Automated bulk bag unloading and conveying system for lithium

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

The project required equipment capable of handling a high throughput rate of at least 15 bulk bags per hour, while keeping human intervention to a minimum. Operator safety and ergonomics were essential, especially to reduce the risk of exposure to highly reactive and potentially corrosive fine powders. The discharge station needed to operate continuously and reliably without disrupting production.

Another key challenge involved the prolonged storage of certain bulk bags, which caused compacted powder blocks to form. The system therefore required block-breaking equipment to ensure proper material flow before entering the production line. Additionally, the solution needed to include an optimized filling system to maintain a steady, uninterrupted supply of raw materials to downstream equipment.

The client was looking for a turnkey solution that would include bulk bag reception, automated conveying, high throughput, operator and environmental safety, and full process automation—eliminating the need for operators to manually handle lithium and iron oxide powders. The aim was to limit manual handling of sensitive materials, especially during filling and discharge stages, while maintaining tight process control for optimal performance. The equipment also had to ensure safe, efficient product handling in full compliance with the industry's strictest standards.

To meet the client’s needs, a fully integrated solution was implemented, including an automated conveying line, SmashR units with integrated conveyors, an EF500 automated bulk bag unloading station, a pallet shredder, and a bulk bag shredder. The system also features an optimized filling mechanism to ensure a continuous and reliable supply of raw materials. The unloading station enables efficient product extraction while maintaining a high level of safety. The full system is designed in a logical sequence to minimize manual handling and optimize material flow, ensuring smooth, uninterrupted production:

1. Conveying line (19 conveyors):
   • Transfers bulk bags to the next processing stages, with a barcode reader on the final conveyor to ensure traceability.
   • Load capacity: 1.5 tonnes
   • Galvanized steel frame to resist corrosion
   • Variable speed drives for optimized flow
2. SmashR line with integrated conveyor:
   • Motorized conveyor mounted on an elevating table for massaging the bulk bag on multiple faces and at various heights
   • Massage cycle automatically adjusted based on the bulk bag label
   • Main block decompacting to improve unloading efficiency
3. EF500 line (automated bulk bag unloading):
   • 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 secure and precise positioning
   • U-shaped blade inside the hopper to create a full cut-out for rapid, controlled product discharge
   • Two hydraulic claws to hold the bulk bag during the unloading process
   • Integrated weight monitoring system to alert operators if product remains in the bag after cutting
4. Bulk bag shredder:
   • 5.5 kW motor with hardened steel blades
   • Volume reduction of up to 70%
   • Cleated discharge conveyor routes shredded bags to a separate collection container
5. Pallet shredder:
   • Two 22 kW motors with hardened steel blades
   • Discharge chute feeds shredded material into a dedicated container

This integrated system achieves a throughput of 15 bulk bags per hour, delivering smooth, continuous production through automated conveying, secure operation within a sealed enclosure, and fully automated handling using a hydraulic clamp system.

The installation includes several industrial systems developed by Palamatic Process, specially adapted to the challenges posed by the client’s ultra-fine, reactive powders. It features an optimized filling system designed to ensure safe bulk handling and a controlled, continuous material flow throughout the process.

• Conveying line:
  • 19 stainless steel conveyors designed to resist aggressive industrial environments
  • Optical detection system for accurate bulk bag positioning
  • Variable frequency drives for precise flow control
• SmashR units with integrated conveyor:
  • Motorized conveyor integrated into a lift table
  • Massaging flaps to break down compacted material
• EF500 enclosed bulk bag unloading station:
  • 304L stainless steel structure for maximum durability
  • Controlled-opening piercing blade to minimize dust dispersion
• Lump breaker at the bottom of the hopper:
  • Power: 2.2 kW
  • Hardened steel blades for extended service life
• Bulk bag shredder:
  • Volume reduction of up to 70%
  • Robust 5.5 kW motor
• Pallet shredder:
  • Two robust 22 kW motors
• Advanced HMI interface:
  • IP65-rated touchscreen for intuitive use in industrial environments
  • Real-time monitoring of process stages

The client now benefits from a system that meets the highest industrial standards, ensuring performance, safety, and durability while maintaining full control over the challenges of handling fine powders used in LFP battery production. The integration of an optimized hopper facilitates smooth material transfer, while the bulk bag discharge system ensures safe and efficient bag handling. Additionally, enclosing the bags during the process helps reduce dust emissions and enhances operator safety throughout the operation.