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Category: indpro blog

Dilute phase vs dense phase conveying

Posted on by Indpro

Dilute phase vs
dense phase conveying

When one decides to automate their bulk material handling using a pneumatic conveying system, the question that arises is whether to go for a dilute phase vs dense phase system. Different people have different opinions on why one technology is better than the other, but it is important to know the facts which will help you in deciding which is best suited for your application. 

Dilute Phase Pneumatic Conveying

Dilute phase pneumatic conveying is a method of transporting bulk materials through a pipeline using a stream of high velocity but low-pressure air. The high velocity of air suspends the bulk material in the air, by virtue of which, the material is then transported at high velocities.

Dilute phase pneumatic system - indpro

Advantages of Dilute Phase Pneumatic Conveying

  • High conveying speeds.
  • Low capital cost.
  • Easy to install, operate and maintain.
  • Can handle a wide range of materials.
  • Compact and space saving.

Disadvantages of Dilute Phase Pneumatic Conveying

  • Material degradation due to high velocities.
  • Material separation during transport.
  • High energy consumption.

Dense Phase Pneumatic Conveying

Dense phase pneumatic conveying is a method of transporting bulk materials through a pipeline using a stream of low velocity but high-pressure air. The high-pressure of air aids in formation of plugs or dunes of the bulk material in piping, by virtue of which, and the material is transported at low velocities.

dilute phase pneumatic conveying - indpro

Advantages of Dense Phase Pneumatic Conveying

  • Low material degradation.
  • Reduced material separation.
  • Lower energy consumption.
  • Can handle long distances.

Disadvantages of Dense Phase Pneumatic Conveying

  • High capital cost.
  • Difficult to install, operate and maintain.
  • Limited range of materials.
  • Equipment is space consuming.

Comparison of Dilute Phase and Dense Phase Pneumatic Conveying

The key differences between dilute phase and dense phase pneumatic conveying include:

  • Material compatibility: Dilute phase pneumatic conveying systems are better suited for materials that can withstand high velocities and are not easily degraded, while dense phase systems are better suited for materials that are fragile and may get damaged during handling.
  • Air pressure: Dilute phase systems operate at lower pressures, typically between 0.1 and 1 bar(g), while dense phase systems operate at higher pressures, between 1 and 6 bar(g).
  • Conveying distance: Dense phase pneumatic conveying systems can handle longer distances, while dilute phase systems are better suited for shorter distances.
  • Energy consumption: Depending on the application, dilute phase systems may consume more energy than dense phase systems due to their high velocity conveying.
  • Maintenance: Dense phase systems require higher maintenance than dilute phase systems due to additional moving parts and more complex operation philosophy.

Applications of Pneumatic Conveying

Pneumatic conveying systems are used in a wide variety of industries, including:

    • Plastics and Polymers
    • Food and Spices processing
    • Pharmaceuticals
    • Chemical manufacturing
    • Minerals
    • Mining
    • Recycling

Selection of a Pneumatic Conveying System

When selecting a pneumatic conveying system, there are several important factors to consider, including:

  • Material to be conveyed and the necessary physical and chemical properties.
  • Distance to be transported, along with the routing.
  • Throughput of conveying required.
  • Specific operating conditions that may be encountered during the process.

By carefully evaluating these factors, it is possible to select the right system for the job to ensure that materials are transported safely and efficiently.

System Maintenance

The maintenance requirements of pneumatic conveying systems depend on the type of system used. Different parts of each system have specific considerations for calculating the maintenance cost of the system. For certain materials, dilute phase pneumatic conveying systems require more maintenance due to the high velocity conveying, which can cause wear and tear of certain equipment. Maintenance tasks for dilute phase systems may include cleaning, replacement of piping components, replacement of wear components, and monitoring of air pressure and flow rates. Maintenance tasks for dense phase systems may include periodic cleaning, replacement of valves, inspection of piping, replacement of wear components, inspection of electrical components, and monitoring of air pressure and flow rates.

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Why should you convey your material pneumatically?

Which Industries Use Pneumatic Conveying System?

How is plastic recycled

Posted on by Indpro

How is plastic recycled?
Turning Trash into Treasure

Do you know what happens with various plastic bottles that you use once and throw away?

Plastic is one of the most widely used materials in the world, but it also poses a significant environmental threat due to its non-biodegradable nature. Recycling plastic is a crucial step in reducing its negative impact on the environment. In this blog, we will discuss how plastic is recycled and the role of silo storage and pneumatic conveying systems in the process.

Step 1: Sorting

The first step in the plastic recycling process is sorting. Plastic waste is collected from various sources, such as households, industries, and commercial establishments, and transported to a recycling facility where it is sorted based on its type. Sorting is essential because different types of plastics have different properties and cannot be recycled together. Sorting is a crucial step in plastic recycling and can be done manually or with the help of machines. Manual sorting involves visually inspecting and separating plastic waste into different categories such as PET, HDPE, PVC, LDPE, and others. Machines such as conveyor belts, infrared sensors, and air classifiers are used for automated sorting.

Step 2: Shredding

The sorted plastic waste is then shredded into small pieces using machines such as granulators or shredders. Shredding makes it easier to handle and transport plastic waste to the next stage of the recycling process. The shredders use high-speed rotating blades to cut the plastic waste into small pieces. The size of the shredded pieces depends on the type of plastic waste and the desired product.

Step 3: Washing

The next step in the recycling process is washing. The shredded plastic is washed in hot water to remove any dirt, debris, and other impurities. The plastic is then dried using centrifugal force or hot air. The washing process removes any contaminants from the plastic waste, making it ready for further processing.

Step 4: Secondary sorting

After washing and drying, the plastic is once again sorted based on its type and color. This step ensures that the recycled plastic is of high quality and free of cross contamination. It can be used to make new products. The sorted and processed plastic waste is stored in large silos to protect it from environmental elements such as moisture, dust & heat. The plastic waste, either pre-sorted or post-sorted, can be transported from the sorters to silos or from silos to extrusion area using a pneumatic conveying system. This system uses air pressure to move the plastic waste through a network of pipes and into the extruder.

Step 5: Melting and Extrusion

In the next stage, the sorted plastic is melted and extruded into long tubes or strands. The melting process is done in a large machine called an extruder. The extruder consists of a screw that heats and melts the plastic as it moves through the machine. The extruder also shapes the molten plastic into a continuous tube or strand.

Step 6: Pelletization

The extruded plastic is then cut into small pieces called pellets. Pelletization makes it easier to transport and store the plastic. The final plastic pellets are stored either in 25 kg bags or 500 to 1000 kg jumbo bags for easy transportation which are filled semi-automatically or automatically using bagging machines. The pellets are uniform in size and shape and can be easily melted and molded into new products.

Step 7: Making New Products

The final stage in the recycling process is the manufacturing of new products. The pellets are transported to factories where they are used to make a variety of products such as plastic bags, containers, and bottles. The pellets are melted and molded into the desired shape using machines such as injection molding machines or blow molding machines. The finished products are then sent for quality control checks to ensure that they meet the required standards. The products made from recycled plastic are cost-effective and eco-friendly, and they help in reducing the amount of plastic waste that ends up in landfills or oceans.

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Why is pilot-plant testing essential

Why Should You Convey Your Material Pneumatically?

Pilot-Plant Testing for Pneumatic Conveying System Design

Posted on by Indpro

Why is pilot-plant testing essential for designing pneumatic conveying systems?

Pilot-plant testing can be very helpful in designing a pneumatic conveying system as it allows you to evaluate the performance of the system in real-world conditions before investing in a full-scale system. Here are some ways in which pilot-plant testing can help:

1. Determine conveying capacity:

Pilot-plant testing can help you determine the conveying capacity of your system. By testing the system with a given material and at different conveying rates, you can determine the maximum capacity of the system and accordingly design the full-scale system.

2. Evaluate material characteristics:

Different materials have different characteristics that can affect the performance of the system. By testing the system with a given material, you can evaluate how these characteristics, such as particle size, density, moisture content, abrasiveness, etc can affect the system’s performance.

3. Optimize system components:

Pilot-plant testing can help to optimize the design of the various components of the system, such as the air compressor, blower, cyclone separator, valves, filter, and receiver. By testing different configurations and settings, one can determine the most effective design for your specific application.

4. Identify potential problems:

Pilot-plant testing can help you identify potential problems that may arise in the full-scale system. By testing the system under different conditions, you can identify issues such as blockages, material buildup, system wear, underperformance, and adjust the design accordingly to address these issues.

5. Determine material compatibility:

Pilot-plant testing can help determine the compatibility of different materials with the conveying system. For instance, some materials may be abrasive, sticky, or prone to moisture absorption, which can impact the performance of the system. By testing the system with different materials, you can assess the impact of these properties and make necessary adjustments to the system design.

6. Evaluate energy consumption:

Pilot-plant testing can help evaluate the energy consumption of the pneumatic conveying system. By testing the system under different operating conditions, you can determine the optimal settings for the blower, air compressor, and other components to minimize energy usage while maintaining the desired conveying rate.

7. Test new technologies:

Pilot-plant testing can be used to test new technologies or components before implementing them in a full-scale system. For example, you may want to test the performance of a new type of valve, piping element, or separator to determine if it can improve the efficiency of the system.

8. Ensure safety and compliance:

Pilot-plant testing can help ensure the safety and compliance of the pneumatic conveying system. By testing the system with different materials and under different operating conditions, you can identify potential safety hazards and ensure that the system meets all applicable regulations and standards.

Pilot-plant testing can provide valuable information to help you design a more efficient and effective pneumatic conveying system. By identifying potential issues and optimizing the design, you can reduce the risk of costly mistakes and ensure that your system meets your specific needs and requirements.

Our customers often bring their materials for testing to our pilot plant where we demonstrate these aspects and ensure we design the system accordingly keeping all material properties in mind. You can visit our page to know more about Indpro’s Technical Center.

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Spices Manufacturing Process​

Why Should You Convey Your Material Pneumatically?

Choosing the Perfect Flexible Screw Conveyor

Posted on by Indpro

What information is needed to select the right flexible screw conveyor?

When selecting a flexible screw conveyor, it is important to consider the following factors in more detail:

flexible auger conveyor indpro

Material properties:

The type of material being conveyed, including its bulk density, particle size, and abrasiveness, can affect the design and configuration of the conveyor. For example, materials with a high bulk density will require a more powerful motor to move the material as compared to one with a low bulk density. Similarly, abrasive materials will require a conveyor with harder wearing components such as the screw and tubing. The particle size of the material will help determine the size of the inlet and outlet openings and the type of screw to use.

Conveying rate:

The required conveying rate, typically measured in cubic feet per hour or pounds per hour, will help determine the size and power of the conveyor. This will help to select the right size of the screw, drive motor and the gearbox.

Conveying distance:

The distance the material needs to be conveyed, including any vertical or horizontal distances, will help determine the length of the conveyor and the required power to move the material. Longer conveyors will require a more powerful motor to move the material over the longer distance.

Operating environment:

The conditions under which the conveyor will be operating, such as temperature, humidity, and exposure to chemicals, will help determine the materials of construction and any necessary seals or coatings. For example, if the conveyor is used in a high temperature environment, it will require a conveyor with heat resistant components or ones suitable for that temperature class. Similarly, if the conveyor is used in a humid environment, it will require an appropriate seal to prevent moisture from entering the conveyor.

Sanitary requirements:

If the conveyor will be used in a food, pharmaceutical or other sanitary application, it’s important to select a conveyor that meets the appropriate sanitary standards such as 3-A, USDA and FDA. The conveyor should be easy to clean and should have a smooth surface finish to minimize crevices and corners that can trap debris.

Space constraints:

The available space for the conveyor and any necessary clearances for access and maintenance will affect the size and configuration of the conveyor. A compact design may be required if space is limited, or a conveyor with a small footprint to minimize the floor space it occupies.

Special requirements:

If the application has any special requirements, such as explosion proof or high temperature, it is important to select a conveyor that can meet these requirements by selecting appropriate materials of construction and/or adding explosion proofing features.

In summary, it’s important to consider all these factors when selecting a flexible screw conveyor to ensure that the conveyor is properly sized and configured for the specific application, and to minimize the risk of problems arising during operation.

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Spices Manufacturing Process​

Why Should You Convey Your Material Pneumatically?

Why is bulk material handling automation required in your plant?

Posted on by Indpro

Why is bulk material handling automation required in your plant?

Optimizing the first mile, like most processes, is made possible by technology, but it takes the right tools to fully automate your manufacturing process plant. Advanced manufacturers recognize that the first mile of automation begins with how raw materials are received, stored, and transported from the moment they enter a facility.

Manufacturers are constantly under pressure to produce goods more quickly and at a lower cost, but never at the cost of quality. Of course, any technology expenditure made to achieve these objectives must have a positive return on investment.

Bulk material handling automation services offer a single point of contact for all your raw material handling automation needs. Bulk material handling automation equipment is commonly found in industrial plants where mass production entails the use of heavy gear to transform raw materials into consumable goods. Automated bulk raw material handling equipment is used by businesses because it helps all process industries enhance their productivity, eliminates waste & increases safety in terms of raw material handling which results in significant cost savings. In the production process, material handling automation equipment lowers the requirement for human intervention. As a result, there is less chance of human error or damage.

This type of machinery is frequently employed for tasks that would otherwise be beyond a human’s physical capabilities, such as transporting material in bulk quantities or working with hazardous or explosive materials.

Applying automated bulk material handling technology to any industrial plant’s network results in significant cost reductions and a quick return on investment. Automated raw material handling, conveying, storing, weighing and batching and bagging of bulk materials helps in achieving excellence in process flow management, product production planning, resource allocation, forecasting, ensuring repeatability, customer delivery, and control.

What is an automated bulk material handling system, and how might it
help your plant become more productive?

Your raw material handling systems control everything from how you keep your raw materials to how they convey across your process plant to achieve your finished product. Bulk material handling management is a key function in raw material handling, so make sure you’re transporting your bulk material as efficiently and cost-effectively as possible. When you start looking into your alternatives, you’ll notice that there is a lot of different bulk material handling systems to choose from. Bulk material handling can be done manually, automatically, or in a combination of both.

To assist you in selecting the best bulk raw material handling systems for your plant, we will go through the benefits and drawbacks of bulk material handling automation systems, as well as how they can benefit you. So, how about we have a look?

The raw material is efficiently delivered from one point in the manufacturing area to another to produce goods, whether inside the same department or bay, on opposite sides of the manufacturing floor, or even in two distinct buildings, thanks to automated bulk material handling systems. An automatic bulk material handling system uses the route and process step information from the MES to transfer raw materials utilizing either technology involving pneumatics or mechanical systems.

One of the most important requirements in a bulk raw material handling system is to optimize processes, get more control and efficiency, and so become more competitive. Furthermore, it is a fact that each industry encounters unique hurdles in providing a product of the quality that your client wants.

 

Manufacturers can reap numerous obvious and verifiable benefits from automated bulk material handling systems, such as lower operating costs and higher material throughput, enhanced productivity, and safety in terms of material handling but the benefits can go even further.

About Automation in Bulk Raw Material Handling

When we talk about bulk material handling, we are referring to the complete process of moving raw materials from one location to another, protecting raw materials, storing, weighing & batching into and between various material processing equipment. It also covers bagging of bulk material of finished goods. Consumption, distribution, positioning, and disposal of raw materials are all part of the process. Various types of equipment are also employed throughout this process, some of which are manual and others are automated. Any company that wants to improve its production efficiency should examine its raw material handling equipment. Most businesses opt for automated bulk material handling since it is not only more efficient but also saves time and effort.

The correct bulk material handling automation system provider will provide all the necessary equipment, including conveying systems, weighing systems, storage systems and many more. Manufacturers are under constant pressure to finish projects as rapidly as possible while maintaining high quality.

Now you will learn about the major advantages of automated bulk material handling equipment and systems for your process plant.

Process area space optimization

You can make the most of all the space in your process area of the production plant by implementing automation in raw material handling. The system solution prioritizes making the most effective and efficient use of the given area.

Handling of various types of raw materials

You will have multiple raw materials which require handling; thanks to Indpro’s pneumatic conveying systems for raw material handling and some of the standard products such as iTransfer, Bag dump station, Jumbo bag unloading station, DisKCon, and many more which are compatible to handle various raw materials. This is critical if you want your process area inside the plant to flourish with an optimized system solution.

Continuous control of the entire production

Bulk raw material handling automation equipment allows you to have complete control over everything that leaves the production process lines. You will have a record of how much raw material have you consumed for production, how much you need to store, and how much you need to use in the process line to produce finished good products.

Real-time statistics

Through the use of centralized integrated computers and the data being fed into them from the material handling system, you will be able to acquire production figures in real-time basics. Real-time data access is possible because of the plant’s connected technology. Get in touch with Indpro’s experts to know more about the IOT & Industry 4.0 compliant solutions we provide.

Improved labour management & dependency ​

Raw material handling automation helps with labour management during the manufacturing process in your plant which is one of the most significant advantages. Assigning higher-value activities to your workers that require more human attention and effort. You may also be able to reduce the number of people needed for the project. You can do the task in less time and spend less money on labour and increase efficiency at the same time.

Ensures repeatability of process

It is not a high-skill task to move raw materials from storage areas to production areas or weighing & batching various raw materials to process equipment or to fill finished goods into bags, and many more. However, there are chances of errors propping up due to manual interventions at these stages. Automation systems ensure repeatability of these tasks without errors.

The factory that is more connected

Bulk material handling automation also makes connecting your complete factory a lot easier. Technology allows you to link a large number of materials handling automated systems and handle their tasks more precisely. Once all of the automation is connected, sending and receiving data and handling future actions will be straightforward.

Batch cycle times have improved

Bulk material is not left stranded when no one is available to inspect it. Indpro’s technology does this, allowing the operation to run independently of operators while they focus on their assigned responsibilities. The time it takes to go from one step to the next becomes more predictable, allowing for more accurate cycle time forecasting and customer due date forecasting.

Customer experience enhancement

Bulk material handling automation is advantageous not just during the manufacturing process, but also throughout time. Every business wants to give its consumers the best experience possible. When you use bulk material handling automation, you’re speeding up your production process while also improving the quality of your output. Furthermore, when you save a substantial amount of money using technology, you can offer better prices to your customers which having a more sophisticated manufacturing setup.

Indpro has the technology to build suitable solutions to fit your requirements, allowing your business to expand. Please contact our experts for a consultation on how you can effectively grow your business by automating your production process.

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Spices Manufacturing Process​

Why Should You Convey Your Material Pneumatically?