Complete line for breaking filter cake and bagging in super sacks

Our customer's main objective was to set up an industrial process to recondition nickel hydroxide, a key by-product used in the manufacture of batteries, while meeting productivity, safety and efficiency criteria. Our customer, engaged in the production of battery materials, needed to manage a critical phase of its manufacturing process, which involves treating nickel sulphate in powder form, mixed with sodium hydroxide and other additives in a reactor. At the end of this stage, a liquid containing the nickel hydroxide precipitate is sent to a filter press, the aim of which is to separate the liquid phase and recover the solid part in the form of filter cake.

The customer was faced with several challenges: on the one hand, it had to ensure that the nickel hydroxide cake obtained was correctly compressed and released by the filter press. This solid cake, which forms under pressure, had to be transferred efficiently under the press to be recovered without loss or contamination. On the other hand, it was imperative that this product be repackaged in bulk bags for safe transport to another plant, where it would be integrated into the battery production line. The customer was aiming for a sustained production rate of 10 super bags filled per hour.

In addition to output requirements, our customer wanted to minimise manual interaction to ensure operator safety and reduce the risk of human error. The repackaging process therefore had to be fully automated, from recovery of the filter cake to its final packaging in bulk bags. The customer also wanted to optimise the ergonomics of the entire process, ensuring traceability and hermetic sealing of the super bags in order to preserve product quality and avoid any loss or contamination. These objectives were of crucial importance, as they determine the quality and reliability of the materials supplied for the manufacture of high-performance batteries.

To meet the customer's needs, Palamatic Process proposed a tailor-made solution based on the integration of a fully automated packaging line comprising several key stages, from recovery of the nickel hydroxide cake to its repackaging in super bags.

The first phase of the process involves recovering the solid cake formed in the filter press. A special tubular screw has been installed under the press to transport the cake efficiently. Unlike a simple standard screw, this one has several turns to help convey the material to a perpendicular screw designed to break the cake into more manageable pieces. This design not only saves space but also ensures a continuous feed to the next stage of packaging.

The broken cake is then conveyed to a Flowmatic®03 bulk bag filling station. This specific model was chosen for its ability to weigh each super bag accurately throughout the filling process. The Flowmatic® 03 is equipped with integrated weighing systems to ensure strict compliance with weight requirements, with minimal tolerance. At the same time, an automatic closing mechanism, comprising a rotating head and a clipper, has been integrated. Once the target weight has been reached, the filling sleeve is automatically closed and crimped with a staple, ensuring that the product is sealed and protected without manual intervention. This fully automated process reduces not only the risk of human error but also manual handling, improving operator safety and process efficiency.

Finally, to meet the throughput requirements of 10 super sacks per hour, the system has been configured to run continuously, synchronising the pressing and filling cycle. Thanks to this automation, our customer can recondition the bulk bags without interruption, thereby increasing the line's overall productivity.

This solution, which includes cutting-edge technologies such as the tubular screw and Flowmatic®03, not only ensures efficient packaging of the nickel hydroxide cake, but also guarantees the quality and safety of the repackaged product for transport to the battery production plant.

The installation set up to meet the customer's needs is based on two main pieces of industrial equipment: the tubular screw and the Flowmatic®03 bulk bag filling station. Each piece of equipment has been chosen and configured specifically to guarantee the reliability, performance and safety of the nickel hydroxide packaging process.

The tubular screw

The tubular screw installed under the filter press plays a central role in the recovery of the filter cake. This equipment is specially designed to ensure that the solid cake is transported smoothly and efficiently, thanks to its multi-turn design that facilitates the movement of the material. The advantage of this screw over conventional screws is its ability to break the cake into smaller, more manageable pieces before conveying them to the packaging stage. This feature prevents the accumulation of material, improves the fluidity of the process and helps maintain a constant flow rate.
The use of the tubular screw also reduces the risk of blockages and guarantees uninterrupted operation, which is essential if the production targets of 10 super bags per hour are to be met.

The Flowmatic®03 bulk bag filling station

The Flowmatic® 03 is a high-performance bulk bag filling station designed for packaging operations requiring precision and efficiency. This equipment is equipped with weighing cells that ensure accurate weight measurement during each filling cycle. Super bags are filled to predefined weight tolerances, reducing variations and ensuring optimum product packaging.

One of the main advantages of the Flowmatic® 03 is its automatic closing mechanism. Once the super sack has been filled to the required capacity, a rotating head secures the sleeve and an automatic clipping machine crimps the opening of the bulk bag with a staple. This automated process eliminates the need for manual handling, not only improving operator safety but also speeding up the operation. The system also helps to seal the super bags, preserving product quality during storage and transport.

Full automation

The entire process, from recovering the cake under the filter press to filling the bulk bags, is fully automated, guaranteeing a high level of productivity while reducing manual intervention.

Weighing accuracy

Thanks to the Flowmatic®03, each bulk bag is filled with precision, ensuring that the packaging meets the specifications required by the customer.

Increased safety

The automatic closing system reduces the risk of human error and guarantees safe handling of the bulk bags, in compliance with industry standards.

High throughput

The synchronisation of the filter press with the tubular screw and the filling station enables a sustained production rate to be achieved, meeting the customer's requirement to pack 10 super bags per hour.

This tailor-made installation guarantees optimum management of nickel hydroxide repackaging, increasing productivity while reducing the risk of human intervention and ensuring safe, standard-compliant packaging.

The solution offered by Palamatic Process, the CakeBagger® process line, was able to meet the customer's requirements for reconditioning nickel hydroxide for battery production.

Thanks to the integration of high-performance equipment such as the tubular screw and the Flowmatic®03 filling station, the process has been automated to maximise productivity while ensuring operator safety.

Compliance with the criteria of precision, speed and reliability enabled the customer to maintain a high production rate, with optimal packaging of 10 super sackss per hour.

This installation demonstrates Palamatic Process commitment to providing tailor-made technical solutions, adapted to the most rigorous industrial requirements. Visit our website or contact our team of powder handling experts.

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