Automated bulk bag unloading and conveying system for lithium

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

The system needed to support a high throughput rate, handling a minimum of 15 bulk bags per hour, with minimal human intervention. Operator safety and ergonomics were key factors, particularly to minimise the risk of exposure to fine, highly reactive, and potentially corrosive powders. The unloading station was to be designed for continuous, reliable operation without disrupting production flow.

Another major challenge involved extended storage of certain bulk bags, which led to the formation of compacted powder blocks. Therefore, the solution required an integrated decompacting system to ensure consistent flow prior to transfer into the production line. An optimised filling mechanism was also required to guarantee a steady and controlled supply of raw materials to downstream equipment.

The client sought a turnkey solution that included bulk bag reception, automated conveying, consistent throughput, operator and environmental safety, and full process automation. The aim was to eliminate manual handling of sensitive powders, particularly during filling and unloading stages, while ensuring precise control over the entire process. The equipment also had to enable safe and efficient handling in line with the most stringent industry standards.

To meet the client’s requirements, a complete solution was implemented, comprising an automated conveying line, SmashR units with integrated conveyors, an EF500 bulk bag unloading station, a pallet shredder and a bulk bag shredder. The system also includes an optimised filling system to ensure a constant and reliable supply of raw materials. The unloading station ensures efficient product extraction while maintaining a high level of safety. The process sequence was designed to minimise manual handling and optimise product flow, ensuring smooth and uninterrupted operation across the production line:

1. Conveying line (19 conveyors):
   • Transports bulk bags to subsequent stages with an integrated barcode scanner on the final conveyor to ensure traceability
   • Load capacity: 1.5 tonnes
   • Galvanised steel frame for corrosion resistance
   • Variable speed drives for optimised flow control
2. SmashR line with integrated conveyor:
   • Motorised conveyor on a lifting table for massaging all faces of the bulk bag at different heights
   • Automated massage cycle based on bulk bag label
   • Decompacting main powder blocks to facilitate unloading
3. EF500 line (automated bulk bag unloading):
   • Overhead crane covering a 12 m x 18 m area
   • Total structure height: 7 m – Lifting travel: approx. 3 m
   • Clamp equipped with two hydraulic arms for secure and precise bag positioning
   • U-shaped blade in the hopper to create a full bottom opening for controlled and rapid discharge
   • Two hydraulic claws to hold the bulk bag in place during unloading
   • Integrated weight monitoring system alerts the operator if any material remains after discharge
4. Bulk bag shredder:
   • 5.5 kW motor with hardened steel blades
   • Reduces volume by up to 70%
   • Cleated conveyor directs shredded bags to a separate collection container
5. Pallet shredder:
   • Two 22 kW motors with hardened steel blades
   • Discharge chute for filling a dedicated collection container

This fully integrated system achieves a rate of 15 bulk bags per hour, ensuring smooth conveying operations, safe processing within a sealed enclosure, and automated bag handling via the hydraulic clamp unit.

The system is built around several industrial solutions developed by Palamatic Process, specifically designed to meet the challenges of ultra-fine, reactive powders. It includes an optimised filling system to ensure safe handling of bulk materials. The filling process is engineered to maintain a continuous and controlled material flow throughout production.

• Conveying line:
  • 19 stainless steel conveyors designed for use in aggressive environments
  • Optical detection system ensuring precise bulk bag positioning
  • Variable frequency drives for precise flow control
• SmashR units with integrated conveyor:
  • Motorised conveyor integrated with a lifting table
  • Massaging flaps for loosening compacted product
• EF500 enclosed bulk bag unloading station:
  • 304L stainless steel structure for maximum durability
  • Bulk bag piercing blade with controlled opening to limit dust dispersion
• Lump breaker at the hopper base:
  • Power: 2.2 kW
  • Hardened steel blades for extended durability
• Bulk bag shredder:
  • Volume reduction up to 70%
  • Robust 5.5 kW motor
• Pallet shredder:
  • Two heavy-duty 22 kW motors
• Advanced HMI interface:
  • IP65 touchscreen for intuitive operation
  • Real-time monitoring of processing steps

The client now benefits from a system that meets the most demanding industrial standards, delivering performance, safety and durability while maintaining full control over the challenges of handling fine powders used in LFP battery production. The integration of an optimised hopper facilitates efficient material transfer, while the bulk bag unloading system ensures safe and reliable bag handling. Additionally, bag containment during the process limits dust emissions and enhances operator safety across the entire installation.