weigh batching directly from bulk bags.

by:Yucai     2020-01-11
Bulk bags (
Also known as Super Market, FIBC, big bag, etc. )
It is a large flexible intermediate bulk container, usually used to transport bulk solid materials from manufacturers to distributors and end users of materials.
However, as their popularity increases, many uses suchhouse pre-
Transportation and Storage of mixed and final products have been developed.
The most common bags in the industry are made of woven polyethylene, although there are many other materials to choose from.
Bags are usually squared from 30 \"to 48.
Height 36 to 84, weight 500. to 4,000 lbs.
Although the most typical bag size is 36 \"square feet, it is in bulk material.
60 High, 2,000 high. of material.
The most common package includes lift bands on each of the top four of the package.
Bags with padding and no padding are available.
In some cases, the padding is mounted on the inside of the bag.
However, the most common liner is a long tube made of thin sheet polyethylene.
Although this type of liner is more economical than the one installed, it is very problematic because it will lengthen during the discharge process.
This may cause the liner to be discharged into downstream equipment.
Before filling the bag, gather the pipe ends together and bundle or seal them at the bottom.
Then, insert the closed end of the tube into the bag by filling the mouth on the top and drain the mouth down through the bag and the bottom.
When the bag is full, the material pressure keeps the padding against the inner wall of the bag.
When filling, the top of the tube is tied or sealed in order to prevent contamination, etc.
Most bag manufacturers make bags according to your specifications.
However, the use of standard available bags certainly has an economic and functional advantage.
The diameter of the bag inlet and outlet mouth is generally between 12 \"and 22.
The appropriate diameter of the discharge nozzle for the appropriate discharge of a particular material depends on the flow properties of the material after transportation and storage.
A lot of materials are free.
Flow, easy to handle, because the bag becomes compacted after it is filled, and it is difficult to discharge after transportation and storage.
Like the bin flow design, materials that tend to be compact during storage often flow more easily from the larger diameter bag outlet mouth.
Most often, the inlet mouth is the same diameter as the discharge mouth.
The use and benefits of industrial bulk bags many companies have achieved great benefits by designing systems to adapt to the use of bulk bags in new processes.
Existing processes also benefit from modifications adapted to receiving and using materials (s)in bulk bags.
Bulk Bags provide safe and economical means for handling and storing bulk materials.
Since the shipping and storage methods of bulk bags are very similar to the pallets of smaller paper bags, there are any major changes to the equipment or procedures that move to bulk bags that do not need to be used at the receiving terminal or storage area.
An important benefit of safe, convenient and economical handling and storage of bulk bags for use is the improvement of the safety of operators.
As there is no need to manually lift the material, the operator is least likely to be injured.
All lifting and movement of the bag is done using a fork track, pallet jack and/or trolley and chain hoist.
Claims for healthier labor and fewer workers will reduce insurance premiums and increase profits.
Especially when dealing with hazardous materials, paper bag handling costs may have a significant impact on the total cost of using a particular material.
In addition, it is not uncommon to handle up to 1% to 5% of the material as well as bags.
The proper bulk bag remover can remove all the dust coating inside the bulk bag, thus minimizing material waste.
Empty bags are usually returned to the supplier for refilling.
Bag handling costs are eliminated in many cases.
The use of bulk bags is in line with today\'s ecological problems compared to paper bags.
It is doubtful that a method will be developed to reuse or recycle paper bags.
As a result, almost all the contaminated waste paper is finally buried.
In addition to achieving greater utility for each package through multiple trips from supplier to user, a separate industry has been developed to rearrange and recycle damaged or worn packages.
This significantly reduces the amount of contaminated container waste that must be sent to landfill sites, thereby reducing the risk of groundwater and soil contamination.
Another advantage of using bulk bags is that suppliers tend to have lower costs when supplying bulk bag materials.
These savings may be passed on to material users as the price of raw materials decreases.
The process challenges of using bulk bags to discharge materials common process challenges related to the use of bulk bags are not encountered with paper bags.
The first challenge is to get the material out of the bag correctly.
Each material may face unique challenges in this regard.
Some materials may be difficult to discharge, while others may open the bag without controlling the flow of the material and produce unsafe, uncontrolled material bursts.
The appropriate discharge shall include flow control valves and materials that are compacted or difficult to flow from the discharge to facilitate effective means of discharge.
When the bulk bag is full, it stands out on the side, which produces a relatively lower bag height than when the bag is empty.
On the contrary, when the bag is emptied, the bag is lengthened and the height increases.
If the design of the discharger cannot compensate for the elongation of the bag, some material will be retained at the bottom of the bag and the bag will not be empty without manual intervention.
Moving the material to the process, although sometimes the appliance can be found above where the material is needed, space limitations often require the delivery and lifting of the material into the process.
In addition, many processes require that the material be fed into the process at a controlled rate for proper absorption, dissolution, etc.
The best unloader is designed to be flexible and can accommodate various types of mechanical conveyors and feeder as well as Pneumatic conveyors.
Processing and storage of bulk bags the whole bag material is received and stored in almost the same way as paper bags.
However, attention must be paid to ensuring that the materials used and the types of bulk bags are suitable for the atmosphere in which they are stored.
For example, heat-sensitive materials that tend to absorb moisture should be stored in lining bags in cool and dry places.
While the same problem applies to paper bags, 50 lbs of solidified. or 100 lb.
Bags usually deal with problems less than 2,000.
The material block will be.
When designed and operated at that time, protecting the operator and atmosphere, the bulk bag discharge station can significantly reduce the risk of exposure of the operator and atmosphere to the material.
By closing out the bag mouth and controlling the rate at which the material flows from the bag, the possibility of contamination by the operator and/or the factory is minimized.
We found that the iris-type valve with flexible, non-permeable diaphragm is very suitable for this purpose.
The closed bag mouth can be closed by the Iris valve, when the pull rope of the mouth is untied through the bag mouth entrance door on the outlet mouth entrance chute.
The entrance door can then be closed before allowing the material to flow from the bag.
Once the entrance door is closed, the Iris valve can be gradually opened, resulting in a minimum displacement of air speed, thereby reducing the chance of dust leakage.
The Iris valve also provides a way to tie part of the empty bag.
Application precautions for removing materials when applying the bulk bag remover to your process, one of the most important precautions is the type of material to be disassembled.
Obviously, it is much easier to discharge plastic particles from bulk bags than to discharge packed, applied sub-bags
Zinc oxide of micron size.
Therefore, the first step in applying the bulk bag remover is to understand the behavior of the material in various forms and under various conditions.
For example, many antioxidants are easily discharged in the form of granulation.
However, these same materials may be difficult to handle as powders.
In addition, changes in temperature and humidity can lead to significant changes in the flow properties of the material.
Particle size distribution and wide particle size distribution and irregular shape can cause the material to weave and solidify in bulk bags, which makes it difficult to discharge.
Storing the pressure, vibration, and thermal cycling of materials during transport contributes to the packaging of materials and deteriorates the impact of these trends.
Before purchasing the discharge equipment, the manufacturer should test the actual bulk bag of each material that the user will receive under realistic conditions.
Working with a manufacturer with successful experience with your materials can usually provide you with performance assurance without the time and effort required to test.
However, be careful to take inappropriate shortcuts at this point.
In the long run, the extra time and effort may be well worth it.
The discharge mode requires that the discharge mode is very important when deciding which functions the discharge system needs.
The three basic types of emissions that are possible are intermittent or continuous emissions.
The most common discharge mode in the rubber industry is the batch mode.
Bulk emissions are only required to discharge a given amount of material within the maximum time frame.
In the batch mode, the actual delivery rate is usually not important, but the amount of material delivery is critical.
When the container or surge bin must be refilled on a regular basis, intermittent discharge is usually required.
Use position based on level control to start recharging (s)or timer(s)
Is a good example of intermittent emissions requirements.
When the process requires the delivery of materials at a specified speed, continuous discharge is appropriate.
This type of discharge must include a closed-loop control system that monitors the discharge rate and makes constant adjustments to meet the discharge rate of process requirements.
The required batch/flow rate accuracy has several parameters to decide whether it is appropriate to weigh the ingredients from the bulk bag and, if appropriate, what type of weighing system should be used.
The most important of these is the total weight of the allowed batch and discharge time, bag and discharge equipment (i. e.
If the system is intended to be supported by scale)
, And the allowable deviation from the batch target weight.
Since most processes represent the allowable deviation of the target batch weight by weight as a percentage of the total batch, it is easier for larger batches to avoid inaccuracies.
However, if a larger batch has to be delivered in a short period of time, a larger capacity conveyor/feeder will be required, which may affect the accuracy that can be obtained.
The distance/path from the discharge to the destination where the material must be delivered relative to the discharge position is one of the most important parameters for selecting the discharge feeding device.
If the discharge appliance is located directly above the delivery point, a rotary feeder or a short spiral feeder may be required.
However, if the material must be delivered horizontally and/or raised, a flexible screw conveyor or other type of mechanical or pneumatic conveyor can be used.
The discharge conveyor should have the flexibility to adapt to physical obstacles and transport islands.
The available clearance of the discharge position and delivery point will also affect the selection of the discharge device.
Simple loading and unloading of bulk bag unloader bulk bag has two basic methods of loading and unloading bulk bags into the unloader.
The first approach involves loading forklifts of the type of loader and using the forklift track to transport and load bulk bags into the loader.
The second method is to use the forklift track, or maybe a pallet jack, to place the bag on the floor of the discharge appliance.
The bag is then lifted and placed in the discharge appliance using an electric trolley and chain hoist.
Once the bag is in place and opened, many materials do not flow freely from the outlet.
The common problem is that the exit mouth is square into a bridge, and only the material from the bridge is discharged.
Although many disclaimers include vibration and/or rotational flow promotion, our research and field experience have shown that a mechanical massage bag is the most effective way to discharge difficult materials from a bulk bag.
When it is simply required to discharge the full contents of the bag into a bin or container by gravity, vibration/rotational flow promotion may be effective.
However, when the material flow from the bag is limited, just as often happens when the bag is discharged through the feeder or conveyor, the material may be packed in the bag to prevent discharge.
In addition, it is not recommended to start and stop the vibration/turning device frequently. Flow-
Flexers is a pneumatic massage paddle that effectively promotes discharge even with the most difficult packaging materials. Flow-
Flexers can cycle frequently as needed without damage.
Since massage movements do not tend to pack materials in bags, they are ideal for applications where the feeder or conveyor receives materials at the outlet of the bag. When flow-
Using a flexible device, massage the bottom of the bag using a large pneumatic rotary plate.
When activated, the plate raises the relative bottom of the bag to loosen and discharge stubborn material.
With the reduction of bag space and resistance, the stroke of the cylinder increases to lift the bottom of the bag to a steep \"V\" shape, thus completely discharging the material.
Empty as a complete bulk bag, the bag will lengthen, the total length of the bag will increase, causing the bag to relax.
If measures are not taken to compensate for this elongation, the bottom of the bag will remain flat and the material will not flow to the discharge mouth. Pop-
The top spring loaded bulk bag support bar lifts the top of the bag when the bag is emptied and provides continuous tension to eliminate slack.
This tends to produce a tapered bag bottom, eliminating the dead material area of the bag bottom, in order to completely discharge the contents of the bag without manual intervention.
In today\'s ever-changing environment for process and processing equipment layout, providing flexibility for future changes, it is important to choose carefully to design flexible systems.
The interface between the pocket Port and the process should make the equipment not useless due to the process change.
For example, if the use of a forklift to load bags becomes undesirable, the modular design provides a simple transformation for the electric trolley chain hoist.
In addition, care must be taken to select controls that allow expansion to accommodate the needs of future management information systems without being out of date.
Since the bulk bag contains 500 anywhere, the measurement of the material discharged. to 4,000 lbs.
, The design process is very difficult, so a batch of products need material for the whole bag increment, usually need to discharge a smaller part of the contents of the bag consistently and reliably.
Although some materials and processes use a batch timer and a calibrated feed rate to measure the discharged material, the weighing ingredient remover can achieve more consistent and reliable results.
There are two basic types of weighing ingredients available for bulk bag unloader.
The first type is called gain-in-weight batcher.
The second type is called loss-in-weight batcher. A gain-in-
The weight batching system uses an overall conveyor/feeder to discharge the material into a hopper or container mounted on the scale.
Scales and containers can be installed on bulk bag unloader or independently.
Select batch target weight by batch controller keyboard and software.
When a batch starts, the conveyor/feeder starts to drain the material into the container for weighing.
When the material weight in the container is close to the target batch weight, the discharge speed of the conveyor/feeder is reduced to the pre-selected dribble speed to complete the batch accurately.
Gain Advantage-in-
Weight ingredients are that the required scale capacity is usually reduced as the scale resolution ratio increases.
In addition, since the batch can usually be created during the process of consuming the previous batch, it is generally possible to use a smaller capacity conveyor/feeder to improve the batch accuracy.
The disadvantage of getting-in-
Weight ingredients are multiple ingredient batches that require the discharge of ingredients in order and weighing, which takes more time to create the batch.
In addition, batch sizes are often limited by the space available for weighing containers above the point of use of the material. In a loss-in-
The weight batching system, the bulk bag remover and the entire conveyor/Feeder are usually installed on the scale.
Once the batch target weight is selected and the batch is started, the conveyor/feeder begins to discharge the material from the system.
When the material weight taken out of the system is close to the selected target batch weight, the discharge speed of the conveyor/feeder slows down and the batch cannot be completed accurately.
Advantage of loss-in-
The weight ingredient is to discharge multiple ingredients into the process at the same time, reducing the mass production time.
In addition, since intermediate containers can be eliminated, the space requirements are reduced, and the maximum batch size is almost infinite.
A disadvantage of loss-in-
The weight discharge system requires a larger scale.
This usually results in a reduction in scale resolution.
The structure of the bulk bag remover should be strong and hard to withstand a typical harsh factory environment.
The support frame should be constructed of heavy steel members to resist damage caused by occasional bumps and scratches on forklifts and pallet jacks.
In the case of lossin-
Weight discharger, all factory personnel should be notified that the discharger is installed on a sensitive zoom system, and be careful not to impact the zoom system, especially when the batch is in mass-finished dribble mode.
Controls and instruments taking into account the number of materials and formulas that need to be in bulk, and the number of formulas that must be stored, will affect the type of controls that are appropriate for a particular application.
In addition, the complexity of the batch routines required will affect the relevant software and hardware requirements.
If it intends to be currently or in the future connected to plant process control and auxiliary equipment (such as gate valves or related equipment to drive motors), during the design phase, the necessary software and hardware modifications should be discussed with your device vendor.
This will avoid the possibility of buying controls that do not meet your current or future needs or require expensive redesign and modifications.
In addition, the supplier should understand the capability and capacity of the factory system.
Some of the features of the batching process, such as recipe storage, can be done without the need for additional hardware or modifications.
The resolution of the weighing system is defined as the minimum weight increment that the system can \"see.
\"Resolution is strictly a function of the total capacity of the scale and the number of graduates that can be divided by scale.
For example, if the total size capacity is 4,000.
The scale rating allows 10,000 departments, and the scale resolution will be [+ or -]4,000 lbs.
/10,000 division = [+ or -]0. 4 lbs.
Scale resolution should not be confused with system accuracy, which takes into account all sources of system inaccuracy, such as ambient vibration, electrical and mechanical noise, and changes in material flow properties.
Typical accuracy obtained by lossin-
About the weight of [bulk bag]+ or -]1 lb.
If your process needs better ingredient accuracy [+ or -]1 lb. , gain-in-
Weight ingredients should be considered.
As mentioned earlier, the batch continuation after the bag changes, the required batch weight size is usually inconsistent with the total bulk bag weight.
This inevitably results in incomplete batches and empty bags in bulk. The loss-in-
The software of the weight discharge appliance must be able to store incomplete batches so that after the empty bag is replaced by the complete bag, the operator can start the batch completion.
Usually, it takes about 5 to 10 minutes to change the package.
In key applications, it is prudent to create enough capacity in the system to accommodate at least a batch of materials after the bulk bag is empty.
Some applications may require additional surge capacity or redundant discharge appliances to meet the process material requirements during bag conversion.
Due to the continuous progress of electronic and related computer hardware and software, current and future technical support, it is not uncommon for new advanced technologies to appear before installing a given control and meter system.
Therefore, a future-oriented supplier should be chosen.
Controls and meters should be flexible enough to accept on-site modifications in the future to take advantage of subsequent developments.
In addition, manufacturers must maintain continuous technical support and parts for outdated control systems.
Be sure to discuss your supplier\'s policy of handling out-of-date systems and make sure you don\'t lose support and component sources for the system too early.
Summary and conclusion the use of bulk bags can provide significant process advantages and reduce costs and increase profits.
Due to the almost elimination of the phenomenon of manual lifting of materials, the bulk bag system can help you maintain a healthier labor force and reduce the compensation premium for workers.
The use of bulk bags reduces the amount of contaminated waste sent to landfill sites, thereby reducing the associated environmental and health risks.
Choosing the right bulk bag-out equipment can improve the final product quality and make it more consistent while reducing the production cost.
Since each batch is weighed and verified separately by the system, production off-
Specifications end product is minimized or eliminated due to operator error.
If you are not sure whether the transfer to bulk bags is suitable for your specific factory and process, you should contact a reputable manufacturer of bulk bag discharge appliances for advice.
Be sure to ask about similar systems that have been successfully designed, manufactured and installed before.
Please get a second opinion if you have any questions.
Confirm that \"weighing ingredients directly from bulk bags\" is based on a paper given at the rubber department meeting in May 1997.
\"Understanding the effects of polymer and composite changes on the extrusion of B-C rubber\" is based on a paper at the rubber sector meeting in October 1997. \"On-
The extrusion and tire line scan \"is based on a paper given at the rubber department meeting in October 1997.
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