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Bulk Bag Handling System with Powder Dispersion

For this project, Rheo designed and built an integrated system for transferring solids bulk bags into process vessels through a high shear induction mixer. This turnkey system featured a Hoist, a Docking Station, a K-Tron Screw Feeder, an Inline IKA Disperser, and an integrated control system.

The Hoist provides a fast and simple docking process controlled by the system’s HMI and PLC. An integrated tension load cell prevents unintentional lifting of overweight bags. Ultrasonic sensors communicate with the control system to automatically lift and position the bulk bags into the docking station.

The Docking Station consists of a powered bag clamp, dust extraction, pinch valve, and bag tensioning. The powered bag clamp seals the bulk bag liner neck to the transfer chute with integrated dust extraction to provide containment. The bag tensioning cylinders stretch the neck to ensure proper flow of solids from the bag. The pinch valve squeezes off the neck of the bulk bag controlling the flow of the solids.

The materials are then fed to the K-Tron Screw Feeder which controls the introduction of the solids to the IKA Disperser. The IKA Disperser is an inline high shear mixer that disperses product from the hopper into the liquid stream as it recirculates through the process vessel until the desired solution blend is achieved.

The entire transfer process is managed by the latest controls, instrumentation, and HMI to enable optimized operational sequencing while minimizing operator input. This allows for increased productivity and process control. The controls are integrated with safety interlocks; including a light curtain, keeping the limited operator interaction safe.