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Pneumatic Conveying: A Unique approach to Maximizing Powder & Bulk Material Transfer

Posted on by Indpro

Pneumatic Conveying: A Unique approach to
Maximizing Powder & Bulk Material Transfer

Industrial material handling poses a constant challenge to the efficient and reliable transfer of powders and bulk materials. An innovative and flexible technology, pneumatic conveying is one of the most effective and efficient methods for conveying materials. This blog explores the intricacies of pneumatic conveying, highlighting its distinctive approach to maximizing the transfer of powders and bulk materials in various industries.

Understanding Pneumatic Conveying

Typically, moving bulk materials through a pipeline with the help of a gas, such as air or nitrogen, is known as pneumatic conveying. With precision and flexibility, pneumatic conveying can handle a wide range of materials, from fine powders to larger granular particles.

How does Pneumatic Conveying System Works?

The process involves several steps, and the specific configuration can vary based on the type of pneumatic conveying system (dilute phase, dense phase, or others) and the characteristics of the materials being conveyed. Here’s a general step-by-step explanation of how a pneumatic conveying system works:

Step 1: Material Pickup

Typically, as the first step, bulk material is picked up from a storage silo or hopper. Several devices can be used to achieve this, including rotary valves, screw feeders, dense phase vessels, and venturi eductors, depending on the system’s design.

Step 2: Material introduced in Conveying Line

The material is passed into a conveying line, which is typically a pipeline or duct that connects the pickup point to the destination or receiving point. The conveying line is designed to transport the material using a controlled flow of air or gas.

Step 3: Air or Gas Supply

Compressed air or another gas is supplied to the conveying line to create a flow that carries the material. The pressure and flow rate of the air or gas are controlled based on the design criteria of the conveying system.

Step 4: Material Suspension (Dilute Phase) or Material Plug (Dense Phase)

Material is conveyed in a dilute phase pneumatic conveying as a low-density mixture of air that resembles fluid, also known as suspension flow. In dense phase pneumatic conveying, the material is conveyed as a dense plug or slug with a higher material-to-air ratio.

Step 5: Material Conveying

The material-air mixture travels through the conveying line, overcoming the effects of gravity and any resistance encountered in the pipeline. During this process, the material is moved by the force of moving air or gas.

Step 6: Air Material Separation

Near the destination point, the conveying air or gas is separated from the material. This can occur using various separation devices such as cyclones, filters, or other air-material separation equipment. The separated gas can be recycled back into the system to maintain the temperature, humidity or inert gas concentration.

Step 7: Material Receiving

The conveyed material is discharged at the destination point, such as a storage vessel, reactor, mixer, or other processing equipment.

Step 8: Dust Collection (Optional)

In systems conveying dusty materials, dust collection equipment may be employed to capture and separate airborne particles from the conveying air, ensuring a clean and safe working environment.

The entire pneumatic conveying process is controlled and monitored by a control system. This system regulates parameters such as air or gas flow, pressure, and material feed rates to ensure efficient and reliable operation. Sensors and instruments provide real-time feedback for monitoring and adjustments.

It’s important to note that the specific design and components of a pneumatic conveying system can vary based on factors such as the type of material, conveying distance, required flow rates, and the characteristics of the process. Proper system design and selection are essential for achieving optimal performance in pneumatic conveying applications.

How pneumatic conveying is maximizing efficiency in powder & bulk material transfer?

Pneumatic conveying process offers several advantages that contribute to its efficiency and effectiveness in material handling. Here are some benefits of pneumatic conveying that contributes to maximizing powder and bulk material transfer:

1. Efficient Material Transfer:

Pneumatic conveying systems enable efficient and rapid transfer of powder and bulk materials from one point to another at various desired capacities.

2. Reduced Material Degradation:

The gentle handling nature of dense phase pneumatic conveying minimizes material degradation during transfer. This is crucial for handling fragile or sensitive materials where maintaining product integrity is essential.

3. Clean and Enclosed Operation:

Pneumatic conveying systems operate in enclosed pipelines, minimizing the risk of contamination and ensuring a clean transfer process. This is particularly important in industries such as food, pharmaceuticals, and chemicals.

4. Versatility in Conveying Materials

Pneumatic conveying systems are capable of handling various powder and bulk materials, from fine powders and granules to pellets and abrasive substances, making them highly adaptable across different industries.

5. Flexibility in System Design:

The flexibility in design of pneumatic conveying systems allows them to be customized for various facility layouts, making it possible to convey materials over long distances or through complicated routes.

6. Reduced Manual Handling and Labor Costs:

Automation in pneumatic conveying reduces the need for manual labor in material loading, unloading, and transportation. This results in increased efficiency and improved workplace safety.

7. Space Efficiency:

The use of pneumatic conveying systems is often more space-efficient than the use of mechanical conveyor systems. A conveying system can navigate around existing equipment or within a limited amount of space in facilities where space is limited.

8. Energy Efficiency:

Modern pneumatic conveying systems are designed with energy efficiency in mind. Variable frequency drives (VFDs), efficient blower designs, and optimized control systems contribute to energy savings.

9. Integration with Process Automation:

Pneumatic conveying systems can be easily integrated into overall process automation. This allows for precise control, monitoring, and optimization of material flow, contributing to overall operational efficiency.

10. Reduced Environmental Impact:

Enclosed pneumatic conveying systems minimize dust emissions, contributing to a cleaner and safer working environment. The enclosed nature of these systems also prevents material spillage and waste.

11. Continuous and Reliable Operation:

Pneumatic conveying systems can operate continuously, ensuring a consistent flow of materials. Their reliability is further enhanced by features like automatic controls, monitoring systems, and preventive maintenance measures.

12. Material Quality Preservation:

The gentle conveying process helps preserve the quality of materials, preventing issues such as segregation, attrition, or contamination.

By combining these features, pneumatic conveying systems maximize the efficiency of powder and bulk material transfer, making them integral to numerous industries where reliable and contamination-free material handling is essential.

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What is Weighing & Batching Hopper?

Posted on by Indpro

What is Weighing & Batching Hopper?

The weighing & batching hopper stands as a cornerstone of precision in industrial processes where accuracy and efficiency are paramount. It is an integral part of many manufacturing processes, contributing to the consistency and reliability of the measurement and dispensing of materials. In this blog, we explore weighing & batching hoppers, product dosing methods, and the components of weighing & batching systems to explore what weighing & batching is all about.

Understanding weighing & batching:

Weighing & batching is a method of dispensing materials in predetermined quantities by weight. This precise approach is crucial in industries where the composition and consistency of products are paramount, such as pharmaceuticals, food processing, chemicals, and more. Weighing & batching ensures that the correct proportions of raw materials are used in each batch, leading to consistent product quality.

What is a Weighing & batching Hopper?

A weighing & batching hopper is at the heart of a weighing & batching system. Based on the weight of the material, this vessel is designed to hold and measure the desired quantity of material. This material can be accurately dosed using the hopper’s load cells or weight measurement devices, which provide real-time feedback to the control system.

Product Dosing Methods

In weighing & batching hoppers, materials are dispensed accurately using various dosing methods. In choosing a dosing method, factors such as material nature, accuracy requirements, and overall manufacturing process need to be considered. Common dosing methods include:

Gain-in-Weight Dosing:

In this method involves filling the weighing & batching hopper with the material gradually until the target weight is reached. Throughout the feeding process, the system monitors the weight gain and adjusts the feeding rate accordingly.

Loss-in-Weight Dosing:

The loss-in-weight method begins with a full hopper, and material is gradually removed until the desired weight is reached. The system monitors the weight loss and adjusts the feed rate accordingly.

Volumetric Dosing:

Volumetric dosing relies on measuring the volume of material rather than its weight. It is simpler than weight-based dosing, but less accurate than that, and often used in non-critical situations.

Components of a weighing & batching System:

Weighing & batching Hopper:

The central component, the weighing & batching hopper, is designed to securely hold and measure the materials based on weight.

Load Cells:

Load cells are sensors integrated into the weighing & batching hopper, providing real-time weight measurements. These measurements are crucial for accurate dosing.

Feeding Mechanism:

The feeding mechanism, such as a conveyor belt or screw feeder, is responsible for transporting materials into the weighing & batching hopper at the desired rate.

Control System:

The control system oversees the entire weighing & batching process. The microcontroller interprets data from load cells, adjusts the feed rate as required in coarse feed & fine feed, and ensures that the correct quantity of material is dispensed.

Discharge Mechanism:

Once the correct weight is achieved, the discharge mechanism, often a gate or valve, releases the materials from the weighing & batching hopper into the downstream process.

Calibration of Weighing & Batching Hopper

Weigh hopper calibration can be performed using different methods, and two common approaches are static test weigh calibration and material tests. Each method has its advantages and may be chosen based on factors such as the application, the type of material being handled, and the precision required. Here’s an overview of both methods:

1. Static Test Weigh Calibration:

Procedure:​

  • Zero Calibration: Ensure that the weigh hopper reads zero when empty. This is the initial step to account for any offset or drift in the weighing system.
  • Application of Calibration Weights: Apply known calibration weights to the weigh hopper. These weights should cover the expected range of loads the hopper will handle.
  • Comparison: Compare the actual weight applied to the weigh hopper with the recorded weight displayed by the weighing system.
  • Adjustments: Make any necessary adjustments to the calibration settings based on the comparison results.

Advantages:

  • Static test weigh calibration provides a straightforward and direct method to calibrate the weighing system.
  • It is suitable for applications where the material properties or handling characteristics are not critical to the calibration process.

Considerations:

This method assumes that the weighing system behaves consistently under static conditions, and the material properties do not significantly affect the calibration.

2. Material Tests:​

Procedure:​​

  • Zero Calibration: Zero the weigh hopper when empty.
  • Material Loading: Load the weigh hopper with the actual material it will handle during normal operations.
  • Weighing Process: The process of weighing the material should be recorded as the material is being loaded and discharged. This involves simulating the actual operating conditions.
  • Comparison and Adjustments: Compare the recorded weights with the expected values. Make adjustments to the calibration settings based on the comparison.

Advantages:

  • Material tests take into account the specific characteristics of the material being handled, including factors such as flowability, density, and handling dynamics.
  • This method provides a more realistic representation of the weighing system's performance under actual operating conditions.

Considerations:

  • Material tests may be more time-consuming and may require careful control of the material flow to ensure accurate results.
  • The material used for testing should be representative of the materials the system will handle in normal operations.

Advantages of Weighing & batching:

  • Precision: Weighing & batching ensures precise measurement, minimizing variations in material composition and contributing to consistent product quality.
  • Efficiency: By accurately dispensing materials, weighing & batching reduces waste and ensures that the right amount of raw materials is used in each batch.
  • Flexibility: Weighing & batching systems can be adapted to a wide range of materials and manufacturing processes, making them versatile in various industries.
  • Quality Control: The accuracy of weighing & batching contributes to stringent quality control measures, meeting regulatory standards and customer expectations.

In the symphony of industrial processes, the weighing & batching hopper plays a virtuoso role, ensuring harmony and precision. From pharmaceutical formulations to food recipes, the reliability and accuracy of weighing & batching systems are indispensable. As industries continue to prioritize consistency and efficiency, the weighing & batching hopper stands as a testament to the art and science of precision manufacturing, shaping the landscape of diverse industrial sectors.

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Increasing the Lifespan of Bulk Material Handling System

Posted on by Indpro

Increasing the Lifespan of
Bulk Material Handling System

In industrial operations, where efficiency and longevity are paramount, the lifespan of bulk material handling systems plays an important role in determining overall productivity. From conveyors to storage silos, these systems form the backbone of material transport in various industries. The focus of this blog is to understand how to increase the lifespan of bulk material handling systems, ensuring sustained performance, and minimizing downtime.

The Crucial Role of Maintenance:

The key to a reliable and efficient bulk material handling system is a well-executed maintenance strategy. Regular maintenance prevents unexpected breakdowns and costly downtime, as well as extending the lifetime of critical components. Here are some key aspects of an effective maintenance strategy.​

Regular Inspections:

Ensure that all pneumatic conveying components, such as pipe connections, valves, filters, and rotary airlock valves, are routinely inspected visually. Inspect your system for signs of wear, leaks, obstructions, or abnormalities.

Filter Inspection and Cleaning:

Keep filters clean and inspect them regularly to prevent dust buildup and maintain proper airflow. Clogged filters can lead to reduced system efficiency and increased pressure drop. Although most filters nowadays come with pulse jet cleaning technology, some process changes can lead to clogging of filters.

Check Seals and Gaskets:

Periodically inspect the seals and gaskets in rotary airlock valves, diverter valves, and other components. Any worn or damaged seals should be replaced to prevent air leaks and maintain the system’s performance.

Rotary Valve Maintenance:

When your system includes rotary airlock valves, conduct regular maintenance. Clean and inspect the valves, replacing any parts, such as rotor blades and seals, that show wear or damage.

Inspect Pneumatic Conveying Pipes:

Inspect pneumatic conveying pipes for signs of wear, corrosion, or damage. Promptly address any issues to prevent leaks and maintain the system’s integrity.

Lubrication:

Lubricate moving parts, including bearings, chains, and pneumatic actuators, as per the manufacturer’s guidelines. Proper lubrication ensures smooth operation and minimizes wear.

Air Compressor and Blower Maintenance:

Perform regular maintenance on the air compressor and blower. This includes changing filters, checking oil levels, and inspecting for signs of wear or malfunction. This is the most essential device that is responsible for running the system.

Check Pressure Relief Devices:

Ensure that pressure relief devices, such as safety valves, are functioning correctly. These devices are crucial for preventing over pressurization in the system.

Material Leakage Prevention:

Address any material leakage issues promptly. Material leaks can lead to product loss, contamination, and safety hazards.

Inspect Instrumentation and Controls:

Regularly inspect and test instrumentation, sensors, and control systems to ensure they are accurate and functioning correctly. Calibrate instruments as needed.

Inspect Pneumatic Conveying Fans:

If the system includes fans or blowers, inspect and maintain these components regularly. Check for proper alignment, clean fan blades, and ensure the motor is functioning as intended.

Vibration Analysis:

Perform vibration analysis on rotating equipment, such as fans and blowers, to detect imbalances or misalignments that could lead to equipment failure.

Training and Documentation:

Provide training to operators and maintenance personnel on the proper operation and maintenance of the pneumatic conveying system. Maintain comprehensive documentation, including manuals, maintenance schedules, and records of repairs.

Emergency Preparedness:

Establish and communicate emergency procedures, including shutdown protocols and response plans. Make sure that personnel are trained on emergency response.

System Optimization:

Periodically review and optimize the pneumatic conveying system to improve efficiency. Consider adjustments to air velocities, conveying parameters, and system configurations based on changing requirements.

Importance of Maintenance:

Maintenance is critically important for bulk material handling systems for several reasons, and its significance can be summarized as follows:

1. System Reliability:

Regular maintenance is essential for ensuring the reliability of bulk material handling systems. By addressing potential issues before they lead to breakdowns, the system can operate consistently and meet production demands.

2. Prevention of Downtime:

Downtime in a bulk material handling system can be costly in terms of lost production and revenue. Proper maintenance helps prevent unscheduled downtime by identifying and addressing issues proactively.

3. Equipment Longevity:

Well-maintained equipment tends to have a longer lifespan. Regular inspections, lubrication, and part replacements contribute to the longevity of components, reducing the need for frequent replacements.

4. Operational Efficiency:

Maintenance makes sure that the system operates at optimal efficiency. This includes addressing issues such as misalignments, wear and tear, and material buildup, which can otherwise lead to reduced throughput and increased energy consumption.

5. Safety Compliance:

Maintenance is essential for ensuring that the bulk material handling system complies with safety standards and regulations. Regular inspections and repairs contribute to a safe working environment for personnel.

6. Cost Savings:

Investing in preventive maintenance is more cost-effective than handling emergency repairs and replacements. Regular maintenance tasks are usually cheaper and can help avoid expensive major failures.

7. Product Quality:

Maintenance is essential for ensuring that the bulk material handling system complies with safety standards and regulations. Regular inspections and repairs contribute to a safe working environment for personnel.

8. Energy Efficiency:

Properly maintained systems tend to operate more efficiently, leading to energy savings. Addressing issues such as misalignments and friction can reduce energy consumption and contribute to overall sustainability efforts.

9. Minimization of Unscheduled Repairs:

Unscheduled repairs can be disruptive and expensive. Maintenance activities help minimize the occurrence of unexpected breakdowns, allowing for planned repairs and replacements during scheduled downtimes.

In the dynamic sector of bulk material handling, where efficiency and reliability are crucial, a solid maintenance strategy is essential for success. Prioritizing routine inspections, effective lubrication, thorough cleaning, and predictive maintenance technologies ensures the efficiency and longevity of material handling systems. Maintenance is not just a reactive measure but a proactive investment in operational resilience and industrial success. As industries progress, a well-maintained material handling system is key to smooth and efficient material transport.

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Types of valves used in pneumatic conveying systems

Posted on by Indpro

Types of valves used in
pneumatic conveying systems

Valves play a crucial role across various industries, serving to control the flow of gas and fluid through specific connection lines. With diverse types and functions, valves aid in redirecting or restricting the flow of substances within a system.

Industrial valves are designed to regulate, start, change, separate, or stop the flow of fluid or gas in a set direction. Besides that, they can also help ease excessive pressure from different vessels or systems.

There’s a whole variety of valve types for all wide range of applications. If you’re dealing with industrial setups that use valves for different reasons, understanding the various types is key. Let’s check out the different kinds of industrial valves!

Type of valves used in Pneumatic Conveying System


1. Butterfly Valve: ​ ​​

A butterfly valve is a quarter-turn valve used to control fluid flow in a pipeline. It’s called “butterfly” because the disc inside looks like a butterfly’s wings when it rotates. This disc sits in the middle of the pipe and when turned 90 degrees, it either allows or blocks the fluid flow. These valves are great for isolating vessels or in pneumatic conveying pipelines for handling bulk solids.

Butterfly valves are differentiated in terms of type of construction in the following ways:

Concentric Butterfly Valve

It is the most common type of butterfly valve the where, the shaft which connects the actuator to the disc of butterfly valve known as ‘stem’ is positioned at the center of the disc.

Lug-style Butterfly Valve

This valve has threaded inserts at both sides of the valve body. The valve is mounted between two flanges.

Eccentric Butterfly Valve

The stem of this valve is located off-center, which allows for a more resilient seating arrangement. There are two types: high-performance valves and triple offset valves. High-performance eccentric valves have a slightly offset stem, while triple offset valves have a more pronounced offset.

Wafer-style Butterfly Valve

This valve is designed to fit between two flanges without the need for bolts and nuts through the flange holes, typically 4 in number. It is held in place by the flanges.

Flanged Butterfly Valve

This valve is installed between two flanges using bolts and nuts to secure it in place. It is suitable for applications where the pipeline has flanges at both ends.

Butterfly valves are widely used in various industries due to their simplicity, lightweight design, and relatively low cost. They are suitable for applications where tight shut-off is not critical, and a quick quarter-turn operation is desirable.


2. Knife Gate Valve: ​​

A knife gate valve is a special type designed to cut through thick fluids using an edge blade. These valves are commonly used when you need straight-line fluid flow with minimal restrictions. They’re also used for isolating vessels or feeders handling bulk solids. They are typically designed for heavy loads.

The main types of knife gate valves used are:

Slurry Knife Gate Valve

Specifically designed to handle abrasive and viscous slurry fluids. The gate is designed to cut through the slurry without causing excessive wear.

Uni-Directional Knife Gate Valve

Flow is restricted in one direction only. This type is suitable for applications where a one-way flow is desired.

Bi-Directional Knife Gate Valve

Flow can occur in both directions. It provides versatility in applications where fluid flow may need to change directions.

Lug-Style Knife Gate Valve:

Like lug-style butterfly valves, these valves have threaded inserts at both sides of the valve body. Typically used in applications where the valve is positioned between two flanges.

Wafer-Style Knife Gate Valve

This valve is designed to fit between two flanges without the need for bolts and nuts through the flange holes, typically 4 in number.


3. Ball Valve: ​​​​ ​

Ball valves have a design with a big sphere and central hole for smooth fluid flow. They’re great at controlling high-pressure liquids and gases while reducing pressure drop. Their quick response time makes them efficient for fast opening and closing actions. Ball valves are versatile and perfect for different pneumatic conveying system applications. Here are some common types of ball valves used in pneumatic conveying:

The main types of ball valves used are:

Two-way (shut-off) ball valve

controls the flow of air or gas in a straight-through path. It allows the system to start and stop as needed.

Three-Way (Diverter) Ball Valve

These valves have three ports and can redirect the flow of air or material between two different paths. Used for diverting air flow to different destinations within the pneumatic conveying system.

V-Port Ball Valve

These valves have a V-shaped port in the ball, allowing for more precise control of flow by partially opening or closing the valve. Used in applications where throttling or modulating the flow is required.

Full-Port Ball Valve

These valves have a larger port size, providing minimal restriction to flow and reducing pressure drop. Suitable for applications where maximizing flow capacity is important.

Trunnion-Mounted Ball Valve

provides additional support for the ball , ensuring stability and reducing pressure on it . Used in high-pressure pneumatic conveying systems.

Metal-Seated Ball Valve

These valves have metal seats, providing better wear resistance and durability, especially in applications with abrasive materials. Suitable for handling abrasive materials in pneumatic conveying systems.

Floating Ball Valve

The ball in these valves is not fixed and can move slightly to ensure a tight seal against the seats. Used in applications where a tight seal is crucial to prevent leakage.

Cavity Filled Ball Valve

These valves have a cavity filled with a sealing material to enhance sealing performance. Suitable for applications requiring enhanced sealing in pneumatic conveying.

Butterfly, ball and knife gate valves can be operated using various methods, including manually, electrically, pneumatically, or hydraulically. The choice of actuation method depends on the specific application requirements and the preferences of the system designer. These valves are commonly actuated by the following methods:

1. Manual Operation:

Handwheels or levers are used to manually turn the stem and control the position of the disc or gate.

2. Pneumatic Operation:

Compressed air is used to actuate the valve. Pneumatic actuators are common for these valves, especially in applications where quick and efficient operation is needed.

3. Hydraulic Operation:

Hydraulic systems use fluid pressure to actuate the valve. Hydraulic actuators provide more force and are suitable for larger valves or applications with higher operating pressures.

4. Electric Operation:

Electric motors drive the valve’s actuator. Electrically operated valves are suitable for applications where continuous modulation of the valve position is required.

The choice between hydraulic, pneumatic, or electric actuation depends on factors such as the size of the valve, the required operating pressure, the speed of operation, and the automation level desired for the system. In many cases, pneumatic actuation is a popular choice for these valves due to its simplicity, cost-effectiveness, and the ability to provide rapid on/off control.


4. Diverter Valve: ​​ ​

Diverter valves are classified based on their diverter mechanism and application. Three common types of diverter valves are:

Flap-Type Diverter Valves​

This type finds its application for flow of bulk solids due to gravity, facilitating diversion to multiple destinations, in a vertical format. It is ideal for scenarios where the movement of bulk solids needs to be directed to various receiving points. These are typically operated using a pneumatic actuator.

Dual Tunnel Diverter Valves​

Primarily used in pneumatic conveying systems and bulk solids handling applications of powder or granular material to redirect the flow from a single inlet to two separate outlets or vice versa. The versatility allows this unit to be mounted in any direction, depending on the configuration of the pipeline. It diverts dense or lean phase solids conveying to various destinations without disrupting the gas flow. These can be used up to a pressure of 6 bar(g) in usual applications. These are typically operated using a pneumatic actuator.

Single Tunnel Diverter Valves​

Similar in application to a dual tunnel diverter valve, however instead of having 2 tunnels on the inside, this unit consists of just 1 tunnel. For larger sizes, this design is better suited since it is more compact and easier to maintain.


5. Non-Return Valve:

Non-return valves, also known as check valves, are essential in pneumatic conveying systems to allow one-way flow of air while preventing backflow of either air or material. Common types include swing check valves, lift check valves, spring-loaded check valves, in-line check valves, diaphragm check valves, disc check valves, wafer check valves, and dual-plate check valves. Their selection depends on factors like material type, system pressure, and application orientation. These valves play a crucial role in maintaining system efficiency and preventing issues such as material contamination and equipment damage.


6. Pressure Regulating Valve: ​

In pressure regulating valves, high-pressure fluid or gas initiates the process. A spring within the valve exerts a consistent force to slightly open it. This allows the fluid or gas to flow through, filling the outlet end. As the outlet pressure builds, it pushes the valve upward, closing it. Essential in industrial processing, water distribution, and steam systems dealing with high pressure.

Pressure regulating valves in pneumatic conveying systems control and maintain a consistent pressure of conveying air or gas. They come in direct-acting and pilot-operated types, with an adjustment mechanism for setting desired pressure levels. These valves prevent over pressurization, contribute to system efficiency, and can be integrated into control systems for automated adjustments. Proper selection, installation, and maintenance is crucial for reliable pneumatic conveying performance.


7. Pressure Relief Valve: ​

Pressure relief valves in pneumatic conveying systems automatically release excess pressure to prevent over pressurization, safeguarding equipment from damage. They come in direct-acting and pilot-operated types, with a set pressure point for activation. These valves serve as safety features, protecting pipelines and components. Some models reset automatically, while others may require manual intervention. Compliance with safety standards and regular maintenance is crucial for their effective operation in pneumatic conveying applications.


8. Solenoid Valve

Solenoid valves are essential in pneumatic conveying systems for controlling the flow of air or gas. They operate electromechanically, responding to electrical signals to open or close. Types include Normally Closed (NC), Normally Open (NO), Three-Way, and Four-Way valves. They play roles in diverting airflow and integrating with control systems. Solenoid valves are chosen based on pressure ratings, material compatibility, voltage requirements, and response times, contributing to the efficiency and automation of pneumatic conveying systems. Regular maintenance is crucial for their reliable operation.

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Dedusting System for Plastic Pellets

Posted on by Indpro

Dedusting System for Plastic Pellets

In the plastic manufacturing industry, maintaining product quality and manufacturing efficiency is paramount. One critical aspect of this is the management of dust and streamers, which are commonly generated during the pneumatic conveying process or during mixing and blending operations. To address this, an effective plastic pellet dedusting system is essential.


Sources of Dust and Streamers

Dust and streamers in the plastic industry primarily arise from two types of pneumatic conveying processes:

1. Dilute Phase Pneumatic Conveying:

This method involves material transfer at high speeds, resulting in increased dust and streamer production. The swift motion induces abrasion and friction, degrading pellets into fine particles and streamers.

2. Dense Phase Pneumatic Conveying:

Although generating less dust and streamers due to lower velocities, this method still produces fine particles that require removal to ensure high product quality.

3. Mixing and Blending Processes:

During the mixing and blending of plastic pellets, mechanical agitation can cause friction and impact, resulting in the generation of dust and streamers. The interaction of materials in these processes often breaks down the pellets, contributing to dust formation.


Impact of Dust and Streamers

The presence of dust and streamers can trigger various adverse effects in the plastic manufacturing process:

Surface Blurring

Vaporized dust particles can blur the surface of final plastic products, impacting their appearance and aesthetic appeal.

Increased Scrap Rates

Fine particles may burn within molds, leading to heightened scrap rates and reduced manufacturing efficiency.

Wire Insulation Defects

Dust can provoke defects in wire insulation, jeopardizing the safety and functionality of electrical components.

Gel Formation in Films

Dust presence may instigate gel formation within plastic films, influencing clarity and uniformity.

Sink Marks on Parts

Dust accumulation in molds can result in unsightly sink marks on plastic parts, affecting their structural integrity and visual appeal.


How Dedusting system for plastic industry works:

The New Patented technology of Plastic Pellet Dedusting system PelletPurge® is specially designed to clean plastic pellets by removing dust and streamers, setting a new benchmark in plastic pellet manufacturing. Positioned strategically beneath storage silos before plastic processing or packing, it effectively eliminates impurities, enhancing the overall product quality. Embrace this cutting-edge solution with us and take your manufacturing processes to new levels with PelletPurge®! 


Applications for the Plastics Processing Industry​

  • Cleaning plastic pellets at the machine feed throat before Injection molding or extruder to ensure optimal optical clarity.
  • It can also clean pellets as they are fed into central surge bins or day bins, feeding multiple machines or dryers.
  • Whether at a cleaning station in a Railcar or truck unload system, drying process, regrinds operation, packaging area.
  • Even recycling plants, this system eliminates dust before loading into storage silos or processing equipment.
  • You can install PelletPurge® system under silos, loading hoppers of packing machines, extruder feed hoppers, or even on injection molding machines. Experience the efficiency and quality improvements that this system brings to the plastic industry!

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