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.
Bulk Bag Unloader with Explosion Protection Design Controls Combustible Dusts; Polycarbonate Enclosure Protects Process Area
Perhaps one the most significant factors contributing to the danger of combustible dust in the workplace is what goes unknown to production and maintenance staff. Consider this, the U.S. Chemical Safety Hazard Board (CSB), in reviewing the MSDSs of 140 substances known to produce combustible dusts, found that 59% of the MSDSs did not state hazard information specific to the combustible dust, or did not place the hazard information on the MSDS in a manner clearly recognizable by the worker. The CSB also found that the remaining 41% of the MSDSs presented poor or inadequate information regarding the potential hazards of the dusts. So, how can processing and packaging operations that handle dry bulk materials protect themselves from hazards they may not even know exist? The answer may lie in machine design that proactively incorporates protection from, and prevention of dusting of combustible materials.
This bulk bag unloader system, manufactured by National Bulk Equipment (NBE),
Bulk Bag Unloader with Explosion Protection Design Also Reduces Combustible Dust Escape
uses protective and preventive machine design elements to significantly reduce the level of airborne contaminants migrating into process areas. A proactive protection element in this design is a 9.525mm, polycarbonate encasement surrounding the bulk bag unloader. This protective element works to control dusts that piggyback on the exterior of bulk bags from becoming airborne and entering the work zone during bag conditioning and bag collapse. A proactive prevention element of this design is the E3(tm) closed-cycle dust recovery system. The E3(tm) secures and encloses the bulk bag spout within a sealed containment cylinder. The combustible material is introduced, dust-free, through the E3(tm), directly to an integrated surge hopper. The NBE surge hopper is constructed with explosion protection and control features, including: an explosion venting system, calculated on a Kst value of 170 and a Pmax of 9.5, to direct and release overpressure to prepared areas. The hopper construction includes reinforced walls and a reinforced cover, and is rated for 4.5 PSI internal pressure.