Bulk Bag Unloading Station:
Vibrating Hopper and Spout Clamp with Powder Induction System

Transferring and mixing bulk solids to liquids in vessels can raise a number of process challenges; powder clumping when introduced to the solution, agglomerations on the vessel side-walls, extended downtime for cleaning between batches, the need for accurate dosing, and maintain efficient mixing times.

The Rheo Bulk Bag Unloading Station: Vibrating Hopper and Spout Clamp with Powder Induction System configuration offers the following benefits to address these challenges:

• Liquid and solids are simultaneously introduced and immediately mixed in powder induction tooling before transferred to tank, eliminating powder clumping and side-wall agglomerations.
• Powder Induction System achieves mixing concentration 5-20X faster than traditional agitator.
• Batch Production Time (bag dump through mixing): down to 20 minutes
• Bulk Powder Transfer Rate : 350 kg/min
• Requires buffer hopper and feeding device to achieve dosing accuracy less than +/- 1000 g

The integrated powder induction system allows the bulk bag to unload into a disperser system that can mix the product with a solution and pump it directly to, or recirculate through, the receiving vessel. Minimal dry cleaning areas improve the mix times for transferring to liquid vessels.

We will design custom configurations for your specific process. The Rheo design library allows our team to efficiently tailor our products to meet the specific requirements of each application. During the design phase, the Rheo engineering team analyzes the application to develop a custom and comprehensive material handling solution. By using standard options as well as custom-designed features, a GMP operator-centric design can be achieved.

Integrated Weighing

An automatic weighing system can be designed into the Bulk Bag Unloading Station configured as either a gain-in-weight (GIW) or a loss-in-weight (LIW) system. The SoliValve® or a pinch valve will automatically adjust to slow down and stop material flow to hit the target weight and to allow for partial bag unloading.

Inline Process Components

Crushers, mills, or screeners can be easily integrated in-line to help with material flow and to reduce a process step.

CIP Spray Devices

Spray devices can be added to the product contact areas to ensure the system is fully Cleanable in Place (CIP). Our GMP retractable spray device fully retracts out of the product stream during powder transfer to ensure no blockage or retention and only extends during the cleaning process.

Water coverage of the CIP system can be validated (Riboflavin) during a Factory Acceptance Test.

Controls and Automation

Typical controls for the Bulk Bag Unloading Station include a touchscreen HMI that can be connected to your plantwide network. Simpler control options are also available.

Sensors can be integrated into the system to recognize when product flow has slowed or stopped which can trigger flow aids to turn on or warn the operator to intervene.

Pinch Valve

Controlling the flow of the bulk powder stream can be a challenge to the unloading process. The pinch valve is often used in conjunction with the spout clamp to control flow. It is designed with high powered cylinders to quickly and reliably cut-off the powder stream, capable of achieving dosing accuracy within +/- 1 kg.