Bulk Materials Handling Process Integration
Application Case Studies
Bulk Bag Dischargers
This fully integrated bulk material handling system uses RFID-driven process communications to automate simultaneous batching of multiple, and varied, chemical mixtures during a single processing operation.
This bulk bag unloader system, handling highly caustic, severely agglomerated material, operates as a closed process; ensuring the protection of operators from migrant, airborne material and eliminating the possibility for contamination of material in-process.
This 5-station, bulk bag unloader system combines high-capacity structural construction with a centralized controls and automation architecture to safely and accurately supply to downstream process operations a total of 12 million pounds/year of five, combustible input ingredients.
This bulk bag unloader system is designed for use in highly contaminant-sensitive process areas handling bulk materials known to generate combustible dusts. A 9.525mm, polycarbonate encasement surrounds the bulk bag unloader to prevent migrant dusts that piggyback on the exterior of bulk bags from becoming airborne and entering the work zone during bag conditioning and bag collapse.
This NBE bulk bag discharging system, designed and built specifically for food and pharmaceutical processing and packaging operations, helps ensure compliance with domestic and international sanitary standards. Application-specific construction, including 304-2b stainless steel framework, with continuous weld seams ground to a No. 4 finish, enables CIP sanitizing.
The NBE E3™ bulk bag discharge spout interface protects operators and facilities from exposure to airborne material dusts that can often escape during bulk bag spouting. The NBE E3 closed-cycle dust recovery system secures and encloses the bag spout within a sealed containment cylinder. The sealed cylinder then lowers to elongate the spout and form the bag into a conical shape, aiding in complete material discharge from the bulk bag. The sealed cylinder also works to protect the material, and the total process operation, from the introduction of migrant contaminants.
A multi-national household products conglomerate had an application to introduce a dry powder, methyl cellulose, into a liquid mix tank without agglomerates or fisheyes. Methyl cellulose is a finely divided, extremely hygroscopic powder that has poor flow properties. It is used as a thickening or extending agent.
E3 bag spout interface bulk bag discharger system installed to reduce material dust, product loss, production downtime, and other material handling issues associated with a customer’s bulk carbon black unloading process.
Bulk Bag Fillers
NBE introduces this automated, bulk material handling and packaging system built on the NBE integrated construction and controls infrastructure. The complete process sequence, including: pallet/base supply, slipsheet pick-and-placement, bulk material infeed, packaged contents isolated densification, NTEP-certified weighing, and finished-package accumulation conveyance operates on paired, process-specific structural framework chassis with all automation and control functions centralized to a single, menu-driven HMI to enable standardized and system-wide data reporting.
This bulk bag filler system, handling irregular, non free-flowing, adhesive material, is specifically designed to ensure the filled weight of each bulk bag is accurate to +/- .01% of the 2,000-pound, filled-bag capacity. To support a total process rate of 24,000 lbs./hour, this bulk bag filler uses an automated, NTEP-certified weigh device linked to the system-wide, central HMI, designed and built by NBE.
This NBE, automated bulk bag filling system processes and packages fast, free-flowing, dust-generating material that is static-charged and an explosion hazard. Processed material is transferred from upstream supply to the NBE bulk bag filler station. The physical ergonomic design of the bulk bag fill station helps maintain ideal operator posture for safe, efficient operation.
This fully automated, NBE bulk bag filling system provides NTEP-certified bulk bag weighing, accurate to +/- .01% up to a total bulk bag fill weight of 4,500 pounds. NBE design-stage integration of NTEP-certified weigh devices, and proper calibration and fabrication during original system construction, ensure precise, NTEP-certified weigh accuracy and repeatability.
NBE’s automated bulk bag fillers are engineered for accurate, repeatable, and dust-free material filling while maximizing the productivity of the material filling and downstream processing operations.
This fully automated, food-grade bulk material handling system was built to be compliance-ready at start-up and to conform to the specific, regulated processes and practices of the wash-in-place (WIP) application. The integrated system, including: powered infeed conveyor; 2,000 lb.-capacity container lift carriage; 304-2b stainless steel custom discharge hood, surge hopper, and vibratory conveyor is structurally designed with angled-plane, rounded-radius framework and highly finished plate to reduce solids build-up and speed moisture removal.
This NBE sanitary tote dumper is designed specifically for food processing and pharmaceutical processing applications where compliance with FDA, USDA, 3-A, BISSC, or international standards is required.
This fully automated, self-contained, bulk material handling system completely manages material from the introduction stage, through discharge and conditioning, to downstream supply of finished material into manufacturing operations. Human interaction is limited to container loading and removal.
This NBE automated material handling system provides a total process solution for moving highly fragile food product through multiple process operations into bulk storage for temporary holding prior to final packaging. At a process rate of 12,000 pounds per hour, bulk totes of the food product are nested into a lift carriage; the tote is sealed to a custom-designed discharge hood. The tote is vertically conveyed, using 1-1/2 inch, solid 304 stainless steel track and cam rollers, to a 23-foot discharge height.
The NBE process and design engineering teams put into place a bulk system to automate, and fully integrate the bulk material introduction and handling, as well as the material transfer operations of the processing line. The system includes NBE lift & seal container dischargers, incline belt conveyors, and touch screen PLCs running production-line specific programs developed by NBE.
Minimizing horizontal surfaces and areas for material and contaminates to collect while providing a rugged construction to withstand the harsh plant environment and required duty cycle of the equipment were mutual design challenges NBE solved with this 5000 pound capacity container discharger.
Mixing & Blending
Designed specifically for handling bulk materials known to generate combustible dust, this agitator hopper is constructed with explosion protection and control features, including: an explosion venting system, calculated on a Kst value of 170 and Pmax of 9.5, to direct and release overpressure to prepared areas. Hopper construction includes reinforced walls and a reinforced cover, and is rated for 4.5 PSI internal pressure.
This NBE high-volume material mixing system is fully integrated with twin, high-speed, 2,500-pound capacity box dumpers; and two, 8-inch diameter discharge spouts to completely process, from introduction to downstream supply, 25,000 pounds per hour of homogeneously blended material.
Designed specifically for fully automated introduction, transfer, mixing, and blending of multiple, sluggish materials; this NBE, integrated mixing system produces such homogenous blends that downstream production scrap is virtually eliminated.
Multiple mechanical conveying methods are integrated into this automated bulk material handling system to move highly fibrous, non free-flowing material from infeed to discharge, from material conditioning to supply metering, and from metering to downstream processing.
NBE mechanical conveying systems for bulk material containers and packaging are critical to the effective transfer of material during production operations. Whether moving material containers into or out of production, conveying containers from process to process, or from processing to packaging, NBE mechanical conveying systems ensure material is moved efficiently and accurately.
Designed specifically for fully automated handling and processing of highly abrasive, non free-flowing metal flake material, this NBE, self-contained bulk material handling system ensures reliable, repeatable material supply to integrated feeders that meter material for introduction to an inline briquetter. Processed briquettes are conveyed downstream for reclamation.
This pneumatic conveying system, specially treated to transfer a highly corrosive, granular material, uses integrated automation to minimize human exposure to the material and to optimize process efficiency with the upstream bulk bag unloading system.
This self-contained, high-volume bulk material packaging system processes up to 50,000 pounds/hour of combustible materials of varied physical characteristics, including: interlocking flakes and free-flowing, friable rods. Process operations include: material discharge from bulk bags; material introduction from belt flaker units; enclosed, vertical conveying; high-capacity bulk storage; material conditioning; and packaging into bulk bags.