Automated Bulk Bag (FIBC) Unloader with Integrated Lump Breaker
.
The Challenge: Overcoming Manual Feeding Bottlenecks and Caked Material
A fertilizer plant was originally processing 25kg sacks through a stainless steel hammer mill, achieving a limited output of 1,500 kg/h. This process was labour-intensive and relied on operators to manually “guess” the feed rate. Additionally, the raw material often arrived in “petrified” clumps, which caused irregular surges and mechanical strain on the high-speed mill.
A fertilizer plant was originally processing 25kg sacks through a stainless steel hammer mill, achieving a limited output of 1,500 kg/h. This process was labour-intensive and relied on operators to manually “guess” the feed rate. Additionally, the raw material often arrived in “petrified” clumps, which caused irregular surges and mechanical strain on the high-speed mill.
.
The Solution: High-Efficiency FIBC Discharge & De-Lumping System
We transformed the production line by replacing manual feeding with a fully automated Bulk Bag Unloader (Tonne Bag Station) featuring an Integrated Lump Breaker:
We transformed the production line by replacing manual feeding with a fully automated Bulk Bag Unloader (Tonne Bag Station) featuring an Integrated Lump Breaker:
- Primary De-Lumping: Before the material reaches the conveyor, the Integrated Lump Breaker shears through large agglomerates. This ensures that only free-flowing granules enter the system, protecting the downstream equipment.
- Precision Screw Feeding: The material is then metered into the hammer mill via a slow-rotating screw conveyor. This provides a perfectly consistent “drip-feed” that prevents the mill from choking.
- Heavy-Duty Construction: The entire system is built for the corrosive environments of fertilizer plants, utilizing high-grade stainless steel for long-term durability.
.
The Result: 120% Increase in Throughput with Zero Manual Labour
As demonstrated in our project video, the transition from manual 25kg sacks to automated FIBC discharging revolutionized the plant’s efficiency.
As demonstrated in our project video, the transition from manual 25kg sacks to automated FIBC discharging revolutionized the plant’s efficiency.
- Capacity Doubled: With the exact same hammer mill, the system output jumped from 1,500 kg/h to over 3,400 kg/h.
- Labour Savings: Operator manpower was eliminated from the feeding process, allowing staff to be redeployed to higher-value tasks.
.
.
FIBC Discharger – Technical Specifications Table
| Specification | Technical Details |
|---|---|
| System Type | FIBC / Bulk Bag Unloader with De-Lumper |
| Integrated Components | Lump Breaker & Metering Screw Conveyor |
| Primary Material | Fertilizer (Granular & Petrified) |
| Original Manual Output | 1,500 kg/h (via 25kg Sacks) |
| New Automated Output | 3,400+ kg/h (120% Increase) |
| Unloading Capacity | Standard 1,000kg “Tonne Bags” |
| Control Method | Consistent “Drip-Feed” slow-rotation auger |
| Material Construction | Reinforced Stainless Steel |
| Key Advantage | Eliminates manual labor & surges in hammer mill feed |