Bulk Filling and Discharging Equipment Guide Book Presents In-use Advantages of Application-specific Sanitary Equipment Versus Force-fit General Equipment
The second in a series of bulk material handling equipment guide books has been released. This newest guide book, entitled, Sanitary Bulk Filling and Discharging Systems Data and Specification Guide Book, was developed to bring clarity to the common, yet inaccurate, perceptions of complexity and confusion associated with the integration of bulk material handling equipment to sanitary process operations.
The Sanitary Bulk Filling and Discharging Systems Data and Specifications Guide Book addresses two primary areas of concern shared amongst production and process engineers, plant operations and management personnel, and corporate managers, with respect to sanitary
The Sanitary Bulk Filling and Discharging Systems Data and Specifications Guide Book details bulk bag filler systems, bulk bag unloader systems, bulk container dumper systems, and bag dump stations. Specific content includes: materials of construction guidelines for sanitary structures and components; WIP, CIP, and SIP-ready equipment design and construction; U.S. and IEC/ISO controls and automation compliance; and application-specific risk assessment implementation.
bulk material handling equipment. These concerns are: (i) identifying alternatives to force-fit, general industrial equipment designs touted as sanitary merely because of their stainless steel materials, and (ii) gaining confidence in matters relating to regulatory compliance of sanitary bulk material handling equipment, and the conformance of sanitary bulk equipment to regulated processes and practices. The guide book responds to these, and other issues, by explaining how application-specific, compliance-ready, sanitary bulk material handling systems eliminate the inspection failures, retrofits, corrective fabrication and finishing, and re-programming and re-inspection resulting when general, industrial equipment designs are force-fit into sanitary applications. The guide book also addresses the issue of sanitary equipment relative to process and practice acceptance, and the corresponding importance of selecting a bulk material handling equipment manufacturer based on an assessment of their proficiencies in areas such as: domestic and international regulatory matters; SCADA and single-unit controls and automation integration; manufacturing resources; systems commissioning; and installed base of relevant, integrated, sanitary bulk material handling systems.
The Sanitary Bulk Filling and Discharging Systems Data and Specifications Guide Book details bulk bag filler systems, bulk bag unloader systems, bulk container dumper systems, and bag dump stations. Specific content includes: materials of construction guidelines for sanitary structural framework and components; WIP, CIP, and SIP-ready equipment design and construction features; U.S. and IEC/ISO controls and automation compliance capabilities; and application-specific risk assessment implementation. The guide book also offers a summary overview of other bulk material handling equipment, including: bulk material mixing and blending, bulk material weighing, and bulk material storage systems.
The first guide book in this series is entitled, Automated Bulk Filling and Discharging Systems Data and Specifications, and is also available for immediate download.
Bulk Material Handling in Sanitary Applications: Regulatory Influences and Compliance-ready Equipment Design
The signing into law of the Food Safety Modernization Act, on January 4, 2011, enabled the Food and Drug Administration to, "...set in motion sweeping improvements to the security and safety of our nation's food supply." Close on the heels of the FSMA, the FDA, on April 20, 2011, released its 'Strategic Priorities 2011 - 2015' document. One of the strategic priorities presented in the document is to, 'Strengthen Compliance and Enforcement Activities to Support Public Health'. Within the context of this particular strategy the FDA makes clear that it will be, "...implementing a number of new programs designed to sharpen the effectiveness and timeliness of its regulatory, compliance, and enforcement systems." Certainly the complexities of international supply chains, and the quantity and diversity of touchpoints throughout the farm-to-table spectrum call for greater attention and more effective oversight on the part of the FDA and other governing bodies. But, what does this mean for food processing and packaging operations? How can a production facility respond?
Clearly, the best course of action is to be proactive. The FDA, in its strategic documents, is emphatic about taking enforcement action more rapidly, and, "...protecting the public health through criminal prosecution...to deter conduct that violates FDA-enforced laws." One of the first proactive actions in a food processing operation should be a thorough evaluation of any bulk material handling equipment used in a sanitary food processing application; whether in early-stage material input processes, or later-stage operations integrated deeper into the process. Sanitary process operations are no place to settle for force-fit, general-industry bulk material handling equipment. NBE sanitary-application bulk material handling systems eliminate the inspection failures, retrofits, corrective fabrication and finishing, re-programming, and re-inspections resulting when general industry units are force-fit into sanitary processes. Each NBE sanitary bulk material handling system, including: bulk bag fillers, bulk bag unloaders, container dumpers, and bag dump stations is designed and built to be compliance-ready and to conform, from the ground up, to the specific regulated processes and practices of each application. NBE expertise in domestic and international standards across design categories, such as: electrical and mechanical, hydraulics and pneumatics, and safety and controls provide proactive assurance of best-practice sanitary equipment and process design. Just because equipment is built of stainless steel doesn't make it process-compliant. bring clarity and confidence to material handling equipment compliance and process acceptance procedures with the advantages of NBE sanitary-construction material handling equipment and proactive regulatory compliance capabilities.
Bulk Material Filling and Discharging Equipment Guide Book Assists In Bulk Material Handling Systems Evaluation
A guide book entitled, Automated Bulk Filling and Discharging Systems Data and Specifications is the first in a series of guide books being offered to assist production and process engineers, plant operations and management personnel, and corporate managers in their evaluation of application-specific, bulk material filling systems and bulk material unloading systems.
Automated Bulk Filling and Discharging Systems Data and Specifications Guide Book provides materials of construction guidelines; performance capacities, pressures, and accuracies; and electrical standards guidelines for multiple bulk material handling equipment types.
The Automated Bulk Filling and Discharging Systems Data and Specifications Guide Book details bulk bag filler systems, bulk bag unloader systems, and bulk container dumper systems. Specific content includes: materials of construction guidelines for structural framework and components; ranges of performance for operating capacities, pressures, and accuracies; and electrical standards guidelines for each bulk material handling equipment type. The guide book also presents the integrated automation capabilities of each system type and their ability to centralize multiple process controls, including upstream and downstream process operations, into a single, menu-driven controller interface. The guide book also offers a general overview of other bulk material handling equipment, including: bulk material mixing and blending, bulk material weighing, and bulk material storage systems.
The second guide book in this series is entitled, Sanitary Bulk Filling and Discharging Systems Data and Specifications, and is scheduled for release in June, 2011.
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.
Fully Automated Bulk Container Dumper Reduces Operator Interaction; Increases Process Throughput
According to findings from a report of the U.S. Department of Labor, Bureau of Labor Statistics; persons in occupations involving manual material handling, such as: repetitive placing, grasping, or moving of objects or materials, are 80% more likely to experience injuries requiring days away from work than persons who complete similar tasks with the aid of machinery.
This fully automated, self-contained, bulk tote dumper system completely manages material from the introduction stage, through discharge and conditioning, to downstream supply of finished material into manufacturing operations. Human interaction is limited to bulk container loading and removal with a fork truck.
The National Bulk Equipment, Inc. lift-and-seal carriage receives each 1,450-pound bulk container and precisely aligns and seals it to the custom, stainless steel discharge hood using an automatic centering system. The 2,000-pound capacity lift carriage raises and rotates the container 180 degrees, ensuring complete material discharge. The 100 cubic-foot capacity, stainless steel receiving hopper with integrated agitator pre-conditions the material. A 9-inch diameter auger feeds pre-conditioned material to a high-capacity, dual-shaft size reduction crumbler for final conditioning of the material prior to pneumatic conveying to downstream process operations. High capacity, chain drive, live roller conveyors and 90-degree rotation turntables provide container indexing and accumulation. Electrogalvanized, zinc-coated, carbon steel conveyor rollers provide superior corrosion resistance and extended duty cycles in the harsh environment.
Complete bulk material process automation engineering and integration, including controls, sensors, monitoring, and data reporting are all centralized to a single, menu-driven touch screen HMI, built by NBE. Legacy upstream and downstream equipment automation integrates with NBE automation to the facility’s SCADA center.
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.
Bulk Bag Filler Provides USDA, 3-A, and BISSC Certified Construction
Bulk bag fillers provide sanitary, safe operation; simplify integration to food, pharma, and medical applications
In previous posts we've discussed the issues associated with accurately identifying and harmonizing the various codes and standard necessary for bulk material handling equipment; particularly in food, pharmaceutical, and medical applications. This post will give an example, in a bulk bag filler application, of the successful harmonization and integration of multiple codes and standards into the physical construction and the controls automation of a bulk bag filler system used in food processing and packaging.
This bulk bag filler, built to achieve USDA, 3-A, FDA and BISSC compliance includes features such as 32 Ra surface finishes to simplify cleaning; tool-less, demountable assemblies to speed inspection; 3-A compliant components to aid in sanitary standards conformance; HEPA air filtration for sanitary bulk bag inflation; and a structural framework leak test system to facilitate clean-in-place (CIP) procedures. Food-grade non-metal components provide excellent material release and resistance to corrosive food ingredients and cleaning chemicals.
NTEP-certified Weighing on Bulk Bag Filling Systems
There seems to be an increased recognition throughout the industry of the process advantages, and financial value, of NTEP-certified weigh systems used in bulk bag filling and bulk container filling applications. NTEP may have once been perceived as only appropriate for pharma or other applications with cGMP; but, outside of that, accurate weighing was good enough. The industry is now recognizing, regardless of the application, accurate weighing is only of real value when it can be done consistently and repeatedly, and with the assurance that the weigh values are certified accurate. There are obvious advantages to precision weigh accuracy in bulk bag filling systems such as reduced material waste and eliminating re-work. NTEP-certified bulk bag filling systems provide those advantages plus reduced labor allocation, improved process optimization, and downstream (or customer-side) assurance that incoming packages are process-ready. NTEP-certified weighing is available for bulk bag filling systems as well as other bulk container filling systems, including drums, totes, gaylords, and others.