August 2024

Container Discharger System for PET, PP Plastic Chop Trim, Plastic Flake, Plastic Pellets

This customer’s overall scope involved handling three different materials, each with different properties, some dusty, delivered in varying container sizes, to be pneumatically conveyed to downstream molding equipment. A compact footprint was required to maximize plant space and operator safety during operation and maintenance was also essential. For the chop/trim/flake products, lift and seal dischargers were incorporated into the system. The hood seals to the top of the container prior to rotation, and mate with the surge bin through 12-inch roller gates that open when rotation is complete. This allows the entire contents of the container to empty with a sealed/ dust free connection. These receiving bins also are equipped with agitation inside the hoppers to promote flow and the product also passes through a light duty crumbler prior to entering the conveying line. For the pellet product, a high lift and discharger unit was used. Dust was not a concern, so the receiving bin had an open top with a grate incorporated to catch large debris. A mezzanine was added to give operators access to the equipment and for maintenance. For safe operations, a laser scanner on the mezzanine was included to disable the discharger/slide gate when obstructed, preventing operator injury when in motion. Safety caging and interlocked access doors on the loading side prevent operation when not closed.

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Bulk Bag Discharger for Reactive Calcium Carbonate

The customer was looking for a bulk bag discharger with a rigid screw conveyor to mount on a customer-supplied flat bed truck to discharge RCC material onto their client’s mixer. The bulk bag discharger is equipped with a portable base with fork pockets for ease of movement, with bolt together frame section to allow the unit to be disassembled for transport. The upper framework includes additional fork pockets and lifting eyes on the rigid screw conveyor for ease of raising and lowering. The framework assembly was also equipped with an air compressor to provide compressed air to massage paddles, air-purged shaft seals, etc. The assembly also included a dog house cover to protect the equipment from weather elements. The bulk bag discharger was equipped with load cells to shut off the rigid screw conveyor after the desired weight was discharged.

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Bulk Bag Filling System for Refined Carbon Filter Cake

The customer required three (3) single-loop cantilever bulk bag filling systems (with a future fourth) for filling refined carbon filter cake from filter presses conveyed through a customer supplied radial stacker with a discharge height of 43.5’ that would gravity feed into any of one of three surge bins through chutes and gravity pivoting diverter valves. The surge bins would gravity feed into the single-loop cantilever fillers. The surge bins were equipped with integral dust collection, live bottom bin activators to promote flow out of the surge bins, and Cv Technology explosion mitigation system since the refined carbon filter cake had a high Kst value. Each single loop cantilever bulk bag filling system was equipped with a single loop bag support hook, custom fill head assembly to adapt to the single loop bag, inlet valve, densification bag pre-inflation, and integral powered roller conveyor. The single loop cantilever bulk bag filling system also included a common pallet dispenser, turn tables, infeed, and accumulation powered roller conveyors to meet the customer layout requirements.

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Drum Filling System for Absorbent Granules Filter Media

National Bulk Equipment worked with the customer to design a 4 drum-filling system to meet their packaging needs. The product is conveyed over to the filling system pneumatically and discharged into a 3-deck screening system. A certain particle size distribution was required and the discharge off the middle deck of the screener was targeted for the drums. The usable product from the screener flows into an intermediate surge hopper allowing a continuous process of filling the drums. The filling of the drums occurs automatically with each drum indexing on a turntable and filled to the desired weight. When all four of the drums are filled the operator removes the pallet of filled drums and places new drums within the filler. The system was supplied with complete electrical controls and programming allowing for recipe-driven flexibility.

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Powdered Activated Carbon Slurry Making System

Customer had very limited space and overhead height and needed a solution to transfer powdered activated carbon from bulk bags into a slurry mixing tank. NBE was able to design a low-overhead version of our fork-style bulk bag unloader with dual fork locations to fit within their requirements. An offset combo hopper was incorporated to allow for small bag additions, and helped tighten up the overall space required to convey the material to the slurry mixing tank. NBE designed and fabricated the 600 gallon stainless steel mixing tank to accommodate the customer’s slurry batch requirements. The tank was provided with load cells to capture the correct additions of liquid and the powdered activated carbon, which are then mixed with the integrated Brawn mixer. Dust collection is included and sized to adequately capture dust from the bulk bag unloader, small bag area, and dust in the head space of the tank. Collected dust is systematically returned to the slurry mixing tank, eliminating waste.

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Liquid Detergent Blending System for Sodium Bicarbonate, Sodium Formate & Citric Acid

The customer needed a solution to convey multiple powders from three bulk bags unloaders and two small bag stations into a final mixing tank for liquid detergents. A powder induction system was chosen to allow precise batch control of various dry additions. The dry additions flow through bulk bag unloaders equipped with E2, dust collection, lump breaker, and flexible screw conveyor into powder induction valves. A liquid pumping system carries the dry additions along with water to the final mix tank. High accuracy of additions is achieved with load cells on the dry additions and magnetic flowmeters on the water side, with the ability to dose a wide range of additions. The small bag stations are set up similarly and are used as a backup to the bulk bag unloaders. NBE provided a full control package including PLC and HMI set up for automatic additions based on customer flow rates and recipes. The system also includes custom NBE platforms for operator and maintenance access.

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Bentonite Slurry Make-Up System

The customer was moving their manufacturing facility to a new location and needed to duplicate their capabilities while maintaining operability at the existing site along with upgrading the process for improved quality and future growth. The slurry material is used in the process of manufacturing black pipe in the integrated foundry. The system includes a complete delivery system for the bentonite material that is installed in a sealed process room to help control airborne dust concerns, and a complete storage and delivery system for the feldspar (including a reserve bulk bag discharger to prevent lapses in bulk supply concerns) installed outside of the main building. The batch is started by partially filling the blending tank with approximately 2/3rds of the required water and starting the integrated high-shear mixer at low speed; the two (2) materials are then fed (by weight) into the mixing tank based on pre-set recipe details. The mixer is ramped up to full speed to ensure the materials are properly sheared to meet Q/A requirements. Once the chemistry is approved by quality control, the viscosity is adjusted by adding water to reach the desired consistency. The final batch is then transferred using the integral pump skid to the holding/process tank. The slurry is transferred through filtration to remove any unwanted agglomerates larger than 200 mesh to ensure reliable use by the foundry. The finished slurry is fed from the process tank into process bins that are used to interface directly with the foundry process. The system includes complete recipe-based controls with all necessary instrumentation and devices to provide the specified slurry at the desired consistency.

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Kraton Polymer Pellet Discharging and Feeding System

NBE has a wide range of experience in handling the various grades of Kraton available in the marketplace. In this application the customer was developing a new project related to the production of asphalt. The customer was receiving the polymer in supersacks and would charge a bulk surge bin with enough capacity to cover a full 24 hr day. The supersacks were received without spouts and discharged using a piercing hopper. The bulk Kraton was stored in custom surge bins with integrated agitator hoppers. The additive ingredient was discharged from a small bag dump station. Both ingredients were refilled into weigh feeders which metered the material into transfer augers supplying the customer’s wetting tank. NBE designed the platforms and supports so that the system can be expanded into multiple duplicate stations serving additional lines in the future.

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Portable Single Drum Fill Station for Zinc Stearate & Calcium Carbonate

Portable single drum fill station designed to integrate with the current bulk bag filler. An operator will manually position the drum filler under the existing Bulk Bag Filler. The equipment includes independent pneumatic knife gate, drum filler controls with a load cell scale package. The controls will open and close an existing feed valve.

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Modular Bulk Bag Unloader Forklift Frame for Ceramic Powders

The customer needed to discharge and screen ceramic powder from supersacks and fill back into supersacks or surge bins. This bulk bag discharger includes a removable upper frame with bag hanger, bag support pan, and forklift pockets. This allows to a minimum load height for operator safety and provides additional loading provisions when working with ceiling height restrictions

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