controls with SCADA, DCS or similar systems. Implementing new silo equipment or several safety devices may require substantial effort. Depending on mechanical and electrical configuration of pneumatic conveying system, a local control panel handling all silo functions might be much more convenient. Polimak silo filling control system panels have the capability of connecting to DCS or SCADA units. Start, stop, level, alarm and pressure signals can easily be transmitted between both units, providing cost efficient and practical way of implementation.

	A start signal comes from plant’s main electrical control unit to inform the silo filling control system that pneumatic conveying system will start filling the silo.
	Silo control system automatically checks silo for safety. A self test is applied on pressure relief valve, dust collector (silo top jet filter) , process air supply and silo level. If any problem is detected (high level, malfunction in pressure relief valve or jet filter), system does not allow filling, does not send confirmation signal to main electrical control unit and keeps pinch valve closed.
	If silo is not full, jet filter and pressure relief valve self tests are passed, system starts operation. and sends confirmation signal.
	Silo top jet filter (dust collector) is operated.
	Pinch valve is opened.
	Confirmation signal is sent to main electrical control unit to start filling.
	Product level in the silo is continuously measured during silo filling.
	Silo pressure is continuously measured during silo filling.
	If the pressure inside the silo rises over the limits (overpressure), silo pressure relief valve opens to decrease the silo pressure , a signal is sent to electrical panel to stop filling. Built in pressure sensor is also available for double protection if the pressure relief valve malfunctions. In this case the signal coming from pressure sensor is used to stop filling.
	Alarm signal is sent to main electrical control unit to stop filling. After a determined time, system closes the pinch valve to protect the silo.
	If the powdered product in the silo reaches top level, system sends signal to stop pneumatic conveying. After a definite time pinch valve is closed and dust collector is stopped.
	Process values are recorded for future use

Silo Filling Control System For Bulk Tanker Truck Filled Silos

Silos that are filled by bulk trucks (also known as road tankers) have several equipment to be controlled for safe and efficient silo loading. Automatic filling control system has a PLC controlled electrical panel that has full control over silo equipment. Silo top jet filter, silo inlet pinch valve, level sensors, pressure sensors and other components are connected to control panel. The power of air compressor of bulk solid tanker truck is supplied by built in power supply plug. Silo filling control system checks silo before filling for safety, controls the power sent to bulk truck, checks the product level, silo inner pressure during silo filling. System both controls the equipment and protects the silo from overfilling and over pressure. Silo top air vent jet filter, silo pressure sensor, silo level sensors, pinch valve , pressure relief valve, explosion vent panel, pinch valve and other silo components are connected to silo control system.

	Truck driver connects the hose to silo filling pipeline. Pushes start button on the panel.
	Silo control system automatically checks silo for safety. A self test is applied on pressure relief valve, dust collector (silo top jet filter) , process air supply and silo level. If any problem is detected (high level, malfunction in pressure relief valve or jet filter) , system does not allow filling, does not supply power to truck and keeps pinch valve closed.
	If silo is not full, jet filter and pressure relief valve self tests are passed, system starts operation.
	Silo top jet filter (dust collector) is operated.
	Pinch valve is opened.
	Power is provided to bulk truck to start filling.
	Product level in the silo is continuously measured during silo filling.
	Silo pressure is continuously measured during silo filling.
	If the pressure inside the silo rises over the limits (overpressure), silo pressure relief valve opens to decrease the silo pressure , a signal is sent to electrical panel to stop filling. Built in pressure sensor is also available for double protection if the pressure relief valve malfunctions. In this case the signal coming from pressure sensor is used to stop filling.
	Electrical panel closes the pinch valve and cuts the power of truck immediately after receiving the overpressure signal.
	If the powdered product in the silo reaches top level, system sends audible alarm to the truck driver to stop truck compressor. After a definite time, truck power is cut, pinch valve is closed and dust collector is stopped.
	Truck driver removes the hose from silo filling pipe.
	Process values are recorded for future use.

Silo Control, Silo Protection and Silo Monitoring Systems

Bulk material storage silos provide a safe and efficient way of storing valuable raw materials. Filling and discharging of silos should be carefully handled to keep plant and operators safe. Polimak silo control and monitoring systems include wide range of powder handling equipment, automation systems and software solutions to operate and protect the silos in most efficient way. Polimak brings one of the most sophisticated silo control, monitoring and protection system to bulk materials handling industry, letting the plant owners monitor and manage their silos at one or more locations locally or globally.

Silo Control System

Silo control and protection systems play an essential role in bulk material storage and handling processes. PLC based systems provide realtime full control over silo while maintaining plant, silo and worker safety. Full control concept includes not only the silo itself, but also the connected upstream and downstream equipment. Silo filling equipment could be any kind of pneumatic or mechanical conveyor like bucket elevator, dilute or dense phase pneumatic conveying system, bulk tanker truck etc. By processing the signals coming from several sensors, silo control system prevents overfilling, overpressurizing and underpressurizing of the silo. Health of critical components are monitored continuously. A self testing system is operated periodically and before each filling operation.

Silo Filling Control System For Bulk Truck Filled Silos

Silo Filling Control System For Silos Filled By Dense or Dilute Phase Pneumatic Conveying Systems

Silo Filling Control System For Silos Filled By Mechanical Conveyors.

Silo Discharge Control System

Silo Safety and Silo Protection System

Some of the most frequent risks during powder handling in silos and relevant protection systems are as follows:

– Silo overpressure protection

– Silo underpressure protection

– Silo overfilling protection

– Explosion protection for combustable dusts

– Operator safety warning system for adverse weather conditions

Silo Equipment Health Monitoring System

Condition monitoring of following equipment is available depending on application and expected safety level:

– Pressure relief valve condition monitoring

– Jet filter (dust collector) condition monitoring

– Pinch valve condition monitoring

– Process air supply monitoring

– Motor vibration monitoring

Industrial IOT Based Silo Level Monitoring and Inventory System

Silo level monitoring system is developed specifically for tracing the level or weight of bulk solids in storage silos and providing meaningful insights to plant operators for managing raw material storage efficiently. Amount of powdered material inside a silo could be measured by using level sensors and loadcells to provide level and weight information respectively. These sensors are connected to Polimak-Politrace inventory monitoring platform on the cloud. Sensor values are sent through industrial Iot gateways with increased security. Using the web based user interface, users can keep an eye on their inventories at all times locally and globally.

Depending on the application and handled material, followig data are available for silo monitoring:

– Name of the stored bulk material

– Silo filling level

– Silo Filling and discharging rate

– Filling and discharging dates

– Name of involved operators

– Alarms whenever certain thresholds are reached (high level, low level, overpressure etc.)

– Maps showing geographic location of monitored silos with storage levels

Industries Served

Our bulk solids handling solutions have assisted many large and small companies within a variety of industries. Some of the bulk materials we have been working with include: cement, calcium carbonate, ash, plastic pellets, lime, sand, paints and pigments, gypsum, carbon black, pvc, coatings, fly ash, coal, coal dust, flour, seed, chickpea, rubber, carbon black, bean, sesame, almond, grain cereals, chestnut, coffee grain, coffee powder, sugar, corn, starch, salt, spice, glass powder, marble powder, sawdust pet food, ingredients and extracts, dairy products and industrial products.

Industrial Iot Solutions

POLITRACE

A New Era in Condition Monitoring

Condition Monitoring

Predictive Maintenance

Cost Reduction

Big Data Analysis

Real-Time Data Tracking

Improve Safety

Enhance Performance

Predictive Quality

It is most crucial for industries (smart industries) to monitor machines and processes in real time as well as guarantee optimal performance so as to improve production. Polimak industrial IoT solution – Politrace is an integrated IoT solution that combines process conditioning, machine health and inventory management, and computerised maintenance management technologies from a single source. Our strength is embedded in the collaboration of experts in software technology and the process industry to provide a single-source industrial IOT solution.

Industry 4.0 concepts and the Industrial Internet of Things (IIoT) are revolutionizing industrial processes. Connecting assets throughout the industrial value chain provides complete operational visibility to allow for real-time monitoring, analytics, decision making and improved levels of quality and efficiency. However running, operating and maintenance of each production line and industrial processing system necessitate deep expertise and knowledge based on long years of experience in the field. The mere connection of machinery to sophisticated software is not sufficient to comprehend the operations in the production line. It is also important to understand the physical meaning of the acquired data.

Industrial IoT Features

Predictive Quality

Predictive quality analytics helps obtain insights from data sources such as industrial equipment or systems and the enviroment. This feature utilises statistical algorithms like machine learning to predict future outcomes by simply determining trends and patterns. The objective of predictive quality is to determine needs that will improve the quality of the output in a factory. Decisions to improve products and processes at an early stage can be made with the help of predictive quality.

Predictive Maintenance

Predictive maintenance analytics are typically used to measure and ascertain the real-time state of industrial equipment and systems. This helps the managers or/and operators to identify possible malfunctions prior to their occurrence, thereby, preventing downtime. The user is able to plan maintenance activities and keep the right inventory to avoid unplanned outages. The use of Politrace predictive maintenance analytics in industries increases personnel safety, improves the life cycle of machines and optimizes the supply chain.

Condition Monitoring

Politrace enables users to continuously monitor and infer the performance, health and status of operating equipment and systems in industries. With condition monitoring, the state of various machines can be measured with sensors by inspecting temperatures, pressures, vibrations, vacuum levels, power consumption etc. With condition monitoring, the user can access data from various endpoints and monitor the health and performance of various machines within an operating facility.

Industrial IoT Use Cases

Polimak Industrial IoT solution – Politrace has numerous application areas in industries. Politrace use cases include the following:

Silo Level Monitoring and Inventory System

Numerous industries utilise storage silos to store dry bulk materials. Maintaining these silos and inventory reserve vessels at optimal levels for efficient operations is of paramount importance. The maintenance of raw material reserves at levels that ensure optimal operations is very crucial because it helps industries cut out unnecessary additional storage or material runouts. With Politrace you are able to track the levels or weight of dry bulk materials in storage vessels (silos) using sensors, thus, providing meaningful insights to users for efficient management of raw materials. The data collected by the sensors is sent to the Politrace condition monitoring portal at high security. Users are able to keep a closer eye on their inventories anywhere at any time by using Politrace web-based user interface.

Rotary Valve Condition Monitoring

Rotary valves are essential in various industries for different industrial applications. They play an important role in modulating material flow processes which necessitate uninterrupted operations. Politrace enables its users to monitor the valve’s operating condition variables using multiple sensors during material discharge. Sensors can easily pick up varying signals of different variables such as rotor speeds, valve body and bearing temperatures and vibrations, power consumption, motor temperatures and vibrations, purge air pressures, pressures/vacuums at inlet and outlet ports, and safety protector case detections. These sensors relay the collected data to a gateway and then upload it to the cloud. The user can easily monitor the collected data in real time through the Politrace condition monitoring portal and make necessary adjustments.

With Polimak industrial IoT – Politrace, we transform your rotary valves into smart rotary valves.

Dust Collection System Monitoring

Dust collection systems are present in hundreds of thousands of industries across the world, from cement industries and metal fabricators to food and chemical processing industries. In most operations, dust collection systems act as ancillary equipment because they protect core production assets. Managing and maintaining dust collectors can be challenging in various operating facilities but the integration of industrial IoT solutions can help better production demands, cost-effective operations and unplanned downtimes.

Emission levels at discharge points are a parameter that could be monitored with Politrace and in a case where dust concentration levels approach or exceed permissible thresholds, users can be notified and take necessary measures. Other parameters that could be monitored include pressure drops across filters, energy consumption, mechanical health etc. Tracking the data of these parameters in real time with industrial IoT solutions enables users to make immediate adjustments that optimize the operating performance of the systems.

Quality Improvement and Preservation

Continuous monitoring of conditions critical to quality (e.g., product quality) is essential and can be attained by using sensors. Signals from sensors are sent to the Politrace condition monitoring portal and through which the management can easily receive notifications whenever quality thresholds are crossed and monitor them in real time. For instance in food products operations, variables like temperature and humidity can be of the essence to the quality of the end product. In such instances, whenever temperature and humidity thresholds are reached or crossed the management can be swiftly notified and take necessary measures thereby preserving product quality.

Production Line Performance Monitoring

Numerous easy-to-install sensors are available for monitoring any machinery such as CNC machines, hydraulic presses, rolling machines, packaging machines etc. Real time data of variables such as temperatures, vibrations, humidities, start-stop signals, failure signals, energy consumptions, press strokes etc., can be collected. The collected data is securely sent to a Politrace condition monitoring portal and analysed continuously.

How Politrace Works

How We Help

Process Analysation

We are capable of coordinating our engineering team to analyse your machines and production lines depending on the requirements. They obtain process-related information i.e., a project’s expected output and determine the important data collection points in conjunction with our customer’s team.

Correct Architecture Determination

To run a problem-free service, proper configuration of sensors, gateways and server networks is key and some of the things that can be taken into consideration include production site location, current configuration network, safety concerns and service suppliers. We are capable of analysing your production lines and offer reliable architecture.

Supplying IIoT Platfroms and Equipment

We provide simple-to-install sensors and gateways together with appropriate mechanical and electrical connectors. Our customers are free to use sensor and gateway brands of their choosing. Polimak IIoT software platform is user friendly and provides simplified operations.

Asset Management Service

The asset management service incorporated in our Industrial IoT platform has simple yet powerful features. It is possible to assign assets to teams, furthermore, maintenance schedules, manuals, documents and photos can be easily added and traced from anywhere at any time. Our systems ensure full control of individual assets in the plant by operators.

Data Visualization and Analytic Service

Polimak Industrial IoT solution opens the doors to the magic world of big data analytics. It readies various facilities for the future concerning business intelligence, predictive quality and maintenance, and artificial intelligence algorithms in a secure and user-friendly manner.

Benefits of Industrial IoT

Polimak Industrial Internet of Things solution – Poltrace presents the right data at the right time, hence users have their desired information at the snap of their fingers to make precise decisions. Some of the benefits offered by Politrace include the following:

Predictive and preventive maintenance.
Machine health and condition monitoring.
On-time alerts and notifications on any abnormalities.
Improved machinery performance.
Reduced maintenance costs.
Detailed downtime analysis and optimised machine utilisation.

Industrial IoT FAQ

What is the Industrial IoT?

In the context of Industry 4.0, Industrial Internet of Thing (IIoT) – also referred to as Industrial Internet, is typically the use of Internet of Things (IoT) technologies to bring machines and processes together for the purposes of monitoring, exchanging, collecting and analyzing real-time data from sensors to provide significant insights. IIoT integrates machine learning (ML) and big data to harness sensor data.

What does Industry 4.0 refer to?

Industry 4.0 is a phase, a place in time in the Industrial Revolution. It simply refers to the fourth Industrial Revolution which is about translating data into information. Industry 4.0 encompasses a lot including IIoT and smart production, automation, big data, digital transformation and machine learning to create a more complete and improved ecosystem connection for various manufacturing industries.

What is the difference between IoT and IIoT?

Industrial Internet of Things – IIoT is a subcategory of the Internet of Things – IoT, however, the two are targeted at distinct application categories. IoT refers to devices that are embedded with sensors, software and other technologies that allow these devices (things) to connect and exchange data with different devices and systems through the internet. On the other hand, IIoT refers to interconnected sensors, machines and other networked industrial devices with computers in operating industries. IoT is more client-centric (customer-oriented) whereas IoT is industrial-centric.

Why Polimak Industrial IoT Solution?

So many IoT platforms are provided by software companies that do not have expertise in industrial processes. We have expertise in a wide range of industrial processes and know the real meaning if the collected data.

What is Predictive Quality?

Predictive quality analytics simply refers to the process of analysing incoming data to identify and solve problems beforehand. It helps manufacturing industries reduce quality losses by identifying problem root causes effectively, thus, preventing losses in advance.

Preventive vs. Predictive Maintenance: What is the difference?

Preventive maintenance (PM) and Predictive maintenance (PdM) are how the majority of industries implement industrial maintenance.

Predictive Maintenance: PdM is a data-driven method that utilises performance monitoring tools to predict possible faults and fix them ahead of time. This maintenance technique is aimed at reducing repair costs and downtime caused by faulty components.

Preventive Maintenance: PM is a maintenance technique implemented daily to reduce downtime and machinery failure probabilities. Preventive maintenance encompasses numerous factors including repairs, cleaning, lubrications and faulty components replacement.

Simply put, predictive maintenance – PdM relies on real-time data and uses it to send warning signals whenever a fault is noted, whereas preventive maintenance – PM relies on common practices and historic data.

Pneumatic Conveying Systems

Pneumatic conveying systems are broadly used throughout bulk material handling industries to move dry bulk materials through a facility. They move the bulk material in a pipeline generally with air being used as a conveying agent. When it comes to utilising pneumatic conveying systems to transport dry bulk materials, facility owners find themselves in a position to of needing to make a choice between pressure conveying or vacuum conveying. In other operations, a combination of both, vacuum and pressure conveying systems may be the best solution. Ultimately, Polimak experts will have to consider what is feasible given the available resources and suggest which method will best suit the transportation of the bulk material.

The design, production and installation of pneumatic conveying systems for bulk materials require a great deal of know-how and long years of experience. Simple installation, low maintenance need, long years of problem-free service and endurance for harsh environments are key features of quality pneumatic conveying systems. Polimak brings pneumatic conveying solutions and expertise to a variety of industries including chemicals, food, plastics and cement. A well designed pneumatic conveying system is a practical and cost-effective method of transporting dry bulk materials from one point to another.

Types of Pneumatic Conveying Systems

There are several ways to pneumatically transport dry bulk materials and the key difference in each method is the conveying phase. Conveying phases are modes of how dry bulk materials being conveyed through a conveying pipe. Pneumatic conveying phase mode can be categorised into two, the dilute phase and the dense phase.

Dilute Phase Pneumatic Conveying

Dilute phase pneumatic conveying systems, also known as lean phase conveying systems, involve the transportation of dry bulk materials at velocities above the saltation velocity. These systems generally use air entry pressures below 1bar to move dry bulk materials through conveying pipelines at relatively high velocities. Bulk material particulates are wholly suspended within the airstream throughout the conveying pipe in dilute conveying systems. The material transfer within the system is described as low pressure high velocity, hence the name “low pressure systems”. The particle velocity is paramount in these systems because it affects the material end product, very low velocity may result in the material collapsing to the bottom of the pipe from the airstream and very high velocity may cause particle-to-particle collision and particle-to-wall collision resulting into bulk material degradation. The two methods that can be performed are dilute phase pressure conveying and dilute phase vacuum conveying.

Dilute phase conveying systems are the most common pneumatic conveying systems used in many bulk material handling industries to transport bulk solids. These systems are ideal for transporting non-abrasive bulk materials, products with low bulk density and bulk materials that are hard to break. Some of the dry bulk materials that can be processed using dilute phase pneumatic coveying systems include sugar, flours, pellets, chemicals, polymers (resins and compounds), calcium carbonate, cement and coal dust.

Dense Phase Pneumatic Conveying

Dense phase conveying systems are pneumatic conveying systems that utilise relatively low velocity gas and rely on high pressure differential, positive or negative, to transport dry bulk materials in pipelines. The velocities in these systems are typically below the saltation velocity. Dense phase pneumatic conveying systems can be referred to as high pressure conveying systems. Low velocities within these systems result in a gentle and efficient transfer of bulk materials. Dry bulk materials move with less wear and impact inside a conveying pipeline and their flow (dense phase transfer form) generally occur in two forms, plug flow or dune (wave) flow. Dense phase transfer form is primarily dependant on the nature of the bulk material and the configuration of the plant. This type of pneumatic transport system is ideal for most abrasive, friable, fragile and mixed-batch dry bulk materials. The two methods that can be performed are dense phase pressure conveying and dense phase vacuum conveying.

These systems are used across many different bulk handling industries to convey bulk products. Higher conveying rates and longer conveying distances are often possible with dense phase conveying systems. Some of the handled bulk materials include sand, limestone, gypsum, fly ash, cement, CaCo3 and many more.

Pneumatic Conveying Systems Industrial Application

Most bulk material handling industries make use of mechanical conveying systems to handle their dry bulk materials. Industries such food processing industries, pharmaceutical industries and chemical industries need to maintain high levels of hygiene throughout the handling processes of bulk materials. The use pneumatic conveying systems help industries maintain high levels of hygiene during material processing.

Power and Energy Industry

Pneumatic conveying systems are extensively utilised in coal-fired power plants to transport fly ash in its dry form. Glassy droplets of as are produced during the burning of coal. Fly ash is one of the residues produced during coal combustion and comprises fine particles. Pneumatic conveyors offer an ideal choice for handling dry fly ash. Fly ash from various hoppers is evacuated using pneumatic conveying systems up to an intermediate silo.

Designing reliable systems (pneumatic conveyors) is not a trivial task, it necessitates a considerable amount of knowledge of the characteristics of the handled product and the intricate solids-gas-pipe wall interaction. Poorly built systems may result in significant losses in terms of increased energy consumption, decreased delivery, and premature wearing of hardware among other things. Polimak provides versatile, robust and low-maintenance fly ash conveying systems that offer dustless operations and can handle high temperatures.

Cement Industry

Cement is an essential element wherever things are being built, hence the cement industry plays an important role in construction operations as it is responsible for supplying the raw material cement. Pneumatic conveying systems are vital in this industry when it comes to effectively transporting cement in various facilities. Several pneumatic conveying (pressure conveying or vacuum conveying) technologies can be utilised to transfer cement. Finding the appropriate solution for your application can pay dividends, particularly in terms of lowering energy consumption in your plant. Polimak’s qualified and experienced engineers help its clients come up with efficient cement conveying equipment for a specific application. We offer innovative pneumatic technologies for broad cement handling processes.

Mining Industry

Coal mining is one of the mining sectors that utilise pneumatic conveying systems for handling various raw materials including rock dust (usually pulverised limestone). Both dilute phase and dense phase pneumatic conveying systems are applicable in the mining industry.
With the growth of the mining industry, Polimak has taken up an opportunity to supply quality pneumatic conveying systems to this industry. Our products are extremely versatile, reliable and durable even under the most challenging operating conditions. We take pride in offering high-quality pneumatic conveyors suitable for the mining industry to ensure efficient and safe transportation of dry bulk materials within pipelines.

Food Industry

Food production is one of the world’s largest, most diverse and important industries. The food industry is a huge industry that consistently requires higher hygiene and efficiency during bulk material processing. Pneumatic conveying systems provide hygienic and flexible material handling processes. A broad variety of food products such as sugar, rice, corn, spices, grains, cereal, flour and animal feed can be transported using pneumatic conveying mechanisms. The design and production of pneumatic conveying systems and experience-based engineering solutions for any type of bulk material is a challenge. Polimak provides complete solutions of pneumatic conveyors for use in the food industry.

Chemical Industry

The chemical and petrochemical industry is one of the prominent sectors that make use of pneumatic conveying systems to move chemicals through enclosed pipelines from a single or multiple source(s) to a single or multiple destination(s). With the rising usage of virgin polymers in several products, the petrochemical industry is required to generate building block ingredients for the majority of chemicals in large quantities. Bulk materials in this industry may be dangerous, hence the containment of the materials is very crucial to prevent cross-contamination, reduce explosion risks and protect the environment by combating dust emissions.

Plastics Industry

Plastics and polymers industries produce and export a broad range of raw materials and pneumatic conveying systems are suitable for moving plastic pellets and materials in powdered form. Processes such as blending, mixing, extruding and moulding are performed in the plastics industries. Pneumatic conveying systems can be used to feed extrusion machines and mixing machines.

Bulk Material Conveying

Bulk materials do not pass through fast-moving parts in pneumatic conveying systems unlike other mechanical systems such as belt conveyors, screw conveyors, vibrating conveyors, drag conveyors, bucket elevators, etc. In this way, most contaminations/damages to the transported dry solids are prevented. Some of the dry bulk solids transported with pneumatic conveyors include sugar, spices, salt, flour, maize corn, popcorn, coffee beans, sand, limestone, cement, coal, gypsum, plastic pellets, plastic powders, calcium carbonate and many more.

Pneumatic Conveying Systems Advantages

Pneumatic conveying systems provide numerous benefits to users including the following:

They can run long distances and the conveying pipes can be installed vertically or horizontally.
Materials are conveyed in a closed pipeline. In this way, conveyed materials stay clean and dust leakage to the atmosphere is prevented.
Because of their compact design, it’s easy to integrate pneumatic conveying systems around existing equipment, making them more versatile than mechanical systems.
A pneumatic system can convey a product at any place a pipeline can run.
These systems do not occupy a lot of space.
Pneumatic conveying systems have a few main parts such as a pump/blower, pipeline, feeding device etc., and all parts can be repaired independently, so, they are easy to maintain.

Pneumatic Conveying Systems FAQ

What is a pneumatic conveying system?

A pneumatic conveying system or simply a pneumatic conveyor is a system used to convey dry bulk materials through pipelines by using the flow of air or any other suitable gases. Bulk materials in different forms such as powder, granule or pellet can be pneumatically conveyed. Pneumatic conveying systems can be built as pressure conveying systems or vacuum conveying systems. In some applications, a combination of the aforementioned systems is possible.

What is pressure pneumatic conveying ?

In pressure pneumatic conveying systems, air is used to push against the bulk material being conveyed, hence these systems are considered to be positive pressure systems. Pressure pneumatic conveyors are best used where the bulk material is to be conveyed from a single feeding point to multiple delivery points. These systems are generally preferable when conveying materials at longer distances and high throughputs.

What is pneumatic vacuum conveying ?

Vacuum conveying systems are used to convey bulk materials through a network of pipelines by suction, hence these systems are considered to be negative pressure systems. Vacuum pneumatic conveyors are best used where the bulk material is conveyed from multiple feeding points to a single delivery point. These systems are also prefered for conveying dry bulk solids that tend to plug or pack in positive pressure systems.

What is combined vacuum and pressure pneumatic conveying ?

Combined vacuum and pressure pneumatic conveying is simply the transportation of bulk materials from one point to another by utilising vacuum blower packages and pressure blower packages. A combination of vacuum and pressure pneumatic conveying systems can be applied in several bulk handling facilities. Vacuum conveying and pressure conveying systems are interconnected and can be operated simultaneously.

How does a pneumatic conveying system work ?

Pneumatic conveying systems work according to the principle of pneumatic conveyance. The principle of pneumatic conveyance is based on the concept that bulk materials can be transported through a pipeline by using a gas (air). The moving air exerts a propulsion force on the bulk material causing it to propel along the conveying pipeline. A pressure difference between the beginning and the end of the pipeline is always required for a pneumatic conveying system. Blowers or compressors can be used to overcome the pressure differential.

What is plug flow and dune flow ?

Plug flow and dune flow (also referred to as wave flow) are two distinct flow patterns of dry bulk materials flow through a conveying pipeline in a dense phase pneumatic conveying system. The bulk material fully fills the conveying pipeline during a plug flow pattern and it moves along with air gaps between each plug. In a dune flow pattern, bulk material particulates begin to settle out on the pipe wall forming dense flow regions with patterns like sand dunes.

Mobile Bulk Truck Loading Systems

Mobile Big Bag Discharging and Bulk Truck Loading System

Bulk solids in the shape of powders and pellets are stored and moved around in many industrial applications. They are stored in bags, bulk bins, and godowns and have to be moved around by using trucks or other bulk carriers. Loading and discharging these solids is a major logistic issue and has to be managed. Our systems give you a strong capability to move around such materials efficiently, safely, and economically due to their excellent design and robust construction. Check out these systems and select the one best suited to your application.

3 Different Systems are available;

Big bag System

Mobile big bag discharge silo truck loading system sack discharge jumbo bag handling

Large Hopper System

Vacuum System

How Mobile big bag discharge silo truck loading system work how to discharge sack how to handle jumbo bag

Fast, Robust and Economical

Look at our Mobile Bulk Truck loading processes. Our unique technology guaranties quick emptying of bags and robust, automatic and dust-free loading in the truck .

That is why our Mobile Truck loading systems are being used all over the world with very high client satisfaction.

They are not only efficient, easy to maintain and above all economical. If your applications require Big bag discharging and loading look at our models and we are sure that you will find one that exactly suits your needs.

Our System consists of a mobile platform, big bag discharger, loading screw, telescopic loading chute and dust collector. System can be towed by a forklift and screw conveyor can be brought to horizontal position for easier and safe transport.

There are many options to choose from. Select the model that meets your requirements completely.

Bulk Truck Loading System in Transport Mode

The system is shown with the screw conveyor in a horizontal position, optimized for mobility. Towable by forklift or manpower, its compact design allows it to fit easily into sea freight containers for efficient transportation.

Bulk Truck Loading System in Ready Mode

The system is depicted with the screw conveyor inclined, prepared for operation. Four screw jacks on the main chassis are extended to stabilize and rigidify the platform during loading, ensuring safe and reliable performance.

Bulk Truck Loading System in Operation Mode

The system operates with the telescopic chute extended, securely seated on the tanker inlet. Big bags are unloaded using a forklift, with material flowing dust-free into the truck via the screw conveyor and chute.

Bulk Truck Loading System for Mining Industry in Operation Mode

Tailored for rugged mining environments, the system is presented in its operational configuration, ready to discharge big bags and load bulk trucks efficiently. The integrated dust collector minimizes emissions, ensuring safety and regulatory compliance.

Bulk Truck Loading System for Mining Industry in Transport Mode

Tailored for mining applications, the system is displayed in its compact transport configuration. The horizontal screw conveyor and towable design enable easy relocation across mining sites or shipping via containers.

Bulk Truck Loading System for Food Applications

Featuring product-contact parts made of stainless steel, this system is ideal for food-grade materials. The image, captured at a sugar handling facility, highlights its hygienic design and dust-controlled operation.

Truck Filling Operation with Dust Collection

During truck filling, the integrated dust collector captures emissions from the big bag unloading hopper. This ensures a clean, safe environment throughout the material transfer process.

Truck Filling Operation with Sealed Telescopic Chute

The telescopic chute firmly seats on the tanker inlet, preventing dust escape. Connected to the dust collector, it ensures dust-free loading and retracts automatically, guided by a level sensor, once the tanker is full.

Custom-Colored Bulk Truck Loading System

This image showcases a system painted in a custom color, available upon request. The design retains full functionality while offering aesthetic flexibility to meet client preferences.

Polimak Vacuum Conveying and Bulk Truck Loading System

This innovative system features a suction hose for collecting material from stockpiles or processing lines, paired with a screw conveyor for truck loading. It offers versatile, dust-free material handling.

Bulk Truck Loading System for Mining Industry in Transport Mode

Vacuum Conveying System in Action

An operator uses the suction hose to gather material from a stockpile, loading it into a truck via the screw conveyor. The high-capacity system ensures rapid, dust-free transfer with minimal environmental impact.

Advantages of our Bulk Loading Systems

Mobile: Wheeled mobile chassis that allows easy transportation of the system to the desired location.

Functional: Compact form can be moved easily from one place to another.

Efficient: The system can transfer large quantities of material in a short time.

Easy to Operate: Very few operators are necessary to handle both discharging and loading trucks/tankers at the same time.

Remote Control Available: Operator can control the whole operation with a remote controller.

Reliable: It can work a long time without any need for maintenance, which enables you to save money.

Suitable for Uneven Ground: The screw jack leveling legs can be adjusted to any place to place the system.

Flexible: The loading bellow can be extended and retracted concerning the height of the bulk truck.

Environmental Friendly: Built-in dust collection system captures dust and prevents material loss.

Robust Design: The system will work for continuous long hours without failure.

Handled materials with Bulk Truck Loading System

Materials in powder and granule form like cement, fly ash, mining minerals, calcium carbonate, pvc, plastic pellets, plastic powders, polyethylene, ceramic powders,alumina, bentonite, bauxite, coal, cement clinker, gypsium, perlite, kaolin, limestone, marble powder, soda ash, quartz, urea, sodium suplhate, wheat, flour, animal feed, seed, corn, rice, sugar, salt and similar powdered or granular dry bulk solids.

Links

Big Bag Discharge and Loading System

Mobile Truck Loading System with Front End Loader Hopper

Mobile Truck Loading System with Vacuum System

Mobile Bulk Truck Loading Systems

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of mobile bulk truck loading systems.

Silo Control System

Silo control systems are generally used in silos which are loaded by pneumatic conveying systems especially from bulk solid trucks. Silo filling, silo level tracking and silo discharging are handled by silo control systems. Required silo equipment are operated, safety devices are taken and necessary information is given to the operator by the silo control system.

Operation of Silo Control System

– The electricity of air compressor of bulk solid tanker truck is supplied by silo control system. – Silo top air vent jet filter, silo pressure sensor, silo level sensors, pinch valve and other devices are connected to silo control system. – Pinch valve is attached to the inlet of silo loading pipeline. It controls the flow of material to the silo. – When the system is started, it checks the bulk solid level in the silo. If the silo is full, it does not give electricity to the bulk solid tanker truck. – If the silo level is low, first the silo vent jet filter is operated. After that pinch valve is opened. At last electricity is supplied to tanker truck compressor. – Silo level, and silo pressure is continuously measured during silo filling. – If the pressure inside the silo is increased too much, the electricity supply of the tanker truck is cut. At the same time silo pressure relief valve is opened to decrease the silo pressure and alarm signal is given to the operator. – If the tanker truck compressor receives the power supply from another source and silo loading cannot be stopped, then the pinch valve is closed automatically to stop material flow. – After the silo is filled, the silo jet filter continues to operate for some time and stopped. – The silo control system also controls and checks the pressurized process air required for silo vent filter and pinch valve. – If required amount of pressurized air cannot be supplied, the system warns the user by alarm. This makes troublefree silo filling operation. – The silo control system can also control the silo discharge process. Bulk solid in the silo can be discharged into another truck by loading bellow. It can be transferred to another silo or process equipment by screw feeders, pneumatic coneying systems or mechanical conveyors.

Advantages of Silo Filling and Discharge Control System

– It provides dust free and clean air in the region. – It maintains silo safety. – Safety of industrial plant is maintained. – The bulk solid level in the silo is controlled. – Silo overfilling is prevented by using silo level sensors. – The operating life of silo equipment is increased. – Silo filling time is decreased.

Components of Silo Control System

Silo Control System Operator Panel

System is controlled by an operator panel. The silo level switches, jet filters, pinch valves, tanker truck power supply, silo pressure sensor, compressed air supply, alarm conditions are checked and operated continuously. All operation parameters can be adjusted by the user. Silo operations are handled by a PLC controller.

Silo Level Switch / Sensor

Silo level switches (sometimes called as silo level sensor) are used to monitor the bulk material level in the silo. A rotating paddle on the sensor is submerged into the silo. When the product fills the surroundings of the paddle, it can not rotate anymore. And a signal is generated to indicate that the level is over the position of level sensor.

Silo Pressure Relief Valve

Silo pressure relief valve is used to prevent any high pressure generation within the silo. During filling of the silo with pneumatic conveying, there may be risk of pressure increase within the silo. Pressure relief valve vents the silo if the pressure level rises above the determined level and maintains low pressure. Silo pressure relief valves are one of the important safety devices used in bulk solid storage silos

Silo Pressure Sensor

Silo pressure sensors are used to measure the air pressure level within the silo. It sends signals to silo control systems or automation systems to indicate the pressure level.

Process Air Pressure Sensor

Compressed air pressure is checked continuously to maintain air to silo vent filter and pinch valve to ensure silo safety. If there is not enooufh air pressure system alarms the user and cuts power supply of bulk truck.

Alarm Devices

Silo control system sounds and light alarms in case of any problem.

Bulk Tanker Truck Electricity Plug

Electricity plug used to supply power top tanker truck air compressor. It is energized by silo control system.

Pinch Valve

Pinch valves are used to control the flow of bulk solids in pneumatic conveying lines. Actuation of the valve, the pinching action is accomplished by air pressure placed on the sleeve. The flexible sleeve tightly closes the line. When the valve is open, there is no internal parts or geometries that can block or slow down the flow.

Silo Control System Applications

– Concrete batching plants – Gypsum production plants – Industrial plants – Mining plants – Calcium carbonate, PVC, polypropylene, polyethylene filling processes – Sand, soda, cement filling applications – Bulk solid filling and discharging applications for wide range of industrial processes

Silo Equipment

Bulk solid storage silos has several equipment attached to them to function properly. Product level in the silo is monitored. Silo filter is used for dust collection. Pressure sensors, pressure relief valves work for silo safety. Discharge aid equipments work for durable product flow. Valves and feeders control the silo discharge.

Silo equipments

Jet Filter

Silo jet filters are used to prevent any dust emmission from silo. During pneumatic conveying of bulk solids to the silo, there exists air and dust within silo. Jet filter is used to discharge the air and filter the dust. Cement, ash, food, plastics, minerals are generally loaded to silos by pneumatic conveying systems of bulk trucks. Silo filters are used to vent these silos without dust emmission.

Silo Level Switch / Sensor

Silo Pressure Relief Valve

Silo Pressure Sensor

Silo pressure sensors are used to measure the air pressure level within the silo. It sends signals to silo control systems or automation systems to indicate the pressure level.

Silo Aeration Pads / Air Jets

To fluidize the bulk solid within the silo, aeration pads are used. The fluidized material will flow easily and silo discharging will be better. Aeration pads / air jets are placed near the discharge outlet flange of the silo. Pressurized air is applied to air jets and makes the bulk solid flow better.

Silo Discharge Butterfly Valve

Butterfly valves are used to control the discharge of bulk solids from silos.

Silo Discharge Screw Conveyor

Screw conveyors are widely used below the silos to control the flow of bulk solids.

Rotary Valve

The rotary valve placed under the silo, is used to control the bulk solid (in powder or granule form) discharge from these units and feed equipments like conveyor, screw feeder, mixer etc.

Bin Activator

Bin activators are also know as vibrating bin dischargers. They generate a vibration below the silo to fluidize the bulk solid in the silo, make it flow downwards and discharge easier. Bin activators are very helpfull for bulk solids that flow hard. Brochure of Bin Activator

Silo Control System

Silo control systems are used in silos where bulk trucks load the silos by pneumatic conveying system. They check the level of product in the silo, inner pressure of silo, they control the jet filter, inlet and discharge valves for safety and reliability.

Pinch Valve

Activated Carbon Injection System

Activated Carbon Injection Systems

In the process of combustion at high temperatures, various gases spread out to the atmosphere. They are toxic and harmful to human health. Powdered activated carbon (PAC) is high performance adsorbent engineered to eliminate such toxic gases like dioxins, furans and other chemicals like mercury. In addition to flue gas treatment, another area of application is the removal of micropollutants in wastewater cleaning and drinking water treatment. Environmental problems affecting air and water are solved through the use of activated carbon.

PAC is commonly used in chemical plants, steel mills, waste disposal facilities, coal-fired power plants and casting plants. Under normal conditions, baghouse filters are not eligible to prevent the spreading of the flue gases produced by the incineration process. Injecting PAC to the pipeline at the baghouse filter inlet adsorbs these gases. PAC within captured flue gases like dioxins, furans are captured by the filter bags and prevent the release to the atmosphere.

PAC dosing activated carbon injection

Implementation difficulties of PAC in such industries are the storage of raw material (sacks, big bags, silos) , conveying to dosing systems and dosing to the desired process afterwards. However, this is too costly to meet the need for a large space in the plant. Inefficient methods increase operation time, labor and energy costs. Polimak activated carbon injection (ACI) system with its high-efficiency control of gas emissions provides a long-term solution that consists of a packaged system that takes less space in the plant, simple to install and simple to operate. The packaged PAC handling system is designed for PAC delivered in bulk bags and consists of hoist, big bag discharging platform, storage silo, weighing, dosing unit and pneumatic conveying system for PAC injection. It can also be integrated with lime dosing systems to provide better functionality.

ACtivated carbon injection weighing dosing system for bag house filters

Operating Principle of PAC Injection System

Powdered activated carbon (PAC) comes in the big bag and placed to the carrier platform of the unit by the help of forklift or hoist. The FIBC bag outlet connection is released, activated carbon is fed into the powder hopper and discharged into the storage silo. The dosing system below the silo is used to discharge the silo and feed the pneumatic conveying pipeline automatically. PAC is injected into the pneumatic conveying pipeline at the desired speed by the help of a feeder placed under the weighing device. PAC conveying in the pipeline by the help of a roots blower is injected into the process line which is generally another pipeline in the dust collection line. This injection process may operate in the same or opposite direction with the airflow. PLC controlled automation system is used to control the precisely definable amount of injected PAC to the pipeline. Material transfer at desired capacity, speed and time are regulated by the control panel.

Big Bag Discharge Powdered Activated Carbon PAC Dosing and injection system

Advantages of Activated Carbon Injection Systems for Flue Gas Treatment

Compact and packageds design for simpler big bag handling, activated carbon storage and injection
Short delivery times
Easy installation
Quick commissioning
Space-saving design
Lower investment and operation costs

Lime and PAC dosing systems big bag dischargers

Lime and activated carbon injection systems

Big bag discharge and activated carbon injection system

Flue gas treatment activated carbon injection

PAC bulk bag discharge storage weighing dosing and injection system

PAC storage silo and dosing unit

powdered activated carbon in bulk bag discharger

PAC big bag discharge and dosing unit

Screw Jack

A screw jack often referred to as a jackscrew or a mechanical screw jack, is a mechanical power transmission equipment that is used in applications where linear motion is required. Jackscrews are used to lift heavy and moderate loads like raising and lowering of stages, provide adjustable support in construction applications, lift vehicles, lift machinery for assembly purposes etc. The mechanical capacity of screw jacks is generally between 5kN and 2000kN. Jackscrews can be used as linear motors, linear actuators, or mechanical lifts depending on the type of motion. Jackscrews can be driven by either AC/DC motors or manual handweheels. Screw jack systems from Polimak be utilized individually or in multiple configurations.

Screw Jack Catalog

Screw Jack Selection Questionnaire

SCREW JACK WORKING PRINCIPLE

The main components of screw jacks are; trapezoidal lifting screw also known as lead screw, worm screw, worm gear and gear housing. A worm screw is rotated manually or by a motor. With the rotation of the worm gear, the lead screw in it moves upwards or downwards linearly. The feed rate of the screw depends on the turning speed, the number of teeth of the gears and the size of the screw pitch.

In some models of jackscrews, The lifting screw does not move up and down. It only rotates around its axis. A lifting nut (also known as a travelling nut) moves along the lead screw. The lifting nut of the screw jack is made of bronze to decrease friction.

SCREW JACK TYPES

There are three main types of screw jacks; Travelling Screw Type, Travelling Wedge Screw Type and Travelling Nut Type.

V-Travelling Screw Type

If the screw end connection is connected to the free load, the screw rotates around its own axis without moving up and down. If it is connected to a fixed load, the gearbox in the jack receives the movement from the gear unit and the trapezoidal screw translates only linearly up and down. In other words, it acts the same as the wedged type, so there is no need to open the wedge channel to trapezoidal screw.

K-Travelling Wedge Screw Type

The wedge channel is opened to the screw to prevent the rotation of the screw and only the upward and downward movement of the screw is provided. In this way, the importance of the screw connection to an external fixed part is eliminated.

T-Travelling Nut Type

With the rotation of the gear, the lead screw that is inside the screw jack only rotates around its axis. The flange, which is produced from the bronze material on the screw shaft translates linearly upwards or downwards. One of the purposes of using such systems is the lack of ducting or storage for the movement of the screw used in the screw type and wedge screw type. In addition, the screw does not come down from the jack base.

SCREW JACK END TYPES

Plain End

Plain end type screw jacks are used in multipurpose applications. Linear motion is provided thanks to the wedge option in free loads. Screw jack systems with self-locking systems prevent the load from slipping back. This type is used in projects that require efficiency and precision.

Clevis End

Clevis end type screw jacks provide positive mechanical movement, precise positioning and smooth lifting speeds. Its standard configurations include pulling and pushing features. Its self-locking system keeps the load steady and prevents the load from going back. Due to its movable head, it is used in angular moving mechanisms.

Flange End

Flanged screw jacks provide positive mechanical movement, precise positioning and smooth lifting speeds. Its standard configurations include pulling and pushing features. Its self-locking feature keeps the load steady and prevents it from going back.

Travelling Nut

Travelling nut type screw jacks provide positive mechanical movement, precise positioning and smooth lifting speeds. Its self-locking feature keeps the load steady and prevents it from escaping. It can be used as a product lifting system on movable bronze nuts with fixed rotation of the screw in places where the trapezoidal screw should not come down, like platform lifting units.

INDUSTRY SOLUTIONS

Screw jacks are used to raise, align, position and hold loads and are found all over the world. They are ideal for a wide range of applications because of their excellent reliability and synchronization which is hard to achieve with other handling methods such as pneumatic or hydraulic lifting systems. Jack screws are increasingly finding use as an alternative to hydraulic and pneumatic systems.
Click here for our screw jack applications.

What is a Screw Jack?

A screw jack is a mechanical power transmission device that translates rotational motion into linear motion. It is a versatile device that uses force to hoist heavy or moderate loads and is utilized in various industries for a variety of industrial applications

What is a Lead Screw?

Sometimes referred to as a translating screw or a power screw, a lead screw is simply a screw linkage in a machine utilized to translate rotational motion into linear motion. It is a common component on linear actuators.

What is the difference between mechanical jacks and hydraulic jacks?

Mechanical screw jacks use screw threads for hoisting loads whereas hydraulic jacks utilize hydraulic fluid as their primary power source. Because mechanical jacks are self-locking, they are considered to be safer than their hydraulic counterparts. Moreover screw jacks can be used for precise positioning of the load. On the other hand, hydraulic jacks tend to be stronger and can lift heavier loads higher.

Bulk Material Storage Silos

Bulk materials in powder and granular form are used in wide range of industrial procceses. Large amount of raw material have to be stored in safe and efficient way for further proccessing. Though, silos are used to serve as storage vessels for such materials taking minimum amount of floor space in industrial plants. Being an integral part of production lines; a great deal of know how is essential in designing silos with correct configuration, geometry and size. Polimak provides reliable solutions for bulk solid storage systems and silos from concept design to turnkey installation.

Extensive range of silos are available depending on type of application, handled bulk solid and environment conditions. Starting from small sized temporary storage silos up to high capacity gigantic silos, each storage vessel is designed with state of the art engineering methods for maximum performance and minimum operational costs.

Turnkey Dry Bulk Storage Solutions

The ability to provide expert solutions to wide range of industries derives from a team of experts who have long years of experience in designing, production and installation of industrial components and systems. Each phase of a bulk material storage project is critical to achieve desired performance and required safety. Our team of highly experienced engineers provide industrial solutions designed for safety, reliability and performance

Dry bulk material storage silo erection installation and commissioning turnkey powder handling applications

Capabilities

– Feasibility Analysis – Concept Design – Initial design in 2D / 3D – FEA (Finite element analysis) of silo for structural safety – Cabling, instrumentation and piping design – Detailed design in 2D / 3D – Fabrication – Installation – Commissioning

Silo Design

There exists several aspects that affect the silo design. Each one should be considered carefully to achieve an efficient bulk material storage and handling solution. Physical and chemical properties of stored bulk solid (bulk density, particle size, angle of repose, flowability, moisture, corrosivity, minimum ignition temperature etc.) storage volume, silo filling and discharge capacity, process limitations, connected equipment, wind loads, seismic loads are some of the important factors in silo design. Process and occupational safety considerations are also the key elements in engineering design of silos.

Altough silos are considered as simple structures for bulk material storage, there exists several risks in operation of silos. Depending on product properties and environment conditions, flow problems like arching (bridging), piping or funnel flow are seen occasionally; consequently, silo geometry (width, height, cone angle, outlet size, etc) surface roughness, flow aid equipment are to be determined properly for smooth discharging of bulk solids from silos. Weight of the stored bulk solid, seismic loads and wind loads may impose danger if not considered properly. Though, finite element analysis (FEA) are applied to ensure structural stability.

Bulk solid powder storage silo design FEA structural load calculation

Powder loading silo storage bulk filling discharging calcium carbonate silos with telescopic chute truck loading

Bulk solid storage silos are generally connected to other equipment and / or machinery. Therefore, mechanical or pneumatic conveying systems are needed to transfer bulk material between silos and other equipment. Additionally, in large industrial plants where high volumes of bulk materials are processed, a series of silos may be integrated together for higher storage capacity.

Advantages of Silos in Bulk Material Storage

– Reduced floor space – Clean and contamination free storage – Low operational costs – Very low level of dust emmission – Easier stock and inventory control of bulk material – Optimum filling and discharge rates – Easier integration to industrial processes. – Suitable for interior and exterior use

Fly ash silo with vibrating bin activator

Bulk Materials That Are Stored in Silos

Cement, calcium carbonate, ash, plastic pellets, lime, sand, gypsum, carbon black, pvc, fly ash, coal, coal dust. flour, seed, chickpea, bean, sesame, almond, grain cereals, chestnut, coffee grain, coffee powder, sugar, corn, starch, salt, spice, glass powder, marble powder,sawdust.

Brochure of Bulk Material Storage Silos

Application Gallery

Power plant fly ash handling system & fly ash storage silo

Stainless steel silos

Corn starch silo with explosion vents

Bulk powder storage silo with telescopic chute

Dry Bulk Chemical powder silo cyclone loading

Stainless steel silo with pneumatic conveying system

Steel silo with tanker loading chute

Calcium carbonate storage silo installation

Silo erection installation commissioning

Silo installation on power plant

Powder storage silos with telescopic truck loading bellows

Fly ash handling storage conveying truck loading silo

Fly ash storage silo for coal fired power plant

Bulk powder silo container stainless steel

Stainless steel silos for bulk material

Atex Certified Diverter Valves and Flow Control Valves

Explosive or potentially explosive atmospheres occur where fine dust of combustable bulk materials accumulate and become a dust cloud with high concentrations. Any kind of ignition source like spark, overheating, exccessive friction might lead to hazardous dust explosion in the zone. Almost all flammable bulk materials that arise as a result of, or that are used during industrial proccesses, are combustible and can cause dust explosions under certain conditions. Examples of such bulk materials include coal, flour, sugar, cereals, wood, corn starch, aluminium, magnesium, cotton and certain plastics. These explosions may occur when the combustable dust suspends on air, accumulated on hot surfaces, slides through chutes or conveyed within pipes etc. To decrease dust explosion risk to acceptable levels, industrial proccesses should be designed and operated carefully. ATEX directives which are prepared and published by EU Community, are used as guidelines and obligatory rules for manufacturers, system integrators and end users. Production lines should be designed with respect to ATEX regulations and directives.

Atex diverter valves bulk material dust explosion protection certified ex-proof valves wo way diverters

Pneumatic conveying line Y diverters Atex valves dust explosion

Atex diverter valve for coal dust explosion protection

ATEX Certified Diverter and Flow Control Valves

For potentially explosive atmospheres, Polimak produces diverter and flow control valves with respect to ATEX directives 94/9/EC and 2014/34/EU. A great deal of know how is required to select proper type and configuration of diverter valves. All components of diverter valves are designed to isolate temperature, static electricity, spark and ignition sources from handled bulk material. Ex-proof electrical motors, Atex certified actuators, sensors, low friction bearings are used in these diverter valves to ensure process and environment safety. Atex slide gate valves dust discharge bulk solid silo explosion preventation ex-proof sliding blade valve

Atex slide gate valves dust discharge bulk solid silo explosion preventation ex-proof sliding blade valve

Screw Feeder & Conveyor Technical Documents

Technical documents, catalogs and brochures of screw conveyors.

Links

Screw feeders helical screw conveyors powder conveying systems

Screw Conveyors & Feeders

Screw conveyors are used to mechanically transfer powdered materials from point to point. Wide range of powdered and granular materials like cement, calcium carbonate, PVC, wheat, flour can be transported by screw feeders.

Screw conveyor feeder dosing batching loading discharging applications

Screw Feeder Applications

Industrial applications of screw feeders; silo discharging, dosing bulk material feeding etc. Wide range of screw feeders are available for special needs.

Screw feeder models screw conveyor types U-Type screw feeder Tubular screw conveyor stainless steel feeding bulk material powder loading

Screw Feeder Models, Options and Accessories

Extensive range of screw conveyor models and configurations are avaliable for different applications , process parameters and environment conditions

Screw Feeder Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of screw conveyors and feeders.

Screw Feeder & Conveyor Models Options and Accessories

Screw Conveyor Types, Models and Configurations

There exist several types of screw feeders & conveyors. Depending on process requirements, screw conveyor configurations may change.

Tubular Screw Conveyors

Tubular screw conveyors have single tubular shaped outer body with at least one inlet and one outlet. Helicoid screw witch shaft turns within the tubular body and transfers the bulk material from inlet port to outlet.

U Type Screw Feeders

U shaped or V shaped outer body is used in U type screw feeders and conveyors. There exist removable top cover above the screw feeder for easier cleaning and maintenance.

U Type V Type Screw conveyors and feeders

Stainless Steel Screw Conveyors

Used in food production, processing, packaging, and in pharmaceticual industry.

Hardox Screw Conveyors

Used in abbrassive products. Helicoid screw can be made from hardox steel for longer operating life.

Screw Conveyors With Mulitple Inlet Ports

Screw conveyors can be used to collect product from multiple points and transport to receiving point.

Multiple inlet screw conveyors with inlet valves for multiple hoppers and baghouse pulse jet filter units

Screw Conveyors With Multiple Outlet Ports

Screw conveyors can be used to feed multiple processes at the same time or sequentially. Slide gate valves or butterfly valves are installed to outlet ports to control product flow.

Mobile Screw Conveyor With Hopper

Used in different locations in production plants. Can easily be moved by the help of wheels. Weighing equipment can be added for applications that need measurement.

Mobile screw conveyor and hopper assembly

Dosing Screw Feeder

Used for adjustment of the amount of product to be fed into the process. Generally used in food, chemical and in plastics industries. Volumetric dosing is controlled by screw feeder shaft speed. Weighing scales are to be used with screw feeders for gravimetric dosing applications.

Powder dosing batching screw feeder system mixer loading bulk material process

Microdosing Screw Feeder

Small amounts of dosing is possible with special designed microdosing screw feeders.

Custom Designed Screw Feeders and Conveyors

In addition to extensive range of screw feeders, custom designed and engineered feeders are available depending on process requirement.

Screw Conveyor vs. Feeder Screw, What is the Difference?

In bulk material handling industry, screw feeders are mistakenly dubbed as screw conveyors because their functions are nearly identical. The basic construction is the same in screw feeders and conveyors; a rotating helicoid screw inside a tubular or U shaped body used to transfer the powdered or granular bulk material from inlet port to outlet port. The key difference is intended use of the equipment. Screw conveyors are used for moving the bulk material between two points with generally maximum possible or optimum transportation speed. While screw conveyors are capable of handling free flowing bulk solids, they are generally unable to regulate the speed at which they discharge material. Silo discharging, dust collector discharging, truck filling, continous process feeding are typical applications for screw conveyors. Screw feeders are used specifically to deliver bulk materials from one part of the feeder mechanism to the other in a controlled manner. The speed of product flow is determined and generally adjustable with respect to process requirements. Feeding with determined throughput, volumetric dosing and gravimetric dosing are done by screw feeders. Equipment design (i.e the diameter, pitch, body geometry) is much more important in achieveing desired performance.

Screw Feeder & Conveyor Applications

Screw conveyors and feeders are widely used in bulk material handling industry to transfer bulk materials between different points in a practical way.

Silo, Hopper Emptying With Screw Conveyor

Screw feeder placed under the silo, hopper or other container system is used to control the bulk solid (in powder or granule form) discharge from these units and feed equipments like conveyor, mixer etc.

calcium carbonate gypsum Silo discharge screw conveyor mixer feeding

Dust Collection Systems, Baghouse Dust Filters

Dust collectors, filters, jet pulse filters are used to collect dust from production lines. Screw conveyors installed under dust collection systems, are used to unload the collected dust.

Mixing, Batching, Dosing Systems

Screw feeders can be used to control the amount of discharging of bulk solids. By controlling the shaft speed of screw feeder, volumetric measurement is possible for both powdered and granule type bulk materials. Gravimetric feeding of mixers or containers are done by measuring the weight of handled product.

Bulk material dosing batching screw feeders recipe preparation pvc mixer dosing system

Bulk Solids Processing Equipment Feeding / Discharging With Screw Conveyors

In several industrial processes, bulk solid processing equipment can be fed or discharged with the help of screw conveyors. Feeding, batching, mixing, crushing processes are some of the examples that utilize screw conveyors.

Bulk solid proccessing screw feeder screw conveyor system

Other Industries and Applications of Screw Feeders & Conveyors

Chemical and process technology
Power plants
Cement and lime
Foodstuffs
Paper industry
Flour mills
Iron and Steel Foundries
Dust collection systems
Painting machines
Grain handling
Agriculture applications

Handled Materials By Screw Conveyors

Cement, calcium carbonate, ash, plastic pellets, pvc, fly ash, coal, coal dust. wheat, flour, barley, feed, seed, corn, chickpea, bean, sesame, rice, rice flour, dried fruit, nuts, peanut, almond, sunflower seed, cotton seed, grain cereals, chestnut, coffee grain, coffee powder, sugar, salt, spice, glass powder, marble powder,sawdust.

Application Gallery

Screw conveyor of bulk material FIBC Big bsg discharge station

Big bag discharge station screw conveyor

Screw feeder mixer filling system bulk solid powder dosing system

Bag dump station screw feeder for mixer filling

Pneumatic conveying system feeding screw conveyor and rotary airlock

Continuous feeding by screw conveyor and rotary valve

Bulk solid powder dosing weighing system screw feeder PVC mixer

Bulk material batching and dosing system screw feeders

Powder conveying screw feeder silo discharge system

Silo discharge and powder process feeding screw conveyor

Dust collection system screw conveyor and slidegate valves

Baghouse dust collector screw conveyor

Stainless steel Screw feeders

Screw conveyors silo discharge mixer unit weighing system bulk solid

Silo discharge system and screw feeders for mixer loading

Multiple outlet screw conveyors

Screw Conveyors & Feeders

Screw feeders screw conveyors bulk solid conveyors powder feeder screw

Screw Feeders and Conveyors

Bulk material handling processes including plastics production, power plants, construction, food processing and mining depend heavily on industrial bulk material transportation equipment such as screw feeders and screw conveyors also known as helical conveyors. They are used in conveying powdered and granular materials mechanically. There exist wide range of screw conveyor types and configurations. The physical properties of bulk solids and type of application effects the design of screw feeder. Conveying capacity, horizontal and vertical distances, type of bulk solid should be considered to select a proper screw conveyor model. Screw diameter, screw pitch, inlet and outlet dimensions, motor power and casing type are major properties of screw conveyors., Polimak designs and manufactures the screw conveyors to meet specific design parameters and applications.

Diverter and Flow Control Valves Technical Documents

Technical documents , catalogs and brochures of diverter and flow control valves.

Brochure of Diverter Valves

Custom Designed Valves

Custom Engineered Valves

In addition to standard production range, custom designed diverter and flow control valves are available for the most demanding applications. Different bore sizes, unique flange connections, non-standard body designs and special accessories are accomplished through our engineered products group. Custom engineered production incorporates problem definition, conceptualization, design, validation, production and installation. Polimak carries out these steps efficiently and provides custom engineered solutions in short times.

Custom designed engineered diverter valves conveying line diverter valves bulk solid conveying powder handling 2 way line diverter valve

Application Parameters For Valve Selection

Each process for each valve has its own unique requirements. Selecting the most efficient valve for a particular system requires detailed information about that system. Collecting correct technical specifications of a dry bulk handling system plays cruical role in determining the features of the valve. The factors that are used in valve selection are described as follows: Intended use of the valve; shut-off, flow regulation, diverting, converging, venting etc Material to be handled Shape of the bulk material; powder, granular, pellet, flake etc Particle size of the bulk material Bulk density of the handled material Physical properties of the bulk material; sticky, abrasive, corrosive, dust content, temperature level Inlet and outlet connection shapes and sizes Size of the connected pipelines, chutes, hoppers, silos or other equipment Pressure or vacuum level at inlet and outlet ports Installation location; indoors, outdoors Type of application; food, sanitary, explosive area etc. Site conditions; minimum and maximum ambient temperature, moisture content, offshore etc Valve construction material; carbon steeel, stainless steel, aluminium, hardox, welded body, cast body etc Any need for fluidization, aeration or vibration for bulk material flow control Operation frequency, amount and speed of valve Power and process air supply Sealing concerns Cross contamination concerns Type of actuation; manual control, pneumatic piston, pneumatic actuator, hydraulic piston, electrical actuator, pneumatic positioner, electrical positioner, handwheel, hand lever, chain wheel etc. Feedback signal requirement Required certifications (food grade, explosion protection, Atex certification etc.)

Engineered valves custom designed diverter valves stainless steel food grade diverter valve

Custom Designed Bulk Material Handling Valve Application Examples

Silo discharger valve Double gate gravity discharge valve Dosing valve Rod gate valve (şişli klepe) Two-way converger valve Double slide gate diverter valve Maintenance gate valve Shut off valve Flow controller Double dump Valve 3 way diverter valve Aeration rotary throttle valve (dosier) Custom designed engineered diverter valves conveying line diverter valves bulk solid conveying powder handling 2 way line diverter valves

Custom designed engineered diverter valves conveying line diverter valves bulk solid conveying powder handling 2 way line diverter valves

Handled Materials

Materials in powder, pellet, granular and aggregate form like cement, fly ash, mining minerals, calcium carbonate, pvc, plastic pellets, plastic powders, polyethylene, ceramic powders,alumina, bentonite, bauxite, coal, cement clinker, gypsium, perlite, kaolin, limestone, marble powder, soda ash, quartz, urea, sodium suplhate, wheat, flour, animal feed, seed, corn, rice, sugar, salt.

Flow Control Gate Valves

Flow control gates are designed to provide controlled discharging of bulk solids from silos and bins. Installed on airslide conveyors, flow control gate valves are used for shut-off, flow regulation and metering. A flow control gate valve has two chambers inside. Lower chamber supplies fluidization air to upper chamber. It works like an airslide conveyor, keeps continuous material flow. A fabric permeable to air divides the upper and lower chambers and maintains constant air flow to upperside. Upper chamber has a rotating drum with an aperture around its perimeter. Rotating the drum in one direction provides dust tight shut-off. Rotating the drum to opposite direction provides an adjustable cross sectional passage for material flow. By adjusting the exact position of the drum, bulk material flow speed can be adjusted with precision. Leak tightness between rotating drum and valve body is achieved by a flexible felt gasket. Rotating drum can be actuated by pneumatic piston, electrical motor, pneumatic positioner or manual hand lever. Flow control gate valves are widely used in cement silos to adjust material flow from silo to downstream equipment. Depending on the application, bulk truck loading, packaging, weighing or production line equipment are fed by flow control gate valves.

Design Features and Benefits of Flow Control Gate Valves

Uninterrupted bulk material flow when the valve is fully open Flow control gate valve can be actuated while material is being conveyed through airslide conveyor. Built in replacable felt gasket to prevent product leakage Cast steel, cast aluminium and welded steel construction flow control gate valve designs available depending on application requirements. Can be operated by pneumatic piston, electrical drive, pneumatic positioner, Kinetrol pneumatic actuator, manual hand lever or manual handwheel . Rotating drum position can be adjusted with special position controller to maintain product flow speed at intended level. Built in limit switches and position indicators to check the valve position. Custom designed flow control gate valve models are available. Dust free operation.

Flow control gate valves kinetrol airslide cement loading truck filling silo discharge

Handled Materials

Materials in powder form like cement, fly ash, mining minerals, calcium carbonate, ceramic powders,alumina, bentonite, bauxite, coal, cement clinker, gypsium, kaolin, limestone, marble powder, soda ash, quartz, urea, sodium suplhate.

Iris Valves

Iris valves are designed to provide an efficient method for controlling the flow of free flowing dry bulk materials. An iris valve is generally installed at the outlet of big bags, chutes, hoppers or any similar gravity discharge points. Big bags also known as FIBC or bulk bags are discharged by big bag discharging stations. Iris valves that are installed on big bag discharge systems are used to control product flow from the bulk bag without having any contact with flowing material. It directly closes the big bag discharge spout. A flexible sleeve inside the iris valve is used to open or close the valve. Actuation of the valve, the pinching action is accomplished by a hand lever that twists the sleeve. The flexible sleeve tightly closes the outlet with the help of actuation force. When the iris valve is in open position, bulk material flows freely through the full bore of the valve. Iris valve can shut off the flow of the product completely or it can be kept open at intended level to control product flow speed.

Design Features and Benefits of Iris Valves

Low profile valve body design maintains a minumum flange-to-flange height to minimize space requirements. It adapts easily to new installations and retrofits. Uninterrupted bulk material flow when the valve is fully open Iris valve can be actuated while material is being discharged in gravity flow line. DIN or ANSI flanges are available Can be operated by , pneumatic piston , electrical drive or manual handwheel. Flexible sleeve closing amount can be adjusted to maintain product flow speed at intended level. Built in limit switches and position indicators to check the iris valve position. Custom designed iris valve models are available.

iris valves for bulk bag discharge applications

Manual handle iris valve powder flow control diverter

Handled Materials

Flap Type Pneumatic Conveying Diverter Valves

Flap type pneumatic conveying diverter valves are designed to divert flow of bulk solids within pneumatic conveying lines. Bulk materials in powder, pellet, flake or granular form are re-routed from one feeding point to two or more receiving points in pressure or vacuum conveying lines. Diverter valves have cast iron or cast aluminium outer body. The small angular deviation between the inlet and outlet ports provide smooth air and material flow. Wear resistant swivel flap is used for diverting the flow inside the valve. It consists of a flexible poliurethane rubber which is sandwiched between two metal plates for better sealing. Changes in cross sectional area are kept minimum through the valve to reduce pressure drop in the conveying line. Pneumatic conveying diverter valve can be actuated while bulk material is being conveyed.

Flap Type Pneumatic conveying line diverter valves bulk solid conveying powder handling 2 way line diverter valve

Design Features and Benefits of Pneumatic Conveying Diverter Valves

Heavy duty construction flap valve ensures long years of reliable operation Low pressure drop through the valve due to smooth internal geometry with no lodgement points Flat blade pneumatic conveying diverter valve can be actuated while material is being conveyed DIN or ANSI flanges are available Built in replacable polyurethane and silicone seals to prevent product leakage Cast steel, cast aluminium and welded steel construction diverter valve designs available depending on application requirements. Heavy duty swivel blade with flexible poliurethane blade seal Stainless steel diverter valve models are avaliable for food and sanitary applications Hardox steel models are available for abbrassive bulk solids. High temperature gravity discharge valve models up to 200C Can be operated by pneumatic actuator , pneumatic piston , electrical drive or manual handle. Built in limit switches and position indicators to check the valve position. Optional side inspection door. Custom designed 2 way outlet and 3 way outlet diverter valve models are available. Atex certified pneumatic conveying diverter valves are available

Pneumatic Conveying Diverter Valve Discharge Leg Configurations

Two 30^O symmetric legs One straight leg, one 30^O offset leg One straight leg, two 30^O offset legs Custom designed outlets with any angle to suit the application.

Bulk solid powder conveying system diverter valves flsp diverters

Flap diverter valves powder conveying flow control valves

Handled Materials

Pinch Valves

Bulk materials in powder, pellet, flake or granular form can be handled by pinch valves in pneumatic conveying systems. A pinch valve functions as a shut-off valve and prevents the product flow completely with the aid of proper sealing. Actuation of the valve, the pinching action is accomplished by air pressure applied on the sleeve. The flexible sleeve tightly closes the line with the help of actuation pressure. When the pinch valve is in open position, bulk material flows freely through the full bore of the valve. Since there is no change in cross sectional area through the pinch valve, pressure drop is kept minimum.

Design Features and Benefits of Flexible Pinch Valves

Low profile pinch valve body design maintains a minumum flange-to-flange length to minimize space requirements. It adapts easily to new installations and retrofits. Uninterrupted bulk material flow when the pinch valve is open due to smooth internal geometry with no lodgement points. No pressure loss during product flow. Pinch valve can be actuated while material is being discharged in gravity flow line. Easy to replace flexible sleeve. Heavy duty flexible sleeve ensures long years of reliable operation

how pinch valves work pneumatic conveying systems

Pinch Valve Application Examples

Pinch valves are widely used in bulk material storage silos that are filled by bulk tanker trucks. They are installed at the inlet of silo filling pipeline to control product flow from bulk truck to silo. When installed on the pneumatic conveying lines, pinch valves are used to allow or prevent product flow in determined pipeline routes.

Pinch valve for pneumatic conveying systems for powder bulk solids

Pneumatic conveying pinch valve pressurized air operated

Handled Materials

Multiport Diverter Valves

Multiport diverter valves also known as multiway diverter valves are used in pneumatic conveying systems to divert bulk material flow from one feeding point to multiple receiving points. Bulk materials in powder, pellet, flake or granular form can be re-routed within pressure conveying and vacuum conveying lines. Multiport diverter design incorporates a rotary tube multiway selector mechanism. A distributor pipe rotates around an axis to connect single inlet port to multiple outlet ports. PLC controlled rotary tube can be positioned to the desired outlet port in short time with maximum sealing. Small angular deviation between the inlet and outlet ports provide smooth air and material flow. Since there is no change in cross sectional area through the multiport diverter valve, pressure drop is kept minimum. Rotary tube selector and inner surfaces are designed to prevent cross contamination between inlet and outlet ports. Steel piping provides higher pressure and temperature ratings, and is suitable for abbrassive bulk materials.

Design Features and Benefits of Flexible Multiport Diverter Valves

Up to 20 outlet ports are available. PLC controlled rotary tube selector system. Any outlet port can be selected with multiway selector valve. Multiport diverter valve can be controlled locally or via central plant automation system. Heavy duty distributor pipe ensures long years of reliable operation Low pressure drop through the valve due to smooth internal geometry with no lodgement points DIN or ANSI flanges are available Can be operated in both directions. Used as diverter valve or converger valve. Dust free operation Stainless steel distributer tube and valve body are avaliable for food and sanitary applications Built in limit switches and position indicators to check the valve position. Optional side inspection door. Atex certified pneumatic conveying multiway tube diverter valves are available High temperature multiport diverter valve models up to 200C

Multiport diverter valve rotary tube selector valve multiway diverter valve

Multiport selector valve mutiway diverter valves pneumatic conveying systems

Rotating-Tube-Selector-Multiport-Diverter-Valves

Handled Materials

Flexible Tube Diverter Valves

Flexible tube diverter valves are used in pneumatic conveying systems to divert bulk material flow from one feeding point to two or more receiving points. Bulk materials in powder, pellet, flake or granular form can be re-routed within pressure conveying and vacuum conveying lines. Flexible tube design with small angular deviation between the inlet and outlet ports provide smooth air and material flow. Since there is no change in cross sectional area through the flex tube diverter valve, pressure drop is kept minimum. Flexible hose and inner surfaces are designed to prevent cross contamination between inlet and outlet ports.

Design Features and Benefits of Flexible Tube Diverter Valves

Heavy duty flexible tube ensures long years of reliable operation Low pressure drop through the valve due to smooth internal geometry with no lodgement points DIN or ANSI flanges are available Can be operated in both directions. Used as diverter valve or converger valve. Dust free operation Food grade flexible hose and stainless steel valve body are avaliable for food and sanitary applications Can be operated by pneumatic piston , electrical drive or manual handle. Built in limit switches and position indicators to check the valve position. Optional side inspection door. Custom designed 2 way outlet and 3 way outlet flexible hose diverter valve models are available. Atex certified pneumatic conveying flex tube diverter valves are available

Flexible tube diverter valve flextube flexible hose diverter pneumatic conveying bulk solid valves

Flexible tube diverters flextube diverter valve pneumatic conveying diverter valves bulk solid handling and transfer systems.

Handled Materials

Materials in powder, pellet, granular and aggregate form like cement, mining minerals, calcium carbonate, pvc, plastic pellets, plastic powders, polyethylene, alumina, urea, wheat, flour, animal feed, seed, corn, rice, sugar, salt.

Two way flextube diverter valve flexible tube converger valves pneumatic conveying systems

Flexible tube pneumatic conveying line diverter valves flexible hose valve

Flap Type Gravity Diverter Valves

Gravity discharge diverter valves are designed to divert gravity flow of bulk solids from one feeding point to two or more receiving points. Bulk material in powdered, pellet, flake or granular form falls freely through the diverter valve. Wear resistant swivel flap is used for diverting the flow inside the valve. Depending on the application it consists of a flexible poliurethane rubber which is sandwiched between two metal plates for better sealing. Flap type diverter valves are installed on outlets of dry bulk storage silos, bins, chutes, conveyors and similar equipment.

Flap type gravity diverter valve Bulk solid handling

Design Features and Benefits of Gravity Discharge Diverter Valves

Heavy duty construction flap valve ensures long years of reliable operation Flat blade diverter valve can be actuated while material is being conveyed Rectangular and circular inlet / outlet flanges are available DIN or ANSI flanges are available Built in replacable polyurethane and silicone seals to prevent product leakage Cast steel, cast aluminium and welded steel construction diverter valve designs available depending on application requirements. Stainless steel diverter valve models are avaliable for food and sanitary applications Hardox steel models are available for abbrassive bulk solids. High temperature gravity discharge valve models up to 200C Can be operated by pneumatic actuator , pneumatic piston , electrical drive or manual handle. Diverter flap position can be adjusted with special position controller for proportioning the product flow to two outlets. Built in limit switches and position indicators to check the valve position. Optional side inspection door. Custom designed 2 way outlet and 3 way outlet diverter valve models are available. Atex certified gravity discharge diverter valves are available

Hopper discharge Silo filling flap diverter valve

Flap Type Diverter Valve Discharge Leg Configurations

Two 30^O or 45^O symmetric legs One straight leg, one 30^O or 45^O offset leg One straight leg, two 30^O or 45^O offset legs Custom designed outlets with any angle to suit the application.

Gravity Diverter Valve Application Gallery

Flap diverter valve gravity discharge manual control bulk solids handling

Manual flap diverter valve

Gravity discharge valves flap diverter valves

Gravity Discharge Flap Diverter Valves

Pulverized coal gravity discharge to conveyors flap diverter valve

Coal handling flap diverter valve

Gravity discharge pneumatic conrol bulk material powder valve

Flap diverter valve

Silo emptying diverter valves flap gravity bulk solids powder

Food grade stainless steel diverter valves for silo discharge

Gravity discharge two way diverter valves

Flap diverter under rotary airlock valve

Bulk material silo discharge diverter valve

Two way flap diverter valve

Powder handlind valves gravity diverters

Diverter valve for powder discharge

Handled Materials

Slide Gate Valves

Slide gate valves are designed to provide an efficient method for controlling the flow of free flowing dry bulk materials. Altough there are some major differences, slide gate valves are also known as knife gate valves. These type of gate valves are generally installed at the outlet of dry bulk storage bins, silos, hoppers, chutes, mechanical conveyors or any similar gravity discharge points. A rectangular blade (knife) made of thick sheet metal moves horizontally in the valve body. It can shut off the flow of the product completely or it can be kept open at intended level to control product flow speed. When the blade is in open position, bulk material in powdered, pellet, flake or granular form falls freely through the slide gate valve. When the blade is in closed positon, it functions as a shut-off valve and prevents the product flow completely with the aid of proper sealing. Additionally, sliding blade can be adjusted to any position to maintain desired product flow rate.

Design Features and Benefits of Slide Gate Valves

Low profile valve body design maintains a minumum flange-to-flange height to minimize space requirements. It adapts easily to new installations and retrofits. Proper selection of sliding knife and seal material leads to problem free flow control of bulk solids. Uninterrupted bulk material flow when the valve is fully open Can be used as fast shut off gate valve Slide gate valve can be actuated while material is being discharged in gravity flow line. Rectangular and circular inlet / outlet flanges are available DIN or ANSI flanges are available Built in replacable polyurethane, gland packing and silicone seals to prevent product leakage Cast steel, cast aluminium and welded steel construction slide gate valve designs available depending on application requirements. Stainless steel slide gate valve models are avaliable for food and sanitary applications Hardox steel models are available for abbrassive bulk solids. High temperature gravity discharge knife gate valve models up to 200C Can be operated by , pneumatic piston , electrical drive, manual handwheel or manual chainwheel Sliding blade position can be adjusted with special position controller to maintain product flow speed at intended level. Built in limit switches and position indicators to check the valve position. Custom designed slide gate valve models are available. Atex certified gravity discharge slide gate valves are available

Knife Gate Valve Slide Gate Valve cement coal powder discharge

Slide Gate Valve Application Examples

Silo discharge slide gate valves are generally actuated by pneumatic pistons. They are used for opening and closing product flow automatically to discharge the product to downstream equipment. Manually operated slidegate valves installed below silos or hoppers are generally used for maintenance operations of equipment like rotary valve, screw feeder etc that are installed below slide gate valve When installed on the gravity flow line, electrically actuated knife gate valves are used to adjust product flow speed. Slide gate valves can be installed at the inlet and outlet of dry bulk mixers. Feeding of powdered or granular materials are done before mixing. And mixed product is discharged after mixing.

Stainless Steel Slide Gate Valve

Knife gate valve bulk solid powder feeding

Slide Gate Valve Above Diverter Valve For Bulk Material Feeding

Slide gate valve diverter valve silo discahrge

Slide Gate Valve Below Silo

Knife gate valve silo powder bulk material filling system

Silo Discharge Slide Gate Valve and Rotary Valve

Slide Gate Valve

Custom Designed Manual Slide Gate Valves

Slide gate valves for conveyor belt feeding

Hopper discharging bulks solid discharge

Hopper discharge slide gate valves with screw conveyor

Electrical motor operated slidegate valves

Handled Materials

Butterfly Valves

Butterfly valves are designed to provide an efficient method for controlling the flow of free flowing dry bulk materials. They are generally installed at the outlet of dry bulk storage bins, silos, hoppers, chutes, mechanical conveyors or any similar gravity discharge points. Heavy duty butterfly valves are suitable for installation on pneumatic conveying pipelines. Butterfly valves consist of a disc which rotates 90° in circular hollow body. When fully open, butterfly valve’s disc turns and becomes parallel to the flow direction, allowing minimum flow resistance. Bulk material in powdered, pellet, flake or granular form falls freely through the butterfly valve. When fully closed, butterfly valve’s disc is perpendicular to the flow direction and sealed against a seat. It functions as a shut-off valve and prevents the product flow completely with the aid of proper sealing.

Butterfly valve animation gif how it works

Butterfly Valve Types

Double Flanged Butterfly Valves: There exist bolted flange connections in two sides of butterfly valve. Suitable to fit on silos, hoppers, screw feeders etc. Single Flanged Butterfly Valves: One side of the valve has bolted flange connection. The other side has a built in short pipe suitable for fixing a flexible sleeve. Wafer Type Butterfly Valves: Butterfly valve is sandwiched between two flanges. Rubber sealing at two faces of the valve provides tight seal between flanges and wafer butterfly valve.

Design Features and Benefits of Butterfly Valves

Used for bulk materials in powder, granule, flake and pellet form. Low profile valve body design maintains a minumum flange-to-flange height to minimize space requirements. It adapts easily to new installations and retrofits. Proper selection of butterfly swivel disc and seal material leads to problem free flow control of bulk solids. Butterfly valve can be actuated while material is being discharged in gravity flow line. DIN or ANSI flanges are available Cast steel, cast aluminium butterfly valve designs available depending on application requirements. Stainless steel, food grade butterfly valve models are avaliable for food and sanitary applications. High temperature gravity discharge butterfly valve models up to 250C. Can be operated by , pneumatic actuator, pneumatic piston , electrical drive or manual hand lever. Built in limit switches and position indicators to check the valve position. Custom designed butterfly valve models are available. Atex certified gravity discharge butterfly valves are available

Buttterfly Valve Application Examples

Silo discharge buttterfly valves are generally actuated by pneumatic actuators. They are used for opening and closing product flow automatically to discharge the product to downstream equipment. Manually operated butterfly valves installed below silos or hoppers are generally used for maintenance operations of equipment like rotary valve, screw feeder etc that are installed below buttterfly valve. Buttterfly valves can be installed at the inlet and outlet of dry bulk mixers. Feeding of powdered or granular materials are done before mixing. And mixed product is discharged after mixing.

Butterfly valve pneumatic actuator bulk solid discharge

Butterfly Valve with Pneumatic Actuator

Pneumatic conveying diverter butterfly valves

Butterfly Valves on Pneumatic Conveying System

Wafer Butterfly Valves bulk solid handling

Wafer Type Butterfly Valve

Rotary valve butterfly valves pneumatic conveying system

Pneumatic conveying butterfly valve and rotary valve

Batching dosing system butterfly valve bulks solid filling

Butterfly valves for batching and dosing system

Butterfly valve product discharge bin activator rotary valve

Butterfly valve below bin activator

Bulk Powder Silo discharging butterfly valve

Silo discharge butterfly valve

Dust collection system butterfly valves pneumatic actuator dedusting

Butterfly Valve for Dust Collection System

Handled Materials

Diverter Valves and Flow Control Valves

Diverter valves flow control valves bulk material handling discharge

Valves for Bulk Solids Handling Systems

Diverter valves and flow control valves are essential components in bulk solid handling systems. They are used to shut off flows, adjust flow speeds and change conveying directions of powders, pellets and granular bulk materials. Extensive range of flow control and diverter valves are available for handling dry bulk material in pneumatic conveying and gravity flow applications. In addition to standard production range, custom designed valves are available for wide range of applications.

Gravity diverter valve flap valve for silo loading bucket elevator discharge

Flap type 2 way diverter valve gravity discharge application of bulk solids

During proccessing of bulk solids, material flow should be controlled in different locations. In gravity discharge applications, Flow control valves and diverter valves are generally installed at the outlet of dry bulk storage bins, silos, hoppers, chutes, mechanical conveyors or any similar points. Flow control valves are used to allow or prevent bulk material discharge. Diverter valves are used to divert gravity flow of bulk solids from one feeding point to two or more receiving points. Knife gate vales slide gate valve sliding blade valve bulk solid powder discharge handling

In pneumatic conveying applications diverter valves are used to divert bulk material flow from one feeding point to two or more receiving points. Bulk materials in powder, pellet, flake or granular form can be re-routed within pressure conveying and vacuum conveying lines. Pneumatic conveying line flap type 2 way diverter valve

Pneumatic conveying line flap type 2 way diverter valve

Designing valves for bulk solid handling processes require great deal of know-how and long years of experience. Selecting the most efficient valve for a particular system plays cruical role in obtaining long years of service. Polimak carries out specific engineering and production activities to provide trouble free solutions.

Roots Blower Technical Documents

Brochure of roots blowers

Links

ROtary lobe blowers positive displacement blower pumps

Roots Blower

Roots blowers are positive displacement, rotary lobe type air pumps. Blowers are used for generating air flow at high flow rates with low pressure and vacuum levels for wide range of industrial applications.

Blower Applications

Rotary lobe blowers are used in pneumatic conveying, waste water treatment, aquaculture , fish farms, vacuum systems, thermal forming, surface treatment and similar applications.

Roots Blower Rotary Lobe Blower Euqipment Component Accessories blower silencer filter motor relief valve

Blower Options and Accessories

Wide range of roots blower models and configurations are avaliable for different applications , process parameters and environment conditions

Roots Blower Rotary Lobe BLower user manual catalog brochure

Blower Models and Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary lobe blowers.

Roots Blower Options and Accessories

Rotary lobe blower systems have wide range of accessories and optional components for different process conditions.

Pressure Safety Relief Valve

Clogging of the pipeline, over feeding of bulk solid in pneumatic conveying system, incorrect adjustment of valves, high back pressures are some of the reasons that cause extra force on blowers. Safety relief valve protects the blower from over-pressurization. If the air or gas pressure in the pipeline exceeds the process limits, the valve opens and allows air to bleed off.

Vacuum Safety Relief Valve

Similar to pressure relief valves, vacuum safety relief valves protect the blower from under-pressurization. If the air or gas vacuum level in the pipeline exceeds the process limits, the valve opens and allows air to enter the pipeline and reach the desired vacuum level.

Silencer

The two lobes of positive displacement blowers cause continuous pressure fluctuation at each turn. This fluctuation causes high levels of noise. Blower inlet / suction silencers and blower outlet /discharge silencers are used to decrease the amount of this fluctuation and reduce the noise.

Inlet Filter

Dust built up and small particles will cause damage on blower impellers. Inlet filters of roots blower are critical components to maintain long service life. Depending on environment and process conditions, different types of blower inlet filters are used.

Sound Enclosure / Acoustic Enclosure

To decrease the noise coming from blower packages, sound enclosures are used. Any mechanical noise coming from blower, motor , mechanical coupling etc. are eliminated by these acoustic enclosures.

Advantages of Acoustic Enclosures

Low noise level Easy maintenance and easy access to internal equipment Efficient air circulation and cooling Optional fan for extra cooling and ventilation Optional built in control panel Robust construction suitable for outdoor operation and harsh environment

Inlet Air Cooler

Especially in pneumatic conveying of food materials such as sugar, plastic pellets etc, physical and chemical properties of conveyed material are negatively affected from elevated air temperatures. Air cooling systems are used in such kind of applications where the process air temperature is to be kept below a determined level.

Automatic Blower Control System

Automatic blower control system is a PLC controlled automation system that controls flow rate, pressure and temperature level of the air / gas supplied by blower with respect to process conditions.

General Features

System is used to control the air supplied from the blower units. Air flow rate, temperature and pressure in pipelines are continuously measured by sensors. Air flow rate, pressure or temperature can be adjusted to fulfill the demands of process at any time The control system can be adjusted to supply constant air flow rate, constant air pressure or constant temperature to the process. If the process limits are exceeded, the system automatically changes to safe working mode and informs the user by alarm. The control system has PID control. The air flow control is handled continuously, which leads to supplement of demand accurately. This also leads to decrease of energy consumption by 20-40%. (depends on process conditions) Air flow rate control, temperature control, pressure control system for positive displacement blowers.

Air flow rate control, temperature control, pressure control system for positive displacement blowers.

Other Optional Components and Accessories of Roots Blowers

Pressure Gauge Vacuum Gauge Non Return Valve/check valve V-Belt Steel Construction chasis

Roots Blower Applications

Rotary lobe positive displacement blowers supply pressurized and vacuum gases for wide range of industrial applications.

Blowers For Pneumatic Conveying of Bulk Materials

Pneumatic conveying system are used to transfer powders, granules, and other dry bulk materials through an enclosed pipeline. The motive force for this transfer comes from a combination of pressure differential and the flow of a gas, such as air or nitrogen. Positive displacement blowers generate pressurized or vacuum air to provide the pressure differential along the pipeline.

Depending on type of application, pneumatic conveying systems can be designed in four different configurations: – Pressure conveying; for low and high capacities and long distances – Vacuum conveying; for unloading, short distances, collecting bulk materials from more than one points. – Vacuum-Pressure combined pneumatic conveying systems. – Closed loop pneumatic conveying systems; for materials that are sensitive to oxygen or moisture, nitrogen is generally used in these applications. Proper selection of roots blowers play crucial role in overall performance of pneumatic conveying systems. Physical and chemical properties of bulk material, transfer capacity, conveying distance, environment conditions are key factors to be used in determination of proper type and sizing of roots blower.

Pneumatic conveying system of bulk solids Rotary lobe roots blower

Blowers For Water and Waste Water Treatment (sewage treatment)

In biological waste water treatment plants aeration chambers are utilized to remove organic content from the water. Microorganisms are used to brake down the organic material in waste water. Roots blowers supply required oxygen to microorganisms in the aeration chamber.Pressurized air is delivered through aeration pads below the chamber. The air that bubbles up not only provides oxygen to the process, but also keeps the microorganisms suspended in the water so they don’t settle out. Depending on biochemical oxygen demand , rotary lobe blowers provide desired amount of constant volume of air flow. Proper selection and sizing of roots blowers play crucial role on economical operation of a wastewater treatment plant . The field of operation that the rotary lobe blower system will be subjected to consists of the following parameters: Site conditions ; atmospheric pressure, discharge pressure, ambient temperature, relative humidity Type of aeration system Mass flow of air at any moment in time depending on process conditions Upstream and downstream equipment, filters, valves etc Other system and process variables

Rotary lobe blower waste water treatment plant aeration

Blowers in Surface Treatment Applications

Roots blowers supply air and provide mixing of pools in surface treatment processes like galvanizing, chrome plating. The oil free air of blowers is important to keep the surface treatment liquid clean.

Roots blower surface treatment technology

Blowers in Thermal Forming Applications

In thermal forming, a pattern is made to represent the inside surface of an object. A thin plastic sheet is placed over the pattern and it is heated by hot air generally. After a certain temperature level sheet plastic becomes very flexible. Roots blower removes the air between the pattern and the plastic sheet by vacuum and atmospheric pressure pushes the plastic down tightly over the pattern. After cooling, the formed piece is removed and trimmed.

PD Roots blower vacuum thermal forming system application

Vacuum Tables

Vacuum tables are used to hold sheet materials for mechanical processing. Router machines utilize vacuum pumps to prevent movement sheet material during cutting. Roots blower pumps provide vacuum air for these applications.

Rotary lobe positive displacement blower vacuum table

Blowers For Fish Farms and Aquaculture Applications

Roots type blower pumps supply continuous fresh air for fish farms (for fish aeration) and aquaculture applications. Fish ponds and tanks are to be fed by air to supply oxygen to fish inside. Positive displacement blowers provide continuous air for aquaculture applications.

Positive displacement blower fish farm aeration system aquaculture application

ULV Fogging Applications

ULV( ultra low volume) fogging machines are used to fight with insects. High pressure air about 400 – 500 mbar is used to spray insecticide with very low size. This makes insecticide kept on air for long times and increases its efficiency. Roots blowers supply the required air for ulv systems.

Roots blower ultra low volume ULV fogging mist application

Other Industries and Applications of Blowers

Chemical and process technology Power plants Cement and lime Foodstuffs Paper industry Flour mills Jet pulse filters, blowers supply pressurized air for pulse jets Aeration of flocculation tanks in mining industry Vacuum systems, vacuum handling Biodiesel plants Dust collection systems Sand blasting processes Painting machines Grain handling Agriculture applications Air knife systems

Application Gallery

Vacuum blower for conveying premix feed additive.

Vacuum blower for use in a pneumatic conveying system.

Roots blowers for pneumatic conveying system

Vacuum blowers of food plant

Automatic filter system and blower for sanitary application

Positive displacement blower pump

Bulk solids conveying system rotary lobe blower unit

PD blower station for pneumatic conveying system

Polimak blower unit for pressure conveying system

Rotary lobe blowers in energy plant

Roots blower packages

Roots blower unit on bulk tanker truck

Roots blower and rotary valve on powder conveying system

Blowers for flocculation plant

Roots Blower

Roots Blowers, Rotary Lobe Blowers

Roots blowers are rotary lobe compressors that generate pressurized or vacuum air for industrial processes. By utilizing positive displacement technology, rotary lobe blowers find use in applications, which require relatively constant air flow rate at varying discharge pressure conditions. These air and gas handling systems have been used for over a century in many industries.

Roots Blowers for Toughest Applications

Design, production and installation of proper equipment for harsh environments and toughest applications requires a great deal of know-how and long years of experience. Polimak manufactures roots type positive displacement blower packages for extensive range of industrial applications. Simple installation, low maintenance need, long years of problem free service, endurance for harsh environments are key features of Polimak blowers. Wide range of roots blower models and accessories are available depending on process parameters and site conditions.

Blower Operating Principle

Main components of the blower are two impellers (also referred as rotors or lobes). These impellers rotate in oppposite directions. As they rotate, a fixed quantity of gas at the inlet side is trapped between the impeller and the casing. The rotating impeller pushes the trapped gas to the discharge side against whatever pressure exists in the system. The cycle repeats six times with every revolution.

How does a “Roots Blower” operate?

Rotary positive displacement pump, also referred to as positive displacement (PD) blowers or roots blowers, are machines that “pushes” a relatively constant volume of gas through a system. Unlike compressors, a roots blower does not internally compress the gas. The compression is achieved through the blower pushing the constant volume against restrictions downstream in a pressure system. Flow through a PD machine is relatively constant, regardless of pressure changes. This is different from a centrifugal compressor, which maintains a relatively constant pressure while the flow varies.

Oil-Free Conveying

Since blower impellers do not make contact with each other and housing, no lubrication is required in gas conveying chamber. Therefore there exists no extra material in the conveying medium. This feature makes roots blowers have a great advantage in applications that require clean air or gas like aquaculture, milling, pneumatic conveying of foods and, chemicals.

Bareshaft Blowers

Positive displacement blowers can be delivered as bare shaft units.

Blower Packages

For an easy installation option, blowers can be prepared within a package unit which contains electrical motor, silencers and other accessories.

Benefits of Polimak Roots Blowers

Air flow rates from 20 m3/h to 20 000 m3/h
Pressure levels up to 1500 mbar, vacuum levels up to 500 mbar
Oil-free clean gas and air supply
Single piece rigid cast iron casing.
Ribbed blower body for high efficiency heat dissipation.
Heavy duty roller bearings for long years of blower service under heavy loads
Precision machined 3 lobe rotor profiles for higher efficiency with minimum noise
Piston ring sealing
Precision machined and heat treated timing gears for minimum vibration and maximum efficiency
Splash oil lubrication for longer service life
Easy to install
Low maintenance design

What is a Rotary Lobe Blower ?

Rotary lobe blower is a positive displacement pump that uses two impellers (rotors or lobes) to displace a fixed quantity of gas. The gas is forced out of the discharge side against whatever pressure exists in the system. This type of pump is often used in industrial applications to move gases that require relatively constant flow rate at varying pressure conditions. The main benefit of using a Roots blower is its ability to maintain high efficiencies over a wide range of flow rates. This makes it an ideal choice for many industrial applications.

What is a Roots Blower?

“Rotary lobe blowers” , “rotary lobe compressors” are other names of “roots blowers” used in industry. The term “Roots Blower” was named after American inventors and brothers Philander and Francis Marion Roots, who in 1854 attempted to improve the efficiency of their water wheel power in Connersville. They patented the basic design in 1860 and The Roots Rotary Positive Blower Principle is now well known throughout the world. and still

How does a “Roots Blower” operate?

Twin lobe rotary air blowers belong to category of positive displacement blowers. They consist of a pair of “lobes” or “rotors” inside an oval shaped casing, closed at ends by side plates. The two lobes are driven by a pair of precision machined gears which rotate at same speed but in opposite direction. As the rotors rotate, air or gas is drawn into inlet side of the blower housing and forced out the outlet side against system pressure. With each revolution, six such volumes are displaced (in tri-lobe blowers). The air, which is forced out, is almost not allowed to come back due to the small clearances between rotors and casing. Only little amount of air can “SLIP” back through the clearances.

What is Positive Displacement ?

Positive displacement pumps are called so because of ”no fluid comes back to its casing during pumping out. A locking is formed by lobes or rotors, that acts like a seal and whole amount of fluid goes through delivery line. A positive displacement blower has an expanding cavity on the suction side and a decreasing cavity on discharge side. Gas flows into the expanding cavity at the inlet side and then the same amount of gas is discharged as the cavity reduces at the outlet side. Thus a constant flow is maintained by the pump. This amount is called positively displaced amount and thats why its called positive displacement blower.

As there is no change in volume of the air and there is no compression within the blower, it merely displaces the air from the suction end to the discharge end. The pressure increase occurs at the discharge end against the system resistance. Similarly the increment of cavity at the suction side develops the suction pressure in vacuum applications.

Positive displacement technology enables roots blowers to be used in industrial applications that require relatively constant flow rates at varying pressure conditions.

What is the Difference Between Blower, Fan and Compressor ?

Compressors, fans, and blowers are widely used in wide range of industrial applications. These devices are quite suitable for complex processes and have become indispensable for today’s industry. Generally speaking, fans, blowers and compressors are differentiated by the method used to move the air and by their compression ratio (or in other terms by the system pressure they must operate against).

Classification With Respect to Compression Ratio

Type	Compression Ratio	Average Operating Pressure *
Fan	0 – 1,3	0 – 0,25 bar
Blower	1,1 – 2,5	0,15 – 2 bar
Compressor	> 2	3 – 12 bar

* Average operating pressure is the pressure range that the system is generally used in today’s industrial applications.

With respect to recent developments in gas handling technologies, it is not easy to define a strict pressure range, compression ratio or method of gas pumping for each type of air handling system. i.e. high pressure fans can reach 0,4 bar and they can still be called either as a fan or a blower depending on industrial application, country or sector. Another example is single stage turbo blowers which follow the compression principle of the centrifugal compressors and they are called blowers instead of compressors.

To make a broad definition:

Fans

Fans are used to move large amounts of gas with a low increase in pressure . They are generally used for air circulation in buildings, ventilation, cooling of machniery, dust collection and similar industrial applications.

Blowers

Blowers provide medium amount of gas pressure or vacuum with moderate pressure levels. Blowers are used in processes where the system resistance is higher than that for a fan. They are used in water treatment, pneumatic conveying systems, vacuum applications, industrial processes, superchargers etc.

Compressors

Compressors provide higher pressures by reducing the volume of gases. They are used across the industries to provide shop or instrument air; to power air tools, paint sprayers, and abrasive blast equipment; to phase shift refrigerants for air conditioning and refrigeration; to propel gas through pipelines; etc.

Links

Roots Blower

Blower Applications

Rotary lobe blowers are used in pneumatic conveying, waste water treatment, aquaculture , fish farms, vacuum systems, thermal forming, surface treatment and similar applications.

Blower Options and Accessories

Wide range of roots blower models and configurations are avaliable for different applications , process parameters and environment conditions

Blower Models and Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary lobe blowers.

Telescopic Combined Loading Chutes for Tanker Trucks and Open Trucks

Combined telescopic loading chutes are used for dust free loading of powdered and granular bulk solids both into tanker trucks and flatbed open trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to trucks. There exists flexible dust skirt and poliurethane coated discharge cone together at the same loading chute unit. Combined loading chutes are suitable for applications where incoming truck types vary.

Operation of Combined Truck Loading Chutes

Combined truck loading chutes have two operation modes selected from control panel at the beginning of truck loading. Depending on type of truck (open truck or tanker truck) loading chute operation scheme changes.

Open Truck Loading Mode

At the beginning of open truck loading, chute is lowered towards the flatbed of truck and stops at the bottom. Flexible dust skirt located at the bottom side of chute keeps the dust content inside the loading region. During material discharge, it provides a closed containment for dust. Dust collection system collects any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading chute dust skirt. When the material level increases, chute is retracted upwards automatically and it maintains a space to let the material flow rapidly. After truck loading is finished, product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Telescopic loading chute automatically retracts to the top position afterwards.

Tanker Truck Loading Mode

At the beginning of tanker loading, chute is lowered and stopped when it reaches to the tanker inlet automatically. Poliurethane coated discharge cone fits vessel inlet to prevent any dust emission during tanker loading. Material falls freely through the inner side of the chute. After bulk tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Dust content in the air is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor placed at the bottom monitors the product level in the tanker truck. Level sensor sends a signal to stop loading, when the tanker is full. Product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading chute retracts to the top position automatically.

Telescopic Combined loading chute for bulk trucks and tanker trucks

Advantages

– Suitable both for open bulk truck loading and bulk tanker truck loading – Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs – Built in flexible dust skirt to prevent dust emission outside of the loading region. – Poliurethane coated discharge cone that fit vessel inlet to prevent any dust emission during tanker loading – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade telescopic loading chutes are available – Simple operation – Easy maintenance

Open truck loading chute dustless telescopic loading of trucks

Handled Materials

Cement, fly ash, mining minerals, calcium carbonate, pvc, plastic pellets, plastic powders, alumina, bentonite, bauxite, coal, cement clinker, gypsium, kaolin, limestone, marble powder, soda ash, quartz, urea, sodium sulphate, wheat, flour, animal feed, seed, corn, rice, sugar, salt and similar powdered and granular dry bulk solids.

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Telescopic Chutes

Open truck , tanker , ship and stockpile loading telescopic chutes are used for rapid and efficient dust free loading of dry bulk materials. Free flowing bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to tankers, open trucks, ships or stockpiles

Telescopic Chute Models

Extensive range of telescopic chutes are available for wide range of applications. Open truck loading, bulk tanker filling, stockpile loading and bulk ship loading chutes provide dust free outloading of bulk materials for industrial applications.

Telescopic Loading chute types inner bellow outer bellow abrasion cone

Telescopic Chute Types and Configurations

Depending on type of discharged bulk solid, loading medium and plant conditions, telescopic chute types change. Bulk material abrasiveness, dust load, particle size, loading capacity are some of the key factors that effect the design of loading chute.

Bulk loading telescopic chute material feeding equipment

Telescopic Chute Bulk Solid Feeding Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials to telescopic chutes. Bulk materials are discharged from silos, hoppers, production lines with these transfer and conveying equipment.

Telescopic Loading Chute accessories dust collector filter spreader bottom closure cone positioner

Telescopic Chute Accessories and Options

Telescopic loading chutes and bulk solid discharge systems can be provided with extensive range of optional components and accessories for different application needs. Proper selection of accessories is essential for efficient and dust-free loading.

Telescopic Chute Catalogs Datasheets User Manuals

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of bulk material loading telescopic chutes.

Telescopic Open Truck Loading Chutes

Open Truck Loading Telescopic Vhutes Bulk Solids Handling Truck Loading

Telescopic open truck loading chutes are used for dust free loading of powdered and granular bulk solids into flatbed open trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to open trucks. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Open Truck Loading Chutes

At the beginning of open truck loading, chute is lowered towards the flatbed of truck and stops at the bottom. Flexible dust skirt located at the bottom side of telescopic chute keeps the dust content inside the loading region. During material discharge, it provides a closed containment for dust. Dust collection system collects any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading chute dust skirt. When the material level increases, chute is retracted upwards automatically and it maintains a space to let the material flow rapidly. After truck loading is finished, product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Telescopic loading chute automatically retracts to the top position afterwards.

How open bulk truck loading chutes work operation princible of loading chutes

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs – Built in flexible dust skirt to prevent dust emission outside of the loading region. – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade telescopic loading chutes are available – Simple operation – Easy maintenance

How open bulk truck loading chute works animation of telescopic loading chute

Handled Materials

Telescopic Open Truck Loading Chute Application Gallery

Bulk solids loading to open bulk trucks by loading chutes

Open bulk truck telescopic loading chutes

Telescopic loading chutes

Bulk material loading spouts telescopic chutes

Wheat truck loading telescopic chute

Telescopic Bulk material loading chute for trucks

Telescopic loading chute with screw feeder

Telescopic spout and loading chute for open bulk truck

Telescopic loading chute

Open truck loading chutes retracted and extended

Telescopic Ship Loading Chutes

Bulk ship loading telescopic chute bulk solid handling loading discharging chutes

Telescopic ship loading chutes are used for dust free loading of powdered and granular bulk solids into dry bulk ships. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to dry bulk carrier ships. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Telescopic Ship Loading Chutes

At the beginning of ship loading, telescopic chute is lowered towards the flatbed of ship and stops at the bottom. Flexible dust skirt located at the bottom side of chute keeps the dust content inside the loading area. During material discharge, chute dust skirt provides a closed containment for dust. Dust collector vacuums any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is then sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading chute dust skirt. When the material level increases, telescopic chute is retracted upwards automatically and it maintains a space to let the material flow rapidly. After ship loading is finished, product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Telescopic loading chute automatically retracts to the top position afterwards.

How telescopic ship loading chutes work 3d information operation princible

Advantages

Dust free loading
Dust free working region, prevention of dust pollution, ensure port and environmental safety.
Suitable for different bulk solids conveying and storage systems
Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc.
Extensive range of models are available for wide range of needs
Built in flexible dust skirt to prevent dust emission outside of the loading region.
No spillage and no product waste
Food grade telescopic loading chutes are available
Simple operation
Easy maintenance

Ship loading spouts telescopic ship loading chutes

Handled Materials

Telescopic Stockpile Loading Chutes

Telescopic stockpile loading chutes are used for dust free discharging of powdered and granular bulk solids to stockpiles. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to stockpile basement. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Telescopic Stockpile Loading Chutes

At the beginning of stockcpile loading, chute is lowered towards the ground and stops at the bottom. Flexible dust skirt located at the bottom of chute keeps the dust content inside the loading area. During material discharge, chute dust skirt provides a closed containment for dust. Dust collection unit vacuums any fugitive dust in the region and prevents dust emission to the surrounding. Collected dust is then sent back to the product stream continuously and material waste is prevented during loading. Built in level sensors monitor the product level below the loading chute dust skirt. When the material level increases, chute is retracted upwards automatically with winch system and it maintains a space to let the material flow rapidly. After stockpile loading is finished, product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Telescopic loading chute automatically retracts to the top position afterwards.

How stockpile loading chutes work infographics

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure port and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Built in flexible dust skirt to prevent dust emission outside of the loading region. – Extensive range of models are available for wide range of needs – No spillage and no product waste – Food grade loading telescopic chutes are available – Simple operation – Easy maintenance

Handled Materials

Telescopic Tanker Loading Chutes

Tanker Loading Spout Telescopic chute for bulk tanker loading

Telescopic bulk tanker loading chutes are used for dust free loading of powdered and granular bulk solids into bulk tanker trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers and screw feeders to tanker trucks.

Operation of Telescopic Tanker Loading Chutes

At the beginning of tanker loading, chute is lowered and stopped when it reaches to the tanker inlet automatically. They utilize poliurethane coated discharge cones that fit vessel inlet to prevent any dust emission during tanker loading. Material falls freely through the inner side of the chute. After bulk tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Dust content in the air is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor placed at the bottom, monitors the product level in the tanker truck. Level sensor sends a signal to stop loading when the tanker is full. Product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Telescopic loading chute retracts to the top position automatically.

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Poliurethane coated discharge cone that fit vessel inlet to prevent any dust emission during tanker loading – Extensive range of models are available for wide range of needs – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade telescopic loading chutes are available – Simple operation – Easy maintenance

Tanker loading spout telescopic bulk truck loading chute

Handled Materials

Telescopic Tanker Truck Loading Chute Application Gallery

Bulk solids silo discharging tanker truck loading system bulk loading telescopic chute

Silo discharge and bulk tanker filling by loading chute

Bulk solids discharging and loading chute below silo

Bulk tanker loading telescopic spout

Bulk tanker truck telescopic chute loading system

Tanker truck loading telescopic chutes

Telescopic chute tanker truck loading bellow

Telescopic loading chute discharging powder to tanker truck

Tanker Truck trailer loading telescopic chutes and spouts

Truck loading chutes below raw material silos

Raw material filling to trucks silo discharge systems loading spouts telescopic chutes

Bulk truck loading chutes

Telescopic loading spout below product silo discharge system

Silo discharging and bulk truck filling telescopic chute

Bin activator and truck loading telescopic chute

Raw material discharge bin and telescopic loading chute

Silo unloading system tanker truck loading chute

Bin activator and bulk truck loading chute

Tanker loading telescopic chute in retracted position

Telescopic Bulk tanker loading chute extension product discharging

Tanker loading chute in extended position

Bulk truck tanker loading telescopic chute

Telescopic Tanker loading chute

big bag unloading system and bulk tanker filling chutes

Tanker loading by big bag discharge station and tanker truck loading telescopic chute

Telescopic Tanker loading bellow telescopic chutes loading spouts

Telescopic Tanker loading chute below silo

Telescopic Bulk loading chutes material feeding equipment

Pneumatic conveying system for tanker loading chute

Telescopic Chute Technical Documents

Technical catalogs and documents of telescopic chutes

Telescopic Chute Accessories and Options

Telescopic dry bulk loading chutes have extensive range of optional components for wide range of needs.

Dust Collector

Dust collectors are key elements of bulk solid loading chutes. They collect any fugitive dust during bulk solid loading and prevent dust emission to the environment. Several telescopic loading chute dust collector models are available depending on application requirements.

In Line Dust Collector

If there exists enough height below discharge unit (silo, hopper, conveyor etc) in line dust collectors can be used in loading chutes. Filter units are installed at the top. Bulk material flows through the space between filters. Dusty air is collected through these filters. Dust content in the air is trapped by filter units. Automatically operated pulse jet filters are used for supplying air shocks to the filters and sending dust back to the stockpile downside.

Inline dust collection filter for bulk solid loading telescopic chute

Offset Type Dust Collector

Offset type dust collectors of telescopic loading chutes are installed at the edge of top flange with an angle. A vacuum fan is utilized to supply required vacuum air. During material discharge, fan unit vacuums the air from the discharge point of loading chute. This vacuumed air passes through the passage between inner and outer chutes. Dust content in the air is trapped by filter units. Automatically operated pulse jet filters are used for supplying air shocks to the filters and sending dust back to the stockpile downside. The inclined design occupies less height and provides easier installation below hoppers and silos.

Offset jet filter and dust collector for truck loading telescopic chute

Separate Dust Collector

Telescopic loading chutes have outlet for dust collection system connection. Any external fan, dust collector or bag house filter can directly be connected to built in outlet. If the loading chute installation area does not have enough space, separate dust collectors can be utilized. These dust collection units are independent systems that have their own fans, filters and discharge hoppers.

Dust collection system for bulk truck loading chutes dustless filling

Central Dust Collector

If central dust collection systems exist in the plant, they can be connected to loading chutes. Air outlet of the telescopic loading chute is used for connection. Air flow speed is to be adjusted with respect to operation conditions. Collected dust is stored in external dust collector. This configuration is suitable for applications where several loading chutes are to be used together at the same place. Single central dust collector can be used for collecting fugitive dust from all loading chute systems.

Bottom Closure and Sealing Cone

Bottom closure and sealing cone is used in tanker loading chutes to prevent any product spillage after loading. The conical shaped valve can move in vertical direction. It normally closes the outlet port of loading chute at the bottom. When the loading chute is placed on the tanker inlet flange, the conical valve moves downward and opens the product discharge passage. After tanker loading is finished, the loading spout is retracted. Telescopic chute retraction moves the bottom closure cone upwards and closes the outlet. Any remaining product within the loading chute is kept inside during retraction and spillage is prevented.

Bottom closure cone of bulk solid tanker loading chutes

Sampler

Material composition, moisture, particle size etc are some of the important attributes of bulk solids and it may be needed to check these values before loading. Bulk solid sampling systems are used to get a sample from free flowing bulk materials. In telescopic loading chute applications, a manual or automatic sampler is installed above the loading chute. During loading, sampler takes out some amount of material from the material flow.

Telescopic Loading Chutes For High Temperature Applications

In case of high temperature bulk solid loading needs like fly ash handling systems, high temperature resistant loading chutes are to be utilized. Mechanical components including electrical motors, sensors etc. are selected from high temperature resistant models. Loading chute and skirt fabrics are chosen from high temperature fabrics. Bulk solids having temperatures up to 300C can be discharged with high temperature resistant loading chutes

High temperature heat bulk solids loading telescopic chutes

Level Sensors

Level sensors of open and closed loading chutes have different functions.

In closed vehicle loading, (i.e tanker trucks) level sensor is used for giving signal when the product reaches the tanker inlet level. Loading operation is stopped when the tanker truck is full.

In open loading chutes, level sensors are used for controlling the vertical position of loading chute. Flexible dust skirt of the chute should cover the product discharging region to prevent any fugitive dust and also keep enough space for rapid product discharge. When the product level increases, flexible dust skirt should raise accordingly to provide dust-free and fast loading.

Atex

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of bulk solid loading chutes. Overheating, dust leakage, static electricity and electrical spark generation should be prevented during material discharge. Bellow fabrics are made of antistatic materials to prevent any static electricity build up. Atex certified and ex-proof equipment are used in such working conditions.

Food Grade Telescopic Loading Chutes

Food grade telescopic loading chute systems are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Bellow fabrics, filter bags, valves and other mechanisms are selected from food certified equipment.

Tanker Truck Loading telescopic chutes for food applications food grade chutes stainless steel bulk filling equipment

Handheld Control Pendant

Standard telescopic loading chutes are controlled by built in electrical control panel. Depending on application requirements, handheld remote control units can be utilized to increase operational efficiency. Wired and wireless remote controls are available upon request.

Handheld remote controlling of bulk loading chutes

Communication With Other Systems

Electrical panel of loading chutes can send signals to other automation systems in the plant and can receive signals from them. Operation of telescopic loading chute can be controlled from external systems. i.e truck weighing scale can send stop signal when the desired amount of product is filled. And loading chute can give signals and operate related equipment from its own panel. Silo discharge valves, conveyors etc can be ran from loading chute control unit.

Bulk solids loading telescopic chute automation system for bulk loading spout

Weighing System

Telescopic loading chutes can be coupled with weighing systems. Weighing hoppers, dosing belt scales, silo weighing systems can be utilized to feed loading chutes. For tanker truck or open truck loading, truck weighing scales can also be used for directly measuring of loaded weight. These systems can send signal to command loading chute to start or stop loading.

Truck weighing scales silo discharge bulk truck loading chutes

3 or 4 Lifting Cables

Telescopic loading chutes can be manufactured with 3 cable or 4 cable configuration. 2 cable design is applicable for standard truck loadings with wide range of bulk materials. 3 or 4 cables are needed for high capacities, long chutes and environments with high side winds. This design increases rigidity of loading spouts and ensures problem-free bulk material loading.

Open truck loading telescopic spout chute lifting wire cables

Vibration Motor

Vibration motors are used for discharging residues of bulk solids from the inner chute parts. They can be operated during or after loading.

Spreader

Depending on the flowing properties, bulk materials cannot be completely filled into the tank. For materials which have low flowability, the tanker cannot be filled up to its maximum carrying capacity. Material spreading systems are developed to solve this issue. The spreader is positioned near the outlet chute in loaders for loading to tanks. Rotating paddles distribute the material uniformly inside the tanker allowing entry of a larger quantity of material. Since the filling efficiency of the tanker is increased, the overall transportation cost will decrease.

Poliurethane Coated Outlet Cone

Closed type tanker loading chutes incorporate poliurethane coated outlet cone that fit vessel inlet to prevent any dust emission during vehicle loading. Abrasion resistant poliurethane coating provides flexible sealing to prevent dust leakage. Conical shape makes it easy to fit different tanker inlet diameters.

Tanker loading telescopic chute discharge spout poliurethane dustproof cone

Manual Winch Mechanism

For low duty applications, tanker truck and open truck loading chutes are available with manual winch mechanism. In this configuration a handwheel operated winch mechanism is used instead of electrically controlled motor, gearbox and pulley system. Handwheel unit can be installed to any location for easier access.

Manual winch operated hand driven bulk truck loading chute system

Telescopic Loading Chute Positioners

Telescopic loading chute positioning systems ensure efficient loading of trucks and railcar wagons. Instead of repositioning vehicle for loading of entire volume, positioning system moves the loading chute when needed. Loading chute is installed below the positioner unit. Remote controlled loading chute positioner moves the chute to the desired location rapidly and accurately. Bulk material transfer is started in very short time, eliminating the time needed for moving the vehicle forward and backwards to be in the precise center of the loading chute. Depending on application requirements, single axis loading chute positioners, double axis loading chute positioners and articulating arm positioners are available.

Single Axis Telescopic Loading Chute Positioners

The single axis loading chute positioner has the capability of moving forward and backwards over the vehicle. A single axis linear motion mechanism is used.

Double Axis Telescopic Loading Chute Positioners

The double axis loading chute positioner has the capability of moving longitudinal or a lateral directions over the vehicle. A double axis linear motion mechanism is used.

Double axis single axis positioner for truck loading chutes

Articulating Arm Telescopic Loading Chute Positioners

Two screw or airslide conveyors connected by rotating joints are incorporated in articulating arm positioners. Discharged product is transfered within these closed conveyors. At the end of articulated arm conveyor, product is discharged directly into the vehicle through loading chute.

Loading chute articulating arm positioner system airslide conveyor

Telescopic Loading Chute Vehicle Access Platform

For opening tanker inlets, guiding loading chutes, maintenance operations and similar tasks above the vehicles, operators should have easy and safe access to loading region. Vehicle access platforms provide safe and fast solution for these tasks. Each application and loading environment has its own structure and arrangement. Vehicle access locations, silo discharge heights, conveyor types are designed with respect to plant needs. Though, loading chute access platforms are custom designed for each application needs.

Bulk truck vehicle access platform for bulk solid loading by chute

Custom Designed Telescopic Loading Chutes

In addition to standard series, loading chutes can be custom designed to conform wide range of application needs. For efficient and dust-free loading, loading chute should be designed carefully. Type and physical properties of handled bulk solid, loading capacity, loading environment, installation limitations are key factors that have effect on loading chute design.

custom designed bulk truck loading chutes

Machine Safety

Bulk material loading chutes manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in sack handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Bulk solids loading chute equipment machinery safety regulations

Telescopic Chute Bulk Solid Feeding Equipment

Telescopic loading chutes are coupled with product feeding equipment. Depending on application requirements, wide range of bulk solids handling equipment can be utilized for feeding loading chutes.

Butterfly Valve

Butterfly valves are generally installed below silos or hoppers. Product discharge outlet can be completely opened or closed in short time with the help of butterfly valves installed above telescopic loading chutes. In truck filling applications, butterfly valves serve to control amount of product loaded.

Slidegate Valve

Slidegate valves are generally located at the silo and hopper outlets. Pneumatic piston controlled slidegate valves are used to start and stop product loading in short time. Screw and gearbox controlled slidegate valves can be used to adjust bulk material loading speed by adjusting gate opening size.

Screw Conveyor

Screw conveyors are used for transferring bulk solids from hoppers, silos or plant machinery to loading chutes with controlled speed and capacity. Depending on loading area conditions, screw conveyors can be used to move the bulk solids to higher levels before entering into loading chutes to save some height for trucks.

Belt Conveyor

Belt conveyors can be utilized to transfer bulk materials to telescopic loading chutes. They are generally preferred in open regions and stockpile loadings. Special designed intermediate hoppers are used for smooth discharge of bulk materials from conveyor belt outlet to loading chute. Depending on dust load of the conveyed material, extra dust collectors can be utilized.

Bulk ship loading bellow bulk solid handling loading discharging chutes

Rotary Valve

Rotary valves are used for discharging bulk materials from silos and hoppers with controlled speed into the telescopic loading chute systems.

Pneumatic Conveying System

Pneumatic conveying systems are preferred in plants where loading area is far from the bulk material storage equipment. Pneumatic conveying systems transfer bulk materials from storage units to telescopic loading chutes within pipelines with air pressure or vacuum. Pneumatic conveying capacity is determined and equipment is selected with respect to transfer distance and loading chute capacity.

Bulk loading chutes material feeding equipment

Airslide Conveyor

Airslide conveyors are utilized in high capacity loading of fine powdered materials such as cement loading to tanker trucks in cement plants. Telescopic loading chutes installed are below the outlet of air slide conveyors. Bulk material is fluidized within airslide conveyors with the help of pressurized air coming from the bottom. By the help of gravity, they move towards the downside direction. The inclination of airslide conveyor directly effects the flow speed.

Telescopic Chute Models

Closed Vehicle Loading Chutes

Telescopic Tanker Truck Loading Chutes, Ship Loading Chutes, Container Loading Chutes Closed loading chutes are used to fill tanker trucks, closed containers, barges and ships with closed containers. They utilize poliurethane coated discharge cones that fit vessel inlet to prevent any dust emission during vehicle loading. After tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Any dust content is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor located at the bottom monitors the product level in the bulk tanker. When the tanker is full, level sensor sends a signal to stop loading. Product discharge valve above the telescopic loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Telescopic loading chute automatically retracts to the top position. Depending on the process requirements, loading amount can also be controlled by other systems such as truck weighing scales. When the determined amount of product is filled, weighing system sends a s signal to control panel of loading chute and loading is stopped automatically.

Telescopic Tanker Loading Chutes

Tanker Loading Bellows Telescopic bulk tanker loading chute

Open Vehicle and Stockpile Loading Chutes

Open vehicle and stockpile loading chutes are used to load bulk material to open region such as flatbed open trucks, ships and stockpiles. Automated retraction mechanism and flexible dust skirt are key elements of open loading chutes. Flexible dust skirt is located at the bottom of loading chute. During material discharge, it provides a closed containment for dust. Dust collection system vacuums any fugitive dust in the region and prevents dust spreading to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading chute. As the level increases, telescopic chute is retracted upwards automatically and it maintains a space to let the product discharge rapidly. When loading is finished, product discharge valve above the loading chute is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector.Telescopic loading chute automatically retracts to the top position afterwards.

Telescopic Open Truck Loading Chutes

Telescopic Open truck loading chute dustless telescopic loading of trucks

Telescopic Ship Loading Chutes

Telescopic Bulk ship loading chute bulk solid handling loading discharging bellows

Telescopic Stockpile Loading Chutes

Combined Loading Chutes for Tanker Trucks and Open Trucks

Telescopic Combined Loading Chutes for Tanker Trucks and Open Trucks

Combined Telescopic loading chute for open truck and tanker trucks

Telescopic Chute Types and Configurations

Depending on process requirements and physical properties of product, telescopic loading chutes are available with extensive range of chute configurations. Proper selection of configuration is essential for efficient and dust-free loading.

Single Outer Bellow

Single outer bellows provide economical solution for low dust content, granular material loading operations. There exists one chute that maintains the confined region in the system. Product flows downward through this chute and any dust is collected upwards within the same region.

Double Bellows

There exists one outer bellow and one inner bellow in this configuration. Product flows through the inner chute downwards and dust is collected through the region between two chutes upwards. As two opposite flows are separated, product loading capacity and dust collection efficiency are increased. The dust collection system is connected to the region between two chutes. Collected dust is sent back through this region again.

Single Outer Bellow With Internal Wear Cones

Wear cones are used to protect bellows from abrasion caused by flow of bulk solids. They are installed at the center of loading chute. Main stream product flow is separated from chute by wear cones. Flowing material does not have contact with chute fabric. Depending on the physical properties of product different type of wear cones are available. While carbon steel cones are suitable for wide range of bulk solids, hardox steel cones are needed for highly abrasive materials. For food products and corrosive materials stainless steel cones are preferred. In high temperature loading applications, wear cones serve as a heat barrier to protect chutes.

Single outer loading bellow with wear cones abrassion resistant loading chutes

Double Bellows With Internal Wear Cones

Inner bellows can be used to cover internal wear cones. This design both protects bellows from abrasion and provides efficient dust collection with rapid product loading. Bulk material flows through the wear cones inside the inner chute downwards and dust is collected through the region between two chutes upwards.

Double bellow with abrasion resistant wear cones bulk solid loading chutes

Loading Chute Selection Chart

Following chart can be used to determine possible loading chute configurations for different applications and conditions.

Loading chutes bellow type selection chart diagram

Heavy Duty Loading Chutes

Single Loading Chute

Telescopic loading chutes are used for high capacity and/or high temperature powder loading to trucks, ships and stockpiles. They are composed of large diameter telescopic steel pipes controlled by winch mechanism. These pipes are used to provide large inner space for easy discharging of powdered material and isolate it from the surroundings.

Single Outer Chute With Internal Loading Chute

An outer chute is used in this telescopic chute configuration to provide closed containment. Any dust leakage is prevented during material flow. Dust collection system connected to flexible dust skirt at the bottom are utilized capture fugitive dust.

Telescopic loading pipe outer loading dust collection chute

Loading Chute With Double Dust Collection Bellows

For high capacity loadings of high dust content materials, flexible dust skirt size is increased. Two bellows are installed at the sides of telescopic chute piping. These two bellows are used to collect higher dust content. Large scale jet filter type dust collection systems are used to prevent any dust emission to the environment.

clinker loading telescopic chute with double dust collection bellows

Telescopic Chutes

Telescopic Tanker Loading Chutes Bulk Solid truck loading bellow telescopic spouts

Bulk Material Loading Telescopic Chutes

Outloading of bulk solids in powder or granular form is a common task in industrial plants. A great deal of know-how is required to automate this process smoothly. Polimak offers wide range of solutions for bulk material loading applications. Being an essential component in bulk solid handling processes, telescopic chutes provide dust-free and safe outloading of powdered and granular materials to trucks, tankers, ships and stockpiles. They are generally mounted underneath silos, hoppers, or installed at the end of conveyors like screw feeders, elevators or pneumatic conveying systems. Bulk materials flowing from the upper side are transferred to the downstream vehicle, ship or stockpile efficiently without any dust emission and product loss.

How telescopic chute works mechanism of tanker truck loading bellow bulk solid unloading

How Telescopic Chutes Work ?

Main idea behind the telescopic chute system is discharging the powdered or granular bulk solid through a vertical column by its own weight and collecting any dust within the same enclosed column upwards. The varying height between the upper discharge point and lower loading point is compensated with making the column flexible. A mechanical winch system is used for adjusting the height while maintaining a closed area and straight passage for high capacity loading. Depending on application requirements different type of chutes, abrasion cones, dust collectors and similar equipment are included in whole loading system.

Depending on the type of loading medium, two main types of loading method exist; open loading and closed loading.

Open Loading

Telescopic open loading chutes are used to fill flatbed open trucks, ships and stockpiles where bulk material is directly exposed to environment. At the beginning of loading, telescopic chute is lowered towards the flatbed of truck / ship or basement and stops at the bottom. Material falls freely through the telescopic chute. Flexible dust skirt located at the bottom side of chute keeps the dust content inside the loading region. Additional vacuum air supplied by dust collection system ensures that any dust emission is prevented effectively. Level sensors installed on the unit are used to check product level continuously. As the product level increases, the telescopic chute raises automatically. After loading is completed, telescopic loading chute is retracted to the top stand-by position. Open truck loading telescopic chutes, ship loading telescopic chutes and stockpile loading telescopic chutes have extensive range of models and configurations depending on bulk material type, loading capacity and application requirements.

Open Truck Loading telescopic chutes Bulk solids loading to trucks

Open truck bulk solid loading chute in action

Ship loading telescopic chutes open loading

Closed Loading

Telescopic closed loading chutes are used to fill tanker trucks, barges and ships with closed containers. At the beginning of loading, telescopic chute is lowered and stopped when it reaches to the tanker inlet. After that, product flow is started. Material falls freely through the inner side of the chute. Tanker is filled by the product. Air content of the tanker is transferred back through the chute and then discharged through the air vent. Level sensor located at the discharge point of telescopic chute monitors the product level in the tanker and stops the operation when the tank is full. After loading is completed, telescopic chute is retracted to the top stand-by position.

Tanker loading spout telescopic chutes loading bellows

Dustless closed truck loading telescopic chutes fly ash loading to truck

Dry bulk tanker ship loading telescopic chutes

Bulk tanker truck loading telescopic chute

Advantages of Telescopic Chutes

– Dust free loading. – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems. – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs. – Auto raise feature. When loading is completed, loading chute retracts automatically, saving valuable operator time. – No spillage and no product waste. – Materials with high temperatures up to 300 C can be loaded. – Food grade telescopic loading chutes are available. – Simple operation. – Easy maintenance.

How tanker loading telescopic chute working animation

Handled Materials

Durable open truck loading bellow

Loading bellow to load tanker trucks

Loading bellows for loading open trucks

Loading chute with double dust collection bellows

Open truck loading bellows with built in pneumatic conveying system

Ship loading bellow with an extension height of 24 meters

Ship loading bellow with a 360 degrees rotating spoon

Ship loading bellow loading materials at a loading dock

Ship loading bellow loading bulk solids into a ship at a loading dock

Stockpile loading bellow

Tanker truck loading bellow loading up the truck

Tanker truck loading bellow connected to bin activator

Tanker truck loading bellow

Versatile loading spouts for stockpile loading

Tanker Loading Spouts

Bulk tanker loading spouts are used for dust free loading of powdered and granular bulk solids into bulk tanker trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers and screw feeders to tanker trucks.

Operation of Tanker Loading Spouts

At the beginning of tanker loading, spout is lowered and stopped when it reaches to the tanker inlet automatically. They utilize poliurethane coated discharge cones that fit vessel inlet to prevent any dust emission during tanker loading. Material falls freely through the inner side of the spout. After bulk tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Dust content in the air is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor placed at the bottom, monitors the product level in the tanker truck. Level sensor sends a signal to stop loading when the tanker is full. Product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout retracts to the top position automatically.

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Poliurethane coated discharge cone that fit vessel inlet to prevent any dust emission during tanker loading – Extensive range of models are available for wide range of needs – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade loading spouts are available – Simple operation – Easy maintenance

Handled Materials

Tanker Truck Loading Spout Application Gallery

Bulk solids silo discharging tanker truck loading system bulk loading telescopic spout

Silo discharge and bulk tanker filling by loading spout

Bulk solids discharging and loading spout below silo

Bulk tanker loading spout

Tanker truck loading spouts

Telescopic loading spout discharging powder to tanker truck

Truck loading spouts below raw material silos

Bulk truck loading spouts

Silo discharging and bulk truck filling telescopic spout

Raw material discharge bin and loading spout

Silo unloading system tanker truck loading spout

Bin activator and bulk truck loading spout

Tanker loading spout in retracted position

Bulk tanker loading spout extension product discharging

Tanker loading spout in extended position

Tanker loading spout

big bag unloading system and bulk tanker filling spouts

Tanker loading by big bag discharge station and tanker truck loading spout

Tanker loading bellow telescopic chutes loading spouts

Tanker loading spout below silo

Bulk loading spouts material feeding equipment

Pneumatic conveying system for tanker loading

Links

Loading Spouts

Open truck , tanker , ship and stockpile loading spouts are used for rapid and efficient dust free loading of dry bulk materials. Free flowing bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to tankers, open trucks, ships or stockpiles

Loading Spout Models

Extensive range of loading spouts are available for wide range of applications. Open truck loading, bulk tanker filling, stockpile loading and bulk ship loading spouts provide dust free outloading of bulk materials for industrial applications.

Loading spout types inner bellow outer bellow abrasion cone

Spout Types and Configurations

Depending on type of discharged bulk solid, loading medium and plant conditions, spout types change. Bulk material abrasiveness, dust load, particle size, loading capacity are some of the key factors that effect the design of spout.

Loading Spout Bulk Solid Feeding Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials to loading spouts. Bulk materials are discharged from silos, hoppers, production lines with these transfer and conveying equipment.

Loading spout accessories dust collector filter spreader bottom closure cone positioner

Loading Spout Accessories and Options

Loading spouts and bulk solid discharge systems can be provided with extensive range of optional components and accessories for different application needs. Proper selection of accessories is essential for efficient and dust-free loading.

Loading Spout Catalogs Datasheets User Manuals

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of bulk material loading spouts.

Combined Loading Spouts for Tanker Trucks and Open Trucks

Combined telescopic loading spouts are used for dust free loading of powdered and granular bulk solids both into tanker trucks and flatbed open trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to trucks. There exists flexible dust skirt and poliurethane coated discharge cone together at the same loading spout unit. Combined loading spouts are suitable for applications where incoming truck types vary.

Operation of Combined Truck Loading Spouts

Combined truck loading spouts have two operation modes selected from control panel at the beginning of truck loading. Depending on type of truck (open truck or tanker truck) loading spout operation scheme changes.

Open Truck Loading Mode

At the beginning of open truck loading, spout is lowered towards the flatbed of truck and stops at the bottom. Flexible dust skirt located at the bottom side of spout keeps the dust content inside the loading region. During material discharge, it provides a closed containment for dust. Dust collection system collects any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading spout dust skirt. When the material level increases, spout is retracted upwards automatically and it maintains a space to let the material flow rapidly. After truck loading is finished, product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout automatically retracts to the top position afterwards.

Tanker Truck Loading Mode

At the beginning of tanker loading, spout is lowered and stopped when it reaches to the tanker inlet automatically. Poliurethane coated discharge cone fits vessel inlet to prevent any dust emission during tanker loading. Material falls freely through the inner side of the spout. After bulk tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Dust content in the air is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor placed at the bottom monitors the product level in the tanker truck. Level sensor sends a signal to stop loading, when the tanker is full. Product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout retracts to the top position automatically.

Combined loading spout for bulk trucks and tanker trucks

Advantages

– Suitable both for open bulk truck loading and bulk tanker truck loading – Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs – Built in flexible dust skirt to prevent dust emission outside of the loading region. – Poliurethane coated discharge cone that fit vessel inlet to prevent any dust emission during tanker loading – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade loading spouts are available – Simple operation – Easy maintenance

Open truck loading spout dustless telescopic loading of trucks

Handled Materials

Open Truck Loading Spouts

Open truck loading spouts are used for dust free loading of powdered and granular bulk solids into flatbed open trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to open trucks. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Open Truck Loading Spouts

How open bulk truck loading spouts work operation princible of loading spouts

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs – Built in flexible dust skirt to prevent dust emission outside of the loading region. – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade loading spouts are available – Simple operation – Easy maintenance

How open bulk truck loading spout works animation of telescopic loading spout

Handled Materials

Open Truck Loading Spout Application Gallery

Bulk solids loading to open bulk trucks by loading spouts

Open bulk truck loading spouts

Telescopic loading bellows for open truck loading bulk material handling

Telescopic loading spouts

Wheat truck loading spout

Telescopic loading spout with screw feeder

Telescopic spout and loading bellow for open bulk truck

Telescopic loading spout

Open truck loading spouts retracted and extended

Stockpile Loading Spouts

Stockpile loading spouts are used for dust free discharging of powdered and granular bulk solids to stockpiles. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to stockpile basement. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Stockpile Loading Spouts

At the beginning of stockcpile loading, spout is lowered towards the ground and stops at the bottom. Flexible dust skirt located at the bottom of spout keeps the dust content inside the loading area. During material discharge, spout dust skirt provides a closed containment for dust. Dust collection unit vacuums any fugitive dust in the region and prevents dust emission to the surrounding. Collected dust is then sent back to the product stream continuously and material waste is prevented during loading. Built in level sensors monitor the product level below the loading spout dust skirt. When the material level increases, spout is retracted upwards automatically with winch system and it maintains a space to let the material flow rapidly. After stockpile loading is finished, product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout automatically retracts to the top position afterwards.

How stockpile loading spouts work infographics

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure port and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Built in flexible dust skirt to prevent dust emission outside of the loading region. – Extensive range of models are available for wide range of needs – No spillage and no product waste – Food grade loading spouts are available – Simple operation – Easy maintenance

Handled Materials

Ship Loading Spouts

Bulk ship loading spout bulk solid handling loading discharging spouts

Ship loading spouts are used for dust free loading of powdered and granular bulk solids into dry bulk ships. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to dry bulk carrier ships. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Ship Loading Spouts

At the beginning of ship loading, spout is lowered towards the flatbed of ship and stops at the bottom. Flexible dust skirt located at the bottom side of spout keeps the dust content inside the loading area. During material discharge, spout dust skirt provides a closed containment for dust. Dust collector vacuums any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is then sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading spout dust skirt. When the material level increases, spout is retracted upwards automatically and it maintains a space to let the material flow rapidly. After ship loading is finished, product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout automatically retracts to the top position afterwards.

How ship loading spouts work 3d information operation princible

Advantages

Dust free loading
Dust free working region, prevention of dust pollution, ensure port and environmental safety.
Suitable for different bulk solids conveying and storage systems
Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc.
Extensive range of models are available for wide range of needs
Built in flexible dust skirt to prevent dust emission outside of the loading region.
No spillage and no product waste
Food grade loading spouts are available
Simple operation
Easy maintenance

Handled Materials

Loading Spout Technical Documents

Technical Catalogs Brochures of Loading Spouts

Loading Spout Accessories and Options

Telescopic dry bulk loading spouts have extensive range of optional components for wide range of needs.

Dust Collector

Dust collectors are key elements of bulk solid loading spouts. They collect any fugitive dust during bulk solid loading and prevent dust emission to the environment. Several loading spout dust collector models are available depending on application requirements.

In Line Dust Collector

If there exists enough height below discharge unit (silo, hopper, conveyor etc) in line dust collectors can be used in loading spouts. Filter units are installed at the top. Bulk material flows through the space between filters. Dusty air is collected through these filters. Dust content in the air is trapped by filter units. Automatically operated pulse jet filters are used for supplying air shocks to the filters and sending dust back to the stockpile downside.

Inline dust collection filter for bulk solid loading spout

Offset Type Dust Collector

Offset type dust collectors of loading spouts are installed at the edge of top flange with an angle. A vacuum fan is utilized to supply required vacuum air. During material discharge, fan unit vacuums the air from the discharge point of loading spout. This vacuumed air passes through the passage between inner and outer spouts. Dust content in the air is trapped by filter units. Automatically operated pulse jet filters are used for supplying air shocks to the filters and sending dust back to the stockpile downside. The inclined design occupies less height and provides easier installation below hoppers and silos.

Offset jet filter and dust collector for truck loading spout

Separate Dust Collector

Loading spouts have outlet for dust collection system connection. Any external fan, dust collector or bag house filter can directly be connected to built in outlet. If the loading spout installation area does not have enough space, separate dust collectors can be utilized. These dust collection units are independent systems that have their own fans, filters and discharge hoppers.

Dust collection system for bulk truck loading spouts dustless filling

Central Dust Collector

If central dust collection systems exist in the plant, they can be connected to loading spouts. Air outlet of the loading spout is used for connection. Air flow speed is to be adjusted with respect to operation conditions. Collected dust is stored in external dust collector. This configuration is suitable for applications where several loading spouts are to be used together at the same place. Single central dust collector can be used for collecting fugitive dust from all loading spout systems.

Bottom Closure and Sealing Cone

Bottom closure and sealing cone is used in tanker loading spouts to prevent any product spillage after loading. The conical shaped valve can move in vertical direction. It normally closes the outlet port of loading spout at the bottom. When the loading spout is placed on the tanker inlet flange, the conical valve moves downward and opens the product discharge passage. After tanker loading is finished, the loading spout is retracted. Spout retraction moves the bottom closure cone upwards and closes the outlet. Any remaining product within the loading spout is kept inside during retraction and spillage is prevented.

Bottom closure cone of bulk solid tanker loading spouts

Sampler

Material composition, moisture, particle size etc are some of the important attributes of bulk solids and it may be needed to check these values before loading. Bulk solid sampling systems are used to get a sample from free flowing bulk materials. In loading spout applications, a manual or automatic sampler is installed above the loading spout. During loading, sampler takes out some amount of material from the material flow.

Loading Spouts For High Temperature Applications

In case of high temperature bulk solid loading needs like fly ash handling systems, high temperature resistant loading spouts are to be utilized. Mechanical components including electrical motors, sensors etc. are selected from high temperature resistant models. Loading spout and skirt fabrics are chosen from high temperature fabrics. Bulk solids having temperatures up to 300C can be discharged with high temperature resistant loading spouts

High temperature heat bulk solids loading spouts

Level Sensors

Level sensors of open and closed loading spouts have different functions.

In closed vehicle loading, (i.e tanker trucks) level sensor is used for giving signal when the product reaches the tanker inlet level. Loading operation is stopped when the tanker truck is full.

In open loading spouts, level sensors are used for controlling the vertical position of loading spout. Flexible dust skirt of the spout should cover the product discharging region to prevent any fugitive dust and also keep enough space for rapid product discharge. When the product level increases, flexible dust skirt should raise accordingly to provide dust-free and fast loading.

Atex

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of bulk solid loading spouts. Overheating, dust leakage, static electricity and electrical spark generation should be prevented during material discharge. Bellow fabrics are made of antistatic materials to prevent any static electricity build up. Atex certified and ex-proof equipment are used in such working conditions.

Food Grade Loading Spouts

Food grade loading spout systems are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Bellow fabrics, filter bags, valves and other mechanisms are selected from food certified equipment.

Tanker Truck Loading spouts for food applications food grade spouts stainless steel bulk filling equipment

Handheld Control Pendant

Standard loading spouts are controlled by built in electrical control panel. Depending on application requirements, handheld remote control units can be utilized to increase operational efficiency. Wired and wireless remote controls are available upon request.

Handheld remote controlling of bulk loading spouts

Communication With Other Systems

Electrical panel of loading spouts can send signals to other automation systems in the plant and can receive signals from them. Operation of loading spout can be controlled from external systems. i.e truck weighing scale can send stop signal when the desired amount of product is filled. And loading spout can give signals and operate related equipment from its own panel. Silo discharge valves, conveyors etc can be ran from loading spout control unit.

Bulk solids loading spout automation system for bulk loading spout

Weighing System

Loading spouts can be coupled with weighing systems. Weighing hoppers, dosing belt scales, silo weighing systems can be utilized to feed loading spouts. For tanker truck or open truck loading, truck weighing scales can also be used for directly measuring of loaded weight. These systems can send signal to command loading spout to start or stop loading.

Truck weighing scales silo discharge bulk truck loading spouts

3 or 4 Lifting Cables

Loading spouts can be manufactured with 3 cable or 4 cable configuration. 2 cable design is applicable for standard truck loadings with wide range of bulk materials. 3 or 4 cables are needed for high capacities, long spouts and environments with high side winds. This design increases rigidity of loading spouts and ensures problem-free bulk material loading.

Vibration Motor

Vibration motors are used for discharging residues of bulk solids from the inner spout parts. They can be operated during or after loading.

Spreader

Depending on the flowing properties, bulk materials cannot be completely filled into the tank. For materials which have low flowability, the tanker cannot be filled up to its maximum carrying capacity. Material spreading systems are developed to solve this issue. The spreader is positioned near the outlet spout in loaders for loading to tanks. Rotating paddles distribute the material uniformly inside the tanker allowing entry of a larger quantity of material. Since the filling efficiency of the tanker is increased, the overall transportation cost will decrease.

Poliurethane Coated Outlet Cone

Closed type tanker loading spouts incorporate poliurethane coated outlet cone that fit vessel inlet to prevent any dust emission during vehicle loading. Abrasion resistant poliurethane coating provides flexible sealing to prevent dust leakage. Conical shape makes it easy to fit different tanker inlet diameters.

Tanker loading spout discharge spout poliurethane dustproof cone

Manual Winch Mechanism

For low duty applications, tanker truck and open truck loading spouts are available with manual winch mechanism. In this configuration a handwheel operated winch mechanism is used instead of electrically controlled motor, gearbox and pulley system. Handwheel unit can be installed to any location for easier access.

Manual winch operated hand driven bulk truck loading spout system

Loading Spout Positioners

Loading spout positioning systems ensure efficient loading of trucks and railcar wagons. Instead of repositioning vehicle for loading of entire volume, positioning system moves the loading spout when needed. Loading spout is installed below the positioner unit. Remote controlled loading spout positioner moves the spout to the desired location rapidly and accurately. Bulk material transfer is started in very short time, eliminating the time needed for moving the vehicle forward and backwards to be in the precise center of the loading spout. Depending on application requirements, single axis loading spout positioners, double axis loading spout positioners and articulating arm positioners are available.

Single Axis Loading Spout Positioners

The single axis loading spout positioner has the capability of moving forward and backwards over the vehicle. A single axis linear motion mechanism is used.

Double Axis Loading Spout Positioners

The double axis loading spout positioner has the capability of moving longitudinal or a lateral directions over the vehicle. A double axis linear motion mechanism is used.

Double axis single axis positioner for truck loading spouts

Articulating Arm Loading Spout Positioners

Loading spout articulating arm positioner system airslide conveyor

Loading Spout Vehicle Access Platform

For opening tanker inlets, guiding loading spouts, maintenance operations and similar tasks above the vehicles, operators should have easy and safe access to loading region. Vehicle access platforms provide safe and fast solution for these tasks. Each application and loading environment has its own structure and arrangement. Vehicle access locations, silo discharge heights, conveyor types are designed with respect to plant needs. Though, loading spout access platforms are custom designed for each application needs.

Bulk truck vehicle access platform for bulk solid loading by spout

Custom Designed Loading Spouts

In addition to standard series, loading spouts can be custom designed to conform wide range of application needs. For efficient and dust-free loading, loading spout should be designed carefully. Type and physical properties of handled bulk solid, loading capacity, loading environment, installation limitations are key factors that have effect on loading spout design.

custom designed bulk truck loading spouts

Machine Safety

Bulk material loading spouts manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in sack handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Bulk solids loading spout equipment machinery safety regulations

Loading Spout Bulk Solid Feeding Equipment

Loading spouts are coupled with product feeding equipment. Depending on application requirements, wide range of bulk solids handling equipment can be utilized for feeding loading spouts.

Butterfly Valve

Butterfly valves are generally installed below silos or hoppers. Product discharge outlet can be completely opened or closed in short time with the help of butterfly valves installed above loading spouts. In truck filling applications, butterfly valves serve to control amount of product loaded.

Slidegate Valve

Screw Conveyor

Screw conveyors are used for transferring bulk solids from hoppers, silos or plant machinery to loading spouts with controlled speed and capacity. Depending on loading area conditions, screw conveyors can be used to move the bulk solids to higher levels before entering into loading spouts to save some height for trucks.

Belt Conveyor

Belt conveyors can be utilized to transfer bulk materials to loading spouts. They are generally preferred in open regions and stockpile loadings. Special designed intermediate hoppers are used for smooth discharge of bulk materials from conveyor belt outlet to loading spout. Depending on dust load of the conveyed material, extra dust collectors can be utilized.

Bulk ship loading bellow bulk solid handling loading discharging spouts

Rotary Valve

Rotary valves are used for discharging bulk materials from silos and hoppers with controlled speed into the loading spout systems.

Pneumatic Conveying System

Pneumatic conveying systems are preferred in plants where loading area is far from the bulk material storage equipment. Pneumatic conveying systems transfer bulk materials from storage units to loading spouts within pipelines with air pressure or vacuum. Pneumatic conveying capacity is determined and equipment is selected with respect to transfer distance and loading spout capacity.

Airslide Conveyor

Airslide conveyors are utilized in high capacity loading of fine powdered materials such as cement loading to tanker trucks in cement plants. Loading spouts installed are below the outlet of air slide conveyors. Bulk material is fluidized within airslide conveyors with the help of pressurized air coming from the bottom. By the help of gravity, they move towards the downside direction. The inclination of airslide conveyor directly effects the flow speed.

Spout Types and Configurations

Depending on process requirements and physical properties of product, loading spouts are available with extensive range of spout configurations. Proper selection of configuration is essential for efficient and dust-free loading.

Single Outer Bellow

Single outer bellows provide economical solution for low dust content, granular material loading operations. There exists one spout that maintains the confined region in the system. Product flows downward through this spout and any dust is collected upwards within the same region.

Double Bellows

There exists one outer bellow and one inner bellow in this configuration. Product flows through the inner spout downwards and dust is collected through the region between two spouts upwards. As two opposite flows are separated, product loading capacity and dust collection efficiency are increased. The dust collection system is connected to the region between two spouts. Collected dust is sent back through this region again.

Single Outer Bellow With Internal Wear Cones

Wear cones are used to protect bellows from abrasion caused by flow of bulk solids. They are installed at the center of loading spout. Main stream product flow is separated from spout by wear cones. Flowing material does not have contact with spout fabric. Depending on the physical properties of product different type of wear cones are available. While carbon steel cones are suitable for wide range of bulk solids, hardox steel cones are needed for highly abrasive materials. For food products and corrosive materials stainless steel cones are preferred. In high temperature loading applications, wear cones serve as a heat barrier to protect spouts.

Single outer loading bellow with wear cones abrassion resistant loading spouts

Double Bellows With Internal Wear Cones

Inner bellows can be used to cover internal wear cones. This design both protects bellows from abrasion and provides efficient dust collection with rapid product loading. Bulk material flows through the wear cones inside the inner spout downwards and dust is collected through the region between two spouts upwards.

Double bellow with abrasion resistant wear cones bulk solid loading spouts

Loading Spout Selection Chart

Following chart can be used to determine possible loading spout configurations for different applications and conditions.

Loading spouts bellow type selection chart diagram

Heavy Duty Loading Spouts

Single Loading Chute

Single Outer Bellow With Internal Loading Chute

An outer bellow is used in this telescopic chute configuration to provide closed containment. Any dust leakage is prevented during material flow. Dust collection system connected to flexible dust skirt at the bottom are utilized capture fugitive dust.

Telescopic loading pipe outer loading dust collection spout

Loading Chute With Double Dust Collection Bellows

clinker loading telescopic chute with double dust collection spouts

Loading Spout Models

Closed Vehicle Loading Spouts

Tanker Truck Loading Spouts, Ship Loading Spouts, Container Loading Spouts Closed loading spouts are used to fill tanker trucks, closed containers, barges and ships with closed containers. They utilize poliurethane coated discharge cones that fit vessel inlet to prevent any dust emission during vehicle loading. After tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Any dust content is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor located at the bottom monitors the product level in the bulk tanker. When the tanker is full, level sensor sends a signal to stop loading. Product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout automatically retracts to the top position. Depending on the process requirements, loading amount can also be controlled by other systems such as truck weighing scales. When the determined amount of product is filled, weighing system sends a s signal to control panel of loading spout and loading is stopped automatically.

Tanker Loading Spouts

Tanker Loading Bellows Telescopic bulk tanker loading spout

Open Vehicle and Stockpile Loading Spouts

Open vehicle and stockpile loading spouts are used to load bulk material to open region such as flatbed open trucks, ships and stockpiles. Automated retraction mechanism and flexible dust skirt are key elements of open loading spouts. Flexible dust skirt is located at the bottom of loading spout. During material discharge, it provides a closed containment for dust. Dust collection system vacuums any fugitive dust in the region and prevents dust spreading to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading spout. As the level increases, spout is retracted upwards automatically and it maintains a space to let the product discharge rapidly. When loading is finished, product discharge valve above the loading spout is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading spout automatically retracts to the top position afterwards.

Open Truck Loading Spouts

Ship Loading Spouts

Bulk ship loading spout bulk solid handling loading discharging bellows

Stockpile Loading Spouts

Combined Loading Spouts for Tanker Trucks and Open Trucks

Combined loading spout for open truck and tanker trucks

Loading Spouts

Bulk Material Loading Spouts

Outloading of bulk solids in powder or granular form is a common task in industrial plants. A great deal of know-how is required to automate this process smoothly. Polimak offers wide range of solutions for bulk material loading applications. Being an essential component in bulk solid handling processes, loading spouts provide dust-free and safe outloading of powdered and granular materials to trucks, tankers, ships and stockpiles. They are generally mounted underneath silos, hoppers, or installed at the end of conveyors like screw feeders, elevators or pneumatic conveying systems. Bulk materials flowing from the upper side are transferred to the downstream vehicle, ship or stockpile efficiently without any dust emission and product loss.

How loading spout works mechanism of tanker truck loading bellow bulk solid unloading

How Loading Spouts Work ?

Main idea behind the loading spout system is discharging the powdered or granular bulk solid through a vertical column by its own weight and collecting any dust within the same enclosed column upwards. The varying height between the upper discharge point and lower loading point is compensated with making the column flexible. A mechanical winch system is used for adjusting the height while maintaining a closed area and straight passage for high capacity loading. Depending on application requirements different type of spouts, abrasion cones, dust collectors and similar equipment are included in whole loading system.

Depending on the type of loading medium, two main types of loading method exist; open loading and closed loading.

Open Loading

Open loading spouts are used to fill flatbed open trucks, ships and stockpiles where bulk material is directly exposed to environment. At the beginning of loading, spout is lowered towards the flatbed of truck / ship or basement and stops at the bottom. Material falls freely through the spout. Flexible dust skirt located at the bottom side of spout keeps the dust content inside the loading region. Additional vacuum air supplied by dust collection system ensures that any dust emission is prevented effectively. Level sensors installed on the unit are used to check product level continuously. As the product level increases, the spout raises automatically. After loading is completed, loading spout is retracted to the top stand-by position. Open truck loading spouts, ship loading spouts and stockpile loading spouts have extensive range of models and configurations depending on bulk material type, loading capacity and application requirements.

Open Truck Loading Spouts Bulk solids loading to trucks

Open truck bulk solid loading spout in action

Closed Loading

Closed loading spouts are used to fill tanker trucks, barges and ships with closed containers. At the beginning of loading, spout is lowered and stopped when it reaches to the tanker inlet. After that, product flow is started. Material falls freely through the inner side of the spout. Tanker is filled by the product. Air content of the tanker is transferred back through the spout and then discharged through the air vent. Level sensor located at the discharge point of spout monitors the product level in the tanker and stops the operation when the tank is full. After loading is completed, loading spout is retracted to the top stand-by position.

Dustless closed truck loading spout fly ash loading to truck

Advantages of Loading Spouts

– Dust free loading. – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems. – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs. – Auto raise feature. When loading is completed, loading spout retracts automatically, saving valuable operator time. – No spillage and no product waste. – Materials with high temperatures up to 300 C can be loaded. – Food grade loading spouts are available. – Simple operation. – Easy maintenance.

How tanker loading spout working animation

Handled Materials

Durable open truck loading bellow

Loading bellow to load tanker trucks

Loading bellows for loading open trucks

Loading chute with double dust collection bellows

Open truck loading bellows with built in pneumatic conveying system

Ship loading bellow with an extension height of 24 meters

Ship loading bellow with a 360 degrees rotating spoon

Ship loading bellow loading materials at a loading dock

Ship loading bellow loading bulk solids into a ship at a loading dock

Stockpile loading bellow

Tanker truck loading bellow loading up the truck

Tanker truck loading bellow connected to bin activator

Tanker truck loading bellow

Versatile loading spouts for stockpile loading

Stockpile Loading Bellows

Stockpile loading bellows are used for dust free discharging of powdered and granular bulk solids to stockpiles. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to stockpile basement. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Stockpile Loading Bellows

At the beginning of stockcpile loading, bellow is lowered towards the ground and stops at the bottom. Flexible dust skirt located at the bottom of bellow keeps the dust content inside the loading area. During material discharge, bellow dust skirt provides a closed containment for dust. Dust collection unit vacuums any fugitive dust in the region and prevents dust emission to the surrounding. Collected dust is then sent back to the product stream continuously and material waste is prevented during loading. Built in level sensors monitor the product level below the loading bellow dust skirt. When the material level increases, bellow is retracted upwards automatically with winch system and it maintains a space to let the material flow rapidly. After stockpile loading is finished, product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow automatically retracts to the top position afterwards.

How stockpile loading bellows work infographics

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure port and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Built in flexible dust skirt to prevent dust emission outside of the loading region. – Extensive range of models are available for wide range of needs – No spillage and no product waste – Food grade loading bellows are available – Simple operation – Easy maintenance

Handled Materials

Links

Loading Bellows

Open truck , tanker , ship and stockpile loading bellows are used for rapid and efficient dust free loading of dry bulk materials. Free flowing bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to tankers, open trucks, ships or stockpiles

Loading Bellow Models

Extensive range of loading bellows are available for wide range of applications. Open truck loading, bulk tanker filling, stockpile loading and bulk ship loading bellows provide dust free outloading of bulk materials for industrial applications.

Loading bellow types inner bellow outer bellow abrasion cone

Bellow Types and Configurations

Depending on type of discharged bulk solid, loading medium and plant conditions, bellow types change. Bulk material abrasiveness, dust load, particle size, loading capacity are some of the key factors that effect the design of bellow.

Bulk loading bellows material feeding equipment

Loading Bellow Bulk Solid Feeding Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials to loading bellows. Bulk materials are discharged from silos, hoppers, production lines with these transfer and conveying equipment.

Loading bellow accessories dust collector filter spreader bottom closure cone positioner

Loading Bellow Accessories and Options

Loading bellows and bulk solid discharge systems can be provided with extensive range of optional components and accessories for different application needs. Proper selection of accessories is essential for efficient and dust-free loading.

Loading Bellow Catalogs Datasheets User Manuals

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of bulk material loading bellows.

Ship Loading Bellows

Bulk ship loading bellow bulk solid handling loading discharging bellows

Ship loading bellows are used for dust free loading of powdered and granular bulk solids into dry bulk ships. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to dry bulk carrier ships. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Ship Loading Bellows

At the beginning of ship loading, bellow is lowered towards the flatbed of ship and stops at the bottom. Flexible dust skirt located at the bottom side of bellow keeps the dust content inside the loading area. During material discharge, bellow dust skirt provides a closed containment for dust. Dust collector vacuums any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is then sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading bellow dust skirt. When the material level increases, bellow is retracted upwards automatically and it maintains a space to let the material flow rapidly. After ship loading is finished, product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow automatically retracts to the top position afterwards.

How ship loading bellows work 3d information operation princible

Advantages

Dust free loading
Dust free working region, prevention of dust pollution, ensure port and environmental safety.
Suitable for different bulk solids conveying and storage systems
Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc.
Extensive range of models are available for wide range of needs
Built in flexible dust skirt to prevent dust emission outside of the loading region.
No spillage and no product waste
Food grade loading bellows are available
Simple operation
Easy maintenance

Ship loading bellows telescopic ship loading chutes

Handled Materials

Combined Loading Bellows for Tanker Trucks and Open Trucks

Combined telescopic loading bellows are used for dust free loading of powdered and granular bulk solids both into tanker trucks and flatbed open trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to trucks. There exists flexible dust skirt and poliurethane coated discharge cone together at the same loading bellow unit. Combined loading bellows are suitable for applications where incoming truck types vary.

Operation of Combined Truck Loading Bellows

Combined truck loading bellows have two operation modes selected from control panel at the beginning of truck loading. Depending on type of truck (open truck or tanker truck) loading bellow operation scheme changes.

Open Truck Loading Mode

At the beginning of open truck loading, bellow is lowered towards the flatbed of truck and stops at the bottom. Flexible dust skirt located at the bottom side of bellow keeps the dust content inside the loading region. During material discharge, it provides a closed containment for dust. Dust collection system collects any fugitive dust in the region and prevents dust emission to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading bellow dust skirt. When the material level increases, bellow is retracted upwards automatically and it maintains a space to let the material flow rapidly. After truck loading is finished, product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow automatically retracts to the top position afterwards.

Tanker Truck Loading Mode

At the beginning of tanker loading, bellow is lowered and stopped when it reaches to the tanker inlet automatically. Poliurethane coated discharge cone fits vessel inlet to prevent any dust emission during tanker loading. Material falls freely through the inner side of the bellow. After bulk tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Dust content in the air is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor placed at the bottom monitors the product level in the tanker truck. Level sensor sends a signal to stop loading, when the tanker is full. Product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow retracts to the top position automatically.

Combined loading bellow for bulk trucks and tanker trucks

Advantages

– Suitable both for open bulk truck loading and bulk tanker truck loading – Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs – Built in flexible dust skirt to prevent dust emission outside of the loading region. – Poliurethane coated discharge cone that fit vessel inlet to prevent any dust emission during tanker loading – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade loading bellows are available – Simple operation – Easy maintenance

Handled Materials

Tanker Loading Bellows

Tanker Loading Bellow Telescopic chute for bulk tanker loading

Bulk tanker loading bellows are used for dust free loading of powdered and granular bulk solids into bulk tanker trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers and screw feeders to tanker trucks.

Operation of Tanker Loading Bellows

At the beginning of tanker loading, bellow is lowered and stopped when it reaches to the tanker inlet automatically. They utilize poliurethane coated discharge cones that fit vessel inlet to prevent any dust emission during tanker loading. Material falls freely through the inner side of the bellow. After bulk tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Dust content in the air is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor placed at the bottom, monitors the product level in the tanker truck. Level sensor sends a signal to stop loading when the tanker is full. Product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow retracts to the top position automatically.

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Poliurethane coated discharge cone that fit vessel inlet to prevent any dust emission during tanker loading – Extensive range of models are available for wide range of needs – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade loading bellows are available – Simple operation – Easy maintenance

Tanker loading bellow telescopic bulk truck loading chute

Handled Materials

Tanker Truck Loading Bellow Application Gallery

Bulk solids silo discharging tanker truck loading system bulk loading telescopic bellow

Silo discharge and bulk tanker filling by loading bellow

Bulk tanker loading bellow

Tanker truck loading bellows

Telescopic chute tanker truck loading spout

Telescopic loading bellow discharging powder to tanker truck

Tanker Truck trailer loading telescopic chutes and bellows

Truck loading bellows below raw material silos

Raw material filling to trucks silo discharge systems loading bellows telescopic chutes

Bulk truck loading bellows

Silo discharging and bulk truck filling telescopic bellow

Raw material discharge bin and loading bellow

Silo unloading system tanker truck loading bellow

Bin activator and bulk truck loading bellow

Tanker loading bellow in retracted position

Bulk tanker loading bellow extension product discharging

Tanker loading bellow in extended position

Tanker loading bellow

big bag unloading system and bulk tanker filling bellows

Tanker loading by big bag discharge station and tanker truck loading bellow

Telescopic bulk tanker loading bellows

Pneumatic conveying system for tanker loading

Open Truck Loading Bellows

Open truck loading bellows are used for dust free loading of powdered and granular bulk solids into flatbed open trucks. Free flowing dry bulk solids in powder and granule form are easily transferred from silos, hoppers, containers, screw feeder to open trucks. Built in flexible dust skirt prevents the dust emission outside of the loading region.

Operation of Open Truck Loading Bellows

How open bulk truck loading bellows work operation princible of loading bellows

Advantages

– Dust free loading – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs – Built in flexible dust skirt to prevent dust emission outside of the loading region. – No spillage and no product waste – Materials with high temperatures up to 300 C can be loaded. – Food grade loading bellows are available – Simple operation – Easy maintenance

How open bulk truck loading bellow works animation of telescopic loading spout

Handled Materials

Open Truck Loading Bellow Application Gallery

Bulk solids loading to open bulk trucks by loading bellows

Open bulk truck loading bellows

Telescopic spouts for open truck loading bulk material handling

Telescopic loading bellows

Bulk material loading bellows telescopic chutes

Wheat truck loading bellow

Telescopic loading bellow with screw feeder

Telescopic loading bellow

Open truck loading bellows retracted and extended

Loading Bellow Technical Documents

Brochure of loading bellows

Loading Bellow Accessories and Options

Telescopic dry bulk loading bellows have extensive range of optional components for wide range of needs.

Dust Collector

Dust collectors are key elements of bulk solid loading bellows. They collect any fugitive dust during bulk solid loading and prevent dust emission to the environment. Several loading bellow dust collector models are available depending on application requirements.

In Line Dust Collector

If there exists enough height below discharge unit (silo, hopper, conveyor etc) in line dust collectors can be used in loading bellows. Filter units are installed at the top. Bulk material flows through the space between filters. Dusty air is collected through these filters. Dust content in the air is trapped by filter units. Automatically operated pulse jet filters are used for supplying air shocks to the filters and sending dust back to the stockpile downside.

Inline dust collection filter for bulk solid loading bellow

Offset Type Dust Collector

Offset type dust collectors of loading bellows are installed at the edge of top flange with an angle. A vacuum fan is utilized to supply required vacuum air. During material discharge, fan unit vacuums the air from the discharge point of loading bellow. This vacuumed air passes through the passage between inner and outer bellows. Dust content in the air is trapped by filter units. Automatically operated pulse jet filters are used for supplying air shocks to the filters and sending dust back to the stockpile downside. The inclined design occupies less height and provides easier installation below hoppers and silos.

Offset jet filter and dust collector for truck loading bellow

Separate Dust Collector

Loading bellows have outlet for dust collection system connection. Any external fan, dust collector or bag house filter can directly be connected to built in outlet. If the loading bellow installation area does not have enough space, separate dust collectors can be utilized. These dust collection units are independent systems that have their own fans, filters and discharge hoppers.

Dust collection system for bulk truck loading bellows dustless filling

Central Dust Collector

If central dust collection systems exist in the plant, they can be connected to loading bellows. Air outlet of the loading bellow is used for connection. Air flow speed is to be adjusted with respect to operation conditions. Collected dust is stored in external dust collector. This configuration is suitable for applications where several loading bellows are to be used together at the same place. Single central dust collector can be used for collecting fugitive dust from all loading bellow systems.

Bottom Closure and Sealing Cone

Bottom closure and sealing cone is used in tanker loading bellows to prevent any product spillage after loading. The conical shaped valve can move in vertical direction. It normally closes the outlet port of loading bellow at the bottom. When the loading bellow is placed on the tanker inlet flange, the conical valve moves downward and opens the product discharge passage. After tanker loading is finished, the loading bellow is retracted. Bellow retraction moves the bottom closure cone upwards and closes the outlet. Any remaining product within the loading bellow is kept inside during retraction and spillage is prevented.

Bottom closure cone of bulk solid tanker loading bellows

Sampler

Material composition, moisture, particle size etc are some of the important attributes of bulk solids and it may be needed to check these values before loading. Bulk solid sampling systems are used to get a sample from free flowing bulk materials. In loading bellow applications, a manual or automatic sampler is installed above the loading bellow. During loading, sampler takes out some amount of material from the material flow.

Loading Bellows For High Temperature Applications

In case of high temperature bulk solid loading needs like fly ash handling systems, high temperature resistant loading bellows are to be utilized. Mechanical components including electrical motors, sensors etc. are selected from high temperature resistant models. Loading bellow and skirt fabrics are chosen from high temperature fabrics. Bulk solids having temperatures up to 300OC can be discharged with high temperature resistant loading bellows

High temperature heat bulk solids loading bellows

Level Sensors

Level sensors of open and closed loading bellows have different functions.

In closed vehicle loading, (i.e tanker trucks) level sensor is used for giving signal when the product reaches the tanker inlet level. Loading operation is stopped when the tanker truck is full.

In open loading bellows, level sensors are used for controlling the vertical position of loading bellow. Flexible dust skirt of the bellow should cover the product discharging region to prevent any fugitive dust and also keep enough space for rapid product discharge. When the product level increases, flexible dust skirt should raise accordingly to provide dust-free and fast loading.

Atex

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of bulk solid loading bellows. Overheating, dust leakage, static electricity and electrical spark generation should be prevented during material discharge. Bellow fabrics are made of antistatic materials to prevent any static electricity build up. Atex certified and ex-proof equipment are used in such working conditions.

Food Grade Loading Bellows

Food grade loading bellow systems are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Bellow fabrics, filter bags, valves and other mechanisms are selected from food certified equipment.

Tanker Truck Loading bellows for food applications food grade bellows stainless steel bulk filling equipment

Handheld Control Pendant

Standard loading bellows are controlled by built in electrical control panel. Depending on application requirements, handheld remote control units can be utilized to increase operational efficiency. Wired and wireless remote controls are available upon request.

Handheld remote controlling of bulk loading bellows

Communication With Other Systems

Electrical panel of loading bellows can send signals to other automation systems in the plant and can receive signals from them. Operation of loading bellow can be controlled from external systems. i.e truck weighing scale can send stop signal when the desired amount of product is filled. And loading bellow can give signals and operate related equipment from its own panel. Silo discharge valves, conveyors etc can be ran from loading bellow control unit.

Bulk solids loading bellow automation system for bulk loading spout

Weighing System

Loading bellows can be coupled with weighing systems. Weighing hoppers, dosing belt scales, silo weighing systems can be utilized to feed loading bellows. For tanker truck or open truck loading, truck weighing scales can also be used for directly measuring of loaded weight. These systems can send signal to command loading bellow to start or stop loading.

Truck weighing scales silo discharge bulk truck loading bellows

3 or 4 Lifting Cables

Loading bellows can be manufactured with 3 cable or 4 cable configuration. 2 cable design is applicable for standard truck loadings with wide range of bulk materials. 3 or 4 cables are needed for high capacities, long bellows and environments with high side winds. This design increases rigidity of loading bellows and ensures problem-free bulk material loading.

Open truck loading telescopic bellow chute lifting wire cables

Vibration Motor

Vibration motors are used for discharging residues of bulk solids from the inner bellow parts. They can be operated during or after loading.

Spreader

Depending on the flowing properties, bulk materials cannot be completely filled into the tank. For materials which have low flowability, the tanker cannot be filled up to its maximum carrying capacity. Material spreading systems are developed to solve this issue. The spreader is positioned near the outlet spout in loaders for loading to tanks. Rotating paddles distribute the material uniformly inside the tanker allowing entry of a larger quantity of material. Since the filling efficiency of the tanker is increased, the overall transportation cost will decrease.

Poliurethane Coated Outlet Cone

Closed type tanker loading bellows incorporate poliurethane coated outlet cone that fit vessel inlet to prevent any dust emission during vehicle loading. Abrasion resistant poliurethane coating provides flexible sealing to prevent dust leakage. Conical shape makes it easy to fit different tanker inlet diameters.

Tanker loading bellow discharge spout poliurethane dustproof cone

Manual Winch Mechanism

For low duty applications, tanker truck and open truck loading bellows are available with manual winch mechanism. In this configuration a handwheel operated winch mechanism is used instead of electrically controlled motor, gearbox and pulley system. Handwheel unit can be installed to any location for easier access.

Manual winch operated hand driven bulk truck loading bellow system

Loading Bellow Positioners

Loading bellow positioning systems ensure efficient loading of trucks and railcar wagons. Instead of repositioning vehicle for loading of entire volume, positioning system moves the loading bellow when needed. Loading bellow is installed below the positioner unit. Remote controlled loading bellow positioner moves the bellow to the desired location rapidly and accurately. Bulk material transfer is started in very short time, eliminating the time needed for moving the vehicle forward and backwards to be in the precise center of the loading bellow. Depending on application requirements, single axis loading bellow positioners, double axis loading bellow positioners and articulating arm positioners are available.

Single Axis Loading Bellow Positioners

The single axis loading bellow positioner has the capability of moving forward and backwards over the vehicle. A single axis linear motion mechanism is used.

Double Axis Loading Bellow Positioners

The double axis loading bellow positioner has the capability of moving longitudinal or a lateral directions over the vehicle. A double axis linear motion mechanism is used.

Double axis single axis positioner for truck loading bellows

Articulating Arm Loading Bellow Positioners

Loading bellow articulating arm positioner system airslide conveyor

Loading Bellow Vehicle Access Platform

For opening tanker inlets, guiding loading bellows, maintenance operations and similar tasks above the vehicles, operators should have easy and safe access to loading region. Vehicle access platforms provide safe and fast solution for these tasks. Each application and loading environment has its own structure and arrangement. Vehicle access locations, silo discharge heights, conveyor types are designed with respect to plant needs. Though, loading bellow access platforms are custom designed for each application needs.

Bulk truck vehicle access platform for bulk solid loading by bellow

Custom Designed Loading Bellows

In addition to standard series, loading bellows can be custom designed to conform wide range of application needs. For efficient and dust-free loading, loading bellow should be designed carefully. Type and physical properties of handled bulk solid, loading capacity, loading environment, installation limitations are key factors that have effect on loading bellow design.

custom designed bulk truck loading bellows

Machine Safety

Bulk material loading bellows manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in sack handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Bulk solids loading bellow equipment machinery safety regulations

Loading Bellow Bulk Solid Feeding Equipment

Loading bellows are coupled with product feeding equipment. Depending on application requirements, wide range of bulk solids handling equipment can be utilized for feeding loading bellows.

Butterfly Valve

Butterfly valves are generally installed below silos or hoppers. Product discharge outlet can be completely opened or closed in short time with the help of butterfly valves installed above loading bellows. In truck filling applications, butterfly valves serve to control amount of product loaded.

Slidegate Valve

Screw Conveyor

Screw conveyors are used for transferring bulk solids from hoppers, silos or plant machinery to loading bellows with controlled speed and capacity. Depending on loading area conditions, screw conveyors can be used to move the bulk solids to higher levels before entering into loading bellows to save some height for trucks.

Belt Conveyor

Belt conveyors can be utilized to transfer bulk materials to loading bellows. They are generally preferred in open regions and stockpile loadings. Special designed intermediate hoppers are used for smooth discharge of bulk materials from conveyor belt outlet to loading bellow. Depending on dust load of the conveyed material, extra dust collectors can be utilized.

Rotary Valve

Rotary valves are used for discharging bulk materials from silos and hoppers with controlled speed into the loading bellow systems.

Pneumatic Conveying System

Pneumatic conveying systems are preferred in plants where loading area is far from the bulk material storage equipment. Pneumatic conveying systems transfer bulk materials from storage units to loading bellows within pipelines with air pressure or vacuum. Pneumatic conveying capacity is determined and equipment is selected with respect to transfer distance and loading bellow capacity.

Airslide Conveyor

Airslide conveyors are utilized in high capacity loading of fine powdered materials such as cement loading to tanker trucks in cement plants. Loading bellows installed are below the outlet of air slide conveyors. Bulk material is fluidized within airslide conveyors with the help of pressurized air coming from the bottom. By the help of gravity, they move towards the downside direction. The inclination of airslide conveyor directly effects the flow speed.

Bellow Types and Configurations

Depending on process requirements and physical properties of product, loading bellows are available with extensive range of bellow configurations. Proper selection of configuration is essential for efficient and dust-free loading.

Single Outer Bellow

Single outer bellows provide economical solution for low dust content, granular material loading operations. There exists one bellow that maintains the confined region in the system. Product flows downward through this bellow and any dust is collected upwards within the same region.

Double Bellows

There exists one outer bellow and one inner bellow in this configuration. Product flows through the inner bellow downwards and dust is collected through the region between two bellows upwards. As two opposite flows are separated, product loading capacity and dust collection efficiency are increased. The dust collection system is connected to the region between two bellows. Collected dust is sent back through this region again.

Single Outer Bellow With Internal Wear Cones

Wear cones are used to protect bellows from abrasion caused by flow of bulk solids. They are installed at the center of loading bellow. Main stream product flow is separated from bellow by wear cones. Flowing material does not have contact with bellow fabric. Depending on the physical properties of product different type of wear cones are available. While carbon steel cones are suitable for wide range of bulk solids, hardox steel cones are needed for highly abrasive materials. For food products and corrosive materials stainless steel cones are preferred. In high temperature loading applications, wear cones serve as a heat barrier to protect bellows.

Single outer loading bellow with wear cones abrassion resistant loading bellows

Double Bellows With Internal Wear Cones

Inner bellows can be used to cover internal wear cones. This design both protects bellows from abrasion and provides efficient dust collection with rapid product loading. Bulk material flows through the wear cones inside the inner bellow downwards and dust is collected through the region between two bellows upwards.

Double bellow with abrasion resistant wear cones bulk solid loading bellows

Loading Bellow Selection Chart

Following chart can be used to determine possible loading bellow configurations for different applications and conditions.

Heavy Duty Loading Bellows

Single Loading Chute

Single Outer Bellow With Internal Loading Chute

Telescopic loading pipe outer loading dust collection bellow

Loading Chute With Double Dust Collection Bellows

Loading Bellow Models

Closed Vehicle Loading Bellows

Closed loading bellows are used to fill tanker trucks, closed containers, barges and ships with closed containers. They utilize poliurethane coated discharge cones that fit vessel inlet to prevent any dust emission during vehicle loading. After tanker filling is started, built in vacuum fan evacuates the air trapped in the vessel to increase product flow rate. This vacuumed air passes through the dust collector. Any dust content is trapped by filter units and sent back to the tanker with the help of automatically operated pulse jet valves. Level sensor located at the bottom monitors the product level in the bulk tanker. When the tanker is full, level sensor sends a signal to stop loading. Product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow automatically retracts to the top position. Depending on the process requirements, loading amount can also be controlled by other systems such as truck weighing scales. When the determined amount of product is filled, weighing system sends a s signal to control panel of loading bellow and loading is stopped automatically.

Tanker Loading Bellows

Open Vehicle and Stockpile Loading Bellows

Open vehicle and stockpile loading bellows are used to load bulk material to open region such as flatbed open trucks, ships and stockpiles. Automated retraction mechanism and flexible dust skirt are key elements of open loading bellows. Flexible dust skirt is located at the bottom of loading bellow. During material discharge, it provides a closed containment for dust. Dust collection system vacuums any fugitive dust in the region and prevents dust spreading to surrounding. Collected dust is sent back to the product stream continuously and no material is wasted during loading. Built in level sensors monitor the product level below the loading bellow. As the level increases, bellow is retracted upwards automatically and it maintains a space to let the product discharge rapidly. When loading is finished, product discharge valve above the loading bellow is closed. System waits for few seconds to complete product flow and to collect remaining dust by dust collector. Loading bellow automatically retracts to the top position afterwards.

Open Truck Loading Bellows

Ship Loading Bellows

Stockpile Loading Bellows

Combined Loading Bellows for Tanker Trucks and Open Trucks

Combined loading bellow for open truck and tanker trucks

Loading Bellows

Bulk Material Loading Bellows

Outloading of bulk solids in powder or granular form is a common task in industrial plants. A great deal of know-how is required to automate this process smoothly. Polimak offers wide range of solutions for bulk material loading applications. Being an essential component in bulk solid handling processes, loading bellows provide dust-free and safe outloading of powdered and granular materials to trucks, tankers, ships and stockpiles. They are generally mounted underneath silos, hoppers, or installed at the end of conveyors like screw feeders, elevators or pneumatic conveying systems. Bulk materials flowing from the upper side are transferred to the downstream vehicle, ship or stockpile efficiently without any dust emission and product loss.

How loading bellow works mechanism of tanker truck loading bellow bulk solid unloading

How Loading Bellows Work ?

Main idea behind the loading bellow system is discharging the powdered or granular bulk solid through a vertical column by its own weight and collecting any dust within the same enclosed column upwards. The varying height between the upper discharge point and lower loading point is compensated with making the column flexible. A mechanical winch system is used for adjusting the height while maintaining a closed area and straight passage for high capacity loading. Depending on application requirements different type of bellows, abrasion cones, dust collectors and similar equipment are included in whole loading system.

Depending on the type of loading medium, two main types of loading method exist; open loading and closed loading.

Open Loading

Open loading bellows are used to fill flatbed open trucks, ships and stockpiles where bulk material is directly exposed to environment. At the beginning of loading, bellow is lowered towards the flatbed of truck / ship or basement and stops at the bottom. Material falls freely through the bellow. Flexible dust skirt located at the bottom side of bellow keeps the dust content inside the loading region. Additional vacuum air supplied by dust collection system ensures that any dust emission is prevented effectively. Level sensors installed on the unit are used to check product level continuously. As the product level increases, the bellow raises automatically. After loading is completed, loading bellow is retracted to the top stand-by position. Open truck loading bellows, ship loading bellows and stockpile loading bellows have extensive range of models and configurations depending on bulk material type, loading capacity and application requirements.

Open Truck Loading Bellows Bulk solids loading to trucks

Open truck bulk solid loading bellow in action

Closed Loading

Closed loading bellows are used to fill tanker trucks, barges and ships with closed containers. At the beginning of loading, bellow is lowered and stopped when it reaches to the tanker inlet. After that, product flow is started. Material falls freely through the inner side of the bellow. Tanker is filled by the product. Air content of the tanker is transferred back through the bellow and then discharged through the air vent. Level sensor located at the discharge point of bellow monitors the product level in the tanker and stops the operation when the tank is full. After loading is completed, loading bellow is retracted to the top stand-by position.

Advantages of Loading Bellows

– Dust free loading. – Dust free working region, prevention of dust pollution, ensure plant and environmental safety. – Suitable for different bulk solids conveying and storage systems. – Loading is possible from different equipment like silo, hopper, screw feeder, conveyors etc. – Extensive range of models are available for wide range of needs. – Auto raise feature. When loading is completed, loading bellow retracts automatically, saving valuable operator time. – No spillage and no product waste. – Materials with high temperatures up to 300 C can be loaded. – Food grade loading bellows are available. – Simple operation. – Easy maintenance.

How tanker loading bellow work animation

Handled Materials

Durable open truck loading bellow

Loading bellow to load tanker trucks

Loading bellows for loading open trucks

Loading chute with double dust collection bellows

Open truck loading bellows with built in pneumatic conveying system

Ship loading bellow with an extension height of 24 meters

Ship loading bellow with a 360 degrees rotating spoon

Ship loading bellow loading materials at a loading dock

Ship loading bellow loading bulk solids into a ship at a loading dock

Stockpile loading bellow

Tanker truck loading bellow loading up the truck

Tanker truck loading bellow connected to bin activator

Tanker truck loading bellow

Versatile loading spouts for stockpile loading

Sack Opening Station Technical Documents

Technical Catalogs of Sack Opening Systems

Links

Sack Opening Stations

Sack opening stations provide dust free and easy emptying of sacks and bags. The contents of bags and sacks are easily transferred to silos, mixers, and conveyors etc. Pneumatic conveying systems, screw feeders or similar conveying equipments can be used to transfer bulk solids to required destination.

Sack Opening Station Applications

Sack opening station applications; silo filling, mixer loading, production line feeding, bulk truck loading, packaging systems, weighing, batching and dosing systems.

Sack opening station automatic bag opener bag slitter sack discharger

Sack Opening Station Models

Wide range of sack opening stations are available with respect to different applications. bag dumping systems can be configured according to bulk solid types (powdered, granular, abrasive, food etc) application types (silo filling, mechanical conveying, pneumatic transfer, mixer feeding etc).

Sack Opening station rotary airlock feeder valve screw conveyor diverter valve slidegate valve

Sack Opening Station Bulk Solid Transfer Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials from sack opening system outlet to required destination. Mechanical or pneumatic conveyors can be used according to application needs.

Sack opening system accessories jet filter dust collector glove box bag compactor

Sack Opening Station Accessories

Sack opening and discharge systems can be provided with wide range of optional components and accessories for different application needs.

Sack opening Station PDF Catalogs Brochures Flyers

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of sack opening stations

Sack Opening Station Applications

Sack Opening and Silo Loading

Silo loading systems connected to sack opening stations are used for discharging raw materials from sacks and fill them to storage silos. Silo loading can be done by mechanical conveyors or pneumatic conveying systems.

Sack opener station screw feeder silo filling system

Mechanical Conveying Systems For Silo Loading

Mechanical conveyors can be used for silo loading from sack opening stations. Screw feeders, bucket elevators, rotary valves or chain conveyors are connected to sack dump stations to fill silos. Conveying equipment selection directly depends on conveying distance, height, transferred material and capacity. Bucket elevators are preferred for high silos. Screw feeders are preferred for shorter silos and short distances. Sack opening system can be installed on top of silo for faster filling. In this case rotary valve or butterfly valve are better choices which provide simple flow control. Dust collection systems may be needed depending on dust content of bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some amount of dust together. Having vacuum fan and jet filter, dust collectors prevent any dust emission to the environment. Collected dust is sent back to the silo and product loss is prevented.

Silo Loading With Pneumatic Conveying System

Pneumatic conveying systems installed after sack opening units transfer the bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, sack opening stations can be installed closed to warehouses and pneumatic conveying systems are used to fill silos from long distances. This design prevents extreme use of forklifts and cranes for bulk material transfer in production site and increases overall efficiency.

Pneumatic transfer systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, equipment selection depends on type of bulk material, transfer distance, silo height and transfer capacity. Level sensors, jet filters and other equipment are installed on storage silos to properly run silo filling system.

Sack slitting and discharge station pneumatic transportation and silo loading system

Sack Opening station mixer loading dosing weighing system

Sack Opening and Mixer Filling

Mixer automation systems are used to mix dry bulk solids with respect to certain recipes. Raw materials that are delivered within sacks can be transferred to mixing units by combination of conveying equipment and sack opening system. Depending on type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Sack opening stations can be manufactured with built in dosing system. Amount of raw material to be loaded into the mixer is controlled automatically by the help of weighing and dosing system. Dust collectors can be used to prevent dust emission during mixer filling.

Sack Unloading and Packaging System Feeding

Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks etc. Bulk materials that are delivered within sacks are to be transferred to packaging machines without interruption. Loading hopper of packaging system should be kept full during filling and packaging. Sack opener systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Sack opening system big bag filling packaging machine pneumatic conveying

Bag unloading systems batching weighing and dosing equipment

Sack Opening, Dosing, Weighing and Batching Systems

Sack opening systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. Loading hopper of weighing system should be kept full during dosing and batching. Sack opening systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Sack Discharge and Bulk Truck Loading Systems

Bulk tanker trucks or open trucks are sometimes filled with powdered materials delivered within sacks. These systems are generally composed of sack opening station, mechanical or pneumatic conveyor and loading bellow. Sack opening station transfers the bulk solid from sack to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity sack opening systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from bag opening station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Sack discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.

Sack opening and discharging station bulk tanker truck loading bellow telescopic chute

Application Gallery

Sack opening station with rotary feeder and pneumatic conveying system

Sack opening stations with glove box and dust collector

Sack opening stations for additive feeding to production line

Food grade stainless steel sack opening and discharging system

Sack dumping and discharging unit

Sack discharge hoppers and dosing screws of batching system

Sack opening station with screw conveyor and weighing system

Sack Opening Station Models

Sack opening systems have wide variety of components for wide range of applications.

Sack Discharge Hopper

Sack discharge hoppers are used for bulk solids that have no dust content. They have simple sack placement table for easy slitting and unloading. There is no dust collector in these hoppers. Bulk material is discharged through lower outlet port to down stream equipment. Hoppers can be produced in any dimension with respect to application needs.

Sack discharging hopper and screw feeder

Manual Sack Opening Station

Sacks are opened and unloaded one by one with man power. Bulk material in the sack is discharged manually into the hopper of sack opening unit. Dust content in the air is collected by built in dust collector and sent back into the hopper. Vacuum air is filtered and discharged to the atmosphere. Bulk material is discharged through the discharge port and sent to the next process equipment like conveyor, silo, mixer etc.

Sack opening and discharging system and dust collector jet filter

Semi Automatic Sack Opening and Emptying Station

Semi automatic sack opening systems are used for medium capacity sack opening and unloading processes. In this system, sacks are put on conveyor belt of system one by one. They are then slit by automatic cutting blades and contents are discharged into the loading hopper. Any dust content within the system is collected by built in filter system. Vacuum air is filtered and discharged to the atmosphere. Bulk material is discharged through the discharge port of system automatically and sent to the down stream equipment.

Automatic sack slitting, opening and discharging system

Automatic Sack Opening and Discharging System

Automatic sack opening and emptying systems are used for high capacity sack opening and unloading processes. In this system, pallets full of sacks are placed into the system by forklift or crane. System automatically lifts the sacks from the pallet by automatic grippers. Lifted sacks are slit with rotating blades. And content is discharged into the loading hopper. Bulk material is then discharged through the discharge port of system automatically and sent to the down stream equipment. Waste sacks are put into discharge cage by grippers. Any dust content within the system is collected by built in filter system. Vacuum air is filtered and discharged to the atmosphere.

Automatic sack slitting opening discharging system

Sack Opening Station Bulk Solid Transfer Equipment

Sack opening systems can be supplied with wide variety of equipment for further conveying of the discharged product depending on type of application.

Rotary Airlock Valves or Blowing Seals

Rotary valves provide controlled product flow from sack opening station to the down stream system. Dry bulk materials can be fed into mixers, tanks or other mechanical conveyors through rotary airlocks. Blowing seals are used to feed pneumatic conveying systems and ensure sealing of pressurized air in the pipeline.

Rotary feeder airlock valve for sack slitting , dumping and discharging system

Rotary valve airlock feeder sack tipping system and bag dump station

Screw Feeders

Bulk solids in the sacks can be transferred to other handling systems with the help of screw conveyors installed below the sack opening unit. Screw conveyors can be used to transfer products to packaging machines, production lines, mixers or other similar equipment.

Sack tipping station screw feeder conveyor unit

Slidegate Valve

Slidegate valves can be installed below the discharge hopper of sack dumping station. Product flow speed can be controlled by adjustable valve blade. Manual handwheel or pneumatic piston can be used on slidegate valves depending on type of application.

Sack opening and discharge station slide gate powder discharging valve

Butterfly Valve

Butterfly valves placed on the sack emptying system are simple valves used to open and close product flow in short time. Butterfly valves can be controlled by manual handle or pneumatic actuator.

Batching and Dosing System

Dosing systems feed processes with controlled amount of bulk materials. Depending application requirements, volumetric or gravimetric dosing systems can be installed on sack openers. PLC or computer controlled dosing systems are available.

Bag tipping station sack discharge dosing system for mixers

Pneumatic Conveying System

Instead of mechanical conveyors, pneumatic conveying systems are preferred in processes where the sack opening stations are far from feeding points. Pneumatic conveying equipment and pipeline are connected to sack discharge systems. Powdered or granular bulk materials are transferred from sacks to pneumatic conveying system and then conveyed to the required points. Depending on type of application, pressure conveying system or vacuum conveying system can be installed.

Dense Phase Pneumatic Conveying System

Sack opening stations with built in dense phase pneumatic conveying systems are used in applications where high conveying capacities and long distances are needed. Sack unloading hopper is installed above a pressurized tank also known as pressure vessel. Several sacks are unloaded in one time to the pressurized tank. High pressure air is used to pressurize the tank and send the product through the conveying pipeline. Dense phase pneumatic conveying systems are generally preferred for materials like cement, calcium carbonate, PVC, soda and fly ash where high transfer capacities are needed.

Free Flow

Outlet of sack opening station is kept free of any equipment. Unloaded bulk solids move freely to down stream system.

Bulk bag dumping station powder and bulk solid discharging unit

Sack Opening Station Accessories

Dust Collection System

Dust collection system of sack tipping station is needed for preventing dust emmission during sack discharge. Dust emmissions from bags are seen during cutting or untying of bags, product discharge and removal of empty sacks. Vacuum air supplied by dust collector, collects any dust in the region. A jet filter system with built in fan is used for this purpose. Collected dust is sent back to the sack emptying unit automatically and any product loss is prevented. Vacuum air is cleaned with reverse pulse jet system and discharged to outside.

Bag opening and discharging system and dust collector jet filter

Sack discharging system dust collector jet filter unit

Glove Box

Sack opening station is designed as completely enclosed system for advanced dust containment. System has an sealed sack loading door on one side. Operator puts the sacks through this door. After closing the door, operator uses special gloves through the glove box to cut the sack. A sealed window is installed on front side of the unit. After the sack contents are discharged, the waste bag is discharged through discharge port. Built in dust collection system is to be used in this design to prevent any harmful dust emission to outside.

Bag discharging sack slitting emptying system full containment dust free

Sack tipping station dust collector glove box

Vacuum Sack Lifting Unit, Bag Manupilator

The vacuum lifting equipment enables the operator to lift sacks eliminating any health problems caused by heavy loads. The sacks can be lifted, split, opened and contents emptied into the loading hopper in a safe way.

Bag manipulator of sack dump station bag vacuum lift system

Vibrating Bin Activator

Bin activators are also know as vibrating bin dischargers. They generate a vibration below the sack opening station hopper to fluidize the bulk solid in the hopper, make it flow downwards and discharge easier.

Vibrating bin discharger of sack opening station

Air Jet

To fluidize the bulk solid within the hopper of sack opening station, air jets are used. The fluidized material will flow easily and product discharging will be better. Air jets are placed near the discharge outlet flange of the hopper. Pressurized air is applied to air jets and makes the bulk solid flow better.

Weighing System

When the raw material amount in the sack opening station is to be monitored, weighing system can be used. Sack opening station consists of loadcells on main frame. Weight of the unit is continuously measured and user is informed. System can send signal to another PLC automation system or system can control other equipment connected to the sack opening station.

Sack opening station with weighing batching and dosing equipment

Sack Handling Automation

Sack handling automation systems provide control of whole sack and bulk material handling operations. Vibration motor, dust collector, weighing system, conveying system etc. are connected to automation system. Depending on the complexity and configuration of sack opening station, different type of automation systems can be utilized. For simple sack opening units a small sized manual controlled electrical panel is enough. PLC controlled automation panels are preferred for sack opening stations with many accessories installed on. These units can also take control of other material handling systems that are connected to sack opening station like screw feeders, pneumatic conveying systems, rotary valves etc. Daily, monthly, annual reporting functions are available as an option. PLC controlled systems have option for connecting to other Scada, PC and PLC systems in production plant for better handling and monitoring of complete production process.

Sack Opening stations bulk material transfer batching and weighing automation systems

Lump Breaker

Bulk solids stored in sacks for long time tend to be compacted because of its own weight and possible moisture in the environment and form big sized lumps. During sack discharging, these lumps should be broken before entering to down stream equipment. Lump breakers are installed below sack opening systems to prevent any problems caused by big sized particles and lumps.

Lump breaking unit of sack slitting unit

Screening System

To prevent any oversized particle entrance into the production line, screen is used. Screening systems are installed at the discharge point of sack discharger unit. Depending on bulk material properties and acceptable particle sizes different types of screens can be used. Vibrating screens are one of the most common screen type used in bulk material handling.

Magnetic Separator

Foreign materials in bulk solids will lead to serious problems in production processes. Magnetic separators are used to detect metallic particles in bulk solids and separate them from main product stream. Metal detectors and separators can be installed at the outlet port of sack opening systems and prevent contaminations caused by metallic particles.

Sack Compactor

Sack compacting is an efficient way for disposal of empty sacks. After unloading the sacks, operator puts them into sack compactor inlet. Sack compactor unit has compacting screw that pushes the empty sacks into compaction chamber and discharges them with minimum volume.

Waste bag compacting unit of sack slitting dump and discharging system

Food Applications

Food grade sack openers are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Filter bags, valves and other mechanisms are selected from food certified equipment.

Food grade stainless steel bulk bag opener sack discharge tipping stations

Dangerous Materials and Environment

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of sack opening systems. Overheating, gas or dust leakage, static electricity and electrical spark generation should be prevented. Atex certified and ex-proof equipment are used in such working conditions.

Atex Ex-proof sack discharge stations for hazardous powdered materials

Custom Designed Bag Dump Stations For Different Raw Materials

Design and construction material of sack opening stations can change with respect to handled bulk material and type of application. Stainless steel body made of either AISI 304 or AISI 316 is preferred for food materials, additives, PVC, Polypropylene, Polyethylene, PET, HDPE, LDPE, painting materials etc. High carbon steel and manganese alloys are preferred for abrasive materials such as arc furnace dust, perlite, quartz, silica sand, fly ash etc. Standard steel is used for general purpose applications such as cement, calcium carbonate, activated carbon handling.

Custom designed sack tipping dump equipment and accessories

Machine Safety

Sack discharge systems manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in sack handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Sack Opening Stations

Sack opening stations are designed for opening and unloading of small volume bags of bulk solids bags in effective and safe way. Different types of bulk materials can be handled, starting from free flowing granules to poorly flowing sticky fine powders.

Sack opening and slitting stations for powdered bulk solids

Sack opening and discharge systems are designed to meet wide range of application requirements. Type of bulk material, sack size, discharged medium, down stream equipment, discharge speed, environmental aspects, ergonomics and safety are all important factors that have effect on final design on sack opening unit.

Sack slitting opening and discharging station

Modular design of sack opening systems make them easy to be configured for each application need. While standard models have simple frame and discharge hoppers, high level models have complete solution in single main frame. Sack openning, discharging, product storage, dust collection, dosing and conveying can all be done in single unit.

Sack opening stations are also known as bag dump stations, bag unloaders, bag tip stations, sack tipping stations, bag unloaders, bag emptiers, sack emptiers etc.

Sack opening station pneumatic conveying and silo loading systems

Sack opening equipment mixer feeding pneumatic conveying powder dosing system

Advantages
– Safe and clean working environment
– Dust free environment air
– Simple handling of sacks
– Applicable for different conveying and storage systems
– Wide range of models for different applications
– Easy to clean
– Maintenance free design
– Rigid, steel construction
– Filter system for preventing dust.

Bag Dump Station Technical Documents

Brochure of bag dump stations

Links

Bag Dump Stations

Bag dump stations provide dust free and easy emptying of bags. The contents of bags and sacks are easily transferred to silos, mixers, and conveyors etc. Pneumatic conveying systems, screw feeders or similar conveying equipments can be used to transfer bulk solids to required destination.

Bag Dump Station Applications

Bag dumping station applications; silo filling, mixer loading, production line feeding, bulk truck loading, packaging systems, weighing, batching and dosing systems.

Bag dump station automatic bag opener bag slitter sack discharger

Bag Dump Station Models

Wide range of bag dump stations are available with respect to different applications. bag dumping systems can be configured according to bulk solid types (powdered, granular, abrasive, food etc) application types (silo filling, mechanical conveying, pneumatic transfer, mixer feeding etc).

Bag dump station rotary airlock feeder valve screw conveyor diverter valve slidegate valve

Bag Dump Station Bulk Solid Transfer Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials from bag dumping system outlet to required destination. Mechanical or pneumatic conveyors can be used according to application needs.

Bag dumping system accessories jet filter dust collector glove box bag compactor

Bag Dump Station Accessories

Bag dump and discharge systems can be provided with wide range of optional components and accessories for different application needs.

Bag Dump Station Catalogs Brochures Flyers

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of bag dump stations

Bag Dump Station Applications

Bag Dumping and Silo Loading

Silo loading systems connected to bag dump stations are used for discharging raw materials from bags and fill them to storage silos. Silo loading can be done by mechanical conveyors or pneumatic conveying systems.

Bag dump station screw feeder silo filling system

Mechanical Conveying Systems For Silo Loading

Mechanical conveyors can be used for silo loading from bag dump stations. Screw feeders, bucket elevators, rotary valves or chain conveyors are connected to bag dump stations to fill silos. Conveying equipment selection directly depends on conveying distance, height, transferred material and capacity. Bucket elevators are preferred for high silos. Screw feeders are preferred for shorter silos and short distances. Bag dump system can be installed on top of silo for faster filling. In this case rotary valve or butterfly valve are better choices which provide simple flow control. Dust collection systems may be needed depending on dust content of bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some amount of dust together. Having vacuum fan and jet filter, dust collectors prevent any dust emission to the environment. Collected dust is sent back to the silo and product loss is prevented.

Silo Loading With Pneumatic Conveying System

Pneumatic conveying systems installed after bag dump units transfer the bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, bag dump stations can be installed closed to warehouses and pneumatic conveying systems are used to fill silos from long distances. This design prevents extreme use of forklifts and cranes for bulk material transfer in production site and increases overall efficiency.

Bag slitting and discharge station pneumatic transportation and silo loading system

Bag discharge station mixer loading dosing weighing system

Bag Dumping and Mixer Filling

Mixer automation systems are used to mix dry bulk solids with respect to certain recipes. Raw materials that are delivered within bags can be transferred to mixing units by combination of conveying equipment and bag dump system. Depending on type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Bag dump stations can be manufactured with built in dosing system. Amount of raw material to be loaded into the mixer is controlled automatically by the help of weighing and dosing system. Dust collectors can be used to prevent dust emission during mixer filling.

Bag Dumping and Packaging System Feeding

Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks etc. Bulk materials that are delivered within bags are to be transferred to packaging machines without interruption. Loading hopper of packaging system should be kept full during filling and packaging. Bag opener systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Bag dumping system big bag filling packaging machine pneumatic conveying

Sack unloading systems batching weighing and dosing equipment

Bag Dumping, Dosing, Weighing and Batching Systems

Bag dumping systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. Loading hopper of weighing system should be kept full during dosing and batching. Bag dump systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Bag Dump and Bulk Truck Loading Systems

Bulk tanker trucks or open trucks are sometimes filled with powdered materials delivered within bags. These systems are generally composed of bag dump station, mechanical or pneumatic conveyor and loading bellow. Bag dump station transfers the bulk solid from sack to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity bag dump systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from bag opening station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bag dump and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.

Bag dump station bulk tanker truck loading bellow telescopic chute

Application Gallery

Bag dump station with rotary feeder and pneumatic conveying system

Bag dump stations with glove box and dust collector

Bag dumping stations for additive feeding to production line

Food grade stainless steel bag dump system

Bag discharge hoppers and dosing screws

Bag dumping system

Bag dump station with screw conveyor and weighing system

Bag Dump Station Models

Bag dump systems have wide variety of components for wide range of applications.

Bag Discharge Hopper

Bag discharge hoppers are used for bulk solids that have no dust content. They have simple bag placement table for easy slitting and unloading. There is no dust collector in these hoppers. Bulk material is discharged through lower outlet port to down stream equipment. Hoppers can be produced in any dimension with respect to application needs.

Manual Bag Dump Station

Bags are opened and unloaded one by one with man power. Bulk material in the bag is discharged manually into the hopper of bag opening unit. Dust content in the air is collected by built in dust collector and sent back into the hopper. Vacuum air is filtered and discharged to the atmosphere. Bulk material is discharged through the discharge port and sent to the next process equipment like conveyor, silo, mixer etc.

Semi Automatic Bag Dump and Emptying Station

Automatic bag cutting opening and discharging system

Automatic Bag Opening and Emptying System

Automatic bag opening and emptying systems are used for high capacity bag opening and unloading processes. In this system, pallets full of bags are placed into the system by forklift or crane. System automatically lifts the bags from the pallet by automatic grippers. Lifted bags are slit with rotating blades. And content is discharged into the loading hopper. Bulk material is then discharged through the discharge port of system automatically and sent to the down stream equipment. Waste bags are put into discharge cage by grippers. Any dust content within the system is collected by built in filter system. Vacuum air is filtered and discharged to the atmosphere.

Automatic bag slitting opening discharging system

Bag Dump Station Accessories

Dust Collection System

Dust collection system of bag dump station is needed for preventing dust emission during bag discharge. Dust emissions from bags are seen during cutting or untying of bags, product discharge and removal of empty sacks. Vacuum air supplied by dust collector, collects any dust in the region. A jet filter system with built in fan is used for this purpose. Collected dust is sent back to the bag emptying unit automatically and any product loss is prevented. Vacuum air is cleaned with reverse pulse jet system and discharged to outside.

Bag dumping station jet filter and fan units

Glove Box

Bag dump station is designed as completely enclosed system for advanced dust containment. System has an sealed bag loading door on one side. Operator puts the bags through this door. After closing the door, operator uses special gloves through the glove box to cut the bag. A sealed window is installed on front side of the unit. After the bag contents are discharged, the waste bag is discharged through discharge port. Built in dust collection system is to be used in this design to prevent any harmful dust emission to outside.

Bag dumping sack discharging system full containment dust free

Bag tipping station dust collector glove box

Vacuum Bag Lifting Unit, Bag Manupilator

The vacuum lifting equipment enables the operator to lift bags eliminating any health problems caused by heavy loads. The bags can be lifted, split, opened and contents emptied into the loading hopper in a safe way.with the help of bag manipulator.

Bag manipulator of bag dump station bag vacuum lift system

Vibrating Bin Activator

Bin activators are also know as vibrating bin dischargers. They generate a vibration below the bag opening station hopper to fluidize the bulk solid in the hopper, make it flow downwards and discharge easier.

Vibrating bin discharger of bag dump station

Air Jet

To fluidize the bulk solid within the hopper of bag tipping station, air jets are used. The fluidized material will flow easily and product discharging will be better. Air jets are placed near the discharge outlet flange of the hopper. Pressurized air is applied to air jets and makes the bulk solid flow better.

Weighing System

When the raw material amount in the bag dump station is to be monitored, weighing system can be used. Bag dump station consists of loadcells on main frame. Weight of the unit is continuously measured and user is informed. System can send signal to another PLC automation system or system can control other equipment connected to the sack opening station.

Bag Dump station with weighing batching and dosing equipment

Bag Handling Automation

Bag handling automation systems provide control of whole sack and bulk material handling operations. Vibration motor, dust collector, weighing system, conveying system etc. are connected to automation system. Depending on the complexity and configuration of bag dump station, different type of automation systems can be utilized. For simple bag dumping units a small sized manual controlled electrical panel is enough. PLC controlled automation panels are preferred for bag dump stations with many accessories installed on. These units can also take control of other material handling systems that are connected to bag dump station like screw feeders, pneumatic conveying systems, rotary valves etc. Daily, monthly, annual reporting functions are available as an option. PLC controlled systems have option for connecting to other Scada, PC and PLC systems in production plant for better handling and monitoring of complete production process.

Bag dump stations bulk material transfer batching and weighing automation systems

Lump Breaker

Bulk solids stored in sacks for long time tend to be compacted because of its own weight and possible moisture in the environment and form big sized lumps. During bag discharging, these lumps should be broken before entering to down stream equipment. Lump breakers are installed below bag dump systems to prevent any problems caused by big sized particles and lumps.

Screening System

To prevent any oversized particle entrance into the production line, screen is used. Screening systems are installed at the discharge point of bag dump unit. Depending on bulk material properties and acceptable particle sizes different types of screens can be used. Vibrating screens are one of the most common screen type used in bulk material handling.

Bag dumping unloading station screen sieve

Magnetic Separator

Foreign materials in bulk solids will lead to serious problems in production processes. Magnetic separators are used to detect metallic particles in bulk solids and separate them from main product stream. Metal detectors and separators can be installed at the outlet port of bag opening systems and prevent contaminations caused by metallic particles.

Bag Compactor

Bag compacting is an efficient way for disposal of empty bags. After unloading the bags, operator puts them into bag compactor inlet. Bag compactor unit has compacting screw that pushes the empty bags into compaction chamber and discharges them with minimum volume.

Food Applications

Food grade bag dump stations are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Filter bags, valves and other mechanisms are selected from food certified equipment.

Food grade stainless steel bag opener sack discharge tipping stations

Dangerous Materials and Environment

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of bag dump systems. Overheating, gas or dust leakage, static electricity and electrical spark generation should be prevented. Atex certified and ex-proof equipment are used in such working conditions.

Atex Ex-proof bag dump stations for hazardous powdered materials

Custom Designed Bag Dump Stations For Different Raw Materials

Design and construction material of bag dump stations can change with respect to handled bulk material and type of application. Stainless steel body made of either AISI 304 or AISI 316 is preferred for food materials, additives, PVC, Polypropylene, Polyethylene, PET, HDPE, LDPE, painting materials etc. High carbon steel and manganese alloys are preferred for abrasive materials such as arc furnace dust, perlite, quartz, silica sand, fly ash etc. Standard steel is used for general purpose applications such as cement, calcium carbonate, activated carbon handling.

Custom designed bag dump equipment and accessories

Machine Safety

Bag dump systems manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in sack handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Bag Dump Stations Bulk Solid Transfer Equipment

Bag dumping systems can be supplied with wide variety of equipment for further conveying of the discharged product depending on type of application.

Rotary Airlock Valves or Blowing Seals

Rotary valves provide controlled product flow from bag tipping station to the down stream system. Dry bulk materials can be fed into mixers, tanks or other mechanical conveyors through rotary airlocks. Blowing seals are used to feed pneumatic conveying systems and ensure sealing of pressurized air in the pipeline.

Rotary feeder airlock valve for bag dump and discharging system

Screw Feeders

Bulk solids in the bags can be transferred to other handling systems with the help of screw conveyors installed below the bag tipping unit. Screw conveyors can be used to transfer products to packaging machines, production lines, mixers or other similar equipment.

Bag tipping station screw feeder conveyor unit

Slidegate Valve

Slidegate valves can be installed below the discharge hopper of bag dumping station. Product flow speed can be controlled by adjustable valve blade. Manual handwheel or pneumatic piston can be used on slidegate valves depending on type of application.

Bag dump station slide gate powder discharging valve

Butterfly Valve

Butterfly valves placed on the bag dump system are simple valves used to open and close product flow in short time. Butterfly valves can be controlled by manual handle or pneumatic actuator.

Batching and Dosing System

Dosing systems feed processes with controlled amount of bulk materials. Depending application requirements, volumetric or gravimetric dosing systems can be installed on bag dumpers. PLC or computer controlled dosing systems are available.

Pneumatic Conveying System

Instead of mechanical conveyors, pneumatic conveying systems are preferred in processes where the bag dump stations are far from feeding points. Pneumatic conveying equipment and pipeline are connected to bag discharge systems. Powdered or granular bulk materials are transferred from bags to pneumatic conveying system and then conveyed to the required points. Depending on type of application, pressure conveying system or vacuum conveying system can be installed.

Dense Phase Pneumatic Conveying System

Bag dump stations with built in dense phase pneumatic conveying systems are used in applications where high conveying capacities and long distances are needed. Bag unloading hopper is installed above a pressurized tank also known as pressure vessel. Several bags are unloaded in one time to the pressurized tank. High pressure air is used to pressurize the tank and send the product through the conveying pipeline. Dense phase pneumatic conveying systems are generally preferred for materials like cement, calcium carbonate, PVC, soda and fly ash where high transfer capacities are needed.

Free Flow

Outlet of bag dump station is kept free of any equipment. Unloaded bulk solids move freely to down stream system.

Bulk sack dumping station powder and bulk solid discharging unit

Bag Dump Stations

Bag dump stations are designed for opening and unloading of small volume bags of bulk solids bags in effective and safe way. Different types of bulk materials can be handled, starting from free flowing granules to poorly flowing sticky fine powders.

Bag dumping systems are designed to meet wide range of application requirements. Type of bulk material, sack size, discharged medium, down stream equipment, discharge speed, environmental aspects, ergonomics and safety are all important factors that have effect on final design on bag dump unit.

Modular design of bag dump systems make them easy to be configured for each application need. While standard models have simple frame and discharge hoppers, high level models have complete solution in single main frame. Bag opening, discharging, product storage, dust collection, dosing and conveying can all be done in single unit.

Bag dump stations are also known as sack opening stations, bag unloaders, bag tip stations, sack tipping stations, bag unloaders, bag emptiers, sack emptiers etc.

Bag dump station pneumatic conveying and silo loading systems

Bag dumping equipment mixer feeding pneumatic conveying powder dosing system

Advantages

Safe and clean working environment
Dust free environment air
Simple handling of sacks
Applicable for different conveying and storage systems
Wide range of models for different applications
Easy to clean
Maintenance free design
Rigid, steel construction
Filter system for preventing dust.

Polimak’s Latest Innovation in Bulk Material Handling: The Robotic Bag Dump Station

Polimak continues to drive innovation in the dry bulk material handling industry with its latest advancement, the Robotic Bag Dump Station. Designed for sustainability, efficiency, and cost-effectiveness, this latest system automates bagged material unloading, significantly reducing manual labor, operational costs, and environmental impact while ensuring a dust-free workplace.

With advanced robotic technology and seamless integration into production lines, the Robotic Bag Dump Station enables precise, dust-free, and efficient material transfer, enhancing both productivity and workplace safety across various industries. Polimak remains committed to providing sustainable and efficient solutions that meet the evolving demands of bulk material handling.

Atex Certified Rotary Airlock Valve

Atex Certified Rotary Valves

Powdered bulk solids which have explosion risk, have to be handled with care. Temperature, static electricity, spark and ignition sources are to be isolated from these bulk solids. Atex approved rotary valves are used in such applications where the dust explosion risk exist. Polimak Atex series rotary valves are certified with 10 bar explosion tests. All components of rotary valves comply with Atex regulations and provide ex-proof characteristics. Ex-proof electrical motors, Atex certified sensors, low friction bearings are used in these rotary airlock valves to ensure process and environment safety.

Rotary feeder atex certified explosion ex-proof valve

Coal powder, sugar powder, raw materials of paint and similar bulk materials are flammable and explosive in certain conditions. Ex-proof and Atex certified equipment are to be used to prevent dust explosion risks. Polimak rotary airlock valves are designed to conform explosion isolation regulations.

Big Bag Emptying System Technical Documents

Technical documents, product catalogs, user manuals of big bag emptying systems

Links

Big Bag Emptying Systems

Big bag emptying systems provide dust free and easy emptying of big bulk bags. The contents of big bags are easily transferred to silos, mixers, and conveyors etc. Pneumatic conveying systems, screw feeders or similar conveying equipments can be used to transfer bulk solids to required destination.

Big Bag Emptying Applications

Big bag emptying applications; silo filling, mixer loading, production line feeding, bulk truck loading, packaging systems, weighing, batching and dosing systems..

Big Bag Emptying System Models

Wide range of big bag emptying stations are available with respect to different applications. Big bag emptiers can be configured according to bulk solid types (powdered, granular, abrasive, food etc) application types (silo filling, mechanical conveying, pneumatic transfer, mixer feeding etc.)

Big Bag emptying station outlet components

Big Bag Emptying System Bulk Solid Transfer Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials from big bag emptying station outlet to required destination. Mechanical or pneumatic conveyors can be used according to application needs.

Big Bag Emptying System Accessories

Big bag emptying systems can be provided with wide range of optional components and accessories for different application needs.

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of big bag emptying systems an

Big Bag Emptying System Accessories

Big Bag Hanging Unit With Spring and Damper

Big bag hanging units are used on upper frames to hold bigbags brought by overhead cranes and forklifts. A lifting cross is put over the big bag. Big bag handles or straps are fixed to the hooks of lifting cross. It is then lifted together with bigbag by crane or forklift and placed on top frame hanging unit. Spring and damper mechanism applies upwards force to lifting cross. When raw material begins unloading, this mechanism moves big bag upwards and aids product discharge. The strength of springs and dampers can be adjusted with respect to weight or bulk density of raw material. Side massaging pistons and big bag vibration motor can also be utilized to increase big bag unloading speed.

Side Pistons

Pneumatic pistons placed on side frames of big bag unloaders are available as an option to aid emptying of bigbags. These pneumatically actuated massage cylinders apply side forces to the big bag. Massaging system is especially effective when the storage in bigbag cause problems with compressed bulk materials and where vibration aids can cause further compression and prevent uniform discharge. Piston stroke lengths, motion speeds and intervals can be adjusted by built in control panel of big bag emptying station.

Bulk bag emptying system side compression pistons

Pneumatic Big Bag Massaging System

The big bag platform is composed of two independent surfaces connected to pneumatic pistons. These two surfaces apply force and compacting effect from lower two sides to the big bag which aids the product move to the outlet spout of big bag.

Bulk bag emptying station big bag massaging powder fluidizing system

Built In Storage Silo

Storage silos can be installed below the big bag emptying platform. Unloaded material is directly transferred to silo and stored for later use. In this configuration there is no need for additional storage silo and conveying equipment connected to big bag emptying system. Additionaly big bags can be completely emptied and removed in one time. Different silo capacities are available depending on raw material consumption. There exist level sensors on the silo to monitor the product level in the silo. And alarm signal is generated in case of low product levels. Flow aids as air jets or vibrating bin activators are provided as an option for silos. Dust collection systems are connected to big bag emptying stations and storage silos for bulk products with high dust content.

Big bag emptying station built in bulk material storage silo

Dust Collection System

Dust collection system of big bag emptying station is needed for preventing dust emission during big bag unloading. Dust emissions from big bags are seen during cutting or untying of bag spouts, product discharge and removal of empty big bags. Vacuum air supplied by dust collector, collects any dust in the region. A jet filter system with built in fan is used for this purpose. Collected dust is sent back to the big bag emptying unit automatically and any product loss is prevented. Vacuum air is cleaned with reverse pulse jet system and discharged to outside.

Big Bag Weighing System

When the raw material amount in the big bag is to be monitored, big bag weighing system can be used. Big bag emptying station consists of loadcells on main frame. Weight of the big bag is continuously measured and user is informed. System can send signal to another PLC automation system or system can control other equipment connected to the big bag unloader unit.

Iris Valve

Product discharge from the big bag can be controlled by iris valve. Big bag discharge spout passes through the iris valve. A pneumatic piston or manual handle controls the iris valve. Product discharge spout can not only be kept completely open or closed but also it can be adjusted in any level. Big bag emptying speed can be adjusted with this mechanism.

Big Bag Cutting Knives

FIBC emptying system Big bag cutting blades

Big Bag Automation

Big bag automation systems provide control of whole big bag and bulk material handling operations. Vibration motor, iris valve, massaging system, hoist, dust collector, big bag weighing system, conveying system etc. are connected to automation system. Depending on the complexity and configuration of big bag emptying station, different type of automation systems can be utilized. For simple big bag emptying units a small sized manual controlled electrical panel is enough. PLC controlled automation panels are preferred for big bag emptying stations with many accessories installed on. These units can also take control of other material handling systems that are connected to bulk bag emptying station like screw feeders, pneumatic conveying systems, rotary valves etc. Daily, monthly, annual reporting functions are available as an option. PLC controlled systems have option for connecting to other Scada, PC and PLC systems in production plant for better handling and monitoring of complete production process.

Big Bag emptying system automation PLC scada control

Built in Sack Discharger

Time to time raw material is delivered in small bags or sacks instead of Bulk bags. Or small amount of additives are to be fed into the system. Sack tipping unit is installed on big bag discharge hopper. Operator can discharge small bags through this opening to the same place.

Sack discharge and big bag emptying system

Lump Breaker

Bulk solids stored in FIBC bags for long time tend to be compacted because of its own weight and possible moisture in the environment and form big sized lumps. During bulk bag unloading, these lumps should be broken before entering to down stream equipment. Lump breakers are installed below big bag emptying systems to prevent any problems caused by big sized particles and lumps.

Screening System

To prevent any oversized particle entrance into the production line, screens are used. Screening systems are installed at the discharge point of big bag emptying unit. Depending on bulk material properties and acceptable particle sizes, different types of screens can be used. Vibrating screens are one of the most common screen type used in bulk material handling.

Big bag emptying powder screen powder sieve

Magnetic Separator

Foreign materials in bulk solids will lead to serious problems in production processes. Magnetic separators are used to detect metallic particles in bulk solids and separate them from main product stream. Metal detectors and separators can be installed at the outlet port of big bag emptying systems and prevent contaminations caused by metallic particles.

Food Applications

Food grade big bag emptying systems are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Filter bags, valves and other mechanisms are selected from food certified equipment.

Powdered food grade big bag emptying station stainless steel

Dangerous Materials and Environment

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of big bag emptying systems. Overheating, gas or dust leakage, static electricity and electrical spark generation should be prevented. Atex certified and ex-proof equipment are used in such working conditions.

Bulk Bag emptying system Atex certified Ex-proof dust explosion proof

Custom Designed Big Bag Unloading Systems For Different Raw Materials

Design and construction material of big bag emptying stations can change with respect to handled bulk material and type of application. Stainless steel body made of either AISI 304 or AISI 316 is preferred for food materials, additives, PVC, Polypropylene, Polyethylene, PET, HDPE, LDPE, painting materials etc. High carbon steel and manganese alloys are preferred for abrasive materials such as arc furnace dust, perlite, quartz, silica sand, fly ash etc.Standard steel is used for general purpose applications such as cement, calcium carbonate, activated carbon handling.

Jumbo bag emptying station custom designed big bags

Machine Safety

Big bag emptying systems manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in big bag handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Big bag emptying equipment machinery safety regulations

Big Bag Emptying System Bulk Solid Transfer Equipment

Big bag emptying systems can be supplied with wide variety of equipment for further conveying of the discharged product depending on type of application.

Rotary Airlock Valves or Blowing Seals

Rotary valves provide controlled product flow from bulk bag emptying station to the down stream system. Dry bulk materials can be fed into mixers, tanks or other mechanical conveyors through rotary airlocks. Blowing seals are used to feed pneumatic conveying systems and ensure sealing of pressurized air in the pipeline.

Big bag emptying station rotary valve blowing seals

Blowing Seals Rotary Valve for Big bag emptying station

Screw Feeders

Bulk solids in the big bags can be transferred to other handling systems with the help of screw conveyors installed below the big bag emptying unit. Screw conveyors can be used to transfer products to packaging machines, production lines, mixers or other similar equipment.

Big bag emptying station screw feeder conveyor

Slidegate Valve

Slidegate valves can be installed below the discharge hopper of bulk bag emptying station. Product flow speed can be controlled by adjustable valve blade. Manual handwheel or pneumatic piston can be used on slidegate valves depending on type of application.

Butterfly Valve

Butterfly valves placed on the big bag emptying system are simple valves used to open and close product flow in short time. Butterfly valves can be controlled by manual handle or pneumatic actuator.

Batching and Dosing System

Dosing systems feed processes with controlled amount of bulk materials. Depending application requirements, volumetric or gravimetric dosing systems can be installed on bulk bag unloaders. PLC or computer controlled dosing systems are available.

Weighing batching dosing unit big bag emptying equipment

Pneumatic Conveying System

Instead of mechanical conveyors, pneumatic conveying systems are preferred in processes where the bulk bag emptying stations are far from feeding points. Pneumatic conveying equipment and pipeline are connected to bulk bag emptying systems. Powdered or granular bulk materials are transferred from bigbags to pneumatic conveying system and then conveyed to the required points. Depending on type of application, pressure conveying system or vacuum conveying system can be installed.

Dense Phase Pneumatic Conveying System

Big bag emptying stations with built in dense phase pneumatic conveying systems are used in applications where high conveying capacities and long distances are needed. Big bag emptying hopper is installed above a pressurized tank also known as pressure vessel. Several big bags are unloaded in one time to the pressurized tank. High pressure air is used to pressurize the tank and send the product through the conveying pipeline. Dense phase pneumatic conveying systems are generally preferred for materials like cement, calcium carbonate, PVC, soda and fly ash where high transfer capacities are needed.

Dense phase pneumatic conveying and big bag emptying system for silo loading

Free Flow

Outlet of big bag emptying station is kept free of any equipment. Unloaded bulk solids move freely to down stream system.

Big Bag Emptying System Models

Big bag emptying systems have wide variety of components for wide range of applications.

Upper Frame Models of Big Bag Emptying System

Open Top Big Bag Emptying Station

If big bags are delivered with forklift or overhead crane, big bag emptying system can be used without upper frame. Big bag is placed on discharge hopper by overhead crane or forklift. Easy flowing dry bulk solids can be discharged with this configuration. Bulk products can flow through big bag bottom discharge spout and loaded into hopper. Pneumatic pistons placed on side frames are available as an option to aid emptying of bigbag. These pneumatically actuated massage cylinders apply side forces to the big bag. Massaging system is especially effective when the storage in big bag cause problems with compacted, compressed materials and where vibration aids can cause further compression and prevent uniform discharge.

Big Bag Emptying Station Upper Frame With Big Bag Hanging Unit

Big bag hanging units are used on upper frames to hold bigbags brought by overhead cranes and forklifts. A lifting cross is put over the big bag. Big bag straps or handles are fixed to the hooks of lifting cross. It is then lifted together with bigbag by crane or forklift and placed on top frame hanging unit. An optional spring and damper mechanism applies upwards force to lifting cross. When raw material begins discharging, this mechanism moves big bag upwards and aids product discharge. Side massaging pistons and big bag vibration motor can also be utilized to increase big bag unloading speed.

Big bag hanging unit for bulk bag emptying station

Big Bag Emptying Station With Hoist

An electrical hoist exists on top of upper frame. Monorail hoist moves horizontally on I-Beam shaped trackway installed on upper frame. Big bags placed in front of the big bag discharge station are lifted by hoist and placed on the big bag platform. During powder discharge from the big bag, hoist holds the big bag and aids emptying. Side massaging pistons and big bag vibration motor can also be utilized to increase big bag emptying speed.

Big bag lifting hoist for FIBC bag emptying station

Big Bag Holding Platform Models

Big Bag Holding Platform with Hopper and Side Access Door

Holding platform consists of a rectangular table with circular inlet covered by rubber seal and conical hopper on the bottom. Rubber seal prevents any dust leakage from bottom of big bag during emptying and maintains air flow to the dust collection unit. Bottom hopper has a side access door to enable operator an easy access to big bag discharging spout. Operator can untie the spout or cut the bottom by knife and closes the side access door of the hopper. Dust collector vacuums any dust in the area during these tasks and ensures a clean working environment. Vibration motor installed on hopper aids emptying of big bags. Optional cutting blades can be installed in the middle of rubber seal. When big bag is placed on the platform, these blades cut the big bag instantly and provides faster flow. This platform design is suitable for higher capacity big bag handling operations.

Side access door of big bag emptying system hopper

Stainless steel big bag emptying station hopper

Big Bag Holding Platform With Dust Tight Docking Station

Docking station provides a dust tight seal with big bag discharge spout. This design eliminates any dust emission and contamination during big bag emptying process. A manual or pneumatically controlled clamping mechanism is used to clamp and seal big bag discharge spout. It moves in vertical direction and it is adjustable for different big bag sizes. After the big bag inner liner or bottom spout is clamped, operator unties big bag and product flow begins. Dust collection system prevents any dust emission in working zone. An optional iris valve can be used to control material flow through the discharge spout. Iris valve is installed between the big bag holding platform and docking station. Big bag discharge spout passes through the iris valve. A pneumatic piston or manual handle controls the iris valve. Big bag emptying speed can be adjusted with this mechanism.

FIBC emptying system dust tight docking station and iris valve for big bag outlet

Big bag emptying system docking system bag clamping mechanism

Big Bag Emptying Applications

Big Bag Emptying and Silo Loading

Silo loading systems connected to big bag emptying stations are used for unloading raw materials from FIBC bags and fill them to storage silos. Silo loading can be done by mechanical conveyors or pneumatic conveying systems.

Silo Loading With Pneumatic Conveying System

Pneumatic conveying systems installed after bulk bag emptying units transfer the bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, big bag emptying stations can be installed closed to warehouses and pneumatic conveying systems are used to fill silos from long distances. This design prevents extreme use of forklifts and cranes for bulk material transfer in production site and increases overall efficiency.

Big bag emptying station with pneumatic conveying system for silo filling

Bulk bag emptying system with screw feeder and bucket elevator for silo loading

Mechanical Conveying Systems For Silo Loading

Mechanical conveyors can be used for silo loading from big bag emptying stations. Screw feeders, bucket elevators, rotary valves or chain conveyors are connected to bulk bag emptying stations to fill silos. Conveying equipment selection directly depends on conveying distance, height, transferred material and capacity. Bucket elevators are preferred for high silos. Screw feeders are preferred for shorter silos and short distances. Big bag emptying system can be installed on top of silo for faster filling. In this case rotary valve or butterfly valve are better choices which provide simple flow control. Dust collection systems may be needed depending on dust content of bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some amount of dust together. Having vacuum fan and jet filter, dust collectors prevent any dust emission to the environment. Collected dust is sent back to the silo and product loss is prevented.

Big Bag Emptying and Bag Filling Systems

Bulk material stored in big bags can be filled into small bags automatically. Big bag emptying systems have optional built in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper and provide practical and cost effective solution. Big bag unloading and bag filling operations can be handled on single compact system. For higher bag filling needs, bag filling machines are installed near bulk bag emptying stations. Pneumatic conveying systems or mechanical conveyors are used to transfer bulk material from FIBC bag emptying station to bag or sack filling system.

Big bag dumping station with sack filling system

Bulk bag emptying and mixer feeding system with pneumatic conveying

Big Bag Emptying and Mixer Filling

Mixer automation systems are used to mix dry bulk solids with respect to certain recipes. Raw materials that are delivered within FIBC bags can be transferred to mixing units by combination of conveying equipment and bulk bag emptying system. Depending on type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag emptying stations can be manufactured with built in dosing system. Amount of raw material to be loaded into the mixer is controlled automatically by the help of weighing and dosing system. Dust collectors can be used to prevent dust emission during mixer filling.

Big Bag Emptying and Packaging System Feeding

Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks etc. Bulk materials that are delivered within big bags are to be transferred to packaging machines without interruption. Loading hopper of packaging system should be kept full during filling and packaging. Big bag emptying systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Bulk bag emptying sack filling big bag filling and weighing systems

Big bag emptying batching weighing dosing and mixer loading systems

Big Bag Emptying, Dosing, Weighing and Batching Systems

Big bag emptying systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. Loading hopper of weighing system should be kept full during dosing and batching. Big bag emptying systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be used to prevent dust emmission during hopper loading for materials with high dust content.

Big Bag Emptying and Bulk Truck Loading Systems

Bulk tanker trucks or open trucks are sometimes filled with powdered materials delivered within FIBC bags. These systems are generally composed of bulk bag emptying station, mechanical or pneumatic conveyor and loading bellow. Big bag emptying station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.

Big bag emptying bulk truck loading system

Application Gallery

Big Bag Emptying and Powder Transfer System

Big Bag Emptying,, Storage Silo, Weighing and Dosing System

Big Bag Emptying Station with Dosing Unit

Big bag emptying system tanker loading bellow truck filling

Tank Filling With Big Bag Emptying Units

Raw Material Filling to Mixer With Big Bag Emptiers

Big Bag Emptying, Batching and Dosing Stations

Big Bag Emptying Unloading and Pneumatic Conveying System

Bulk Bag Emptying Station With Pneumatic Conveyor

FIBC Emptying, Storage Silo, Dosing and Conveying System

Big Bag Emptying and Mixer Feeding System

Food Grade Stainless Steel Big Bag Emptying Station

Double Component Mixing By Big Bag Emptying Stations

Big Bag Emptying Systems

Big bag emptying unit FBIC discharging station bulk material unloading

Volume of raw material handling operations is increased remarkably in last few decades in wide range of industries. Dry bulk solids are transferred and delivered with different ways. FIBC (Flexible Intermediate Bulk Container) also know as big bags are one of the the most preferred way of handling bulk materials in granular and powder form. Well designed big bag handling systems are needed to be able to fully benefit from big bags.

Big Bag Discharge cyclone filling system

Big bag discharge station weighing system

Big bag Emptying systems Chemical powders=

Big bag emptying stations are designed for unloading of bulk bags in effective and safe way. Different types of bulk materials can be handled, starting from free flowing granules to poorly flowing sticky fine powders.

Big Bag Emptying Systems Big Bag Emptying Stations

Bulk bag emptying systems are designed to meet wide range of application requirements. Type of bulk material, big bag size, discharged medium, down stream equipment, discharge speed, environmental aspects, ergonomics and safety are all important factors that have effect on final design on big bag unloader unit.

Big bag emptying stations pneumatic conveying batching dosing mixer loading

Modular design of big bag emptying systems make them easy to be configured for each application need. While standard models have simple frame and discharge hoppers, high level models have complete solution in single main frame. Big bag emptying, product storage, dust collection, dosing and conveying can all be done in single unit.

Big bag emptying stations are also known as big bag unloaders, bulk bag discharge systems, FIBC dischargers, FIBC unloaders, FIBC emptiers, super sack dischargers, container bag unloaders, container bag dischargers, super sack unloaders and super sack emptiers.

Advantages

Safe and clean working environment
Dust free environment air
Simple handling of bigbags
Applicable for different conveying and storage systems
Wide range of models for different applications
Easy to clean
Maintenance free design
Rigid, steel construction
Filter system for preventing dust.

Big Bag Emptying Systems Bulk Bag Emptying Stations

Bulk bag emptying system screw conveyor mixer filling

Bigbag bulk bag emptying unloading system for mixer filling with dosing screw conveyor

Bulk Food FIBC bag discharge systems stainless steel Bigbag unloader

Big bag bulk powder dust collector big bag discharger safety environment

Big Bag Unloading System Technical Documents

Technical catalogs and manuals of big bag unloading systems

Links

Big Bag Unloading Systems

Big bag unloading systems provide dust free and easy emptying of big bulk bags. The contents of big bags are easily transferred to silos, mixers, and conveyors etc. Pneumatic conveying systems, screw feeders or similar conveying equipments can be used to transfer bulk solids to required destination.

Big Bag Unloading Applications

Big bag unloading applications; silo filling, mixer loading, production line feeding, bulk truck loading, packaging systems, weighing, batching and dosing systems..

Big Bag Unloading System Models

Wide range of big bag unloading stations are available with respect to different applications. Big bag unloaders can be configured according to bulk solid types (powdered, granular, abrasive, food etc) application types (silo filling, mechanical conveying, pneumatic transfer, mixer feeding etc.)

Big Bag discharge station outlet components

Big Bag Unloading System Bulk Solid Transfer Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials from big bag unloader outlet to required destination. Mechanical or pneumatic conveyors can be used according to application needs.

Big Bag Discharge system accessories components

Big Bag Unloading System Accessories

Big bag unloading systems can be provided with wide range of optional components and accessories for different application needs.

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of big bag unloading systems an

Big Bag Unloading System Accessories

Big Bag Hanging Unit With Spring and Damper

Side Pistons

Pneumatic pistons placed on side frames of big bag unloaders are available as an option to aid unloading of bigbags. These pneumatically actuated massage cylinders apply side forces to the big bag. Massaging system is especially effective when the storage in bigbag cause problems with compressed bulk materials and where vibration aids can cause further compression and prevent uniform discharge. Piston stroke lengths, motion speeds and intervals can be adjusted by built in control panel of big bag unloading station.

Bulk bag unloading system side compression pistons

Pneumatic Big Bag Massaging System

Bulk bag unloading station big bag massaging powder fluidizing system

Built In Storage Silo

Storage silos can be installed below the big bag unloading platform. Unloaded material is directly transferred to silo and stored for later use. In this configuration there is no need for additional storage silo and conveying equipment connected to big bag unloading system. Additionally big bags can be completely emptied and removed in one time. Different silo capacities are available depending on raw material consumption. There exist level sensors on the silo to monitor the product level in the silo. And alarm signal is generated in case of low product levels. Flow aids as air jets or vibrating bin activators are provided as an option for silos. Dust collection systems are connected to big bag unloading stations and storage silos for bulk products with high dust content.

Big bag unloading station built in bulk material storage silo

Dust Collection System

Dust collection system of big bag unloading station is needed for preventing dust emission during big bag unloading. Dust emissions from big bags are seen during cutting or untying of bag spouts, product discharge and removal of empty big bags. Vacuum air supplied by dust collector, collects any dust in the region. A jet filter system with built in fan is used for this purpose. Collected dust is sent back to the big bag unloading unit automatically and any product loss is prevented. Vacuum air is cleaned with reverse pulse jet system and discharged to outside.

Big Bag Weighing System

When the raw material amount in the big bag is to be monitored, big bag weighing system can be used. Big bag unloading station consists of loadcells on main frame. Weight of the big bag is continuously measured and user is informed. System can send signal to another PLC automation system or system can control other equipment connected to the big bag unloader unit.

Iris Valve

Product discharge from the big bag can be controlled by iris valve. Big bag discharge spout passes through the iris valve. A pneumatic piston or manual handle controls the iris valve. Product discharge spout can not only be kept completely open or closed but also it can be adjusted in any level. Big bag unloading speed can be adjusted with this mechanism.

Big Bag Cutting Knives

Optional cutting blades can be installed in the middle of big bag platform rubber seal. When big bag is placed on the platform, these blades cut the big bag instantly and provides faster product flow. Bulk bag cutting equipment is generally preferred in applications where high transfer rates are needed.

FIBC unloading system Big bag cutting blades

Big Bag Automation

Big bag automation systems provide control of whole big bag and bulk material handling operations. Vibration motor, iris valve, massaging system, hoist, dust collector, big bag weighing system, conveying system etc. are connected to automation system. Depending on the complexity and configuration of big bag unloading station, different type of automation systems can be utilized. For simple big bag unloading units a small sized manual controlled electrical panel is enough. PLC controlled automation panels are preferred for big bag unloading stations with many accessories installed on. These units can also take control of other material handling systems that are connected to bulk bag unloading station like screw feeders, pneumatic conveying systems, rotary valves etc. Daily, monthly, annual reporting functions are available as an option. PLC controlled systems have option for connecting to other Scada, PC and PLC systems in production plant for better handling and monitoring of complete production process.

Big Bag unloading system automation PLC scada control

Built in Sack Discharger

Sack discharge and big bag unloading system

Lump Breaker

Bulk solids stored in FIBC bags for long time tend to be compacted because of its own weight and possible moisture in the environment and form big sized lumps. During bulk bag unloading, these lumps should be broken before entering to down stream equipment. Lump breakers are installed below big bag unloading systems to prevent any problems caused by big sized particles and lumps.

Screening System

To prevent any oversized particle entrance into the production line, screen is used. Screening systems are installed at the discharge point of big bag unloading unit. Depending on bulk material properties and acceptable particle sizes different types of screens can be used. Vibrating screens are one of the most common screen type used in bulk material handling.

Big bag unloading powder screen powder sieve

Magnetic Separator

Foreign materials in bulk solids will lead to serious problems in production processes. Magnetic separators are used to detect metallic particles in bulk solids and separate them from main product stream. Metal detectors and separators can be installed at the outlet port of big bag unloading systems and prevent contaminations caused by metallic particles.

Food Applications

Food grade big bag unloaders are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Filter bags, valves and other mechanisms are selected from food certified equipment.

Powdered food grade big bag unloader stainless steel

Dangerous Materials and Environment

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of big bag unloading systems. Overheating, gas or dust leakage, static electricity and electrical spark generation should be prevented. Atex certified and ex-proof equipment are used in such working conditions.

Bulk Bag unloading station Atex certified Ex-proof dust explosion proof

Custom Designed Big Bag Unloading Systems For Different Raw Materials

Design and construction material of big bag unloading stations can change with respect to handled bulk material and type of application. Stainless steel body made of either AISI 304 or AISI 316 is preferred for food materials, additives, PVC, Polypropylene, Polyethylene, PET, HDPE, LDPE, painting materials etc. High carbon steel and manganese alloys are preferred for abrasive materials such as arc furnace dust, perlite, quartz, silica sand, fly ash etc. Standard steel is used for general purpose applications such as cement, calcium carbonate, activated carbon handling.

Jumbo bag unloading station custom designed big bags

Machine Safety

Big bag unloading systems manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in big bag handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Big bag unloading equipment machinery safety regulations

Big Bag Unloading System Bulk Solid Transfer Equipment

Big bag unloading systems can be supplied with wide variety of equipment for further conveying of the unloaded product depending on type of application.

Rotary Airlock Valves or Blowing Seals

Rotary valves provide controlled product flow from bulk bag unloading station to the down stream system. Dry bulk materials can be fed into mixers, tanks or other mechanical conveyors through rotary airlocks. Blowing seals are used to feed pneumatic conveying systems and ensure sealing of pressurized air in the pipeline.

Big bag unloading station rotary valve blowing seals

Blowing Seals Rotary Valve for Big bag unloading station

Screw Feeders

Bulk solids in the big bags can be transferred to other handling systems with the help of screw conveyors installed below the big bag unloading unit. Screw conveyors can be used to transfer products to packaging machines, production lines, mixers or other similar equipment.

Big bag unloading station screw feeder conveyor

Slidegate Valve

Slidegate valves can be installed below the discharge hopper of bulk bag unloading station. Product flow speed can be controlled by adjustable valve blade. Manual handwheel or pneumatic piston can be used on slidegate valves depending on type of application.

Butterfly Valve

Butterfly valves placed on the big bag unloading system are simple valves used to open and close product flow in short time. Butterfly valves can be controlled by manual handle or pneumatic actuator.

Batching and Dosing System

Weighing batching dosing unit big bag unloading equipment

Pneumatic Conveying System

Instead of mechanical conveyors, pneumatic conveying systems are preferred in processes where the bulk bag unloading stations are far from feeding points. Pneumatic conveying equipment and pipeline are connected to bulk bag unloading systems. Powdered or granular bulk materials are transferred from bigbags to pneumatic conveying system and then conveyed to the required points. Depending on type of application, pressure conveying system or vacuum conveying system can be installed.

Dense Phase Pneumatic Conveying System

Big bag unloading stations with built in dense phase pneumatic conveying systems are used in applications where high conveying capacities and long distances are needed. Big bag unloading hopper is installed above a pressurized tank also known as pressure vessel. Several big bags are unloaded in one time to the pressurized tank. High pressure air is used to pressurize the tank and send the product through the conveying pipeline. Dense phase pneumatic conveying systems are generally preferred for materials like cement, calcium carbonate, PVC, soda and fly ash where high transfer capacities are needed.

Dense phase pneumatic conveying and big bag unloading system for silo loading

Free Flow

Outlet of big bag unloading station is kept free of any equipment. Unloaded bulk solids move freely to down stream system.

Big Bag Unloading System Models

Big bag unloading systems have wide variety of components for wide range of applications.

Upper Frame Models of Big Bag Unloading System

Open Top Big Bag Unloading Station

If big bags are delivered with forklift or overhead crane, big bag unloading system can be used without upper frame. Big bag is placed on discharge hopper by overhead crane or forklift. Easy flowing dry bulk solids can be discharged with this configuration. Bulk products can flow through big bag bottom discharge spout and loaded into hopper. Pneumatic pistons placed on side frames are available as an option to aid emptying of bigbag. These pneumatically actuated massage cylinders apply side forces to the big bag. Massaging system is especially effective when the storage in big bag cause problems with compacted, compressed materials and where vibration aids can cause further compression and prevent uniform discharge.

Big Bag Unloader Upper Frame With Big Bag Hanging Unit

Big bag hanging units are used on upper frames to hold bigbags brought by overhead cranes and forklifts. A lifting cross is put over the big bag. Big bag straps or handles are fixed to the hooks of lifting cross. It is then lifted together with bigbag by crane or forklift and placed on top frame hanging unit. An optional spring and damper mechanism applies upwards force to lifting cross. When raw material begins unloading, this mechanism moves big bag upwards and aids product discharge. Side massaging pistons and big bag vibration motor can also be utilized to increase big bag unloading speed.

Big Bag Unloading Station With Hoist

Big bag lifting hoist for FIBC bag unloading station

Big Bag Holding Platform Models

Big Bag Holding Platform with Hopper and Side Access Door

Holding platform consists of a rectangular table with circular inlet covered by rubber seal and conical hopper on the bottom. Rubber seal prevents any dust leakage from bottom of big bag during unloading and maintains air flow to the dust collection unit. Bottom hopper has a side access door to enable operator an easy access to big bag discharging spout. Operator can untie the spout or cut the bottom by knife and closes the side access door of the hopper. Dust collector vacuums any dust in the area during these tasks and ensures a clean working environment. Vibration motor installed on hopper aids unloading of big bags. Optional cutting blades can be installed in the middle of rubber seal. When big bag is placed on the platform, these blades cut the big bag instantly and provides faster flow. This platform design is suitable for higher capacity big bag handling operations.

Big bag unloading station side access door of big bag hopper

Stainless steel big bag unloading station hopper

Big Bag Holding Platform With Dust Tight Docking Station

Docking station provides a dust tight seal with big bag discharge spout. This design eliminates any dust emission and contamination during big bag unloading process. A manual or pneumatically controlled clamping mechanism is used to clamp and seal big bag discharge spout. It moves in vertical direction and it is adjustable for different big bag sizes. After the big bag inner liner or bottom spout is clamped, operator unties big bag and product flow begins. Dust collection system prevents any dust emission in working zone. An optional iris valve can be used to control material flow through the discharge spout. Iris valve is installed between the big bag holding platform and docking station. Big bag discharge spout passes through the iris valve. A pneumatic piston or manual handle controls the iris valve. Big bag unloading speed can be adjusted with this mechanism.

FIBC unloading system dust tight docking station and iris valve for big bag outlet

Big bag discharge system dust tight docking station

Big bag unloading system docking system bag clamping mechanism

Big Bag Unloading Applications

Big Bag Unloading and Silo Loading

Silo loading systems connected to big bag unloading stations are used for unloading raw materials from FIBC bags and fill them to storage silos. Silo loading can be done by mechanical conveyors or pneumatic conveying systems.

Silo Loading With Pneumatic Conveying System

Pneumatic conveying systems installed after bulk bag unloading units transfer the bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, big bag unloading stations can be installed closed to warehouses and pneumatic conveying systems are used to fill silos from long distances. This design prevents extreme use of forklifts and cranes for bulk material transfer in production site and increases overall efficiency.

Big bag unloading station with pneumatic conveying system for silo filling

Big bag unloading screw feeder bucket elevator silo filling

Mechanical Conveying Systems For Silo Loading

Mechanical conveyors can be used for silo loading from big bag unloading stations. Screw feeders, bucket elevators, rotary valves or chain conveyors are connected to big bag unloading stations to fill silos. Conveying equipment selection directly depends on conveying distance, height, transferred material and capacity. Bucket elevators are preferred for high silos. Screw feeders are preferred for shorter silos and short distances. Big bag unloading system can be installed on top of silo for faster filling. In this case rotary valve or butterfly valve are better choices which provide simple flow control. Dust collection systems may be needed depending on dust content of bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some amount of dust together. Having vacuum fan and jet filter, dust collectors prevent any dust emission to the environment. Collected dust is sent back to the silo and product loss is prevented.

Big Bag Unloading and Bag Filling Systems

Bulk material stored in big bags can be filled into small bags automatically. Big bag unloading systems have optional built in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper and provide practical and cost effective solution. Big bag unloading and bag filling operations can be handled on single compact system.For higher bag filling needs, bag filling machines are installed near bulk bag unloading stations. Pneumatic conveying systems or mechanical conveyors are used to transfer bulk material from FIBC bag unloading station to bag or sack filling system.

Big bag unloading station with sack filling system

Bulk bag unloading and mixer feeding system with pneumatic conveying

Big Bag Unloading and Mixer Filling

Mixer automation systems are used to mix dry bulk solids with respect to certain recipes. Raw materials that are delivered within FIBC bags can be transferred to mixing units by combination of conveying equipment and bulk bag unloading system. Depending on type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag unloading stations can be manufactured with built in dosing system. Amount of raw material to be loaded into the mixer is controlled automatically by the help of weighing and dosing system. Dust collectors can be used to prevent dust emission during mixer filling.

Big Bag Unloading and Packaging System Feeding

Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks etc. Bulk materials that are delivered within big bags are to be transferred to packaging machines without interruption. Loading hopper of packaging system should be kept full during filling and packaging. Big bag unloading systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Bulk bag unloading sack filling big bag filling and weighing systems

Big bag unloading batching weighing dosing and mixer loading systems

Big Bag Unloading, Dosing, Weighing and Batching Systems

Big bag unloading systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. Loading hopper of weighing system should be kept full during dosing and batching. Big bag unloading systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Big Bag Unloading and Bulk Truck Loading Systems

Bulk tanker trucks or open trucks are sometimes filled with powdered materials delivered within FIBC bags. These systems are generally composed of bulk bag unloading station, mechanical or pneumatic conveyor and loading bellow. Big bag unloading station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.

Big bag unloading bulk truck loading system

Application Gallery

Big Bag Unloading and Powder Transfer System

Big Bag Unloader, Storage Silo, Weighing and Dosing System

Big Bag Unloading Station with Dosing Unit

Big bag unloading system bulk tanker truck filling

Reactor tank loading from bulk bags by FIBC unloader

Tank Filling With Big Bag Unloading Units

Weighing dosing to mixer by bulk bag unloading units

Raw Material Filling to Mixer With Big Bag Unloaders

Jumbo bag unloading weighing dosing systems

Big Bag Unloading, Batching and Dosing Stations

Pneumatic transfer systems big bag unloaders powder transfer

Big Bag Unloading and Pneumatic Conveying System

Big bag unloading system pneumatic transfer equipment

Bulk Bag Unloading Station With Pneumatic Conveyor

FIBC bulk solid unloading weighing batching dosing conveyor

FIBC Unloader, Storage Silo, Dosing and Conveying System

Bulk bag unloading screw feeder mixer filling systems

Double Component Mixing By Big Bag Unloaders

Food application food grade bulk material handling systems big bag unloaders

Food Grade Stainless Steel Big Bag Unloading Station

Mixer filling by screw conveyor and big bag unloading unit

Bulk bag unloading system screw feeder mixer loading

Big Bag Unloading Systems

Big bag unloading FBIC discharging station Bulk Bag Emptying System Station

Big bag feeding system Calcium carbonate

Big bag discharging station bulk material unloading

Big bag unloading stations are designed for unloading of bulk bags in effective and safe way. Different types of bulk materials can be handled, starting from free flowing granules to poorly flowing sticky fine powders.

Bulk bag unloading systems are designed to meet wide range of application requirements. Type of bulk material, big bag size, discharged medium, down stream equipment, discharge speed, environmental aspects, ergonomics and safety are all important factors that have effect on final design on big bag unloader unit.

Modular design of big bag unloading systems make them easy to be configured for each application need. While standard models have simple frame and discharge hoppers, high level models have complete solution in single main frame. Big bag unloading, product storage, dust collection, dosing and conveying can all be done in single unit.

Big bag unloading stations are also known as big bag discharging stations, bulk bag emptying units, FIBC dischargers, FIBC unloaders, FIBC emptiers, super sack dischargers, container bag unloaders, container bag dischargers, super sack unloaders and super sack emptiers.

Advantages

Safe and clean working environment
Dust free environment air
Simple handling of bigbags
Applicable for different conveying and storage systems
Wide range of models for different applications
Easy to clean
Maintenance free design
Rigid, steel construction
Filter system for preventing dust.

Bulk Bag Unloading Systems Big Bag Unloading Stations

Big Bag Discharge Systems Technical Documents

Brochure of Bag Discharge Stations

Links

Big Bag Discharge Systems

Big bag discharge systems provide dust free and easy emptying of big bulk bags. The contents of big bags are easily transferred to silos, mixers, and conveyors etc. Pneumatic conveying systems, screw feeders or similar conveying equipments can be used to transfer bulk solids to required destination.

Big Bag Discharging Applications

Big bag discharge applications; silo filling, mixer loading, production line feeding, bulk truck loading, packaging systems, weighing, batching and dosing systems..

Big Bag Discharging System Models

Wide range of big bag discharging stations are available with respect to different applications. Big bag dischargers can be configured according to bulk solid types (powdered, granular, abbrassive, food etc) application types (silo filling, mechanical conveying, pneumatic transfer, mixer feeding etc.)

Big Bag Discharge System Bulk Solid Transfer Equipment

Bulk solid transfer equipment are used to transfer powdered and granular materials from big bag discharger outlet to required destination. Mechanical or pneumatic conveyors can be used according to application needs.

Big Bag Discharge System Accessories

Big bag discharge systems can be provided with wide range of optional components and accessories for different application needs.

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of big bag discharge systems an

Big Bag Discharge System Accessories

Big Bag Hanging Unit With Spring and Damper

Big bag hanging units are used on upper frames to hold bigbags brought by overhead cranes and forklifts. A lifting cross is put over the big bag. Big bag handles or straps are fixed to the hooks of lifting cross. It is then lifted together with bigbag by crane or forklift and placed on top frame hanging unit. Spring and damper mechanism applies upwards force to lifting cross. When raw material begins discharging, this mechanism moves big bag upwards and aids product discharge. The strength of springs and dampers can be adjusted with respect to weight or bulk density of raw material. Side massaging pistons and big bag vibration motor can also be utilized to increase big bag unloading speed.

Big bag discharger FIBC hanging equipment

Side Pistons

Pneumatic pistons placed on side frames of big bag discharger are available as an option to aid unloading of bigbags. These pneumatically actuated massage cylinders apply side forces to the big bag. Massaging system is especially effective when the storage in bigbag cause problems with compressed bulk materials and where vibration aids can cause further compression and prevent uniform discharge. Piston stroke lengths, motion speeds and intervals can be adjusted by built in control panel of big bag discharging station.

Bulk bag discharge system side compression pistons

Pneumatic Big Bag Massaging System

Bulk bag discharging station big bag massaging powder fluidizing system

Built In Storage Silo

Storage silos can be installed below the big bag discharge platform. Unloaded material is directly transferred to silo and stored for later use. In this configuration there is no need for additional storage silo and conveying equipment connected to big bag discharge system. Additionally big bags can be completely emptied and removed in one time. Different silo capacities are available depending on raw material consumption. There exist level sensors on the silo to monitor the product level in the silo. And alarm signal is generated in case of low product levels. Flow aids as air jets or vibrating bin activators are provided as an option for silos. Dust collection systems are connected to big bag discharge stations and storage silos for bulk products with high dust content.

Big bag discharge station built in bulk material storage silo

Dust Collection System

Dust collection system of big bag discharge station is needed for preventing dust emission during big bag discharge. Dust emissions from big bags are seen during cutting or untying of bag spouts, product discharge and removal of empty big bags. Vacuum air supplied by dust collector, collects any dust in the region. A jet filter system with built in fan is used for this purpose. Collected dust is sent back to the big bag discharging unit automatically and any product loss is prevented. Vacuum air is cleaned with reverse pulse jet system and discharged to outside.

Big Bag Weighing System

When the raw material amount in the big bag is to be monitored, big bag weighing system can be used. Big bag discharge station consists of loadcells on main frame. Weight of the big bag is continuously measured and user is informed. System can send signal to another PLC automation system or system can control other equipment connected to the big bag discharger unit.

Iris Valve

Product discharge from the big bag can be controlled by iris valve. Big bag discharge spout passes through the iris valve. A pneumatic piston or manual handle controls the iris valve. Product discharge spout can not only be kept completely open or closed but also it can be adjusted in any level. Big bag unloading speed can be adjusted with this mechanism.

Big Bag Cutting Knives

FIBC discharging system Big bag cutting blades

Big Bag Automation

Big bag automation systems provide control of whole big bag and bulk material handling operations. Vibration motor, iris valve, massaging system, hoist, dust collector, big bag weighing system, conveying system etc. are connected to automation system. Depending on the complexity and configuration of big bag discharge station, different type of automation systems can be utilized. For simple big bag discharge units a small sized manual controlled electrical panel is enough. PLC controlled automation panels are preferred for big bag discharge stations with many accessories installed on. These units can also take control of other material handling systems that are connected to bulk bag discharge station like screw feeders, pneumatic conveying systems, rotary valves etc. Daily, monthly, annual reporting functions are available as an option. PLC controlled systems have option for connecting to other Scada, PC and PLC systems in production plant for better handling and monitoring of complete production process.

Big Bag discharge system automation PLC scada control

Built in Sack Discharger

Lump Breaker

Bulk solids stored in FIBC bags for long time tend to be compacted because of its own weight and possible moisture in the environment and form big sized lumps. During bulk bag discharging, these lumps should be broken before entering to down stream equipment. Lump breakers are installed below big bag discharging systems to prevent any problems caused by big sized particles and lumps.

Screening System

To prevent any oversized particle entrance into the production line, screen is used. Screening systems are installed at the discharge point of big bag discharger unit. Depending on bulk material properties and acceptable particle sizes different types of screens can be used. Vibrating screens are one of the most common screen type used in bulk material handling.

Big bag discharge powder screen powder sieve

Magnetic Separator

Foreign materials in bulk solids will lead to serious problems in production processes. Magnetic separators are used to detect metallic particles in bulk solids and separate them from main product stream. Metal detectors and separators can be installed at the outlet port of big bag discharger systems and prevent contaminations caused by metallic particles.

Food Applications

Food grade big bag dischargers are available on request. All surfaces that have contact with food are made of food grade materials as stainless steel, silicone etc. All parts are designed and manufactured carefully to prevent any contamination and bacterial growth. Filter bags, valves and other mechanisms are selected from food certified equipment.

Powdered food grade big bag discharger stainless steel

Dangerous Materials and Environment

Handling of explosive and flammable raw materials in hazardous explosive atmosphere need special care both in design and manufacturing of big bag discharge systems. Overheating, gas or dust leakage, static electricity and electrical spark generation should be prevented. Atex certified and ex-proof equipment are used in such working conditions.

Bulk Bag discharge station Atex certified Ex-proof dust explosion proof

Custom Designed Big Bag Discharge Systems For Different Raw Materials

Design and construction material of big bag discharge stations can change with respect to handled bulk material and type of application. Stainless steel body made of either AISI 304 or AISI 316 is preferred for food materials, additives, PVC, Polypropylene, Polyethylene, PET, HDPE, LDPE, painting materials etc. High carbon steel and manganese alloys are preferred for abrasive materials such as arc furnace dust, perlite, quartz, silica sand, fly ash etc. Standard steel is used for general purpose applications such as cement, calcium carbonate, activated carbon handling.

Jumbo bag discharge station custom designed big bags

Machine Safety

Big bag discharge systems manufactured by Polimak are designed to conform human and environment safety regulations. Being CE certified, all safety measures are taken to prevent work accidents in big bag handling systems. Mechanical and electrical locks, alarm systems exist on machinery with respect to work conditions.

Big bag discharge equipment machinery safety regulations

Big Bag Discharge System Bulk Solid Transfer Equipment

Big bag discharging systems can be supplied with wide variety of equipment for further conveying of the discharged product depending on type of application.

Rotary Airlock Valves or Blowing Seals

Rotary valves provide controlled product flow from bulk bag discharging station to the down stream system. Dry bulk materials can be fed into mixers, tanks or other mechanical conveyors through rotary airlocks. Blowing seals are used to feed pneumatic conveying systems and ensure sealing of pressurized air in the pipeline.

Big bag discharge station rotary valve blowing seals

Blowing Seals Rotary Valve for Big bag discharging station

Screw Feeders

Bulk solids in the big bags can be transferred to other handling systems with the help of screw conveyors installed below the big bag discharging unit. Screw conveyors can be used to transfer products to packaging machines, production lines, mixers or other similar equipment.

Big bag discharge station screw feeder conveyor

Slidegate Valve

Slidegate valves can be installed below the discharge hopper of bulk bag discharge station. Product flow speed can be controlled by adjustable valve blade. Manual handwheel or pneumatic piston can be used on slidegate valves depending on type of application.

Butterfly Valve

Butterfly valves placed on the big bag discharging system are simple valves used to open and close product flow in short time. Butterfly valves can be controlled by manual handle or pneumatic actuator.

Batching and Dosing System

Dosing systems feed processes with controlled amount of bulk materials. Depending application requirements, volumetric or gravimetric dosing systems can be installed on bulk bag dischargers. PLC or computer controlled dosing systems are available.

Weighing batching dosing unit big bag discharge equipment

Pneumatic Conveying System

Instead of mechanical conveyors, pneumatic conveying systems are preferred in processes where the bulk bag discharge stations are far from feeding points. Pneumatic conveying equipment and pipeline are connected to bulk bag discharge systems. Powdered or granular bulk materials are transferred from bigbags to pneumatic conveying system and then conveyed to the required points. Depending on type of application, pressure conveying system or vacuum conveying system can be installed.

Dense Phase Pneumatic Conveying System

Big bag discharge stations with built in dense phase pneumatic conveying systems are used in applications where high conveying capacities and long distances are needed. Big bag unloading hopper is installed above a pressurized tank also known as pressure vessel. Several big bags are unloaded in one time to the pressurized tank. High pressure air is used to pressurize the tank and send the product through the conveying pipeline. Dense phase pneumatic conveying systems are generally preferred for materials like cement, calcium carbonate, PVC, soda and fly ash where high transfer capacities are needed.

Dense phase pneumatic conveying and big bag discharge system for silo loading

Free Flow

Outlet of big bag discharge station is kept free of any equipment. Unloaded bulk solids move freely to down stream system.

Big Bag Discharging System Models

Big bag discharging systems have wide variety of components for wide range of applications.

Upper Frame Models of Big Bag Discharging System

Open Top Big Bag Discharge Station

Big Bag Discharger Upper Frame With Big Bag Hanging Unit

Big bag hanging unit for bulk bag discharging station

Big Bag Discharging Station With Hoist

Big bag lifting hoist for FIBC bag discharging station

Big Bag Holding Platform Models

Big Bag Holding Platform with Hopper and Side Access Door

Holding platform consists of a rectangular table with circular inlet covered by rubber seal and conical hopper on the bottom. Rubber seal prevents any dust leakage from bottom of big bag during unloading and maintains air flow to the dust collection unit. Bottom hopper has a side access door to enable operator an easy access to big bag discharging spout. Operator can untie the spout or cut the bottom by knife and closes the side access door of the hopper. Dust collector vacuums any dust in the area during these tasks and ensures a clean working environment. Vibration motor installed on hopper aids discharging of big bags. Optional cutting blades can be installed in the middle of rubber seal. When big bag is placed on the platform, these blades cut the big bag instantly and provides faster flow. This platform design is suitable for higher capacity big bag handling operations.

Side access door of big bag discharging system hopper

Stainless steel big bag discharging station hopper

Big Bag Holding Platform With Dust Tight Docking Station

Docking station provides a dust tight seal with big bag discharge spout. This design eliminates any dust emission and contamination during big bag discharging process. A manual or pneumatically controlled clamping mechanism is used to clamp and seal big bag discharge spout. It moves in vertical direction and it is adjustable for different big bag sizes. After the big bag inner liner or bottom spout is clamped, operator unties big bag and product flow begins. Dust collection system prevents any dust emission in working zone. An optional iris valve can be used to control material flow through the discharge spout. Iris valve is installed between the big bag holding platform and docking station. Big bag discharge spout passes through the iris valve. A pneumatic piston or manual handle controls the iris valve. Big bag unloading speed can be adjusted with this mechanism.

FIBC discharge system dust tight docking station and iris valve for big bag outlet

Big bag discharge system docking system bag clamping mechanism

Big Bag Discharging Applications

Big Bag Discharging and Silo Loading

Silo loading systems connected to big bag discharging stations are used for discharging raw materials from FIBC bags and fill them to storage silos. Silo loading can be done by mechanical conveyors or pneumatic conveying systems.

Silo Loading With Pneumatic Conveying System

Pneumatic conveying systems installed after bulk bag discharge units transfer the bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, big bag discharge stations can be installed closed to warehouses and pneumatic conveying systems are used to fill silos from long distances. This design prevents extreme use of forklifts and cranes for bulk material transfer in production site and increases overall efficiency.

Big bag discharge station with pneumatic conveying system for silo filling

Bulk bag discharge system with screw feeder and bucket elevator for silo loading

Mechanical Conveying Systems For Silo Loading

Mechanical conveyors can be used for silo loading from big bag discharge stations. Screw feeders, bucket elevators, rotary valves or chain conveyors are connected to big bag discharge stations to fill silos. Conveying equipment selection directly depends on conveying distance, height, transferred material and capacity. Bucket elevators are preferred for high silos. Screw feeders are preferred for shorter silos and short distances. Big bag discharge system can be installed on top of silo for faster filling. In this case rotary valve or butterfly valve are better choices which provide simple flow control. Dust collection systems may be needed depending on dust content of bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some amount of dust together. Having vacuum fan and jet filter, dust collectors prevent any dust emission to the environment. Collected dust is sent back to the silo and product loss is prevented.

Big Bag Discharging and Bag Filling Systems

Bulk material stored in big bags can be filled into small bags automatically. Big bag discharge systems have optional built in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper and provide practical and cost effective solution. Big bag discharging and bag filling operations can be handled on single compact system.For higher bag filling needs, bag filling machines are installed near bulk bag discharge stations. Pneumatic conveying systems or mechanical conveyors are used to transfer bulk material from FIBC bag discharge station to bag or sack filling system.

Bulk bag discharge and mixer feeding system with pneumatic conveying

Big Bag Discharge and Mixer Filling

Mixer automation systems are used to mix dry bulk solids with respect to certain recipes. Raw materials that are delivered within FIBC bags can be transferred to mixing units by combination of conveying equipment and bulk bag discharge system. Depending on type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag discharge stations can be manufactured with built in dosing system. Amount of raw material to be loaded into the mixer is controlled automatically by the help of weighing and dosing system. Dust collectors can be used to prevent dust emission during mixer filling.

Big Bag Discharging and Packaging System Feeding

Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks etc. Bulk materials that are delivered within big bags are to be transferred to packaging machines without interruption. Loading hopper of packaging system should be kept full during filling and packaging. Big bag discharge systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Bulk bag discharge sack filling big bag filling and weighing systems

Big bag discharging batching weighing dosing and mixer loading systems

Big Bag Discharge, Dosing, Weighing and Batching Systems

Big bag discharge systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. Loading hopper of weighing system should be kept full during dosing and batching. Big bag discharge systems can monitor the product level in loading hopper and maintain constant level automatically. Depending on dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be used to prevent dust emission during hopper loading for materials with high dust content.

Big Bag Discharge and Bulk Truck Loading Systems

Bulk tanker trucks or open trucks are sometimes filled with powdered materials delivered within FIBC bags. These systems are generally composed of bulk bag discharging station, mechanical or pneumatic conveyor and loading bellow. Big bag discharge station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.

Big bag discharge bulk truck loading system

Application Gallery

Big Bag Discharge and Powder Transfer System

Big Bag Discharger, Storage Silo, Weighing and Dosing System

Big Bag Discharge Station with Dosing Unit

Big bag discharge station tanker truck loading bellow telescopic loading spout

Big Bag Discharge Station Bulk Tanker Truck Loading System

Tank Filling With Big Bag Discharging Units

Raw Material Filling to Mixer With Big Bag Dischargers

Big Bag Discharge, Batching and Dosing Stations

Big Bag Unloading and Pneumatic Conveying System

BulkBag Discharge Station With Pneumatic Conveyor

FIBC Discharger, Storage Silo, Dosing and Conveying System

Big Bag Discharge and Mixer Feeding System

Food Grade Stainless Steel Big Bag Discharge Station

Double Component Mixing By Big Bag Dischargers

Big Bag Discharge Systems

Big bag discharging FBIC Unloading Bulk Bag Emptying System Station

Big bag emptying screw conveyor bulk discharge

Hazardous Material big bag discharge feeding unloading system

Big bag discharging stations are designed for unloading of bulk bags in effective and safe way. Different types of bulk materials can be handled, starting from free flowing granules to poorly flowing sticky fine powders.

Bulk bag discharge systems are designed to meet wide range of application requirements. Type of bulk material, big bag size, discharged medium, down stream equipment, discharge speed, environmental aspects, ergonomics and safety are all important factors that have effect on final design on big bag discharger unit.

Modular design of big bag discharging systems make them easy to be configured for each application need. While standard models have simple frame and discharge hoppers, high level models have complete solution in single main frame. Big bag discharging, product storage, dust collection, dosing and conveying can all be done in single unit.

Big bag discharge stations are also known as big bag unloaders, bulk bag emptying systems, FIBC dischargers, FIBC unloaders, FIBC emptiers, super sack dischargers, container bag unloaders, container bag dischargers, super sack unloaders and super sack emptiers.

Advantages

Safe and clean working environment
Dust free environment air
Simple handling of bigbags
Applicable for different conveying and storage systems
Wide range of models for different applications
Easy to clean
Maintenance free design
Rigid, steel construction
Filter system for preventing dust.

Jet Filter Technical Documents

Jet Filter Catalogues

Brochure of Silo Top Jet Filter

Jet Filter Installation, Operation and Maintenance Manuals

Links

Jet Filter

Dust collection systems and jet pulse filters are used to prevent dust emissions during handling of bulk solids in powder or granule form in industrial processes which are harmful for health and environment.

Jet Filter Applications

Jet filters are used in pneumatic conveying systems, mechanical conveying systems, silos loaded with bulk trucks, hopper loading, packaging machines, truck loading bellows and production lines.

Jet Filter Models

Wide range of filter models are available with respect to process features. Depending on application (Silo, mechanical conveyor, pneumatic transportation system etc.), depending on transferred bulk material (dust content, granular, food, abrasive, high temperature etc.), depending on environment conditions (moisture, temperature, corrosive atmosphere etc.)

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of dust collection systems and jet filters.

Silo Top Filter

Silo top jet filters are used to vent pneumatically filled silos, tanks and containers keeping the dust inside of the silo (or container, tank etc) and letting the pneumatic air to leave it.

Applications of Silo Top Vent Filters

Silo top filters are installed on bulk material storage silos. Blowers and compressors supply required air for pneumatic conveying systems. This air is used to convey bulk solids to silos, tanks and containers. Jet filters are used to filter and discharge this conveying air while keeping the raw material inside the silo.

– Bulk Tanker Truck Discharge – Pneumatic Conveying Systems – Silo Filling – Industrial Plants – Concrete Batching Plants Silo vent filters keep dust content of bulk solids such as cement, fly ash, calcium carbonate, food and plastics in the silo. And keep the environment clean.

Silo top Jet Filter for bulk truck. — Silo Top Filter

Jet Pulse Filter Operating Principle

While filling of silos with bulk materials in powder form, air with dust content is transferred to the filter unit by air pressure. Filter ccartridges or filter bags hold the dust particles and lets the conveying air pass through them. The reverse air jet pulse system is used to blast pressurized air to the filters in the reverse direction to clean the filters periodically. The dust is dropped back to the silo and clean air is discharged. Reverse air pulse jet system is composed of pulse jet diaphragm valves, pressurized air tank, injection nozzles and electrical controller.

Features of Silo Jet Filters

– Cylindrical shape. – Connection flange for connecting to silo top. – Maintenance free reverse air jet pulse system – Weather proof and lockable top cover – Microprocessor control unit – High efficiency cartridge type filter elements – Low dust emission – Simple access to filters – Cartridge filters can easily be changed from the top cover – Inspection flange for inspecting the filters and inside of silo – Ready to install design – Filtering area ranging from 0.5m² to 100m² – Wam filters

Jet Filter Accessories

– Spare filter cartridges – Lower connection flange and adapters – Silo pressure safety valve

Silo pressure safety valve, silo level sensor

Jet Filter Applications

– Cement silo – Gypsum silo – Calcium carbonate silosu – PVC silo – Wheat silo – Dust collection systems – Dust storage silo – Bulk material loading and filling systems – Dosing, batching and weighing systems – Loading and discharging hoppers

Jet Filter Models

Silo Top Filters

Pneumatic conveying systems and bulk solid tanker trucks utilize pressurized air to transfer bulk solids to silos. This air carries powdered materials to the silo and during discharge through the silo vent outlet, this air also carries dust particles to outside. Silo top jet filters installed on bulk material silos prevent these kind of dust emissions and provide healthier environment. Additionally, these filter systems also keep valuable raw material dust inside the silo.

Silo truck top jet filtre — Jet Filter For Bulk Truck Loading

Pneumatic conveying to storage silo and jet filter — Jet Filter For Pneumatic Conveying

Dust Collection System

Industrial plants use central dust collectors to collect dust from different points in the production line. Baghouse filters, de-dusting systems are used in these plants to collect the dust to single point.

Filter Receiver

Filter receivers are used to separate pneumatic conveying air and conveyed bulk material at the end of conveying line. Upper section of filter receiver unit is similar to jet filters. This jet filter can be made of bag filter elements or cartridge type filter elements. Lower section of filter receiver unit is the same as cyclone receiver. This design combines the advantages of cyclones and jet filters in single body.

System Filters

System filters are custom designed jet filters built for individual bulk solids handling applications like big bag discharge systems, bag dump stations, bulk tanker truck loading bellows, compressor inlet filters etc.

Jet filter dust collector of bigbag discharge system — Bigbag discharge system dust collector

Jet Filter Configurations

Jet filter accessories and configurations vary , depending on wide range of application possibilities, dust properties and environmental conditions.

– Jet filter bodies are made of stainless steel, filter bags are FDA approved, overall design is made for contamination free in food applications. – In explosive atmospheres and explosive dust handling, jet filter components are ex-proof and have Atex certification. Filter bags are antistatic. – For high temperature materials such as fly ash, filter body and filter bags are made of heat resistant materials. – For bulk solids which have high moisture content and sticky, inner side of filter body is made of polished material. Filter bags are coated with special coating.

Food application FDA approved jet filter — Jet filter with fan for food application

Jet Filter Applications

Pneumatic Conveying Systems

Silo top jet filters are used to vent pneumatically filled silos, tanks and containers keeping the dust inside of the silo (or container, tank etc) and letting the air to leave it. Blowers and compressors supply required air for pneumatic conveying systems. This air is used to convey bulk solids to silos, tanks and containers. Jet filters are used to filter and discharge this conveying air.

Silo filling with pneumatic conveying system and jet filter installed on silo. — Pneumatic Conveying Silo Filter

Silo Filling By Bulk Truck

Bulk tanker trucks fill the silos by the help of built in air compressors. Jet filters installed on silos are used to keep the dust inside the silo and filter the pressurized conveying air.

Silotop Jet Filter and bulk tanker truck — Silotop Filter

Silo and Hopper Filling With Mechanical Conveyors

High volume of dust emission is seen during filling of silos and hoppers by mechanical conveying systems like screw feeders, chain conveyors and bucket elevators. Jet pulse filters with built in vacuum fan are used to collect the air and dust. Air is filtered and discharged to the atmosphere while dust is collected.

Belt Conveyor Dust Emission Dust Collector Filter Application — Belt Conveyor Discharge

Mixer Filling

Mixer filling and mixing operations lead to some amount of dust emission to the environment. Mixers can be filled manually, by a mechanical conveyor, by pneumatic conveying or by an automatic dosing system composed of different loading equipment. Vacuum fan of jet filter collects any dust content within the region. Jet filters installed above the mixers can discharge the collected dust back into mixers again. This design prevents any valuable raw material lost.

Dust collection system with buit-in fan installed above mixer.

Packaging Systems

Automatic bag filling systems, big bag filling systems and similar packaging machines may have dust leakage problem during filling operation. While the package is filled, the air inside the package escapes outside and brings any dust together. Dust collectors are used to collect this air and dust.

Dust collector of bigbag filling system. — Jet Filter Of Bigbag Filling System

Bulk Truck, Tanker Truck, Ship and Stockpile Loading

Loading bellows also known as telescopic chutes provide dust free loading of trucks, ships and stockpiles. Loading bellows prevent spreading of dust while filling or loading of bulk solids in powder form. But this dust should be collected by a vacuum system. Jet filters supply vacuum air and collect the dust inside the loading bellow. Collected dust can be discharged back to the truck, ship or stockpile again and material loss is prevented.

Open Truck Loading Bellow With Jet Filter

Production Lines

Central dust collection systems are widely used in production lines that utilize bulk solids. Jet filters collect dust from different locations within the production process. Depending on the type of application , baghouse filters or cartridge type jet filters can be installed. Vacuum fans are used to collect the dust to filter units. Collected dust can be sent to storage silos by the help of mechanical or pneumatic conveying systems and filled into bulk trucks for disposal.

Industrial plant de-dusting system jet filter

Other Jet Filter Applications

Crushers and breakers Iron and steel foundries, blast furnaces, electrical arc furnaces Cement Plants Food Industries Gypsum Factories Building Materials Production Plants Coal Burning Energy Plants, fly ash handling and filtering systems Concrete batching plants Mining, ore plants

Jet Filter

During handling of bulk solids in powder or granule form, dust may be spread to the atmosphere which is harmful for health and environment. Dust collection systems and jet pulse filters are used to prevent these emissions from industrial processes.

Storage silos, pneumatic conveying systems, mechanical conveying systems, production lines, loading and discharging systems are key areas that deal with powder and bulk solids. Wide range of filter and dust collection systems are available depending on physical properties of dust and characteristics of bulk solid handling process.

Dust emission from cement silo without jet filter and prevented emission with jet filter installed on the cement silo.

Operating Principle of Jet Pulse Filter

Depending on design of pneumatic or mechanical conveying systems, air with dust content is transferred to the filter unit by pressure or vacuum. Filter cartridges or filter bags hold the dust particles and lets the conveying air pass through them. The reverse air jet pulse system is used to blast pressurized air to the filters in the reverse direction to clean the filters periodically. The dust is dropped back to the process or stored in separate hopper and clean air is discharged. Reverse air pulse jet system is composed of pulse jet diaphragm valves, pressurized air tank, injection nozzles and electrical controller.

Operating principle of bag filter — Dust Collection Bag Filter

Cartridge jet pulse filter and components — Components of Jet Pulse Filter

Different type of powdered and granular bulk materials can be filtered by selecting proper dust collector. Emission of fine dust, raw food materials, big sized granular products, explosive, high temperature raw materials can be prevented.

Rotary Feeder Technical Documents

Rotary Feeder Brochure

Rotary Valve Catalogues Installation, Operation and Maintenance Manuals Bulk Solids Density Charts

Links

Rotary Feeder

Rotary airlocks or feeders are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary feeders provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Feeder Applications

Rotary Feeder Models

Wide range of rotary feeder models and configurations are available for different process conditions and physical properties of transferred bulk solids. According to process (silo, cyclone, jet filter, conveyor, pneumatic conveying system etc.) ; according to bulk material (fine powder, granule, abbrassive, elastic, high temperature etc.)

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary feeders.

Rotary Feeder Applications

Silo Emptying With Rotary Feeder:

Rotary feeder placed under the silo, hopper or other container system is used to control the bulk solid (in powder or granule form) discharge from these units and feed equipments like conveyor, screw feeder, mixer etc.

Rotary Feeder for Silo discharge — Rotary Feeder for Silo Discharge

Cyclone Discharge With Rotary Feeder:

Rotary feeder placed under the cyclone is used to control the bulk solid discharge from the cyclone under pressure or vacuum and feed equipments like conveyor, screw feeder, mixer etc.

Cyclone Discharging Rotary Feeder — Rotary Feeder Installed Below Cyclone

Dust Collection With Rotary Feeder:

Dust collectors, filters, jet pulse filters are used to collect dust from production lines. Rotary feeders installed under dust collection systems, are used to unload the dust.

Rotary Feeder Installed Below Dust Collector Hopper — Rotary Feeder Below Dust Collector

Dosage Control, Mixing, Batching With Rotary Feeder:

Rotary feeders can be used to control the amount of discharging of bulk solids. By controlling the rotor speed of airlock, volumetric measurement is possible for both powdered and granule type bulk materials. Volumetric feeding of mixers or containers are possible.

Dosing of Bulk Solids With Rotary Feeder — Rotary Feeder for Dosing

Pneumatic Conveying Systems With Rotary Feeder:

Rotary airlock feeders are used to feed pneumatic conveying lines from silo, hopper, cyclone, big bag discharge stations etc. Rotary feeders prevent air leakage from conveying line and maintains constant feeding of powders or granules.

Rotary Feeders installed on pneumatic conveying system — Pneumatic Conveying Rotary Feeder

Conveyor Feeding / Discharging With Rotary Feeders:

Conveyors can be feeded from silos, hoppers or other containers with the help of airlocks. Bulk materials dishcarged from conveyors can also be fed into airlocks and then sent to another equipment like pneumatic conveying line, mixer etc. Used widely in baghouse filters and ESP systems.

Rotary feeders dust discharge to chain conveyor — Rotary Feeders Feeding Chain Conveyor

Screw Feeder Feeding / Discharging With Rotary Feeders:

Screw feeders can be fed from silos, hoppers or other containers with the help of airlocks. Bulk materials discharged from screw feeders can also be fed into airlocks and then sent to another equipment like pneumatic conveying line, mixer etc.

Rotary feeder feeding screw conveyor — Rotary Feeder With Screw Conveyor

Bulk Solids Processing Equipment Feeding / Discharging With Rotary Feeders:

In several industrial processes, bulk solid processing equipment can be fed or discharged with the help of airlocks. Boiling, cleaning, surface treatment, mixing, crushing processes are some of the examples that need rotary feeders. Rotary airlock feeders isolate the process from external conditions

Silo discharge and pneumatic conveying with rotary feeders — Production Line Feeding With Rotary Feeders

Bulk Solid Filling:

Several bulk materials are filled into bags, sacks, big bags, containers or drums by volumetric metering with the help of airlocks

Hopper feeding bulk solids rotary feeder — Rotary Feeder For Hopper Feeding

Handled Materials By Rotary Feeder

Rotary Feeder Models

FT Series Rotary Feeder

Flow through rotary airlocks are used in wide range of applications. The material enters from the top and exits from the bottom flange of rotary feeder.

BT Series Rotary Feeder

Blow through rotary feeders are used in pneumatic transport systems. They are suitable for transferring sticky powdered materials. The material enters from the top and exits from side flange and transferred to conveying pipe.

OS Series Rotary Feeder

The Off Set type also referred as side entry type rotary feeders are used for preventing crackage of delicate materials like sunflower seed and peanut. These models are also suitable for hard to shear pellets like nylon or plastic granules.

Other Options

Outside Bearing

To protect bearings from damage of abbrassive and dusty materials, the bearing housing is mounted outside of side flanges. Packing seals are used in these models.

Flange Connection For Piping

Blow through rotary feeders have optional flange connections for easier installation on pneumatic conveying pipelines

Blow Through Rotary Feeder With Pipeline Connection Flanges

Stainless Steel Rotary Feeder

Rotary feeders can be built from AISI 304 and 316 steel for food grade and chemical applications

Hardox Rotary Feeders

For very abbrasive bulk solids like fly ash, cement and sand, the rotor blades and inner housing of airlock are built from hardox steel.

Rotary Feeders For High Temperature Applications

The casing, rotors, bearings and seals of rotary feeders are built to withstand elevated temperatures.

Atex Rotary Feeders

Atex approved rotary feeders are used in applications where the dust explosion risk exist. Polimak Atex series rotary feeders are certified with 10 bar explosion tests. All components of rotary feeders comply with Atex regulations and provide ex-proof characteristics.

Motor and Gerbox Connections

Worm Gear Reducer Connection

Worm gear reducers are installed on rotary feeder shaft

Chain Gear Connection

Chain gears are installed on rotary feeder and gearbox.

Rotor Types

Closed End Rotors

Closed end rotors reduce air leakage. They prevent wear on side covers of airlock when handling abrasive materials.

Open End Rotors

Open end rotors are generally used in blow through type rotary feeders installed on pneumatic conveying applications.

Adjustable Bladed Rotors

Adjustable blades are used in handling abbrassive materials for longer operational life.

Elastic Polyurethane Bladed Rotors

Elastic blades are used for bulk solids that have large particle sizes and also used for abbrassive powders.

Scalloped Rotors

The scalloped rotor design is suitable for sticky materials. They are also used in food grade applications.

Optional Accessories, Special Applications

Inlet Slide Gate

The slide gate is used for adjusting material flow to the rotary feeder.

Pneumatic Conveying Line Connection Adapter

These rotary feeder outlet adapters are used for connecting the FT and OS series airlocks to pneumatic conveying pipeline

Rotary Feeder Pneumatic Convying Line Adapter

Dosage Control System

Different materials can be mixed with precision with the help of rotary feeders. The volumetric dosing system is controlled by PLC and computer. Dosage control software lets the user adjust the mixing percentages.

Custom Designed Rotary Feeders

Polimak can design and produce airlocks for custom applications in very short periods of time.

Handled Materials By Airlock

Cement, calcite, ash, glass powder, marble powder, plastic pellets, sawdust, pvc, fly ash, coal, coal dust, wheat, flour, barley, feed, seed, corn, chickpea, bean, soy bean, sesame, rice, rice flour, dried fruit, nuts, peanut, almond, sunflower seed, cotton seed, grain cereals, chestnut, coffee grain, coffee powder, sugar, salt, spice.

Rotary Feeder

Rotary feeders are important components of pneumatic conveying, bulk solids handling and batching systems. Rotary feeder is also known as rotary airlock, rotary valve or airlock feeder. The main function of a rotary feeder is to control flow of bulk solids from silo, mixer, cyclone or hopper under gravity, pressure and vacuum conditions. Rotary feeders can work on pressure and vacuum applications.

Wide range of rotary feeders are avaliable for different process conditions and physical properties of transferred bulk solids. Abbrassive materials, high temperature powders, food products, big sizes granules can be transferred by selecting proper rotary feeder models.

Rotary Airlock Technical Documents

Rotary Airlock Brochure

Rotary Valve Catalogues Installation, Operation and Maintenance Manuals Bulk Solids Density Charts

Links

Rotary Airlock

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary airlocks provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Airlock Applications

Rotary Airlock Models

Wide range of rotary airlock models and configurations are available for different process conditions and physical properties of transferred bulk solids. According to process (silo, cyclone, jet filter, conveyor, pneumatic conveying system etc.) ; according to bulk material (fine powder, granule, abbrassive, elastic, high temperature etc.)

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary airlocks.

Rotary Airlock Models

FT Series Rotary Airlock

Flow through rotary airlocks are used in wide range of applications. The material enters from the top and exits from the bottom flange of rotary airlock.

BT Series Rotary Airlock

Blow through rotary valves are used in pneumatic transport systems. They are suitable for transferring sticky powdered materials. The material enters from the top and exits from side flange and transferred to conveying pipe.

OS Series Rotary Airlock

Other Options

Outside Bearing

To protect bearings from damage of abbrassive and dusty materials, the bearing housing is mounted outside of side flanges. Packing seals are used in these models.

Flange Connection For Piping

Blow through rotary valves have optional flange connections for easier installation on pneumatic conveying pipelines

Blow Through Rotary Airlock With Pipeline Connection Flanges

Stainless Steel Rotary Airlock

Rotary valves can be built from AISI 304 and 316 steel for food grade and chemical applications

Hardox Rotary Valves

For very abbrasive bulk solids like fly ash, cement and sand, the rotor blades and inner housing of airlock are built from hardox steel.

Rotary Valves For High Temperature Applications

The casing, rotors, bearings and seals of rotary valves are built to withstand elevated temperatures.

Atex Rotary Valves

Atex approved rotary valves are used in applications where the dust explosion risk exist. Polimak Atex series rotary valves are certified with 10 bar explosion tests. All components of rotary valves comply with Atex regulations and provide ex-proof characteristics.

Motor and Gerbox Connections

Worm Gear Reducer Connection

Worm gear reducers are installed on rotary airlock shaft

Chain Gear Connection

Chain gears are installed on rotary airlock and gearbox.

Rotor Types

Closed End Rotors

Closed end rotors reduce air leakage. They prevent wear on side covers of airlock when handling abrasive materials.

Open End Rotors

Open end rotors are generally used in blow through type rotary feeders installed on pneumatic conveying applications.

Adjustable Bladed Rotors

Adjustable blades are used in handling abbrassive materials for longer operational life.

Elastic Polyurethane Bladed Rotors

Elastic blades are used for bulk solids that have large particle sizes and also used for abbrassive powders.

Scalloped Rotors

The scalloped rotor design is suitable for sticky materials. They are also used in food grade applications.

Optional Accessories, Special Applications

Inlet Slide Gate

The slide gate is used for adjusting material flow to the rotary airlock.

Pneumatic Conveying Line Connection Adapter

These rotary airlock outlet adapters are used for connecting the FT and OS series airlocks to pneumatic conveying pipeline

Rotary Airlock Pneumatic Convying Line Adapter

Dosage Control System

Different materials can be mixed with precision with the help of rotary valves. The volumetric dosing system is controlled by PLC and computer. Dosage control software lets the user adjust the mixing percentages.

Custom Designed Rotary Valves

Polimak can design and produce airlocks for custom applications in very short periods of time.

Handled Materials By Airlock

Rotary Airlock Applications

Silo Emptying With Rotary Airlock:

Rotary airlock placed under the silo, hopper or other container system is used to control the bulk solid (in powder or granule form) discharge from these units and feed equipments like conveyor, screw feeder, mixer etc.

Rotary Airlock for Silo discharge — Rotary Airlock for Silo Discharge

Cyclone Discharge With Rotary Airlock:

Rotary airlock placed under the cyclone is used to control the bulk solid discharge from the cyclone under pressure or vacuum and feed equipments like conveyor, screw feeder, mixer etc.

Cyclone Discharging Rotary Airlock — Rotary Airlock Installed Below Cyclone

Dust Collection With Rotary Airlock:

Dust collectors, filters, jet pulse filters are used to collect dust from production lines. Rotary valves installed under dust collection systems, are used to unload the dust.

Rotary Airlock Installed Below Dust Collector Hopper — Rotary Airlock Below Dust Collector

Dosage Control, Mixing, Batching With Rotary Airlock:

Rotary valves can be used to control the amount of discharging of bulk solids. By controlling the rotor speed of airlock, volumetric measurement is possible for both powdered and granule type bulk materials. Volumetric feeding of mixers or containers are possible.

Dosing of Bulk Solids With Rotary Airlock — Rotary Airlock for Dosing

Pneumatic Conveying Systems With Rotary Airlock:

Rotary airlock valves are used to feed pneumatic conveying lines from silo, hopper, cyclone, big bag discharge stations etc. Rotary feeders prevent air leakage from conveying line and maintains constant feeding of powders or granules.

Rotary Valves installed on pneumatic conveying system — Pneumatic Conveying Rotary Airlock

Conveyor Feeding / Discharging With Rotary Valves:

Rotary valves dust discharge to chain conveyor — Rotary Valves Feeding Chain Conveyor

Screw Feeder Feeding / Discharging With Rotary Valves:

Rotary airlock feeding screw conveyor — Rotary Airlock With Screw Conveyor

Bulk Solids Processing Equipment Feeding / Discharging With Rotary Valves:

In several industrial processes, bulk solid processing equipment can be fed or discharged with the help of airlocks. Boiling, cleaning, surface treatment, mixing, crushing processes are some of the examples that need rotary valves. Rotary airlock valves isolate the process from external conditions

Silo discharge and pneumatic conveying with rotary valves — Production Line Feeding With Rotary Valves

Bulk Solid Filling:

Several bulk materials are filled into bags, sacks, big bags, containers or drums by volumetric metering with the help of airlocks

Hopper feeding bulk solids rotary airlock — Rotary Airlock For Hopper Feeding

Handled Materials By Rotary Airlock

Rotary Valve Technical Documents

Brochure of Rotary Valve

Rotary Valve Catalogues

Installation, Operation and Maintenance Manuals

Bulk Solids Density Charts

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Applications

Rotary Valve Models

Handled Bulk Materials

Rotary Valve Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Models

Three distinct rotary valve models ( flow-through, blow-through and off-set) are produced by polimak, each suitable for various applications. Our rotary valve design variation provides our customer with a broad model selection for handling different dry bulk materials with different properties. These valve models can be designed with different rotary valve drive connection configurations. Polimak rotary valve models come with the assurance of decades of experience, great know-how, as well as high-quality materials used in manufacturing.

Flow-through Models

Flow-through valve types are also known as drop-through valves. The two ports (inlet and outlet) on the valve housing are vertically aligned and tend to be the same size. During operation, empty rotor pockets are filled with the bulk solids vertically flowing down from upstream equipment, they are carried through the valve housing and then vertically discharged through an outlet. Drop-through valves are widely used for non-cohesive free-falling dry bulk materials like sand, wheat, rice, coffee beans and many others. Flow-through rotary valve models can be produced from stainless steel (AISI 304 and 316) for food and chemical industrial applications. They can also be built from hardox steel for abrasive dry bulk solids.

Blow-through Models

Blow-through valves are designed with troughs that are used to connect to pneumatic conveying lines, hence they are installed directly in a conveying line without any intermediate equipment. Bulk materials are supplied to the valve via its inlet as the rotor rotates. A filled rotor pocket offloads the bulk materials into the trough where the conveying air conveys the materials through a process line. Blow-through valves are utilised for sticky and cohesive bulk solids flour, milk powder, custard etc. For food and chemical industrial applications, stainless steel (AISI 304 and 316) blow-through rotary valve models are available, whereas hardox rotary valves are available for abrasive bulk materials.

Off-set Models

Off-set rotary valves are sometimes referred to as slide-entry valves. The inlet and outlet ports are offset from the valve’s housing vertical line. When a rotor rotates past a valve’s inlet, this offset allows an upcoming empty rotor pocket to only partially fill. Partial filling minimises bulk material shearing. It also prevents jamming of a rotor caused by dry bulk particles trapped between the rotor and valve housing. The volumetric fill efficiency of an empty pocket may vary depending on the material, generally between 40% to 60%. It is used for bulk materials like sunflower seeds, plastic pellets and peanuts. Stainless steel (AISI 304 and 316) can be used to produce offset rotary valve models for food and chemical industrial applications. For abrasive dry bulk materials, the valves can also be made of hardox steel.

Custom design rotary valves

Polimak has significant expertise across various technology areas and continues to push boundaries of the production of bulk material handling systems such as rotary airlock valves to meet our customer’s application requirements. Our primary skills are technology integration and design synthesis. To ensure that the produced rotary valves meet and exceed our client’s expectations (operation, cost etc.), integrating proper levels of technology for the application is very crucial. Polimak’s custom-engineered production incorporates problem definition, conceptualization, design, validation, production and installation. Our teams successfully carry out these steps efficiently and provide custom-designed rotary valves in a short period of time.

Rotary Valves Specifications

End-plates construction materials: cast iron, stainless steel, hardox, carbon steel.

Housing construction materials: cast iron, stainless steel, hardox, carbon steel.

Rotor construction materials: cast iron, stainless steel, hardox, carbon steel.

Seals: Lip seal, Gland packing.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Valve Applications

Rotary Valves Industrial Applications

Rotary valves are an essential part of any industry that processes dry bulk solids. Our experience within the industry of producing bulk handling systems allows us to design and produce cutting-edge airlock feeders used in various industries like cement, food, chemical, mining, plastics, agriculture etc., for numerous applications. We have the experience to design and supply our customers with the right rotary valves to meet their requirements.

Where are rotary valves used?

Rotary valves are used to their fullest capacity in numerous bulk material handling industries. Some of the industries that make use of airlock feeders include the following:

Food Industry

The food industry is one of the fast-growing industries responsible for the manufacturing and processing of food for both human and animal consumption. Some of the processes involved in the food industry include coffee processing, sugar refining, corn milling etc. Polimak’s food-grade rotary valves constructed from stainless steel with no crevices are ideal for handling food products. Dry bulk food products such as milk powder, coffee powder, sugar, corn flour, cornstarch etc., are processed using food-grade rotary valves.

Agricultural Industry

The agricultural industry is one of the largest industry in the world responsible for crop production. It has played and continuous to play a vital role in economic growth and development. The agricultural industry benefits from the use of various bulk material handling systems including rotary feeders when processing bulk materials. Some of the dry bulks solids processed using rotary valves include wheat, barley, oat, rye, bran, chaff, chickpea, bean, lentil, soybean, sesame, rice, dried fruit, hazelnut, peanut, almond, sunflower seed, grain cereals etc. Standard rotary valves constructed from cast iron or carbon steel are used to handle bulk solids in granular form.

Plastics Industry

Plastic bulk raw materials in form of powder, granules and pellets are frequently processed in the plastic industry. Rotary valves are designed to render reliable performance during operations. The valve body and the valve rotor are precisely engineered to prevent bulk material shearing and jamming. Polymers such as polyvinyl chloride (PVC), polyethylene, polypropylene (PP), acrylonitrile butadiene styrene (ABS) and many other related plastics are some of the bulk materials handled using a rotary valve.

Chemical Industry

Pure and sensitive dry bulk materials necessitate proper design of bulk material handling systems such as rotary valve to prevent contamination. Regular cleaning and inspection is necessary to ensure problem-free operations. Rotary valve built from corrosion resistant material are used to handle various materials such as sodium bicarbonate (baking soda), calcium sulfate (gypsum), sodium chloride (table salt), zinc chloride, calcium carbonate, copper sulphate etc.

Mining Industry

Power Industry

The generation of power (electricity) can be achieved by using fossil fuels like coal in internal combustion steam technologies. A by-product of coal combustion, fly ash, is transported from baghouse filters and ESP systems to bulk material storage systems like silos. Rotary valves can be used for discharging fly ash from the storage silos.

How are rotary valves used?

Rotary valves are used in many bulk material handling industries such as the aforementioned industries. Rotary valve industrial applications such as the discharge of dry bulk materials from upstream equipment to downstream equipment, help the user attain controlled material flow through the process line. Some of the rotary valve industrial applications include:

Bulk solids discharge from silos

Rotary valves are widely used to discharge dry bulk solids from storage silos. The valve is mounted to the bottom of a storage silo cone (at the outlet port). It is used for controlled release of dry bulk materials to a piece of downstream equipment such as screw conveyors/feeders, conveyor belts, bins, pneumatic conveying systems etc. It can also be mounted to hoppers or other bulk containment systems.

Dust particles discharge from cyclones

Sometimes referred to as a centrifugal collector, a cyclone is a dust collection equipment that separates particulates from the air by centrifugal force. It causes an incoming airstream to spin in a vortex. As the airstream is caused to alter direction, the particulates’ inertia drives them in the original direction and causes them to separate from the airstream. The main vortex curls downwards carrying coarse particles while the inner vortex generated at the bottom of a cyclone curls upwards carrying with it fine dust. The rotary valve discharges the coarse dust particles that settle at the bottom of the cyclone.

Dust particles discharge from Baghouse dust collectors

A reverse jet collector is commonly referred to as a pulse jet collector. A pulse jet collector makes use of bags held from a metal cage that is fastened to a tube sheet at the top of a collector. Dust enters the collector and its particles deposit on the outside of the bags. The deposits are cleaned by short periodic bursts of compressed air injected into the bags. These bursts cause flexing of the bags which result in dust particles breaking and falling of the bags. The particles settle at the bottom where they are discharged by an airlock valve. The airlock minimises the need for downtime in a process line and reduces operator intervention.

Bulk solids processing equipment feeding and discharging

Most bulk industries necessitate additional equipment for controlled feeding and discharging of the handled dry bulk materials. Machines such as ball mills, pin mills, cone mills, hoppers, convey systems and many others require a steady rate of material flow to operate effectively. Rotary valves can be used with such equipment to feed or discharge bulk materials in an effective and controlled manner.

Feeding pneumatic conveying systems

Rotary airlock feeders are used to feed dry bulk materials to conveying lines from upstream devices such as storage silos or hoppers. They prevent air leakage while maintaining constant feeding of dry bulk materials.

Handling large-sized bulk materials

Polimak produces quality rotary valves for smoothly handling large-sized dry bulk solids such as chickpeas, broad beans, hazelnuts. Our valves offer safe and efficient bulk handling with 0.1% harm guaranteed.

Which bulk materials can be handled with a rotary valve?

Rotary valves are used to handle a wide range of dry bulk materials. Depending on the characteristics of dry bulk materials being processed, rotary feeders can be manufactured from stainless steel, carbon steel or hardox steel. Some of the bulk materials that can be handled using a rotary valve are sugar, salt, spices, wheat, rice, cornstarch, corn (maize), bran, coffee beans, broad beans, milk powder, coffee powder, wheat flour, cornstarch, plastic pellets, rubber powder, cement, fly ash, sand, alumina, copper oxide, sodium sulphate, calcium carbonate, limestone etc.

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Rotary Airlock

Rotary airlocks are important components of pneumatic conveying, bulk solids handling and batching systems. Rotary airlock is also known as rotary valve, rotary feeder or airlock feeder. The main function of a rotary airlock is to control flow of bulk solids from silo, mixer, cyclone or hopper under gravity, pressure and vacuum conditions. Airlocks can work on pressure and vacuum applications.

Wide range of rotary airlocks are avaliable for different process conditions and physical properties of transferred bulk solids. Abbrassive materials, high temperature powders, food products, big sizes granules can be transferred by selecting proper rotary airlock models.

Rotary Valve

A rotary valve or an airlock feeder is a bulk material handling equipment used to modulate the flow of dry bulk solids from upstream equipment such as storage silos, hoppers and dust collection systems to downstream systems like pneumatic conveying systems, belt conveyors, and screw feeders. Polimak is an industrial company concerned with the design and production of various machinery used for handling dry bulk materials. With over four decades of experience in the bulk solids industry, our objective is to devise and produce cutting-edge bulk solids machinery that provide quality performance during bulk material handling for our clients.

Rotary valves are referred to by various names, with the term airlock valves being the commonly used one. Its primary function is to regulate bulk material flow from one piece of equipment to another and maintain a constant air pressure between the two ports of the valve (inlet and outlet). This is attained with the help of the rotor blades. Airlock valves are a fundamental component in bulk handling systems. They are widely used in many different industries such as food, chemical, plastics, cement, agriculture and many others for various bulk material handling processes.

Rotary Valves Features

Polimak offers various valve configurations depending on the characteristics of the handled bulk materials and the application, respectively. The rotary valve production obeys general practical engineering precision. The fundamental valve components include a valve body (housing) with an inlet port and an outlet port, a rotor (shaft with blades), two end plates (outboard or inboard) and a drive system.

Housing

A rotary valve housing secures the bulk material flowing through it by containing it throughout the material handling. Our housings are produced from several materials of construction such as cast iron, stainless steel and hardox. We render special coatings for abrasive bulk materials as well as highly polished finishes for the food and dairy industries. The three housing configuration types present are flow through, blow through and offset.

Rotors

Rotors function as metering components in rotary valves. These components differ in design from each other. A rotor is also known as a rotor assembly since it is made up of a shaft and blades (also known as vanes) that are welded or cast together. It is the valve’s rotating component. Different rotors have different numbers of rotor vanes; 6, 8 and so on. The space between the vanes is known as a rotor pocket. The lower the number of rotor pockets the higher the pocket capacity.

End-plates

The rotary valve end-plates make sure that the bulk materials don’t spill off on the side of rotor pockets. There are two configuration types of end-plates namely outboard and inboard bearing end-plates. Bearings on outboard plates are moved away from the head plates and are typically used in heavy-duty rotary valve models. These plates contain seals in them. The primary purpose of the seals is to prevent dry bulk material outflow from rotor pockets to the bearing region. Lip seals or gland packing can be used.

Drive Systems

The motor and the gearbox combine to form what is known as the valve’s drive system. Most of the rotary valves are driven through a reduction gearbox that is powered by an electrically induced motor. The reduction gearbox is normally utilized to receive a specific motor speed and produce a low output speed. The three drive arrangements that Polimak offers are; a worm gear reduction connection, a chain gear connection and a direct coupling connection.

Bulk Materials Handled by Rotary Valves

A rotary valve is designed according to the dry bulk materials which it is processing. Different types of dry bulk solids demand different valve designs. Coated surfaces that are non-stick or polished stainless-steel surfaces are commonly used for products having corrosive, sticky, and cohesive characteristics.

Some of the bulk materials that can be handled using a rotary valve are sugar, salt, spices, wheat, rice, cornstarch, corn (maize), bran, coffee beans, broad beans, milk powder, coffee powder, wheat flour, cornstarch, plastic pellets, rubber powder, cement, fly ash, sand, alumina, copper oxide, sodium sulphate, calcium carbonate, limestone etc.

Rotary Valves FAQ

What is a rotary valve?

A rotary valve is a compact mechanical device broadly used in dry bulk materials handling applications to control the flow of dry bulk solids between two systems, upstream and downstream equipment. It is known by a variety of names, airlock valve, star valve, rotary feeder etc.

What is the difference between a rotary feeder and an airlock feeder?

A rotary feeder a valve whose primary function is to feed or meter dry bulk solids from an upstream device to a downstream device without necessarily separating a pressure differential. An airlock feeder on the other hand is a valve that separates a pressure differential while feeding or metering dry bulk materials into a downstream system.

How does a rotary valve work?

The blades of a rotary valve rotate inside the valves housing during operation. This rotation is driven by a motor. As the motor rotates, rotor pockets follow through. Dry bulk solids are supplied to the valve from upstream equipment through its inlet and settle in the pocket. The rotor continues to rotate and then discharges the dry bulk solids through its outlet port. Two types of rotation exist; load side rotation and return side rotation. The former is defined as the rotation of the rotor pockets from the inlet to the outlet, whereas the latter is the rotation of the rotor pockets from the outlet port to the inlet port.

Why are rotary valves used?

Rotary valves are used in several industries for various industrial applications. It is used for several different reasons including; the control of dry bulk solids flows, feeding downstream systems, and maintaining a pressure differential between an upstream device and a downstream device.

Rotary Valves Photo Gallery

Cast iron constructed rotary valve for the mining industry

Drop through rotary feeder attached to a pneumatic conveying line

Durable and versatile rotary valve

Feeding a conveying line with a rotary feeder

Flow through rotary feeders installed to big bag disharge systems

Flow through rotary feeders installed to big bag dischargers systems

Flow through rotary valve under a filter receiver

Offset rotary rotary in a pneumatic conveying line

Offset rotary valve fo handling large sized bulk materials

Offset rotary valve for handling large sized bulk materials

Robust and durable rotary valves

Robust Rotary Valve

Rotary valve for discharging cyclones

Rotary valves to feed a process line

Rotary Valve

Rotary airlocks or valves are used to control the flow of bulk solids from silos, hopper or cyclones. Rotary valves provide continuous, reliable bulk solid flow like wheat, grain, cement, pellets.

Rotary Valve Models

Industries and Industrial Applications

ATEX Certified Rotary Valve

Options and Accessories

Technical Documents

Technical catalogs, product brochures, installation, operation and maintenance manuals of rotary valves.

Cement Silo Filter

Main function of silo filters is to prevent any harmful dust emission to the environment. Concrete batching plants and cement factories utilize cement silos and they should prevent any cement dust spreading around production plant. Bulk tanker trucks fill cement silos by pressurized air. This air carries cement to the silo and during discharge through the silo vent outlet, this air also carries dust particles to outside. Silo top jet filters installed on cement silos prevent these kind of dust emissions and provide healthier environment. Additionally, these filter systems also keep valuable cement dust inside the silo.

Cement Silo Filter Applications

– Bulk cement tanker truck discharging – Pneumatic conveying systems – Silo filling – Industrial plants – Concrete batching plants

Advantages of Cement Silo Jet Filter

– Maintains dust free clean environment around the production plant. – Prevents any raw material loss by keeping it inside the silo. – Maintains emission values below government environmental regulation limits.

Cement silo jet filter

cement silo dust collection filter — Dust emissions from silos before and after installation of jet filters

Technical Features of Cement Silo Jet Filters

– Maintenance free jet pulse system. – Microprocessor controlled jet pulse timing. – High efficiency cartridge type filters. – Bag type filter elements are available on demand. – Easy access to filter elements. – Easy to install. – Filter surface area between 0.5m² – 100m². – Automatic filter cleaning with reverse pulse jet system. – Filter elements can be easily changed with top cover. – Outer body is designed to endure harsh weather and environment conditions. – Cylindrical body can be installed in any direction. – Lower connection flange and adapter for installing instead of different brands. – Low dust emission. – Works with 220V 50-60Hz power supply and 4-6 bar process air. – Wam Silotop filters are available on request

Cement Silo Jet Filter

Jet Filter Accessories

– Spare filter cartridges – Lower connection flange and adapters – Silo pressure safety valve

Cement Silo pressure safety valve and silo level switch

Other Jet Filtre Applications

– Cement Silo – Gypsum Silo – Calcium Carbonate Silo – Wheat Silo – Dust Collection Systems – Dust Silos – Bulk Material Filling and Discharging Systems – Dosing Weighing and Batching Systems – Loading Hoppers

Silo Systems, Cement Silo Equipment

– Silo level sensor – Silo pressure sensor – Silo pressure safety regulator valve – Air pads and air jets for powder flow aid – Butterfly valve at silo outlet – Cement screw conveyor – Silo vibrating bin activator