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 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.
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.
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.
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.
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 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.
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.
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.
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 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 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.
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.
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.
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.
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.