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Why is bulk material handling automation required in your plant?

Posted on by Indpro

Why is bulk material handling automation required in your plant?

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

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

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

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

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

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

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

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

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

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

 

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

About Automation in Bulk Raw Material Handling

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

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

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

Process area space optimization

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

Handling of various types of raw materials

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

Continuous control of the entire production

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

Real-time statistics

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

Improved labour management & dependency ​

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

Ensures repeatability of process

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

The factory that is more connected

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

Batch cycle times have improved

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

Customer experience enhancement

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

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

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Spices Manufacturing Process​

Why Should You Convey Your Material Pneumatically?

Spices Manufacturing Process​

Posted on by Indpro

Spices Manufacturing Process

As food lovers, we Indians are devoted to spices. Spices play a significant role in our festivals, celebrations, and even daily lives. We may be divided by political boundaries, but the love for spices is a bond we share. Indian food is rich in spices unlike other markets, and this can be very well seen in the consumption pattern of spices.  Textiles and perfumes are two of India’s largest exports in Spices. The market is exporting to places like Arabia, Sumeria, Mesopotamia, China, and Egypt.

Since the 1st century AD, spices have been discussed in Roman imperial literature. The Ramayana is one of the many sacred texts dedicated to spices. Spices were also delivered to distant places, such as Carthage, Alexandria, and Rome.

India is the world’s greatest producer of a wide range of species with the most varied aromas and flavours. Spices are grown and harvested in accordance with climatic conditions. The initial phase in this procedure is cleaning and drying, during which the spices are filtered and then dried. The spices are permitted in a crushing machine after they have been cleaned and dried.

With the growing demand, it is essential that the production must also keep up. Hence improving and enhancing spice production process requires plant automation. Cleaning, grinding, blending, sieving, material handling, and bulk storage, batch manufacturing, and packing are all automated procedures in spice processing, resulting in high quality and cleanliness of the finished product.

Indpro provides automated material handling systems for feeding silos, cleaning systems, mills, mixers for salt, starch, spices, and ingredients, and conveying systems for the finished spice combinations to packaging lines, as well as process leading visualization technologies. External and internal silos, loading stations for bags, jumbo bags, and weighing systems for ingredients and minor components are typical offerings from Indpro.

The materials used in the Spices industry –

Chilli Powder, Turmeric Powder, Chaat Masala, Mustard Powder, Coriander Powder, Turmeric Powder, Chaat Masala, Mustard Powder, Coriander Powder, Cumin, Fennel Seeds, Mixed Powder, Pepper, Poppy Seeds.

India's spice manufacturing industry faces several challenges:

1. Problems related to working labour 

Experiencing the strong odour of spices for an extended periods of time can be harmful to health. As a result, it is difficult to find workers in the Indian spice industry.

2. Market credit

Spices have a high credit market risk with distributors, which can cause substantial difficulties for financing the manufacturing.

3. There are leaks in the packaging

The low quality of hand-made packaging in India results in package leakage because of financial constraints. It has always been difficult to use high-tech gear due to the high cost.

4. There are many competitors

The spice sector is highly competitive because there are so many vendors. Rivalry primarily occurs at the regional level. In addition to the many small local businesses, there are also numerous organic spices that have grown in demand because of strict quality standards.

5. Spices wastage at handling level

At every stage of handling of spices, be it for cleaning, storage, processing or packaging, there is wastage due to improper handling of the powders. This ultimately contributes to loss in profit for the manufacturer. Automation systems to avoid this are not available at all sites.

Steps followed by the current industries for manufacturing spices:

Procurement of spices:

Spices grown on Indian fields provide the finest perfume and flavour. It is of paramount essence that the quality control process for us begin on the fields (at the production centres). When it comes to producing high-quality spices, drying is an important step. The results of the other phases in the manufacturing process are greatly influenced by the level of perfection achieved during the drying process. Proper drying is key to keeping the fragrance and flavour of the material. The material is naturally dried by sunlight but roasted if needed to maintain optimum moisture content.

All bulk seeds are gathered in a warehouse and mass dried before being delivered to various places in small and jumbo bags, depending on the needs. A seed is often packaged in 25 kg bags, 625 kg bulk bags, or 1000 kg jumbo bag. To preserve quality, proper transportation is required. It’s critical to have the correct supply chain in place.

Cleaning of dried spices:

Before processing, the crop should be cleaned. The first step is to use a winnowing basket to eliminate dust and grime. Bamboo, palm, or other leaves can be used to make this. Someone who is used to this type of labour can swiftly and effectively remove the dust, grime, and stones. Contaminants are removed from spices and herbs by washing them with weak alkaline cleaning solutions and neutralising agents, then passing them through concentric zones with counter-current flow, spray rinsing, and drying.

Clean and dry material is kept in an intermediate storage silo, a tank, or a hopper near the process area, and the stored material is pneumatically delivered to the grinding machine for further processing. A variety of pneumatic conveying systems can be used depending on the material to be treated, its qualities, and the desired output.

Grinding post-cleaning:

In the regular grinding of spices, energy is used to fracture the large particles into smaller ones while maintaining product quality in terms of flavour and colour. Heat is produced in this process as energy is used to fracture the small particles into smaller ones.

Grinding the spices is done using either low temperature or cryogenic methods. Using cold air in the first situation and liquid nitrogen in the second, heat is controlled within safe limits in the grinding chamber and throughout the milling system. In this way, the final spice powders are more fragrant, colored, and flavourful.

Spices are crushed using horizontal and vertical hammer mills, as well as roller mills, to decrease the size of the material to the desired size. Coarse and fine particle materials are pneumatically handled after grinding and sent to the mixing process, where all elements are blended according to specifications.

Mixing:

By pneumatically connecting grinding equipment to mixers, spice powders can be compressed and mixed according to customer requirements. As with the previous process, this is likewise fully automated and requires no operator interaction. The total processing system is designed to operate continuously, even when mixing is a batch process.  The finished commodities are emptied into the tiny hopper when the mixing cycle is done, and the material is pneumatically carried into the intermediate storage silo/tank.

Post-mixing:

If you want to store the finished spice powders efficiently and easily integrate them into consumer packaging, 25 kg bags or jumbo bags or Intermediate Bulk Containers (IBCs) are a great choice. After final mixing, selecting the appropriate automatic bagging machine for finished goods is vital to guarantee that the material given to the consumer is weighed correctly in its packing. To pick the correct bagging machine, you must first establish the sort of product for which the machine is required, the material of the packaging you wish to use, and the throughput, or the number of bags that need to be filled per minute. The final bags are then either heat sealed or stitched before being dispatched.

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Why should you convey your material pneumatically?

Which Industries Use Pneumatic Conveying System?

Big Bag Unloading System

Posted on by Indpro

What is Big Bag Unloading System

Big bags Unloading– How to improve on your bulk material logistics

The use of big bags in the material handling industry is on the rise. Improved cost-efficiency and high safety standards of bulk bag unloaders for handling a variety of materials have led to the progressive use of bulk bags by a wide range of sectors. Bulk bags unloaders have become a viable distribution source for many products and have resulted in a changeover from the fact that small bags were practically used exclusively, and that the shipment and storage of bulk material have also been changed in the last decade. Likewise, bulk bag dischargers have now revolutionized the way bulk bags are filled, untied, deployed, and withdrawn as operators are no longer forced to enter them manually via restricted access doors and strain to withdraw partially empty bags, clean up spillage after disconnection, dislodge goods from dead spots or flatten bags. This method of loading and unloading large amounts of the material involves technical expertise, which has given rise to the development of such big bag unloading systems. The unloading method of the Jumbo bag operates well even when the material in the bag is not free-flowing making it a very versatile device for the industry.

jumbo bag unaloding indpro

Big bag unloading systems are often classified as unloaders for bulk containers, bag supports, FIBC unloaders, FIBC dischargers, and wide bag dumpers. Used for unloading from a range of bulk bags such as bulk packages, FIBC, Jumbo packages, etc. A basic frame for the mounted bag supporting the lifted bag is equipped with a lift or a hoist to unload the Bulk Bag. The basic setup involves a bag frame that can be connected to the bag’s suspension clips. The frame is then raised and positioned in a way to counterbalance the suspension frame in the unloaded by the hooks on the frame. The bottom of the bag sits on a locking plate, and the loops of the bag hold the bag straight when lowered. The spout is clamped on by a pneumatic clamp to completely seal the system and avoid dust from escaping. This ensures the environment stays clean. Additionally, content in the bag can be discharged into storage, a conveying system, or a process vessel for transfer to another location by gravity. These unloaders use a broad array of devices, such as pneumatic conveying systems, screw feeders, rotating valves, lump breakers, etc., which unload or convey material from the station to various locations

Bulk solids handling products – Market dynamics:

The bulk bag unloaders market is projected to see healthy growth over the forecast period led largely by the economic benefits associated with bulk bags in managing bulk materials that have generated a steady demand for bulk bags and are causing consumer switches from other alternative packages such as rigid IBCs, small bags, Gaylord boxes, etc. These unloaders are equipped with many advantages that drive the competition in the bulk bag unloaders industry.

 

Some advantages are, these systems are compatible with several bag types and are complemented by a broad range of models and accessory models, provide controlled dosage, reduce labor, and enhance productivity. These types of equipment eliminate dust and spillage associated with the use of other bulk bags. Besides, frequent innovation related to the unloading and dispensing of bulk bags is expected to drive growth in the market for bulk bag unloaders over the forecast period.

 

Recent advances and improvements in bulk bag handling products will remove the inconveniences of outdated designs while enhancing comfort, cleanliness, and, safety intensively. The new items are not only intended to create a dust-proof cover, but also to facilitate material movement and complete evacuation.

Components in a big bag unloading system:

  • Hoist
  • Bag holder
  • Discharge funnel
  • Bag massager
  • Discharge chute
  • Heavy metal gives a support frame to the entire structure
  • Sturdy metal frame to support the entire structure
  • Dust extraction system (optional)

How does a big bag unloading system work?

  1. A big bag is attached to a hoist for better handling and a better bulk handling operation.
  2. The hoist picks up and takes the jumbo bag into its discharging location. The outlet of the bag is tightly clamped to the spout clamping arrangement.
  3. A wide access hood is given to untie the big bag outlet spout.
  4. As the outlet completely covers the nozzle, a pneumatically operated seal mechanism is used during release which produces a dust-proof material discharge.
  5. The pneumatically operated massager paddles help to massage and discharge non-free-flowing products.
  6. Optionally, the hopper comes with a flanged dedusting system connection.
  7. The dedusting system creates a vacuum during discharging which makes sure no dust escapes from the crevices.
  8. The heavy steel frame is a sturdy framework with entirely enclosed profiles.
  9. A control panel is used to operate all pneumatic operations of the device.

Indpro’s Jumbo Bag Discharge Solution:

  • Indpro’s big bag discharge systems are particularly equipped for discharging a broad range of bulk material from big or jumbo bag. They eliminate emissions from dust, product loss, or contamination of the product. For safe and hygienic discharge of food ingredients, pharmaceutical products, and toxic materials, several unique options are available.
  • Our range is based on a simple modular structure that allows the basic models to be extended with several options for obtaining a complete solution for discharging big bags aka jumbo bags. Indpro’s expertise in the practical application of such equipment with proven reliability has resulted in the development of various application specific enhancements. This allows all facets of the requirement to be addressed taking into consideration all consumer requirements such as product size, bag form, environmental issues, device capability, and expenditure.
  • Indpro provides intense emphasis for the bulk bag unloading system and associated equipment to ensure secure, effective, and full unloading and, handling of bulk bags.

Advantages:

  • Easy integration into existing setup where big bags must now be used instead of small bags.
  • Minimal space requirement for retrofitting in an existing plant.
  • Available in both stainless steel and carbon steel.
  • Operator safety is ensured.
  • Surfaces made of stainless steel are polished to the desired standards. All mild steel exterior surfaces are coated with high grade paint.
  • Complete discharge of granular and powder is possible with the help of massaging paddles.
  • Entire operation of unloading material from big bags can be made dust free which will ensure hygiene of the plant as well as safety for operators.

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Spices Manufacturing Process​

Why Should You Convey Your Material Pneumatically?

Next-Gen Technology in Mechanical Material Handling

Posted on by Indpro

Next Gen. Technology in Mechanical Material Handling

Methods of Conveying Bulk Solids:

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 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 System:

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.

Next Gen Technology – Tube Chain Conveyor

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.

System Components:

1. Driving Station:

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

2. Tensioning Station:

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.

3. Feeding Unit:

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.

4. Chain-Disk Assembly:

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.

5. Cleaning Devices:

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.

6. Tubing:

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.     

What makes Indpro’s Diskcon Tube Chain Conveyor so Special?

  • 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.

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Spices Manufacturing Process​

Why Should You Convey Your Material Pneumatically?

Air Pollution Control – A need of the hour

Posted on by Indpro

Air Pollution Control – A need of the hour

What is Dust ?

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.

Types of Dust :

Chemical / Pharmaceutical Dusts:

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.

Plastic / Fiberglass Dust:

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:

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.

Concrete Dust:

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:

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.

Industrial Air Pollution Control Equipment: Introduction, Types and Uses

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.

The goals of industrial air pollution control equipment are to:

  • 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.

1. Bag filters:

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.

2. Cartridge Filters:

A 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.

3. Cyclone dust collector:

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.

4. Herding Filters:

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.

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Spices Manufacturing Process​

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