A big bag filling station is composed of two forks. They allow the holding of the big bag during its filling.
The U-type forks are designed for a withdrawal of the Big Bag by the handles. It allows to remove it easily with a forklift. With these, it is possible to slide the forks of the forklift to recover the big bag at the end of the filling.
The round forks are designed for the removal of the Big Bag by pallet using a forklift or a pallet truck.
The U type and round forks are adjustable in height and width.
Gas cylinders are mainly used for the big bag extension system in the emptying phase. But also on the lifting cross-members. They are also used to keep the vidbag hooper door open. Their access requires that the installation is free of any big bag. The gas cylinders are always in groups of 4 and must be in perfect mechanical condition to ensure their synchronisation. We advise you to replace them every two years as the safety of the station depends on their good condition.
For a big bag emptying station, we propose several types of hoists to facilitate handling. There are electric, pneumatic, and manual hoists.
The electric chain hoists are manufactured according to the EC directives for machines and in accordance with the accident prevention regulations. They operate with a cylindrical rotor motor.
A hoist is used for handling the big bag. In most cases, the hoist is attached to a monorail. It is equipped with a hook connected to a lifting chain allowing to choose the height when moving the big bag.
Hydraulic massage is a system for optimising the flow of powders that are difficult to extract. It is recommended for big bags taken in bulk.
It is made up of hydraulic cylinders, large in size and implanted in the lower part of the big bag, which break the vaults and break the mass. Each cylinder is actuated by a piston, providing the necessary force to crush the highly agglomerated products.
It has ram plate ribs that provide a powerful point load, evenly distributed over the edge of the big bag, to break the blocks into small pieces. The conical top and bottom ends prevent damage or even tearing of the Big Bag during the compaction phase.
The sealing during the filling of the big bags is essential, whatever the domain of application. Depending on the storage, transport, and emptying conditions, external contamination of a product is difficult to avoid. The solution exists to solve this problem, the inflatable sealing ring.
It is a holding belt intended for the big bag filling spout on the feeding head. It is necessary to guarantee a perfect seal during the filling of the big bag.
The inflatable ring allows sealing by pinching the big bag liner. When closing, the gasket is completely fitted to the big bag filling spout.
The whole unit is adjustable in height with the action of a hydraulic cylinder, which allows it to adapt to many types and lengths of bags.
The lump breaker is an ideal solution to reduce the size grading of products tending to form lumps. Composed of a primary shaft and a secondary shaft rotating in opposite directions, this assembly allows the crushing of lumps that form during the transport of cohesive products.
It is available in different sizes, from the diameter of 300 to the diameter of 550 mm and it can process a large quantity of product. The lump breaker with a double crushing shaft allows a flow of 40m³ of product per hour.
The lump breaker is integrated under the sealing and pre-transport system. Its limited height enables it to be easily integrated into processes where space is limited.
ISERCO lump breakers are made of steel or stainless steel and include:
A frame with the required installation dimensions
shaft sealing bearings
A passageway grid
1 crushing shaft (or double shaft) with lumping blades
One control unit per gear motor
It is possible to add to this several options like:
A perforated sheeting
Quick disassembly on a slide rail
One blow on cable gland (Pressure setting at 0.3b)
Primary/secondary drive shaft gears
A torque limiter
ISERCO lump breakers are designed to receive 2 different types of drive.
Direct drive: The gear motor drive unit is connected directly to the drive shaft. This design allows a better optimization of the space requirement
Chain drive: The chain and gear transmission system between the primary & secondary shaft allows it to withstand high loads and guarantees a long service life
The lump breaker is used to reduce the particle size of products that tend to form lumps. The lump breaker allows the product to be fluidized.
The lump breaker is integrated under the sealing and pre-transport system.
It is available in different sizes, from the diameter of 300 to the diameter of 550 mm and it can process a large quantity of product.
This lump breaker can be partially or totally disassembled for quick access to the shafts for cleaning. Thus, the inside of the lump breaker can be completely cleaned without having to dismantle the whole unit. The primary and secondary shafts are accessible via the dismantling flange. In the same way, the seals can be changed without having to disassemble the entire system.
This device is particularly appreciated by the food industry which is governed by hygiene standards to be respected.
A quick disassembly is an option for lump-breakers with a simple and double crushing shaft.
The lump breaker is used to crush a lumpy product so that it becomes fluid. Under no circumstances does the lump breaker act as a crusher and therefore cannot be considered as such.
The lump breaker is installed under the sealing system and in front of the product transfer system.
Its limited height enables it to be easily integrated into processes where space is limited.
The lump-breaker with a simple crushing shaft allows a flow of 10m³ of product per hour.
ISERCO lump breakers are made of steel or stainless steel and include:
A frame with the required installation dimensions
shaft sealing bearings
A passageway grid
1 crushing shaft with lumping blades
One control unit per gear motor
It is possible to add different options to this device like :
A perforated sheeting
Quick disassembly on a slide rail
One blow on cable gland (Pressure setting at 0.3b)
Pneumatic massage is used to optimize the flow of products contained in big bags, which are difficult to extract. It is recommended for pulverulent products.
The big bag massage system intervenes in addition to the vibration of the bag emptying hopper when the product has too many flow difficulties to be emptied correctly by the only action of the vibrating motor. Clods of product can form at the outlet of the big bag, and thus stop any possibility of emptying. The action of the massage cylinders is to break the cohesion and to force the product towards the exit of the big bag to evacuate the agglomerates which were formed there. This device should not be used alone, for an optimal result, the actions of vibration and massage must be combined.
There are two forms of pneumatic massage. One is composed of a massage from below with cylinders positioned under the massage paddles. The other is a lateral massage with cylinders located on both sides of the big bag.
Pneumatic conveying works with compressed air, which creates a vacuum in order to suck in air and powdered product. The product is transferred in a pipe from container A to container B.
The suction time is managed by a device called a “pneutimer”.
Pneumatic conveying is usually integrated into big bag emptying stations and hoppers.
The benefits of this system :
It is easy to set up
It is easier to clean than an Archimedean screw system for example
It requires low maintenance
It takes up little space in the installation
It is clean and easy to clean, which makes it a solution of choice in the pharmaceutical or food industry
It is simple to start up for the operator
It is part of a system controlled by automatism.
The absence of friction prevents the product from being damaged during the transfer
ISERCO devices (bin activator, big bag discharge/filling stations) integrate processes more automated. We, therefore, find for security matters presence sensors, which indicate to the PLC if all conditions are met to start an operation. Regularly are fitted sensors of product indication that indicate the level of filling of a bag (beginning/end) to avoid jams. Their replacement will depend on their uses. We recommend regular checks of these sensors, especially on the status of their connectors. We recommend that the user has an available on-site detector model for each type used in the installation.
Pyramidal knives are associated with big bag emptying stations. They allow to rip open the big bag bottom. They are intended for big bags with a lost bottom. They are integrated into the vibrated hopper.
For more resistance and to prevent them from deteriorating at high speed, the pyramidal knives are preferably made of carbon steel. The steel is protected with rustproof paint.
There are on the market many kinds of shaft manufacturing (continuous welds, rolled spiral or constant thickness). The shaft spiral allows the movement of a powder in a closed chamber using friction. There is always wearing on spire tops. The wearing of the shafts spiral depends on their uses. Their replacement will be immediately realized as soon as a loss of flow capacity will be noticed. Shaft spirals are made upon demand according to their specific side. That’s why we suggest keeping spare parts available near the workplace.
This tubular sheath or trough “imprisons the shaft” so that the product can move inside. The inside part of the sheath is also subject to frictions and then wear. The wear will depend on the conditions of use and do not require preventive replacement. However, we recommend that both the shaft and sheath are always kept in stock.
Centrifugal force and frequency of the unbalanced motor(s) are chosen considering the device to move. An inappropriate choice of vibrator can cause a malfunction of the device and in the worst case auto-destruction phenomena (cracks). The lifetime of these motors depends on their uses so that preventive change is not justified. However, we suggest keeping at disposal on site, at least a spare motor for eventual replacement, defined by ISERCO and for each motor type.
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