Bulk Bag Discharge Solution with BFM® Fitting Connections

The powders processed are finely grained (20-100 µm) with a bulk density around 0.4 to 0.8 kg/m³. Due to their sensitivity to moisture, they tend to clump together, necessitating specialised massage and dust control equipment. These powders are handled in fully contained environments to comply with stringent purity standards.

Client Objectives

The client, a global leader in agricultural processing, faced challenges handling bulk raw materials stored and transported in bulk bags. Due to these materials’ tendency to clump, the client encountered delays, frequent stoppages, and an increased risk of dust dispersion, compromising both production efficiency and operator safety.

To maintain a high production rate and ensure the protection of workers, the client needed a flexible solution for quick and efficient bulk bag discharge with minimal manual intervention. Hygiene and safety were of particular concern, as the materials required a dust-free environment and optimal containment.

At the heart of their request was the integration of BFM® fitting connections. Known for their airtight seal and impact resistance, these flexible connections offered an ideal solution for eliminating dust emissions and simplifying the handling of bulk bags while reducing operator intervention. The client expected these connections to provide an airtight seal between discharge and transfer stations, thereby improving production flow.

 

Proposed Solution

To meet the client’s specific needs, Palamatic Process designed and installed a comprehensive bulk bag discharge solution using BFM® fitting connections, ensuring safe and efficient handling of bulk ingredients. The setup includes multiple discharge stations equipped with BFM® fittings, chosen for their high performance in containment and their ability to optimise product flow while minimising dust emissions.

The BFM® fitting sleeves, located at each station, provide a flexible, airtight connection between the bulk bags and transfer equipment. Their unique snap-fit design enables secure, leak-free connections, even for fine, variable-density materials. This solution is especially suitable for the hygiene and safety standards of the food and pharmaceutical industries, as BFM® sleeves meet the applicable regulations, ensuring a clean, contamination-free production environment.

In addition, Palamatic incorporated a pneumatic massage system to facilitate the flow of clumped products within the bulk bags. This device, combined with BFM® fitting connections, ensures a fast and continuous discharge, reducing production interruptions. The setup also includes a high-performance dust extraction system linked to the BFM® sleeves, capturing airborne particles and maintaining a healthy work environment. This integrated approach ensures efficient product transfer while meeting strict safety and cleanliness standards, reducing maintenance needs and optimising production rates.

 

Industrial Equipment Used in the Installation and Benefits of the Palamatic Process Solution

The setup implemented for the client includes carefully selected equipment to meet hygiene, safety, and performance standards in the food and pharmaceutical sectors. Below are the key pieces of equipment and their specific benefits for ensuring a safe, effective, and high-quality production process.

BFM® Fitting Connection Sleeves

These flexible, airtight sleeves, placed between various stations, ensure a hermetic transfer of products. Their design allows quick installation without tools, preventing particle leaks with a secure snap-fit system. Made of impact-resistant materials and certified for food and pharmaceutical applications, these sleeves provide continuous material flow while minimising contamination risks.

Benefits:

  - Maximum Airtightness: Prevents product leakage, reduces dust emissions, and maintains a clean work environment.
  - Simplified Maintenance: Snap-in system allows quick, tool-free replacement, reducing production downtime.
  - Regulatory Compliance: Certified for food and pharmaceutical industries, meeting strict cleanliness and safety
standards.

EasyFlow® EF01 Bulk Bag Discharge Station

The EasyFlow® EF01 discharge station allows for the controlled, safe discharge of bulk bags. Equipped with a pneumatic massage system, it facilitates the efficient discharge of even compacted products. Pneumatic cylinders keep the bags in position and apply targeted pressure to aid material flow without manual intervention.

Benefits:

- Smooth, Fast Discharge: Reduces stoppages and the risk of blockages, increasing productivity.
- Reduced Dust Emissions: Controlled discharge process minimises particle dispersion.
- Operator Safety: Removes the need for manual handling of heavy bags, improving working conditions.

Bag compactor

Installed downstream from the discharge station, this compactor reduces the volume of empty bags following discharge. Using a helical screw, it ensures optimal compaction of bags, simplifying their handling and disposal.

Benefits:

- Waste Reduction: Reduces storage space needed for used bags.
- Hygienic Process: Minimizes waste handling, contributing to a cleaner workspace.
- Optimized Workspace: Helps maintain an orderly work environment.

Dust Collection System

Connected to the discharge and transfer stations, the dust collection system removes airborne particles with an extraction rate of 1,500 m³/h. This device captures dust released during product discharge, ensuring a healthy atmosphere.

Benefits:

- Reduced Waste: Minimises the storage space needed for used bags.
- Hygienic Process: Limits the handling of waste, contributing to a cleaner work area.
- Optimised Workspace: Helps maintain an orderly environment.

Tubular Screw Conveyor

This screw conveyor provides secure, continuous transport of materials to storage hoppers, preserving product quality and preventing any dispersion.

Benefits:

- Total Containment: Ensures safe transfer without external contact.
- Suitable for Sensitive Products: Protects materials from contamination and reduces product loss.
- Easy Cleaning: Designed for quick, simple cleaning, reducing maintenance time.

FlowMatic® 02 Bulk Bag Filling Station 

Meeting the client’s packaging needs, the FlowMatic® 02 filling station enables fast and precise packaging of products into bulk bags. Equipped with an airtight filling sleeve and a pneumatic cylinder, it enables dust-free filling and precise control of product weight.

Benefits:

- Speed and Precision: Can fill 10 to 20 bulk bags per hour with high accuracy
- Airtightness and Cleanliness: The filling sleeve ensures optimal containment, preventing product loss.
- Ease of Use: Reduces the need for operator training with an ergonomic, user-friendly design

Control Automation

This automation system enables real-time supervision of each stage in the discharge, transfer, and packaging processes. It monitors critical parameters and adjusts cycles according to production needs, ensuring optimised management.

Benefits:

- Precise Control: Provides traceability and regulation at every step, ensuring production quality and continuity.
- Enhanced Responsiveness: Enables quick adjustments in response to production changes.
- Resource Optimisation: Reduces human error and improves operational efficiency.

 

Conclusion

With the bespoke solution developed by Palamatic Process, the client successfully achieved their goals of optimising and securing bulk material handling processes. The integration of BFM® Fitting connection sleeves as the core element of the setup ensured perfect material containment, with quick, leak-free connections between equipment. This system not only eliminated dust emissions but also significantly reduced operator intervention time, enhancing workplace conditions and on-site hygiene.

The installation of EasyFlow® EF01 discharge stations, combined with compaction and dust extraction equipment, facilitated smooth, uninterrupted bulk bag discharge, even for challenging materials. The FlowMatic® 02 filling station provided a rapid, accurate packaging solution, meeting the client’s need for production flexibility. Finally, centralised control through automation ensured comprehensive process management, enabling faster response times and reduced interruptions while ensuring optimal traceability.

In summary, the Palamatic Process solution enabled the client to:

- Optimise bulk product discharge and transfer using BFM® Fitting sleeves, providing optimal airtightness at every stage.
- Increase productivity by reducing downtime and simplifying cleaning and maintenance.
- Ensure a workspace compliant with hygiene and safety standards in the food and pharmaceutical industries.
- Improve overall production efficiency while meeting the stringent quality requirements of these sectors.

This installation allowed the client to achieve an unprecedented level of automation and safety while optimising their transfer and packaging operations. Palamatic Process remains a trusted partner, delivering comprehensive, innovative solutions tailored to the needs of the processing industry.