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Category: indpro blog

Battery Recycling Process of Lead-Acid and Lithium-Ion

Posted on by Indpro

Battery Recycling Process

In contemporary times, numerous types of equipment operate on either batteries or gas. The shared characteristic between these two elements is their finite usage; once depleted, the customary practice involves refilling gas or disposing of used batteries and acquiring replacements.

Nevertheless, discarding batteries can contribute significantly to environmental waste, given their widespread use and the presence of harmful materials within them. Consequently, disposing of batteries may not be a prudent course of action. An alternative to discarding used batteries is recycling them.

In contrast to materials like plastic and paper, battery recycling may not be as widely understood. Therefore, we’ve compiled this article to provide you with a fundamental understanding of battery recycling.

Battery Recycling Process Banner

What is battery recycling?

Battery recycling is a vital practice that involves the reuse and reprocessing of batteries, with the primary objective of reducing the volume of batteries being discarded as material waste. Batteries contain a range of hazardous chemicals and heavy metals, and their improper disposal has raised significant environmental concerns, including the contamination of water and soil. Therefore, battery recycling is essential to align with environmental and health regulations, as well as to reap associated benefits.

Batteries, by their nature, have a finite lifespan. Eventually, they either become damaged or cease to function. This is precisely when battery recycling becomes crucial.

How the batteries are recycled?

It is important to understand the process of recycling batteries. There are various types of technologies and material used to produce batteries which must be considered before delving into the recycling process.

Batteries exhibit variations based on their constituent components, which encompass lead-acid, lithium-ion (Li-ion), nickel-metal hydride (Ni-MH), nickel-cadmium (Ni-Cd), lithium-ion polymer, nickel-zinc, and alkaline materials. Manufacturers utilize these components to create various types of batteries, each potentially differing in terms of their intended applications, power output, and the specific recycling processes they entail.


Recycling process of Lead-Acid Batteries​

Lead-acid batteries hold the distinction of being the earliest form of rechargeable batteries worldwide. They are composed of a combination of lead and sulfuric acid.

Recycling process of Lead-Acid Batteries

1. Collection:

The initial step in the battery recycling process entails the collection of discarded lead batteries from various disposal points.

2. Crushing :

Following the collection phase, the subsequent step in the recycling of lead batteries involves their disassembly. Recycling facilities employ mills or industrial crushers to crush the batteries into smaller fragments during this phase.

After crushing, the material is stored in small bags, jumbo bags, or in some permanent storage unit and then it is transferred to the sorting station. Automation solutions can include bag filling machine, big bag unloading station, bag dump station, and pneumatic conveying system for the crushed material to be conveyed to multiple storage silos for storing, and then as per the requirement, it can extract from those silos.

3. Sorting:

In this phase, the lead-acid battery components are meticulously separated. Recyclers distinguish and segregate the plastic and paper components from the lead and metal parts of the battery. The lead and heavy metals extracted from the battery then undergo subsequent processing for recycling.

4. Sieving:

Within this process, recyclers carry out the removal of thermoplastic components present in the battery. Following this, they utilize a sieving process to extract the liquid contents from the battery, leaving behind the dry lead components. Subsequently, the lead and heavy metals proceed to the final stage of the recycling process.

After the sieving operation, dry lead which is in powder form is passed through a cyclone separator to discharge the powder material into the collection unit which is further connected to the extraction process. Automation systems include a cyclone separator & dust collection system which will smoothly carry out the operation for feeding material into the collection unit and the generated dust shall be transferred to the centralized dust collection unit.

The scrap plastic materials from batteries are collected in the warehouse in a loose form and then they get transferred to the washing lines using a pneumatic conveying system for the extraction process. These reprocessed thermoplastics are used to create battery casings and other new plastic products by manufacturers.

5. Extraction:

In the last phase of lead-acid battery recycling, recyclers extract the lead powder and heavy metal components from the remaining battery remnants.

This procedure can be executed in two distinct manners:

Pyrometallurgy based – Pyrometallurgy is a metallurgical process that relies on heat for the extraction and purification of metals. It involves roasting, smelting and refining.

Hydrometallurgy based – Hydrometallurgy is the method employed for extracting metals from ore. It involves leaching, solution-based concentration, and purification & metal recovery.

Both hydrometallurgy and pyrometallurgy ultimately yield molten lead as the end product. Recyclers then shape this molten lead and deliver it to manufacturers to be used in the production of new batteries.


Recycling process of Alkaline Zinc Air /Zinc Carbon Batteries

Recycling alkaline batteries involves a mechanical dismantling process. Similar to other types of batteries, the initial step is the collection of used alkaline batteries. Subsequently, the batteries are sorted after being dismantled.

Following the disassembly of alkaline batteries, recyclers extract three key components for additional processing: steel components, plastic and paper components, and zinc and manganese components.

Subsequently, these materials are packed & sent to recycling facilities, where manufacturers recover them for the production of new products.


Recycling process of Lithium Ion, Nickel Metal Hydride, Nickel-Cadmium Batteries

Lithium-ion (Li-ion) batteries, commonly employed in cars and electronic devices, are rechargeable. Nickel-based batteries, another rechargeable type, find use in portable devices such as cameras and in home or office UPS devices.

Both lithium-ion (Li-ion) and nickel-based batteries share similarities with lead-acid batteries in the final stages of recycling. Here is a detailed step-by-step process for recycling lithium and nickel batteries.

Recycling process of Lithium Ion

Step 1: Collection

Recyclers collect used lithium and nickel batteries from collection points or various other locations.

Step 2: Sorting

During this phase, recyclers carefully separate the plastic materials within the battery from the metal components. Both of these materials can be effectively repurposed in the creation of new products.

Step 3: Shredding

The sorted batteries are passed through a shredder which breaks the battery into coarse particles. After shredding, the coarse material is then transferred to the crushing station using a conveying system.

Step 5: Smelting

In this phase, the components of lithium-ion and nickel-based batteries undergo a process known as High-Temperature Metal Reclamation. During this process, metals present in the batteries, such as nickel, manganese, chromium, and iron, are extracted, conveyed via line to packaging station & and sent to manufacture new products.

Step 4: Crushing

The different types of shredded materials are then crushed into fine particles by using a mill or crusher, and collected material gets conveyed using a conveying system to the smelting process.


Recycling process of Mercury Batteries​

Mercury batteries, after collection, undergo recycling through liquid and heat extraction methods. These batteries contain highly toxic heavy metals, necessitating their processing in carefully controlled extraction environments to minimize environmental and health risks.

The mercury obtained through these extraction processes serves as a valuable resource for manufacturing new mercury batteries, measuring instruments, and components for fluorescent lights. Additionally, manufacturers can repurpose the plastic and other materials obtained from the batteries to create various new products.

Benefits of battery recycling

  • Conservation of Non-Renewable Resources
  • Prevents pollution
  • Minimizes solid waste deposited in landfills
  • Energy saving

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How is plastic recycled?

Which Industries Use Pneumatic Conveying System?

Biscuit manufacturing process

Posted on by Indpro

Biscuit manufacturing process

The term “biscuit” finds its origins in the Latin phrase “bis cotus,” translating to “twice baked.” This culinary concept traces its roots back to the time of the Romans. Nonetheless, the biscuits we recognize today started to evolve during the era of the Middle Ages.

In the 1800s, spurred by the Industrial Revolution, the era of mass-producing cakes, biscuits, and jellies was ushered in. It was during this transformative period that numerous novel biscuit varieties came into existence.

On the global stage, India holds the distinction of being the third-largest biscuit producer, trailing behind only the United States and China. This status is driven by factors such as increased consumer income, a preference for premium biscuits, expanded production capacity, growing health awareness, product innovation, and appealing packaging.

As demand continues to surge, it becomes imperative for production to keep pace accordingly. To enhance and refine the biscuit production process, the implementation of plant automation is crucial. Tasks such as raw material handling, bulk storage, cleaning & sieving, mixing, batch preparation, and packaging are automated within biscuit processing. This automation culminates in the production of a top-tier, high-quality finished product.

Indpro specializes in automated bulk material handling systems, catering to the needs of biscuit manufacturers. Our solutions seamlessly manage raw materials handling, starting with the efficient transfer of materials from bulk containers or bulkers into various storage silos.

Both external and internal silos play vital roles in the production process, serving as indispensable components. The automation solutions include handling of 25 to 50-kg bags and even upto 1000 kg jumbo bags which ensure a smooth transition from handling powders inside the bags into the production line using utmost automation while eliminating dusting & maintaining expected hygiene standards.

Additionally, precise weighing systems for ingredients and minor components ensure accuracy in the production process. This comprehensive suite of offerings plays a vital role in optimizing biscuit manufacturing and other related industries, enhancing efficiency, and maintaining product quality.

Materials used for Biscuit Manufacturing are –

Wheat Flour for biscuit

Flour

Typically, wheat flour is the primary ingredient in biscuit manufacturing, although other flours like rice or corn may also be used.

sugar-for-biscuit

Sugar

Sugar provides sweetness and aids in browning.

Leavening Agents

Baking powder and/or baking soda, play a crucial role in causing biscuits to rise, resulting in their characteristic light and fluffy texture.

milk-for-biscuit

Liquid

Water or milk is added to bind the ingredients together.

chocolate-chips-for-biscuit

Flavorings

Flavorings like vanilla, chocolate chips, nuts, and spices are often added for taste.

butter-for-biscuit

Fats

Fats such as butter, margarine, or vegetable oils contribute to the texture and flavor of biscuits.

Challenges faced by the Biscuit Manufacturing Industry:

Mixing of Foreign Matter:

In the biscuit production process and throughout the raw material supply chain, the inadvertent inclusion of foreign objects like operators’ hair, plastic bristles, packaging materials, sealing threads, needles, and the like, poses a risk of compromising product quality and safety.

Excessive sulfur dioxide:

Excess sulfur dioxide content found in biscuits primarily stems from the breakdown of the dough modifier, sodium metabisulfite. In the biscuit manufacturing process, food companies may occasionally incorporate excessive quantities of sodium metabisulfite to enhance dough extensibility and plasticity, inadvertently leading to elevated sulfur dioxide levels.

Misuse of additives:

Due to fierce market competition, some biscuit manufacturers use cost-cutting additives to improve taste. These additives, when misused, can be harmful to consumers, often going unnoticed.

Cost Escalation

The biscuit industry’s growth is currently hindered by significant inflation in raw material and packaging costs. The cost escalation is impacting to control the final product manufacturing cost ultimately seeing hike in prices.

Steps followed by the current industries for manufacturing biscuits:

Step 1: Raw material receipt:

In the realm of ingredient management, a well-structured warehouse is the hub for gathering and storing various ingredients, packaged in diverse formats such as bags (25 to 50 kg), jumbo bags (500 to 1000 kg), drums (50 kg), and even bulker shipments. Preserving ingredient quality during transportation is critical, requiring a well-orchestrated supply chain.

Automation solutions include Raw Material Handling solutions, including a Manual Bag Dump Station, Bag Lifter & Tilter, Jumbo Bag Unloading System, Bulker Unloading System, Automatic Bag Slitting Machine, Storage Silos, and Pneumatic Conveying System. These solutions streamline ingredient logistics, ensuring efficient and reliable transport, and supporting various industries’ smooth operations.

Step 2: Pre-Mixing:

In the biscuit-making process, the dry ingredients, including wheat flour, sugar, leavening agents, Skimmed Milk Powder, and Malt extract, along with fats, are first combined and mixed until they resemble coarse crumbs.

Here is where automation systems play a crucial role, offering a range of specialized equipment and systems to facilitate this mixing process. These solutions include Specialized Blenders and Weighing & Batching Systems. These solutions ensure a seamless and efficient transition from the initial mixing of dry ingredients to the subsequent stages of biscuit production, contributing to the consistency and quality of the final product.

Step 3: Mixing:

As the biscuit-making process advances, the dough begins to take shape, and this is where the liquid ingredients, along with sugar, are carefully introduced to achieve the desired consistency in the mixture. For biscuits like short dough varieties, a lighter mixing is employed to maintain crispiness and fluffiness.

Step 4: Moulding:

During this crucial stage, the biscuit’s shape is determined, with options ranging from round to various intricate designs. This process divides the dough into desired portions and involves a knife, a forcing roller, and precise control in multiple directions.

Step 5: Baking:

Biscuits are baked in ovens at a specific temperature and time, which varies depending on the type of biscuit being produced. The heat causes the leavening agents to create gas, making the biscuits rise and become crispy.

After baking, a batch or batches of biscuits are checked for their texture, color, cooking level, and height. A meticulous inspection process ensures that they meet the required specifications.

Step 6: Cooling:

After baking, biscuits are cooled on wire racks to room temperature. The biscuits pass through a cooling tunnel, where they are cooled to the desired hardness, preparing them for packaging.

Step 7: Packing:

Once cooled, biscuits are packaged in various ways, including boxes, bags, or individual wrappers. Packaging often includes branding and labeling for marketing purposes.

Step 8: Quality Control:

Biscuit manufacturers implement strict quality control measures to ensure consistency in taste, texture, and appearance. Samples are regularly tested for taste, texture, and shelf life.

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Spices Manufacturing Process

Which Industries Use Pneumatic Conveying System?

Common Powder Flow Problems

Posted on by Indpro

Common Powder Flow Problems and Effective Flow Control Solutions

Powders are present everywhere in different industries, such as chemicals, pharmaceuticals, minerals, food processing and manufacturing. However, managing the flow of powders can be challenging due to their unique properties. We will explore some common powder flow problems encountered in industrial processes and discuss effective flow control solutions to mitigate these issues.

Common Powder Flow Problems:

1. Arching and Bridging:

  • Arching occurs when a stable bridge forms over the outlet of a powder container, preventing the material from flowing freely.
  • Bridging is similar but involves a wider area of material blockage.
  • Common causes: cohesive powders, high moisture content, irregular container shapes, insufficient flow channel available.

2. Rat-holing:

  • Rat-holing happens when a vertical channel forms in the powder material, causing uneven flow.
  • It can lead to inconsistent dosing and inefficient processing.
  • Factors: wide particle size distribution, improper hopper design, and insufficient vibration.

3. Segregation:

  • Segregation refers to the separation of particles based on size or density during handling or movement, leading to uneven composition.
  • It affects product quality and consistency.
  • Contributors: differences in particle size, shape, and density, as well as vibration during transport.

4. Flow Rate Fluctuations:

  • Uneven flow rates can impact production processes and result in inaccurate dosing.
  • Inconsistent flow rates can stem from variations in powder properties or inadequate equipment design.

5. Flow Stagnation:

  • Some powders tend to stick to the walls of containers, causing flow stagnation and reducing discharge rates.
  • Fine particles and cohesive powders are prone to this issue. Moisture in powders also makes them stick to surfaces.

Effective Flow Control Solutions:

1. Powder Bridge breaker (iRotocon):

  • Discharging powder materials from storage silos and hoppers in a controlled manner.
  • It has a bottom panel with thin, radial vanes that revolve inside the hopper.

2. Hopper Design Optimization:

  • Use hopper geometries that minimize dead zones and encourage mass flow.
  • Conical hoppers with appropriate angles can prevent arching and encourage uniform discharge.

3. Vibration and Agitation:

  • Mechanical vibrations help in breaking arches, improving flow.
  • Vibrating devices or agitators can be strategically placed to prevent rat-holing and maintain consistent flow.

4. Air Fluidization:

  • Injecting air into the powder bed can reduce cohesive forces and enhance flowability.
  • It is particularly effective for fine and cohesive powders.

5. Segregation Prevention:

  • Minimize particle size and density variations through proper blending techniques.
  • Maintain consistent flow velocities during transport to prevent particle separation.

6. Equipment Selection and Maintenance:

  • Choose equipment that suits the powder’s properties and flow requirements.
  • Regular maintenance of equipment prevents accumulation and blockages.

7. Testing and Analysis:

  • Conduct flow tests to understand the powder’s behavior under different conditions.
  • Use data to optimize flow control strategies.

Ensuring powder flow problems is crucial for maintaining efficiency and product quality across industries. By understanding the underlying causes of common issues and implementing effective flow control solutions, companies can enhance their production processes and reduce operational challenges associated with powder handling.

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What Is Big Bag Unloading

Why Should You Convey Your Material Pneumatically?

Common Super Sack Unloader Problems

Posted on by Indpro

Common Super Sack Unloader Problems
and How to Address Them

Super sack unloaders, also known as bulk bag unloaders or big bag unloading system, are essential equipment in various industries for efficiently transferring and discharging bulk materials from flexible intermediate bulk containers (FIBCs), commonly referred to as super sacks or jumbo bags. However, like any machinery, super sack unloaders can experience issues that might hinder their performance and efficiency. In this blog, we will explore some of the most common problems associated with super sack discharging and provide insights into how to address them.

1. Material Flow Issues:

Symptoms: Difficulty in material flow or complete blockage during unloading.
Causes: Material bridging, compacting, or improper flow properties.
Solution:
  • Utilize massaging plates to promote material flow.
  • Ensure proper storage and handling of materials to prevent compaction.
  • Select super sack unloaders with features designed to tackle challenging flow properties.

2. Dust Emission and Contamination:

Symptoms: Excessive dust emission during unloading, leading to environmental and health concerns.
Causes: Inadequate dust containment systems, poor sealing, or improper handling of dusty materials.
Solution:
  • Install efficient dust collection and containment systems, such as dust collectors and hoods.
  • Choose super sack discharger with integrated dust control features.
  • Use super sacks with spout liners to prevent material leakage.

3. Incomplete Discharge:

Symptoms: Not all material is discharged from the super sack.
Causes: Improper positioning of the super sack, discharge chute blockage, bag massager not installed or inefficient unloading mechanisms.
Solution:
  • Opt for super sack unloaders with features like electro-pneumatic operated massaging plates to help massage and discharge difficult to flow products.
  • Ensure the super sack is positioned correctly and hanging freely to allow complete discharge.
  • Regularly inspect and clear any blockages in the discharge chute.
Incomplete Bag Material Discharge

4. Equipment Jamming or Overloading:

Symptoms: Unloader jams or stops unexpectedly during operation.
Causes: Overloading the unloader beyond its capacity, foreign objects in the equipment, or mechanical issues.
Solution:
  • Adhere to the recommended weight capacity of the super sack unloader.
  • Implement proper quality control measures to prevent foreign objects from entering the equipment.
  • Regular maintenance and inspection of mechanical components to prevent breakdowns.

5. Operator Safety Concerns:

Symptoms: Unsafe working conditions for operators during unloading.
Causes: Inadequate safety features, lack of operator training, or improper handling of equipment.
Solution:
  • Prioritize safety by choosing super sack unloaders with built-in safety features like interlocks and guarding.
  • Provide thorough training to operators on proper handling and safety procedures.
  • Regularly inspect equipment for potential safety hazards.

6. Mechanical Failures:

Symptoms: Breakdowns, equipment malfunction, or unusual noises during operation.
Causes: Wear and tear, lack of maintenance, or manufacturing defects.
Solution:
  • Establish a routine maintenance schedule and conduct regular inspections.
  • Address any signs of wear or malfunction promptly to prevent larger issues.
  • Work closely with the equipment manufacturer for technical support and replacement parts.

Super sack unloaders are indispensable tools for efficient bulk material handling, but they can encounter various challenges that hinder their optimal performance. By understanding and addressing these common problems, industries can ensure the smooth operation of their bulk bag dischargers, enhance productivity, and maintain a safe working environment for operators. Regular maintenance, proper handling of materials, and investing in quality equipment can go a long way in mitigating these challenges and ensuring the seamless unloading of bulk materials. Get in touch with Indpro’s experts on this subject to learn more on this subject!

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What Is Big Bag Unloading

Why Should You Convey Your Material Pneumatically?

Biodegradable Plastic Manufacturing Process

Posted on by Indpro

Towards a Sustainable Future:
Exploring Biodegradable Plastic Manufacturing

Plastic pollution has become a global environmental crisis, with an estimated 8 million metric tons of plastic waste entering the oceans each year. To combat this issue, there has been a growing interest in the development and manufacturing of biodegradable plastics. Biodegradable plastics offer a sustainable alternative to traditional plastics by breaking down naturally in the environment, reducing their impact on ecosystems. In this blog post, we will delve into the world of biodegradable plastic manufacturing, exploring the processes, materials, and potential benefits of this innovative approach.

What is Biodegradable Plastic?

Biodegradable plastic is a plastic that can be broken down into natural materials by microorganisms such as bacteria and fungi. This means that biodegradable plastics can be composted and returned to the environment, unlike conventional plastics which can take hundreds of years to decompose.

The life cycle of bioplastics

Types of Biodegradable Plastic

There are many different types of biodegradable plastics, each with its own unique properties. Some of the most common types of biodegradable plastics include:

    • Polylactic acid (PLA): PLA is a thermoplastic made from renewable resources such as corn starch or sugar cane. It is often used to make food packaging, disposable utensils, and other items that are designed to be composted.

    • Polyhydroxyalkanoates (PHAs): PHAs are a group of polyesters that can be produced by bacteria. They are often used to make medical devices, food packaging, and other products that require a high degree of strength and durability.

    • Starch blends: Starch blends are made from a mixture of starch and other materials such as cellulose or plastic. They are often used to make disposable cups, plates, and other items that are designed to be composted.

Manufacturing Process of Biodegradable Plastic

The manufacturing process for biodegradable plastics varies depending on the type of plastic being produced. However, there are some common steps involved in the manufacturing of all biodegradable plastics.

Certain raw materials are used in combination to create biodegradable plastics through the process of handling, mixing, extrusion, and cooling. Pneumatic conveying systems and other bulk material handling systems are used as a starting point in the manufacturing of biodegradable plastics.

  • Raw material handling: The first step is to unload and store the raw materials that will be used to make the plastic.  Pneumatic conveying systems are also used to transport raw materials from storage to processing equipment. This can include materials such as starch, polymer pellets, and additives.
  • Mixing and blending: Certain technology of blenders can be used to mix and blend different ingredients in the plastic formulation. This can ensure that the ingredients are evenly distributed before the next step, and that the final product has the desired properties uniformly distributed in the complete batch.
  • Extrusion and Molding: The uniformly blended raw material is then extruded and cooled to a desired shape through a pelletizer. There are several solutions that can Indpro offers to enhance the quality of this final product. The pelletized product can then be conveyed pneumatically to the next step.
  • Packaging and storage: The final product can be stored in storage silos in bulk before final packing. Final packing can be done using an automatic or semi-automatic machine to pack it into small bags or jumbo bags to then dispatch.

Bulk material handling systems can offer several advantages in the manufacturing of biodegradable plastics. These advantages include:

  • Increased efficiency: These systems can help to improve efficiency by reducing the need for manual handling and transportation.

  • Reduced risk of contamination: These systems help reduce the risk of contamination by preventing cross contamination between the raw materials as well as the finished products.

  • Improved safety: Risk of accidents associated with manual handling and transportation is minimized since man movement is not required to produce the products.

  • Healthy work environment: Well-designed material handling systems help improve overall workplace by containing dust which otherwise leads to air pollution issues.

Advantages of Biodegradable Plastic

Biodegradable plastics offer several advantages over conventional plastics, including:

  • Environmental: Biodegradable plastics can be composted and returned to the environment, unlike conventional plastics which can take hundreds of years to decompose. This contributes to resource conservation and pollution reduction.

  • Economical: Biodegradable plastics can be made from renewable resources, which can help reduce the cost of plastic production. Additionally, biodegradable plastics can be used to make a variety of products that are designed to be composted, which can create new markets for these products.

  • Performance: Biodegradable plastics can offer similar performance characteristics to conventional plastics. For example, PLA can be used to make clear food packaging that is just as strong and durable as conventional plastic food packaging.

Disadvantages of Biodegradable Plastic

Despite the advantages of biodegradable plastics, there are also some disadvantages to consider, including:

  • Research required: Biodegradable plastics are still at a nascent stage and more research and development is required for establishing several stable compounds that can be used to replace the plastics used today.

  • Availability: Biodegradable plastics are not as widely available as conventional plastics. This is because they are a relatively new technology, and the manufacturing process is still being refined.

  • Composting infrastructure: To compost biodegradable plastics, they need to be disposed off in a composting facility. This is not always an option, as all communities may not have such composting facilities.
Keeping the advantages and disadvantages of biodegradable plastics, they have the potential to be a more sustainable alternative to conventional plastics and we are excited to see more applications take up this green technology ahead to make the earth a more sustainable place to live.

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How is plastic recycled? Turning Trash into Treasure

Which Industries Use Pneumatic Conveying System?