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Tag: plastic recycling

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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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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