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Next-Gen Technology in Mechanical Material Handling

Next Gen. Technology in Mechanical Material Handling

Everyone has rules of thumb when it comes to choosing a conveying system — rules based on bulk material characteristics, required flow rates and distances, sources and destinations, plant configurations and other variables. But those with experience in all types of systems will understand that the only rule for choosing a conveying technology is that there are no hard-and-fast rules. The fact is, most materials can be conveyed using any of several methods, but which is your best choice? Leave that to the experts to guide you.

There are primarily two types of Conveying System, Pneumatic Conveying System and Mechanical Conveying System.

Pneumatic conveying is by far the most hygienic conveying method for bulk dry powders and granular bulk materials because it’s a totally enclosed system that protects materials from air, dirt, and waste, and in turn, facilities from fugitive dust. Pneumatic conveying uses gas (usually air) to transfer suspended material through tubes. A pneumatic conveyor requires a prime mover to displace air which in turn moves the material.

Mechanical conveying include tube chain conveyors, conveyor belts, aero mechanical conveyors, flexible screw conveyor, and bucket elevators that use a mechanical device which is in direct contact with the material to be transferred. The advantage of a mechanical conveyor is the ability to move large amounts of material with minimal energy consumption and minimal particle breakage.

The very versatile nature of the tube chain conveyor makes it adaptable to any configuration and provides it the power to handle all kinds of bulk solids. Just about any industry that needs to convey material gently and quickly can speed up their process by integrating tube chain conveyor into their setup. One of such well known tube chain conveyors in the market goes by the name of Diskcon. Diskcon is mostly used where gentle material handling is required for fragile and perishable products. They are widely used where space is constrained. In process industries flexible material handling solutions are a need of the hour, especially in brown field project, which is where such tube chain conveyors are used.

Food industries use it to gently convey cereals, grains, coffee, peanuts, almonds as well as small-sized solids such as sugar, pepper, etc. Pharmaceutical and chemical industries use it to convey explosive powders with low minimum ignition energy. The plastic and polymer industries use it to convey polymer powders which are again explosive in nature.

Diskcon is a fully enclosed mechanical conveying system that consists of a tubular case through which the product is conveyed. Material is pulled along the channel through specially designed polymer disks with exceptional compressive strength and low coefficient of friction. Inside is a chain disk assembly which carries the material. This may be used to convey several types of bulk solids, however abrasive, hazardous, or sticky they may be. Our tube chain conveyor system can transfer almost any material gently and securely, without altering the product’s integrity.

Our tailor-made tube chain conveyor systems are used in chemical, pharmaceutical, food, polymer, and other process industries for a wide range of applications. With special versatile technological approaches, we care for individual customer requirements. Tube Chain Conveyor is an innovative concept which addresses three major industrial factors: Energy, Space & Environment. This is a gentle moving machine backed up by a control panel featuring Electronic Logic Controllers and sensors for automated operation of a chain tensioning system and an under-speed monitor, making this equipment practically maintenance-free.

A broad variety of products can be conveyed which includes food stuff, cereals, chemicals, pesticides, animal feeds, salt, sugar, dairy powders, plastics and polymers. Operating temperatures can be up to 200° C. Particles ranging from fines to 20 mm lump size, can be easily conveyed. This conveyor comes in stainless steel constructions, with the conveyor chain made from hardened and tempered steel alloy materials, with high tensile properties and wear-resistant.

The heart of our system lies in the driving station, which gives the chain-disk assembly the necessary force for gentle conveying.

DiskCon’s chain tension station continuously tensions the whole chain length in the conveying direction of the equipment while maintaining minimal tension in the return route. It helps reduce chain-disk mounting, sprocket, valve and pipe.

Every bulk solid has different physical and chemical properties. The sum of cohesive and elastic power that it produces defines its flow behavior and pattern.

When compared to a rope, the chain is less susceptible to exhaustion, tear, and elongation. Individual disks can be substituted in a tube chain conveyor in the event of any unexpected damages and may be substituted completely in the case of cable conveyors. Diskcon’s UHMWPE disks are lightweight, have excellent compression properties, and have a high resistance to wear coupled with low friction. Each of these properties offers optimal conveying for reduced energy usage, with small power requirements.

Cohesive and sticky bulk solids require separating cleaning devices from the chain-disk assembly. This is where the brushes mounted inside the driving station ensure that minimal material residue is left over the chain disk assembly while it returns.

We use specialized conveyor tubes that have extremely accurate dimensions and low resistance to movement. Standard ERW tubes cause excessive wear to conveyor disks. Due to a smooth inner finish, our conveyor tubes have low friction, which helps to minimize power consumption and disk wear. The conveying tubes are built for high tensile strength which requires minimal external supports.     

  • Our conveyor uses a chain rather than a cable, which is why they can be run anywhere between 0 and 100% load.

  • The quality of the bulk material is entirely protected, which means you receive the same material from the outlet like the one you put in the inlet. 

  • The chain tensioning station constantly tensions the whole chain length in the conveying direction of the commodity while maintaining minimal tension in the return route to minimize wear.

  • The very flexible design of the Diskcon helps it to conform to any setup and enables it to accommodate all types of bulk solids. Just about any industry that needs to gently and quickly convey material can speed up its process by integrating Diskcon into its setup.

  • Tube chain conveyors consume less than half the power for the same distance and capacity compared with our pneumatic conveying system.

  • We individually plan your system in a modular design. Layout, materials, and speed will be perfectly adapted to your bulk material.

  • We also supply several accessories, such as a cleaner assembly or air spray to clean the chain disk assembly on the return line, manual or pneumatic slide gate valves to monitor product discharge.

  • Diskcon is the ideal solution to handle fragile, explosive, and hygroscopic bulk solids.

  • Material is gently handled inside the tubing at a very low intensity.

  • Due to its compact dimensions, low maintenance, ease of use, and amazingly low energy consumption, this system operation is completely free from dust.

  • After years of material handling experience, and having experienced a variety of bulk solids, we provide material feeding devices that are best suited to your specific needs.

  • Users can choose which system (speed-size combination) they require for their material from our wide range of conveyors, or we could suggest one based on our experience in handling bulk solids.

  • We offer the following range of tube sizes: 4″, 5″, 6″ and 8″

  • Indpro’s Diskcon is available in Stainless Steel construction for food & pharmaceutical applications.

  • We offer standard configurations: C Type, Z Type, Inline TCC, Inclined TCC, Transfer Type, O Type, Inclined O Type, and Portable Type.

Air Pollution Control – A need of the hour

Air Pollution Control – A need of the hour

World Health Organization (WHO), states “Solid dust, from below 1 mm, to a minimum of 100 mm, are often transmitted or may be transmitted by air, depending upon the quantity. They are usually released into the air by natural forces including pollens in soil, sandstorms, and volcanic ashes “Their structure, physical characteristics, and environmental factors”. Manual processes, i.e. grinding, cutting, and crushing also can generate these. Small in size, this often makes them invisible to the eye, making them difficult to control only by human effort. Dust consists of small particles in its most elementary form which floats within the atmosphere. Dust can mix with anything from pollen, to skin cells, to harmful pollution particles, depending on the environment or industry being worked in. Dust are often produced from a variety of sources.

This kind of dust is generated while conveying pharmaceutical/chemical powders from one place to another for their processing in plants. This will be very harmful as sometimes these powders are hazardous if inhaled. Even the utilization of masks might not be sufficient to arrest them. So dust collectors are necessary for such applications. These dust collectors in first place refrain from releasing such particles within the atmosphere by arresting them in the process itself.

Fiberglass, or glass wool, consists of glass filaments combined with yarn and woven into a cloth. Although there is inadequate data, many suspect that fiberglass can cause respiratory diseases when worn down and turned into an airborne material. Wearing a mask when working with fiberglass or other manufactured plastics is strongly suggested as a precautionary measure.

Metal dust usually forms by grinding metal during any metal manufacturing process. Workers subjected to metal dust can suffer from lung and throat irritation. Other sorts of metal dust are often highly poisonous, particularly if the metal consists of heavy metals such as cobalt, lead, or nickel. If dealing with the metal it is necessary to wear any form of a respirator to avoid injury to the lungs.

The silica dust is airborne while dealing with concrete and might be harmful. Exposure to silica dust may result in a disease caused by inhaling an excessive amount of the silica found in dust. Such small particles may cause the lungs to thicken or scarring of lungs, and eventually trigger lung cancer.

Wood dust is additionally referred to as sawdust, as a result of wood manipulation. Whether it’s by sanding, scraping, digging, or shaving, small wood particles are emitted into the soil, creating a coating of dust until deposited. Wood dust are often hazardous when inhaled. It may cause allergic reactions, problems with the oral mucous membrane, or cancer, although the extent of these risks has not been fully identified.

Air pollution control equipment is a vital component of industrial processes that cannot be neglected. Name any industry, and you will realize the extent of harmful stuff it sends into the environment through its processes. Petroleum, energy production, coal and metal mining, chemical, and waste management industries are a few of the many players that have played a considerable role in polluting the environment. Every industrial procedure – including sourcing of raw materials, manufacturing of the final product, maintenance of the site and machinery, and transporting of the product to different locations – results in some kind of pollution. The burning of fossil fuel releases volatile hydrocarbons, burning wood and coal as fuel produces carbon dioxide and sulfur dioxide, and automobiles are also a key source of harmful carbon. Each industrial activity generates emissions that directly pollute the air, soil, or water.

  • Decrease the release of harmful gases and control the spread of air pollution.

  • Conserve whatsoever natural resources are available for our future generations.

  • Decrease health threats posed by breathed in and otherwise consumed pollution.

Air pollution is a threat to nature and due to rapid industrialization, it has become a need of the hour to control it. Indpro Engineering Systems Pvt. Ltd. is a manufacturer and provider of air quality control equipment. We recognize that the growth of the country is directly related to the production in factories, but also there is a need to monitor airborne contaminants. Let’s see some of the pollution management equipment and there uses.

The bag filter is separated into many sections and every component includes a filter bag that removes the particles throughout the process. The collected particles and dust are spread over the fabric and, as the coating thickens, it can be extracted for washing or be dry cleaned so that it may function more effectively. Such elements can be made of nylon, polypropylene, polyester or porous PTFE.

cartridge filter is an analogous equipment to bag filters, where, instead of using a simple element made of fabric, the element consists of pleats which in turn increase the surface area for filtration per element. This effectively reduces the total space required for such a unit. Depending on the selection of media as per the application, such filters can be either used for surface filtration or depth filtration. Cartridge filters can also remove submicron particulates.

The function of a cyclone dust collector is extremely simple. It works on the principle of centralizing the mixture of air, forming a vortex, and entering the device. It uses a cyclonic separation process to isolate particles without the utilization of filters. The only downside is that it is limited to be used with coarser materials and cannot be used with fine powders.

Uses: They are widely used in industries like power plants and several industries like polyolefin, pulp, and paper plants, cement plants, petroleum and coke industry, metallurgical plant, sawmills, and other units.

Indpro in association with Herding is pleased to offer a revolutionary sintered plate filter element based pulse jet filter used to separate dust particulates from fugitive dust emitting sources & process off-gas. The herding sinter plate filter elements feature a PTFE coating that is embedded into the matrix of the rigid body. This leads to consequent surface filtration and effective protection. The base body (rigid) is sintered and then coated. All Herding filter media are classified therefore as mechanical surface filters which can be cleaned online. They are generally characterized by very high separation rates < 0.2 mg/m³ (depending on the dust) and by a service life of up to 15 years and more. They cover a temperature range of up to 450° C (842° F). It has low maintenance costs thanks to long service life. They are free of fibers and therefore ideal for product recovery processes.

Uses: Used in industries such as woodworking, food processing, pharmaceuticals, painting as well as powder coating, and other industries where the emitting particles are of minute size.

What Is a Powder Transfer System?

What is a Powder Transfer System?

A powder transfer system is an efficient & reliable method to transfer powdered & granular materials. It is a significant enhancement to any conventional, mechanical, or pneumatic material conveying process and provides total dust-free means of material transfer. Powder transfer system being very compact is specifically installed where space is a constraint. It also provides the easiest method of material handling automation with minimum modifications required at an existing setup.

Powder transfer system (iTransfer) conveys material vertically or horizontally to and from process machines. The technology allows direct loading of powder into mixers, closed-hoppers, vessels, reactors, etc. in a safe way preventing dust formation during transfer.

This system facilitates reduction in batch time & total process integration. The system comprises of a suction device, transfer vessel with automated valves & regeneration type filter, vacuum pump, intermediate piping & fittings and control panel. The powder transfer system is easy to use, easy to clean and provides excellent rates of efficiency to optimize your process.

  • Pharmaceuticals
  • Food
  • Chemical
  • Fertilizer

iTransfer helps dust-free environment in the processing area. The residue tight framework improves working environment and reduces the risk of product contamination.

iTransfer eliminates manual powder charging result in no powder spillage and airborne dust. Powder transfer system quickly load & unload the vessels, silos, or closed hoppers.

Our powder transfer system is designed in such a way that minimum residue is left behind in the vessel due to vertical walls. The system has an easy to clean design consisting of components which are ‘quick-release’ so that the system can be disassembled and reassembled quickly to minimize its downtime.

Through PTS we can charge various vessels like silo, blenders, reactors & other processing equipment, which helps to quick transfer of powder & reduce batch time.

Powder transport system has a compact and modular design, which fits well into where the powder must be transferred, where generally space is a limitation.

  • Quick release couplings are installed for quick dismantle and assembly.
  • Single system can be used for multiple products.
  • Minimum residue left behind in the vessel due to vertical walls.
  • Low power consumption helps in achieving quick ROIs.
  • Gentle handling of transfer material.
  • Minimal modifications required to install in existing setups
  • Greatly improves health and safety of all operators
ModelsCapacity
iTransfer 2000.75 TPH to 1.5 TPH
iTransfer 2501.5 TPH to 2.5 TPH
iTransfer 3002.5 TPH to 3.5 TPH
iTransfer 4003.5 TPH to 4.5 TPH

Which Industries Use Pneumatic Conveying System?

Which Industries Use Pneumatic Conveying System?

Why Pneumatic Conveying?

A standardized mechanical conveying device operates in a straight line with minor directional adjustments, usually requiring its own motor and drive for each directional shift. It often has a fairly significant number of moving pieces, usually involving regular maintenance. Often, the machine appears to take up much precious real estate in a plant. Pneumatic conveying system, on the other side, uses a basic pipeline with a small diameter to move material. The pneumatic conveyor system is totally enclosed and has few moving parts as it is electronically managed. It is completely dust free and is easier to maintain.

One of the most important factors to consider is the properties of the material to be conveyed, including bulk density, flow properties, temperature, moisture content, inherent hazards and allowable degree of degradation. Both pneumatic and mechanical conveyors will handle a wide range of products, from fine powders to large particles. Both types are often designed to move materials that are friable or fragile, also temperature-sensitive materials.

Food-industry-Processing

Food production is one of the largest, most varied and important industries in the world. Pneumatic conveying equipment and experience-based engineered solutions for any type of dry food or dry ingredient processing is a challenge. Indpro Engineering Systems Pvt. Ltd. is holding a sizable market share in the food sector by providing complete solutions for the segment, especially pneumatic conveying systems, cleaning & sorting systems, storage, weighing solutions for popular products such as – sugar, rice, corn, spices, grains, maida, seasonings, toppings, coatings, cereal, animal feed and Flour. Propelled by the increasing disposable income, the food sector has been witnessing a marked change in consumption pattern. Currently, India is the world’s second largest producer of food in the world and the food processing industry is one of the largest industries in India.

The food Industry is a huge which constantly needs higher hygiene and efficiency. That’s why our customers many a times prefer to go with pneumatic conveying systems considering they are more hygienic and flexible than the traditional mechanical conveying methods. A wide range of foods may be transmitted through pneumatic conveying mechanisms.

India is the biggest global supplier of generic drugs. Indian pharmaceutical industry provides more than 50% of global market for multiple drugs, 40% of US generic production and 25% of all medicines in the UK. India holds a significant role in the pharmaceutical industry worldwide. Our country also has a large pool of scientists and engineers with potential to bring the industry even more forward.

Pharmaceutical sector is also growing at rapid pace. Indpro provides solutions to this sector in the area of pneumatic conveying of dry powders & filtration solutions for handling of various powders having normal, hazardous, explosive and active nature. Closed loop pneumatic conveying systems are offered for hazardous or explosive products using inert gas as a conveying media. Now a days various powder transfer systems are in great demand. Hygienic, quick clean and no residue design are standard features of pneumatic conveying system. Transferring materials pneumatically also supports a virtually dust-free atmosphere. The system’s air-tight pipes isolate carcinogenic and oxygen-sensitive materials from being released into the air, promoting a safer and healthier workplace, not to mention, environment. Charging the vessel/reactor also needs less manpower, giving employees time to attend to other important tasks.

With an increased use of virgin polymers in various products and an increased use of man-made fibers in textile industry, petrochemical industry is required to produce the building blocks ingredients for the most of the chemicals in abundance. To help address this growth we offer a solution to this sector in the area of bulk solids handling from the receipt of the raw material, various intermediate stages till finished product packaging.

Unloading stations, Pneumatic conveying, filtration solutions during handling of various bulk solids, bagging of finished products forms the major part of system supply. Products in the chemical & petrochemical industry can be dangerous and include precautions such as explosion risks, dust control, protection of the environment and prevention of cross contamination.

Plastic and Polymers:

The Indian plastics industry produces and export a wide range of raw materials, plastic-molded extruded goods, polyester films, molded/ soft luggage items, writing instruments, plastic woven sacks and bags, polyvinyl chloride (PVC), leather cloth and sheeting, packaging, consumer goods, sanitary fittings, electrical accessories, laboratory/ medical surgical ware, tarpaulins, laminates, fishnets, travel ware, and others. The Indian plastics industry offer excellent potential in terms of capacity, infrastructure, and skilled manpower. It is supported by many polymer producers, plastic process machinery and mould manufacturers in the country. Among the industry’s major strengths is the availability of raw materials in the country. Thus, plastic processors do not have to depend on import. These raw materials, including polypropylene, high-density polyethylene, low-density polyethylene, and PVC, are manufactured domestically. The recent trend of replacing metallic parts with engineering plastics, increase in various types of electronic gadgets & packaging concepts has increased the consumption of plastic as a raw material. To match this development for industries in compounding & master batches, Indpro offer following solutions:

  • Combination of mechanical & pneumatic conveying of raw material (calcium carbonate, Talc, polymers, resins, various additives etc.) from its receipt till extruder feed

  • Blending of different polymer grades.

  • Pneumatic conveying of finished product to storage silo.

  • De-duster for removal of fines & streamers, generated due to conveying, from finished products before packing.

  • Bagging & pelletizing solutions for finished products.

India has been lucrative market for global beer giants. India is the third largest and fastest growing liquor market in the world. Alcohol beverage can considered an emerging industry due to its high growth potential and increased social acceptance. According to one research, the market for alcoholic beverages in India is expected to grow by around 7.72% over a 10 year period.

Indpro has been in this sector for 15 years as the most preferred partner by all the corporates when it comes to Greenfield, UB – Breweries across the country, as well as brown-field projects.

Our Pneumatic conveying solutions for Brewery & Distilleries include total dry goods handling section including – Cleaning / Weighing and Milling solutions. Off late we have added to our manufacturing range as end of the line spent grain or DDGS handling solutions. This is a critical application as the moisture of input is in the range of 12 % to 60 %. This changes the product behavioral pattern completely. We have around 200+ installations covering major market share pan India.

Why Should You Convey Your Material Pneumatically?

Why Should You Convey Your Material Pneumatically?

Types of Conveying Systems:

Primarily there are two types of conveying systems i.e. mechanical conveying systems and pneumatic conveying system. While the characteristics of each material and the requirements of the specific process may clearly dictate one technology over another, both mechanical and pneumatic conveyors are suitable for most bulk conveying applications.

One of the most important factors to consider is the properties of the material to be conveyed, including bulk density, flow properties, temperature, moisture content, inherent hazards and allowable degree of degradation. Both pneumatic and mechanical conveyors will handle a wide range of products, from fine powders to large particles. Both types are often designed to move materials that are friable or fragile, also temperature-sensitive materials.

Industries know the importance of pneumatic conveyors in transferring bulk quantities of materials from one place to a different one. Pneumatic conveying systems are specially designed to hold stream of air and mixture of bulk solid material. They contain pipes or ducts which are referred to as transportation lines.

In most of the cases, the bulk solid is in dry powdered or granular form which is being transferred using pneumatic conveying system. They can be food related which being charged into vessels/mixers, chemicals being charged into reactors and even polymer granules being charged into hoppers above extruders or injection moulding machines.

There are two major classes of pneumatic conveyors based on mode of transport: dense phase systems & dilute phase systems; Dense phase pneumatic conveying systems are high pressure systems used to convey material to large distances and are especially useful for fragile or abrasive material due to its low velocity nature. Dilute phase pneumatic conveying systems are low pressure high velocity systems which have utmost flexibility for the kind of range of materials that can be handled. The air flow may be generated with air compressors or blowers.

Pneumatic conveying is typically used to transfer solids of all sizes at process plants with specific intervals. The procurement of several of the elements comprising a conveyor system such as rotary valves, conveying pipes and air movers is examined, particularly because it concerns the reliable operation of a conveyor system.

A standardized mechanical conveying device operates in a straight line with minor directional adjustments, usually requiring its own motor and drive for each directional shift. It often has a fairly significant number of moving pieces, usually involving regular maintenance. Often, the machine appears to take up much precious real estate in a plant. Pneumatic conveying system, on the other side, uses a basic pipeline with a small diameter to move material. The system is totally enclosed and has few moving parts as it is electronically managed. It is completely dust free and is easier to maintain.

There are three basic systems that are used to generate high velocity air stream.

  1. Suction or vacuum conveying systems for drawing material with the ambient air using vacuum produced in the pipeline. The system is operated at low pressure, that can be about 0.4 to 0.5 bar (g) below the atmosphere, which is primarily used to move light-free flowing products.

  2. Pressure type systems can use a positive pressure to move material from one point to another. The device is suitable for moving material from one loading point to different unloading locations.  Conveying pressures can range from 0.5 to 4 bar (g).

  3. Combination systems, utilizing a suction device to move material from a number of loading points and use a pressure method to transfer it to a range of unloading points.

  • Blowers / vacuum pumps / compressor

  • Rotary airlock valve

  • Filter receivers

  • Cyclone Separators

  • Bin vents & Dust collectors

  • Silos day bins and other storage vessels

  • Pipeline

  • Feeding device

  • Air separator

  • Control panels and electrical equipment

Dense-Phase Conveying System:

This type of conveying system transfers the materials whose particles are either heavy and enormous, fragile or abrasive. As heavier particles cannot remain suspended within the air flow, large molecules can’t be conveyed by the high velocity air in dilute-phase system. In such cases, dense phase conveying system is employed which may transfer heavy materials in bit through pipeline. Fragile materials need to be conveyed at a lower velocity to preserve their integrity. Abrasive materials need to be conveyed at low velocities to minimize pipe erosion. Example: Sand, sugar, carbon black.

The dilute  or lean phase pneumatic conveying system depends on the momentum of the airstream to pick up and transfer each particle, keeping the particle in suspension on along the conveyor. The material never settles at the bottom of the pipeline. It works at a fairly high momentum at a relatively low pressure differential. The intake velocity at the outset of the device (i.e the airflow velocity at which material is picked up and transfer at material feed point) is usually regarded to be the most important area in the device, since at this stage the air is at lowest intensity of the whole system. A well designed pneumatic conveying system will have this velocity well optimized and hence minimize energy consumption. The major advantage of the dilute phase conveying system is flexibility. There is a wide range of materials that can be conveyed in the dilute phase as compared to the limited materials that can be conveyed in a dense phase. Examples: meal, maize.

When you have to transfer objects like cans, boxes, and plastic containers, the air-activated gravity conveying system are used. They use pressure for transferring such objects through the transportation lines. These sorts of conveying system work totally different from both of the above types.

  • Pneumatic conveyors offer greater cost effectiveness when conveying in higher capacities and/or over longer distances.

  • Dust-free operation at production point.

  • Materials remain sanitary and promote plant hygiene.

  • A simpler method for product pick-up process.

  • Increased safety to the operators and maintenance workers.

  • It requires very low maintenance.

  • Helps to enhanced flexibility.

  • It helps to prevent any product leakage and contamination.

  • Pneumatic conveying systems require very little space as conveying is through pipes.

  • They are easy and quick to install and maintain.