In the food processing industry, efficient ingredient transfer from bulk bags to mixing equipment is vital. Improperly designed or installed bulk bag discharge systems can hinder productivity.

Adding to the complexity, bulk bag dischargers are often integrated with conveyors that move ingredientsFigure 1: In the food processing industry, efficient ingredient transfer from bulk bags to mixing equipment is vital. Source: Spiroflow Systems further along the processing line. Sometimes, manual transfer using totes or carts is still required and the slowest part of this chain can slow production dramatically.

“A poorly designed bulk bag discharger can reduce the efficiency of downstream processes, turning a five-minute task into a half-hour ordeal. Upgrading to better equipment can help food processors eliminate potential bottlenecks and increase overall processing rates,” said Don Mackrill of Automated Handling Solutions (AHS), which specializes in engineering solutions incorporating specialty conveying, material handling and automation technologies.

Mackrill, a system integration and material handling expert, shares key tips to optimize bulk bag discharge and the entire production process. AHS's portfolio includes Spiroflow, a company providing a range of discharging and filling equipment, including bulk bag unloaders, fillers and automated material handling machinery.

Mackrill highlights how integrating specific upgrades can manage dust, minimize waste and boost overall throughput.

Effective dust management reduces product loss

Basic bulk bag dischargers typically use a simple support frame for products that don’t generate dust. The operator loads the bulk bag into the frame using a forklift or hoist and releases the neckties without needing to regulate the flow.

However, when handling dusty products, bulk bag designs become more complex to ensure complete emptying while containing dust within the system. This reduces material accumulation in dust collectors or on the floor, lowering maintenance and cleanup requirements.

“Bulk bag unloaders should minimize fugitive dust,” said Mackrill. “Our systems aim for 'maximum containment,' featuring specialized supports, an ‘untie’ box to open the spout without dust release and optional accessories like a yoke-type spout closure bar to prevent dust during untying.”

Hygienic liner clamps and spring-loaded bag support arms manage loose liners and prevent liner distension, enhancing dust control.

Ergonomics for improved production

The method of placing bulk bags on discharge equipment varies and can affect production rates. Some systems are less operator-friendly, increasing the time and effort needed to load each bulk bag.

Operators typically tie off the outlet spout, remove the empty bag, place a new bulk bag on the equipment and initiate the next discharge. Less ergonomic designs can cause operators to waste time and effort.

“Choosing a more ergonomic discharger simplifies bag replacement and reduces changeover times,” said Mackrill.

Integrating discharge and weighing systems

Enhancing weighing accuracy can further improve efficiency and reduce costs. “With inaccuracies in weighing increasing waste and affecting batch consistency, food processors aim to discharge ingredients as precisely as possible,” said Mackrill.

Ingredients can often be dispensed in batches directly from the bulk bag, avoiding the need to transfer to a weigh feeder or metal totes. Various methods achieve this and working with an OEM offering a range of bulk bag discharger options, including volume and weight discharge, can improve flow and consistency.

For example, Spiroflow’s Universal T2 bulk bag discharger offers controllable discharge by volume, using an integral conveyor to meter contents accurately to the process vessel. Alternatively, loss-in-weight models allow precise control over the dispensed amount, adaptable for selected batch amounts or continuous batch production.

Conveyor system integration

Upgrading bulk bag fillers may necessitate redesigning conveyor systems that transport products to the fillers. Mackrill notes that several types of enclosed conveyors, including aero mechanical, flexible screw and tubular cable drag designs, can meet these needs.

“Conveyors are usually part of an integrated system with dischargers. The goal is to transport material in a fully enclosed environment to prevent dust release, product loss and exposure to humidity,” added Mackrill.

The food processing industry often deals with powdered ingredients like sugar, flour, coffee and protein concentrates, which can be challenging to convey due to stickiness, hygroscopic properties or caking tendencies. These powders can also pose significant health and safety risks when airborne.

Partnering with experienced system integrators

Food processors can benefit from the expertise of powder conveying integrators with experience in implementing various equipment types in complex applications. An experienced integrator such as AHS, can help select and optimize the best conveyor for specific types of food and processes. Combining both Spiroflow and Cablevey, AHS offers a suite of material handling and industrial automation solutions.

By upgrading the bulk bag discharge process with expert consultation and suitable equipment, processors can increase production efficiency and reduce labor and time, leading to cost-effective success. Determining the best bulk discharge and conveying solution often requires substantial expertise and system customization, therefore connect with a local AHS representative to see how they can help. Visit the Spiroflow website for more information.