Bulk Bag Unloaders Integrate Material Metering and Blending Processes
The bulk material packaging and processing marketplace is expected to reach $134.9 billion in 2011. And, according to a research report published by Visiongain, much of this will be driven by consumer-level market demand for pharmaceutical and chemical products. Naturally, the complexity of end-use product formulations and packaging configurations will increase as bulk material packagers and processors compete to most effectively respond to the increasing demands of their end-market customers and gain market share.
This dual bulk bag unloader integrated material input, metering, and blending into a single equipment footprint, with a central HMI and controls architecture.
Bulk material processing and packaging operations responding to these market pressures are looking to remove, and/or optimize production processes within their bulk material unloading and manufacturing sequences. This integrated, bulk material handling system feeds, meters, and blends very free-flowing dry bulk material and liquid minor ingredients at a 12,000 lb./hr. blended-material process rate; centralizing multiple dry and liquid material handling steps within a single equipment footprint, and within a single controls architecture. Built by National Bulk Equipment (NBE), the dual bulk bag unloaders; constructed of 4" x 4" x 5/16" structural framework, each have a 4,000 lb. frame capacity and meet or exceed ANSI and ASME specifications. NBE bulk bag conditioning systems, built into the framework of each bulk bag unloader, also optimize total bag cycle process times by 25% compared to free-standing bag conditioning designs. The liquid supply tank, built of 304-2b stainless steel and built into the system footprint, discharges the minor ingredient into the blending hopper based the specific recipe and control instruction from the system HMI. The 250 cu. ft. capacity blending hopper is constructed of 3/8", 304-2b stainless steel and has an integral, 14 ga., 304-2b stainless steel dimpled jacket that is ASME inspected and code stamped for –20°F to +400°F, and 125 PSIG. A thorough material mix is provided by the blending hopper’s 10" solid mainshaft and double-ribbon agitator design.
The NBE bulk material handling controls and automation architecture enable standardized system integration to the facility’s SCADA system. Application-specific, operator interaction and process operations risks were identified and properly mitigated by NBE throughout the design, testing, and commissioning stages. NBE expertise in application-appropriate codes, standards, and regulations ensured system compliance at start-up.
Bulk Bag Unloaders Use RFID to Automate Batching and Weighing Process
Bulk bag unloaders are typically not the first things to come to mind when the topic of radio frequency identification (RFID) is considered. Most commonly associated with warehouse management, RFID has found increased favor in other industries due the reduced costs for the required equipment and tags, and its improved reliability (now near 99.9%). Industries quickly adopting RFID technology include healthcare, medical device, financial services, and now, bulk material handling.
This fully integrated bulk bag unloader system uses RFID-driven process communications to automate simultaneous batching of multiple, and varied, chemical mixtures during a single process operation.
The bulk bag unloading process begins when an empty bulk tote is introduced to the system; RFID recognizes the tote and communicates to the system the specific batch recipe assigned to that tote. The primary ingredient is dispensed from a surge hopper into the bulk tote. As the first tote advances to its next batching location, a second tote enters the system. Each tote advances to one, or both, of two subsequent batching stations where secondary ingredients are added based on the RFID recognition of the bulk tote. Each secondary bulk bag unloader batching station consists of four bulk bag unloaders each with integrated material conditioning to ensure consistent bulk material supply is sent to a station-specific gravimetric feeder that provides accurate and repeatable secondary ingredient supply into the bulk tote.
The processor's previous manual measuring and weighing batching system produced one complete batch cycle every 20 minutes. With the fully automated, RFID-driven bulk bag unloader system, the processor now produces one complete batch every three minutes. In addition to the increased process rate, the producer's batch accuracies have increased, material waste is virtually eliminated; labor requirements are reduced; and the automated process efficiency and new equipment construction have enabled the producer to pursue new markets where cGMP-adherent processes are a requirement for entry.
Bulk Bag Unloader with Integrated Bag Conditioning Reduce Process Cycle Time by 25%
The reduction of total process cycle time continues to be an increasingly significant design requirement of many bulk bag unloader installations. From bulk bag loading and bulk bag conditioning, to material size reduction and downstream material supply; process optimization and operator safety have become top priorities in the design and construction of bulk bag unloaders.
To eliminate the time consuming step of using a free-standing bag conditioner, or the highly dangerous manual methods of conditioning bulk bags by ramming with a forklift or beating with sledgehammers, this bulk bag unloader uses a fully integrated, 4-stage material conditioning sequence to prepare an extremely agglomerated, rock-like material for supply to a downstream liquification process.
A dual-opposing bag hoist, enables high-volume input of material to the first conditioning stage where two, hydraulic de-blocking rams each deliver 28,000 pounds of direct material force. Next, dual, hydraulic massage paddles, each with 2,200 pounds of paddle pressure, further reduce material to chunk sizes. A bag spout valve, with 1,000 pounds of material break-up force, and capable of breaking through a static column of material, then reduces the material for supply to the final stage where a high-capacity, size reduction crumbler breaks material in 1/4-inch pieces for conveying downstream.
So, how does all of this contribute to total process optimization? Take a look at this chart.
An integrated, automated bulk bag conditioning sequence can add a total of four, complete bulk bag unloading cycles to a regular 8-hour production shift. That's a 30% increase in the number bulk bag unloading cycles compared to a free-standing-to-bulk bag unloader system design. Increased efficiency with increased safety.