Optimizing Sensitive Powder Processing with a Custom Solution

The battery industry imposes strict standards for handling sensitive powders, such as lithium or NMC compounds, due to their toxic and hygroscopic properties. Palamatic Process has risen to the challenge by developing a custom solution that combines OEB4/OEB5 containment, automated discharge systems, and optimized flow management. Discover how this innovative installation meets safety, productivity, and traceability requirements by drawing from the best practices of the pharmaceutical industry.

Our client, a major player in the engineered materials sector, expressed the need to optimize their sensitive powder processing and handling procedures. Faced with stringent industrial constraints, the main objective was to ensure a high level of operator safety while enabling efficient and confined material handling that complies with strict standards for occupational exposure and cleanliness.

The client aimed to reduce production downtimes caused by manual handling and improve overall process efficiency to support sustained industrial-scale production. Key objectives included:

• Controlling operator exposure to OEB4 and OEB5-classified substances.
• Ensuring optimal containment throughout the processing stages.
• Managing fine and compacted powders efficiently while maintaining constant productivity.
• Providing an automated interface for real-time traceability and supervision of operations.

To meet the client’s specific needs, Palamatic Process developed and implemented a comprehensive, custom solution centered around the IBC Flow OEB and integrating state-of-the-art industrial equipment. This installation leverages a combination of technical innovations to optimize sensitive powder handling and ensure safe working conditions.

Key Features of the Solution

Confined and Automated Discharge Stations with IBC Flow OEB (OEB4 and OEB5)

The IBC Flow OEB is specifically designed to eliminate exposure risks and cross-contamination.

Advanced Containment Technology

• The system features double-sealed valves where the docking between the IBC and process structure forms a unique airtight seal.
• This setup eliminates any possibility of powder leakage during discharge, even for highly volatile or toxic materials.

Enhanced Safety

• Operators are fully protected from exposure through an automated system that eliminates the need for direct intervention.
• Ergonomic and secure design minimizes risks associated with manual handling.

Advanced Dust Collection Systems

• Systems capture airborne particles with an extraction capacity of 1,500 m³/h, reducing inhalation risks with advanced filtration.

Butterfly and Guillotine Valves

• Stainless steel valves ensure precise and leak-proof powder flow management.

Custom IBCs

• Antistatic, corrosion-resistant containers are designed to match powder density and required containment levels.

Automation and Centralized Supervision

• A digital interface manages critical parameters such as flow rate, pressure, and production cadence in real-time.
• Integrated traceability meets industrial and regulatory requirements.

Waste Compactors

• Hermetic compactors effectively reduce the volume of bags and other residues for hygienic disposal.

Meticulously selected and adapted equipment meets the strict requirements of sensitive powders, combining containment, flexibility, robustness, and ease of maintenance. These solutions incorporate proven technologies and innovations tailored to OEB4 and OEB5-classified materials, ensuring optimal performance in demanding industrial environments.

IBC Flow OEB Discharge Stations: Airtight and Highly Functional Design

Main Functionality

• Ensures rapid, controlled, and confined discharge of big bags, even for fine and compacted powders.

Specific Features

• Airtight containment sleeves prevent dust emissions.
• Integrated pneumatic massage system fluidizes powders prone to clumping.
• Ergonomic structure with adjustable settings for various big bag sizes.

Advantages of the IBC Flow OEB

• Reduction of manual handling, enhancing operator safety.
• Smooth and continuous discharge, ensuring consistent production rates.
• Easy cleaning and maintenance, minimizing production downtime.

Butterfly and Guillotine Valves: Precision and Durability

Main Functionality

• Provide precise and secure regulation of powder flows, whether for transfers, dosing, or interruptions.

Specific Features

• Constructed from 316L stainless steel, offering increased resistance to corrosive and abrasive materials.
• Maximum sealing, preventing material leakage or cross-contamination.
• Automatic actuation integrated with the Pal’Touch® automation system for real-time control.

Advantages

• Reduction of material losses through precise flow control.
• Enhanced operator safety by limiting direct exposure to powders.
• Increased durability for demanding industrial environments.

Lump Breakers and Pneumatic Vibrators: Ensuring Powder Fluidity and Uniformity

Main Functionality

• Break down compacted or agglomerated powders, ensuring uniform particle size before transfer or packaging.

Specific Features

• Rotary knife mechanisms efficiently break down lumps.
• Integrated pneumatic vibrators facilitate powder flow through hoppers and transport systems.
• Modular design allows for customized installation based on specific constraints.

Advantages

• Prevention of blockages in transfer systems, reducing interruptions.
• Improved powder quality through complete homogenization.
• Adaptability for various material types, including abrasive and hygroscopic powders.

Tubular Conveyors: Total Containment and Efficiency

Main Functionality

• Ensure continuous and fully enclosed transfer of sensitive powders, avoiding any contact with the external environment.

Special features of tubular conveyors

• High-quality materials (316L stainless steel) with electropolished finishes to minimize adhesion and simplify cleaning.
• Airtight connections between equipment to prevent losses or contamination.
• Hygienic design suitable for pharmaceutical and sensitive industrial environments.

Advantages

• Preservation of material quality throughout the process.
• Reduced changeover times with rapid cleaning solutions.
• Versatility for materials with varied characteristics.

Discover our wide range of conveyors for powder and granulate transfer

Dust Collection Systems: Optimal Safety and Cleanliness

Main Functionality

• Efficiently eliminate airborne particles, ensuring a clean atmosphere that complies with safety standards.

Specific Features

• High-performance HEPA or ULPA filters capturing ultrafine particles (up to 0.3 µm).
• Extraction capacity of 1,500 m³/h, suitable for environments with high dust concentrations.
• Direct connection to discharge stations, hoppers, and conveyors for comprehensive coverage.

Advantages

• Protection of operators from inhaling harmful particles.
• Reduction of dust deposits on equipment, minimizing maintenance requirements.
• Compliance with strict industrial and environmental regulations.

Explore our industrial dust collection solutions.

Maximum Safety: Optimal Powder Containment

Handling OEB4 and OEB5-classified powders requires equipment that ensures strict containment, eliminating any risk of operator exposure and environmental contamination.

Advanced Containment

• IBC Flow EOB discharge stations are equipped with hermetic sleeves and glovebox systems, enabling fully isolated material handling.

Operator Protection

• Connected dust collection systems capture airborne particles at the source, reducing inhalation risks.

Compliance with Strict Standards

• The equipment is designed to meet industrial and pharmaceutical standards, adhering to OEB4 and OEB5 classifications for safety and containment.

Positive Impact

These systems enhance workplace health and safety while reducing potential material losses caused by leaks or accidental dispersions.

Increased Productivity: Reduced Interruptions

One of the project's priorities was to improve operational flow, minimizing downtime and slowdowns caused by blockages or complex handling.

Compacted Powder Management

• The integration of lump breakers and vibrating hoppers ensures continuous material flow, even for agglomerated or hygroscopic powders.

Automated Flow Management

• Butterfly and guillotine valves, controlled by the Pal’Touch® system, enable precise transfers without manual intervention, reducing human errors.

Quick Cleaning

• The equipment is designed for easy and rapid cleaning, minimizing downtime between batches or production campaigns.

Direct Results

• Thanks to these innovations, the client maintained high production rates, increasing overall productivity and operational efficiency.

Operational Flexibility: Integration of New Batches or Lines

The adaptability of the equipment is essential to meet the evolving needs of industries, particularly in advanced materials or pharmaceutical sectors.

Modular Design

• IBC containers, automated valves, and tubular conveyors can be quickly adjusted or replaced to accommodate different powder types or new requirements.

Scalable Installations

• The system allows for the addition of new lines or simultaneous management of multiple batches thanks to a modular architecture.

Integrated Traceability

• The Pal’Touch system provides real-time monitoring, ensuring smooth transitions between batches and rigorous material tracking.

Client Benefits

• This flexibility ensures the ability to meet new market demands without requiring major modifications to existing installations.

Cost Reduction: Limited Downtime and Optimized Flows

Optimizing industrial processes involves reducing operational costs by limiting interruptions and maximizing resource efficiency.

Simplified Maintenance

• Robust equipment designed for easy access requires less time and fewer resources for maintenance.

Reduced Material Loss

• Leak-proof systems and precise transfer mechanisms minimize losses due to leaks or human errors.

Energy Optimization

• High-efficiency tubular conveyors and dust collection systems reduce energy consumption while maintaining high performance.

Return on Investment

• Cost savings from improved flow, material, and human resource management enable a rapid return on investment.

The IBC Flow OEB embodies Palamatic Process's expertise in designing advanced equipment for handling sensitive powders. By combining an automated, confined discharge system with exceptional dosing precision, this solution ensures operator safety, material quality, and optimal industrial efficiency.

With the IBC Flow OEB, the client now has a reliable and high-performing tool that meets the strictest OEB containment and powder flow management standards. By integrating this equipment into a complete process line, large-scale production can be achieved while adhering to safety and quality norms.

Our Solution is Also Applicable for Pharmaceutical Powder Handling

The IBC Flow OEB can be used independently or in combination with other Palamatic Process equipment to create a fully confined and automated process line.

Complementary Equipment

• Flowmatic OEB: Big bag filling and discharge station.
• PalSack OEB: Confined sack discharge.
• PalDrum OEB: Confined drum discharge.
• Cyclone OEB: Powder filtration for efficient fine particle management.

Advantages of a Complete Line

• Secure raw material deconditioning.
• Automated and controlled powder transfer between production stages.
• Strict compliance with OEB containment standards and industrial requirements.

Explore More About Sensitive Powders in Industry

European Powder Metallurgy Association (EPMA)

Battery Materials Handling Standards

OSHA Dust Control Guidelines