Ergonomic improvement of an emptying station

One of the production units of a large group specialising in the chemical industry wanted to replace and improve its big bag emptying stations. The customer was equipped with an installation from a competitor that was no longer satisfactory.

The station installed at the site presented a number of problems:

• Malfunctions and random emptying.
• Loss of product due to insufficient height to properly stretch the big bag, preventing it from being completely emptied.
• Problem with product flowability. Some products are very fluid and cause significant dust emissions. Others are difficult to flow (settle during transport) and require assistance when emptying.
• Dust emissions from an open system. The air in the airlock rises towards the hopper, creating dust.
• Fixed, non-vibrating system, not very ergonomic or safe.

The equipment is designed to handle 2 types of product contained in 7 different sizes of big bag. Once the product has been emptied, it is directed into a pneumatic transport lock via a gravity flow pipe.

The main constraint of the project was the height, which was limited by the customer’s existing roof structure. In addition, the station had to blend in with its surroundings as much as possible, while maintaining the highest level of ergonomics and optimum emptying efficiency. All the while ensuring operator safety.

The ISERCO emptying station solves all these problems, offering efficient, clean and safe emptying, as well as improved ergonomics for the operator.

The installation supplied by ISERCO is as follows.

This station has a low, high framework, mounted on top of an existing structure. The special feature of this framework is the work area designed for the operator. This is an ergonomic area for the operator to place the big bag into the clean connect. This area provides direct, safe access for the operator.

Given the difficulties posed by the lack of space on the site, the solution chosen to assist emptying was the installation of a two-part pneumatic massage. It is partly designed to optimise the use of the available space. This system gives the operator easy access to the big bag sealing system. If emptying is difficult, the operator can activate a pneumatic control. The 2 hopper supports massage the big bag from top to bottom. This feature facilitates product release and ensures more efficient emptying. Each massage paddle is operated by pneumatic cylinders.

The station is also equipped with a Clean Connect Double Skin Emptying System. This is essential for ‘clean’ discharge of a product packed in a big bag. It prevents contamination of the outside/inside and inside/outside of the product. The clean connect seals the big bag by squeezing. When the bag is closed, the clamping flange partially rests on the fixed part of the unit before it is tightly clamped. This ensures that the clamp is perfectly flush with the fixed part of the drum. The height of the entire unit can be adjusted by means of a gas spring, allowing it to be adapted to a wide range of bag types and lengths. The clamps ensure smooth, effortless closing without the risk of the operator being trapped.

This is a double-skinned clean connect (inner bag), fitted with a suction port for degassing the big bag.

• Industry: Chemical
• Product type : Zeolite and clay
• Packaging : Big bags with 7 different sizes of discharge chute
• Particle size: Variable
• Emptying time (min.) 15
• Emptying frequency: 24/day
• Abrasive nature: Yes