Automated Bulk Bag Unloading and Conveying System for Lithium

In a demanding industrial context, the client was looking for a fully automated bulk bag unloading solution to integrate into a lithium iron phosphate (LFP) battery production line. The primary goal was to ensure fast and efficient unloading of bulk bags containing chemical raw materials—particularly lithium carbonate (Li₂CO₃) and black iron oxide (Fe₃O₄)—while guaranteeing optimal containment to protect operators and the environment from toxic dust emissions.

The project required equipment capable of supporting a high throughput rate, with a minimum of 15 bulk bags processed per hour, while significantly reducing human intervention. Operator ergonomics and safety were critical, especially to minimize the risk of exposure to highly reactive and potentially corrosive fine powders. The unloading station had to be designed for continuous operation with high reliability to avoid any production slowdowns.

Another major challenge involved the long-term storage of certain bulk bags, leading to the formation of compacted powder blocks. It was therefore necessary to integrate equipment capable of breaking up these blocks prior to transfer to the production process, ensuring optimal flowability of raw materials. Additionally, the solution needed to include an optimized filling system to maintain a continuous and controlled feed of materials to downstream equipment.

The client was seeking a turnkey solution that included bulk bag reception, automated conveying, consistent throughput, operator and environmental safety, and complete automation of the process. The goal was to eliminate manual handling of sensitive powders, particularly during the filling and unloading phases, while maintaining precise control over the process to ensure optimal performance. The equipment also had to enable efficient product handling in compliance with the industry's strictest standards.

To meet the client’s requirements, Palamatic Process implemented a fully integrated solution including an automated conveying line, SmashR units with integrated conveyors, an EF500 bulk bag unloading station, a pallet shredder, and a bulk bag shredder. The installation also features an optimized filling system to ensure a constant supply of raw materials. The unloading station provides efficient product extraction while maintaining a high level of safety. The entire line was designed to minimize manual handling and optimize material flow, ensuring a smooth and uninterrupted production process.

Conveying line (19 conveyors)

• Transports bulk bags to downstream equipment.
• Barcode scanner integrated at the end of the line to ensure material traceability.
• Load capacity: 1.5 tonnes.
• Galvanized steel frame for corrosion resistance.
• Variable speed drives for optimised flow control.

SmashR line with integrated conveyor

• Motorized conveyor on an elevating table to massage the bulk bag on multiple faces and at different heights.
• Massage cycle automatically adjusted based on the bag’s label.
• Breaking up compacted powder blocks to facilitate the unloading process.

EF500 automated bulk bag unloading station

• Overhead crane covering a 12 m x 18 m area.
• Total structure height: 7 m – Lifting stroke: approx. 3 m.
• Hydraulic clamp with two arms for precise positioning and secure handling.
• U-shaped blade in the hopper to create a full opening in the bulk bag, allowing controlled and rapid discharge.
• Two hydraulic holding claws to secure the bag during the discharge cycle.
• Integrated weighing system to alert the operator if product remains in the bag after cutting.

Bulk bag shredder

• Motor power: 5.5 kW with hardened steel blades.
• Volume reduction: up to 70%.
• Cleated conveyor for transporting shredded material to a dedicated container.

Pallet shredder

• Two 22 kW motors driving hardened steel blades.
• Discharge chute directs shredded material into a separate evacuation container.

This fully integrated solution meets the target rate of 15 bulk bags per hour, ensuring continuous and secure production through a sealed unloading station and a hydraulic handling clamp for automated operation.

The installation is built around several industrial systems developed by Palamatic Process, specifically engineered to meet the challenges associated with ultra-fine and reactive powders. The solution includes an optimized filling system that ensures safe bulk material handling, while the bulk bag filling process has been designed to maintain a continuous and controlled material flow throughout the production cycle.

Conveying Line

• 19 stainless steel conveyors designed for durability in aggressive industrial environments.
• Optical detection system to ensure precise positioning of bulk bags.
• Variable frequency drives for accurate flow control.

SmashR Units with Integrated Conveyor

• Motorized conveyor integrated into a lift table for vertical adjustment.
• Massaging flaps to break up powder clumps and ensure optimal discharge.

EF500 Enclosed Bulk Bag Unloading Station

• Fabricated in 304L stainless steel to maximize durability in sensitive environments.
• Bulk bag piercing blade with controlled opening to minimize dust emissions during unloading.

Discharge Hopper Lump Breaker

• Motor power: 2.2 kW.
• Hardened steel blades for extended operational life and high wear resistance.

Bulk Bag Shredder

• Volume reduction: up to 70%.
• Heavy-duty 5.5 kW motor for efficient shredding of empty bags.

Pallet Shredder

• Two heavy-duty motors (22 kW each) for powerful, continuous shredding.

Advanced HMI Interface

• IP65 touchscreen interface designed for intuitive and safe operator use.
• Real-time monitoring of each processing stage for full system control and traceability.

The client now benefits from an installation that meets the highest industrial standards in terms of performance, safety, and durability. The system ensures full control over the challenges posed by fine powders used in LFP battery production.

The inclusion of an optimized hopper facilitates efficient material transfer, while the automated bulk bag unloading system enables safe and reliable handling of bags. Additionally, the enclosed design ensures effective dust containment throughout the process, enhancing operator safety and protecting the production environment.