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Category: indpro blog

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?

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?