Context
A major company in the sugar industry approached ISERCO to supply a stainless steel big bag discharge station for one of their factories.
The customer needed to replace an existing aging structure.
The new Big Bag emptying station is more ergonomic and includes tools to facilitate extraction (vibrating hopper, mass bag, lump breaker). Sugar is an extremely hygroscopic product, which favors the formation of lumps.
The proposed solution
In order to provide the customer with the best solution, a complete study was carried out. The study and design included the implementation of a new station in the existing environment using 3D scanning.
The emptying station ordered by the customer is equipped with:
- A 3-part framework to fit the dimensions of the site (low, intermediate and high frameworks). The upper section has a galvanized steel monorail.
- A galvanised steel cross-member with a hoist for lifting the Big Bag. It consists of a mechanically welded unit with 2 box beams, an end plate, 4 hooks and a central protection plate. This lifting beam is APAVE 1500 kg certified.
- A vibrating stainless steel hopper. It facilitates the extraction of products with low flow thanks to the use of an unbalanced motor. It rests on 4 silent blocks to prevent the transmission of vibrations to the structure.
- A stainless steel access chamber with a flexible sleeve and sensor support. This allows Big Bags to be opened in a clean, ‘closed’ environment. Installation of an inductive sensor on the door allows product flow to be initiated in a closed environment.
- A stainless steel crusher with 2 horizontal shafts and chain and gear transmission. This machine crushes sugar blocks from big bags.
- A galvanised steel hydraulic big bag massage. It consists of two hydraulic cylinders with flexible hoses situated in the lower part of the big bag. This system is an extraction aid designed to break up any lumps or ridges of sugar that may form in the big bag. The entire system is automated and safe.
- Hydraulic power pack with three-phase motor, APG pump with steel support and drip tray.
- A control box to activate the big bag emptying system. It allows the operator to engage the difficult product discharge system via the vibrating hopper and hydraulic massage paddles. The operator can then start the crusher to break up the blocks of product. At the end of emptying, the operator evacuates the big bag.
This emptying station is connected to an existing screw conveyor to convey the product to the customer’s downstream process. It is also connected to an existited deferrizer to remove foreign bodies by means of a magnetic separation and metal detection system.
In addition to supplying the plant described above, ISERCO was responsible for installing and commissioning the drainage station. Commissioning included production trials and operator training.
Bulk information
- Industry: Sugar Mill
- Product type: Sugar
- Density: 0.8
- Conditioning: Big Bag