W-0433 FullLineA4.qxd
FULL LINE
®
Bulk Handling Equipment
and Engineered Systems
CONTENTS
Overview . . . . . . . . . . . . . . . . . . . . . . 3
Materials . . . . . . . . . . . . . . . . . . . . . . 4
Systems. . . . . . . . . . . . . . . . . . . . . . . . 5
Flexible Screw Conveyors . . . . . . . . . . . 6
BEV-CON™ Conveyors . . . . . . . . . . . . 9
PNEUMATI-CON® Dilute Phase
Pneumatic Conveying Systems . . . . . . 10
Bulk Bag Dischargers. . . . . . . . . . . . . 14
Bulk Bag Conditioners . . . . . . . . . . . . 18
Bulk Bag Fillers . . . . . . . . . . . . . . . . . 19
SWING-DOWN™ Fillers . . . . . . . . . . . . 20
REAR-POST and TWIN-CENTREPOST™ Fillers . . 21
Bag Dump Stations . . . . . . . . . . . . . . 22
Drum Tippers . . . . . . . . . . . . . . . . . . 23
Sanitary Construction and Finishes . . . 24
Weigh Batching and Blending Systems. . 25
Digital Programmable Controls . . . . . 28
Worldwide Engineering, Testing,
Manufacturing and Field Support . . . . 30
Convey, load, unload, weigh, feed,
and process virtually any bulk solid material
Flexicon is a world leader
in the design and manufacture
of bulk handling equipment
and custom-engineered and
integrated plant-wide systems
that transport, discharge, fill,
weigh, blend, deliver and/or
feed a broad range of powder
and bulk solid materials.
Flexicon products range
from individual equipment
to automated systems that
source bulk material from
interior and exterior plant
locations, transport it between
process equipment and storage
vessels, weigh it, blend it, feed
it to packaging lines, extruders,
moulding machines and storage
vessels, and load it into railcars
and trailers.
Choose from a broad range
of reliable, high performance
equipment in carbon steel with
durable industrial finishes, or
in stainless steel designed and
constructed to industrial, food,
dairy or pharmaceutical
standards:
Flexicon can also customengineer automated, plant-wide
bulk handling and processing
systems that integrate Flexicon
equipment with bulk handling
and process equipment of other
manufacturers:
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Flexible Screw Conveyors
Pneumatic Conveying Systems
Volumetric Feeding Conveyors
Bulk Bag Fillers
Bulk Bag Dischargers
Bulk Bag Conditioners
Weigh Batching Systems
Manual Dumping Stations
Lift-and-Seal/Open Chute
Drum Tippers
Storage Vessels
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Gravimetric/Volumetric
Feeders
Silos and other storage
vessels
Dryers/Coolers
Mixers/Blenders
Screeners
Crushers/Grinders
Packaging Machines
Other bulk processing
equipment
®
ATEX
Compliant
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Materials
Handle free- and non-free-flowing bulk products including
problematic materials and blends—with confidence
Whether your bulk material is
comprised of large pellets, fine
powders or both, flows freely or
not at all, has a bulk density of
50 or 5000 kg/cu m, or packs,
plugs, cakes, smears, fluidises,
agglomerates, breaks easily or
separates, Flexicon has most likely
conveyed, fed, discharged, filled,
weighed, dumped or otherwise
handled it many times before.
In fact, moving the most
uncooperative bulk materials
known to the chemical, paint,
food, pharmaceutical and plastics
industries has been a Flexicon
specialty since 1974.
Examples of Flexicon advances
in flow promotion include
FLOW-FLEXER™ bag activators,
POP-TOP™ bag stretching devices,
TELE-TUBE™ telescoping tubes,
POWER-CINCHER™ flow control
valves, BEV-CON™ conveyors,
high flow hoppers, deaeration/
densification decks and a host of
other components and accessories
that promote flow while reducing
degradation, dusting and/or the
separation of blends comprised
of disparate particles.
The ability to move your material
efficiently, together with equipment
designs and finishes that meet
numerous regional and national
codes worldwide for chemical,
food, dairy and pharmaceutical
applications, enables Flexicon to
satisfy virtually every aspect of
your bulk handling requirement,
regardless of material, industry
or location worldwide.
Following is a sampling of
materials handled by Flexicon
equipment and systems. For
performance data on your specific
material(s), please consult your
Flexicon applications engineer.
ABS RESIN
ACETAMINOPHEN
ALMONDS
ALUMINA
ALUMINIUM OXIDE
ALUMINIUM
TRIHYDRATE
AMORPHOUS SILICA
ANIMAL FEED
ANTIOXIDANT
ASCORBIC ACID
ASPARTAME
ASPIRIN
BABY POWDER
BACON BITS
BAKING SODA
BARIUM SULPHATE
BARLEY
BEANS
BENTONITE
BISCUIT MIX
BLOOD, DRIED
BORIC ACID
BREAD CRUMBS
BREWERY YEAST
CAFFEINE
CAKE MIXES
CALCIUM CARBONATE
CALCIUM STEARATE
CARBON ACTIVATED
CARBON BLACK
CARPET DEODORISER
CARRAGEENIN
CASEIN
CAT FOOD
CAT LITTER
CELLULOSE FLOCK
CEMENT
CEREAL FINES
CHEESE POWDER
CHEESE, DICED,
FROZEN
CHEESE, GRATED
CHILI POWDER
CINNAMON & SUGAR
MIXTURE
CITRIC ACID
CLAY
COCOA POWDER
COCONUT
COFFEE BEANS
COFFEE CHAFF
COFFEE, GROUND
COOKIE CRUMBS
CORN
CORN FLOUR
CORN GRITS
CORN KERNELS
CORN MEAL
CORN STARCH
CREAMER
CRUMB RUBBER
CRYOGENIC MEDIA
DETERGENT
DEXTROSE
DIATOMACEOUS
EARTH
DOUGHNUT MIX
DRINK MIXES
EGG POWDER
EPOXY RESIN
FERTILISER
FIBREGLASS
FILTER AID
FLAME RETARDANT
FLOUR
FLY ASH
FRUCTOSE
FUMED SILICA
GARLIC, WHOLE
GELATINE POWDER
GLASS BEADS
GLASS MICROSPHERES
GRAHAM CRACKER
CRUMB
GRAINS
Moist, sticky materials
Abrasive materials
Free-flowing materials
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GRANOLA
GRAPHITE POWDER
GRAVY MIXES
GRITS
CRYOGENICALLY
GROUND PLASTICS
& RUBBERS
GUAR GUM
GYPSUM
HERBICIDE
INFANT FORMULA
IRON OXIDE
IRON POWDER
KAOLIN CLAY
KRATON RUBBER
LACTOSE
LAXATIVE
LEAD OXIDE
LIME, HYDRATED
MAGNESIUM
CHLORIDE
MAGNESIUM OXIDE
MAGNESIUM
STEARATE
MAGNESIUM
SULPHATE
MALT
MALTODEXTRIN
MARBLE DUST
METAL POWDER
MICRO CRYSTALLINE
CELLULOSE
MILK POWDER
MONOSODIUM
GLUTAMATE (MSG)
NUTS, GROUND
NUTS, WHOLE
OATS
PANCAKE MIX
PAPRIKA
PENTAERYTHRITOL
PERLITE
PET REGRIND
Friable materials
Products that pack, cake,
smear or plug
Non-free-flowing products
Contamination-sensitive
products
PHARMACEUTICAL
POWDER
PHENOLIC RESIN
PIGMENTS
PLASTIC FLAKE
PLASTIC PELLETS
PLASTIC POWDER
PLASTIC RESIN
POLY VINYL ALCOHOL
POLY VINYL
CHLORIDE (PVC)
POLYETHYLENE
POTATO FLAKES
POTATO FLOUR
POTATO PEARLS
POTATO STARCH
POTATOES, INSTANT
PRETZEL SALT
PROTEIN POWDER
PSYLIUM HUSKS
PVC REGRIND
PVC RESIN
RED IRON OXIDE
REGRIND
RICE
RICE HULLS
RUBBER
SALT
SAND
SAWDUST
SEASONING
SEEDS
SEMOLINA
SESAME SEED
SILICA HYDRAGEL
SILICON DIOXIDE
SILVER POWDER
SOAP POWDERS
SODA ASH
SODIUM
BICARBONATE
SODIUM CHLORIDE
SODIUM CITRATE
SODIUM SILICATE
SODIUM STEARATE
SODIUM SULPHATE
SODIUM
TRIPOLYPHOSPHATE
SORBITOL
SOUP BASES
SOUP MIX
SOY BEANS
STARCH
STEARIC ACID
SUGAR,
CONFECTIONERY
SUGAR, CRYSTAL
SULFUR
SUPERABSORBENT
TALC
TEA
TEA LEAVES
TEFLON
TEREPHTHALIC ACID
THERMOSET RESIN
TITANIUM DIOXIDE
TONER
TRI-SODIUM PHOSPHATE
UREA
UREA PRILL
VEGETABLES,
DEHYDRATED
VERMICULITE
VINYL RESIN
WHEAT FLOUR
WHEAT GLUTEN
WHEAT STARCH
WHEY
WOLLASTONITE
WOOD CHIPS
WOOD FLOUR
XANTHUM GUM
ZEOLITE
ZINC OXIDE
ZINC PHOSPHATE
ZINC STEARATE
Blends of dissimilar
ingredients
Hazardous materials
Materials that fluidise
Large particles
Systems
Using samples of bulk material
you supply, Flexicon can evaluate
and/or test your material in a
state-of-the-art test laboratory
on full-size equipment configured
and customised to simulate your
system, supply the equipment
on time, help you install it, train
your personnel, guarantee its
performance and service it
on-site.
Because Flexicon offers a wide
range of equipment, including
mechanical and pneumatic
conveyors, as well as systems
that incorporate equipment
of other manufacturers, you
are assured of receiving a
recommendation based on your
requirement, not on limited
equipment availability.
From concept to completion,
Flexicon can provide everything
it takes to solve your bulk
handling problem efficiently,
economically and rapidly.
Flexicon flexible screw and
pneumatic conveying systems offer
distinct differences in performance
relative to specific application
requirements. Since many plants
convey a variety of bulk materials
in a range of capacities over
varying distances, a combination
of pneumatic and flexible screw
conveying is often recommended
to maximise overall performance
and return on investment.
CONVEYOR CHARACTERISTICS
Short distances
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Medium distances
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Long distances
Lowest initial cost
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Lowest energy consumption
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Indirect conveyor routing required
Flexibility of conveyor routing
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Simplest installation
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Multiple material sources
Multiple material destinations
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Mobile units
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Evacuation of material
from conveying system
No separation of blends
DILUTE PHASE VACUUM
PNEUMATIC CONVEYORS
Flexicon can evaluate your bulk
material(s), plant layout, throughput rates, residual product
limitations, cleanliness, noise
limitations, access, cost, cycle
times and other parameters,
and outline the solution to your
bulk handling problem.
DILUTE PHASE POSITIVE-PRESSURE
PNEUMATIC CONVEYORS
Flexicon can submit recommendations in the form of CAD
drawings that integrate equipment manufactured by Flexicon
and by others, with new or
existing equipment in your plant,
and provide a competitive price
quotation.
FLEXIBLE SCREW CONVEYORS
You can alleviate the burden and
risk of designing your system,
coordinating multiple suppliers,
integrating components, troubleshooting start-up and assuming
responsibility for system
performance, by relying
on Flexicon for it all.
CHECK YOUR REQUIREMENTS
One-stop source for engineered, integrated bulk handling systems
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Convey directly from barrel or hopper
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Materials that pack, cake or smear
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Heat-sensitive material
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High temperature material
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Ultra-high temperature destination
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Extreme material in-feed rate fluctuation
Contamination-sensitive material
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Hazardous material
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5
Flexible Screw Conveyors
Move virtually any free-flowing or non-free-flowing bulk material
Only one moving part
The only moving part contacting
material in a Flexicon flexible
screw conveyor is the rugged
flexible screw which is driven
by an electric motor. As it
rotates, the screw propels
material and centres within
the conveyor tube, providing
constant clearance between
itself and the tube wall.
This simple design does not
require cables, chains, disks,
internal bearings, and numerous
moving parts found in bucket
elevators, rigid augers, drag
chains, and/or aeromechanical
conveyors—parts that can add
initial cost, require maintenance,
wear out, breed contamination,
and/or break down.
Enclosed tube
prevents contamination
A Flexicon flexible screw
conveyor is totally enclosed,
dust-free, and mess-free,
preventing contamination of
your bulk products and plant
environment, while preserving
the moisture and temperature
levels of materials being
conveyed.
Compare the smooth interior
surfaces of a Flexicon flexible
screw conveyor with potential
contamination sources found
in other conveyors, and you
may specify the Flexicon
flexible screw conveyor
on the basis of product
purity alone.
Even more importantly, Flexicon
flexible screw conveyors offer
efficiency and versatility,
conveying bulk materials ranging
from large pellets to sub-micron
powders—both free-flowing and
non-free-flowing—including
difficult-to-handle products that
pack, cake, seize, fluidise, plug,
or smear, with no separation
of blends. (See “Materials,”
page 4.)
Gentle product
handling and blending
Flexicon flexible screw conveyors
can handle your products gently,
because the flexible screw selfcentres as it rotates. This
can provide ample clearance
between the screw and tube
wall to prevent grinding,
crushing, and other product
damage.
In addition, the gentle rolling
action created by the screw
prevents the separation of
blends throughout the entire
length of the conveyor.
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Convey in any direction
Whereas many conveyors have
limited angles of incline and/or
straight-only conveying paths,
Flexicon flexible screw conveyors
can move material vertically,
horizontally, or at any angle—
over, under, or around
obstructions, through
small holes in
walls or
ceilings.
Flexible screw pioneer
Fast, thorough cleaning
Perhaps no other manufacturer
has advanced the application
of the flexible screw conveyor
as far and as fast as Flexicon—
the first to introduce 115 mm,
150 mm, and 200 mm
diameter screw/tube
combinations that elevated
the capacity of this category
of conveyor more than 10-fold
in an 8-year period. After
more than 10,000 installations
worldwide involving a gamut
of bulk materials, Flexicon
has amassed a wealth of
performance data on flexible
screws—many of which have
been engineered, machined
and formed to Flexicon
specifications. To you, it
means that Flexicon has most
likely solved your problem in the
most efficient and cost-effective
manner possible—or can do
so as a matter of routine.
A Flexicon flexible screw
conveyor has no internal
cracks, crevices or bearings
that can trap particles or
prevent thorough cleaning.
Simply remove the clean-out
cap and reverse rotation to
evacuate any residual material
prior to flushing with air, water,
steam, or cleaning solution.
The screw and tube can be
removed quickly for easy
and thorough cleaning.
High reliability,
low maintenance
A Flexicon flexible screw
conveyor has no internal
bearings, cables, filters, chains,
buckets, or other potentially
problematic components to
wear, break down, or require
maintenance. The only moving
part contacting material is a
rugged flexible screw which
resists wear and fatigue, and
is driven by an electric motor.
Even under a full load of moist,
dense product—depending on
application parameters—a
Flexicon flexible screw conveyor
can start and stop repeatedly
with no binding or damage
to the unit. The result is
a conveyor without load
limitations that runs dependably,
boosting productivity while
cutting maintenance.
Economical to purchase,
install and operate
A Flexicon flexible screw
conveyor does not require
the internal and external
components that can make
other conveyors expensive to
build and operate. The only
moving part contacting material
is the rugged flexible screw
that resists wear and fatigue,
resulting in extraordinary
reliability and minimal
maintenance.
To suit your cleanliness
requirements, all Flexicon
flexible screw conveyors are
available in carbon steel with
durable industrial finishes, or
in stainless steel designed,
constructed and finished to
industrial, food, dairy and
pharmaceutical standards.
(See “Sanitary” page 24).
Volumetric
feeding conveyors
Flexicon flexible screw
volumetric feeding conveyors
provide simultaneous metering
and conveying of bulk solid
products. The units are
equipped with AC or DC
variable speed drives and
hoppers with flow promotion
devices for continuous
feeding of both freeand non-free-flowing
materials.
Because the screw
and tube are flexible,
and can be routed
easily in any direction,
the intake and discharge
can be positioned where
you need them, in situations
that would be difficult, costly or
impossible to satisfy with other
conveyors.
Flexicon matches an unequalled number and type of standard and custom
flexible screws to a correspondingly
wide selection of hopper designs and
charging adapters to meet all of your
material and process parameters with
the greatest efficiency and reliability.
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Mobile and
custom configurations
All Flexicon flexible screw
conveyors are available on
castor-mounted frames with
conveyor support masts for inplant mobility, reducing the need
for multiple stationary units.
Both mobile and stationary
units are readily customised
using interchangeable screws,
conveyor tubes, motor drives,
hoppers, flow-promotion
devices, sensors, controllers,
and other components to
satisfy the most diverse
and demanding end-use
requirements.
High capacity flexible screw
conveyor with downspout removed
to demonstrate flow of material.
Divergent angles of Flexicon’s patented
high flow hopper design reduce the
ability of non-free-flowing materials to
establish a bridge between the hopper
sidewalls, instead causing material to
topple and flow toward and down the
steep backwall, increasing the flow
of bulk materials while decreasing
residual material in the hopper.
Multiple discharge
point systems
Horizontally-oriented Flexicon
flexible screw conveyors can
feed multiple packaging
machines, moulding machines,
and other process equipment.
The system can convey bulk
material over short to medium
distances, feed multiple
discharge points selectively,
or top off all points on a
timed cycle through manual
or automatic slide gate valves.
Flexicon offers a multitude of
mechanical and pneumatic hopper
accessories to promote the flow of
poor-flowing or non-free-flowing
materials. This hopper features dual
agitators with interlocking paddles
that de-agglomerate bulk material,
promoting void-free charging of
mechanical conveyor intake adapters.
Flexicon’s Low Profile Flexible
Screw Conveyor positions the
motor drive at the inlet end of
the conveyor tube, allowing the
discharge end to fit within
limited headroom areas often
encountered above weigh hoppers
or other receiving vessels.
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BEV-CON™ Conveyors
Handle difficult-to-convey bulk materials
BEV-CON™ flexible screw
conveyors from Flexicon
handle powder and bulk
solids including materials
that tend to pack, cake, smear,
plug, fluidise or separate.
BEV-CON conveyors are also
highly effective for handling
fragile or brittle products that
tend to break or crumble from
the friction, crushing, grinding,
pressure, or impact that can
occur in other conveyors.
Products ideally suited to the
special capabilities of a BEVCON conveyor range from
sub-micron powders to large
pellets and include:
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CHEMICALS:
Titanium dioxide, carbon
black, calcium carbonate,
powdered lime, rubber,
detergent powders and
sulphur
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FOODS:
Cake mixes, soup mixes,
gravy mixes, cocoa powder,
cheese, candy, milk powder,
dehydrated, frozen or raw
vegetables, fruits and nuts
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PHARMACEUTICALS
AND COSMETICS:
Talc, titanium dioxide,
zinc oxide, clay, calcium
carbonate, powder and
finished bulk of all types
Versatile configurations
conform to your application
Moist, sticky materials
BEV-CON units have a straight
conveyor tube which is generally
supported by attaching the
drive/discharge end to an
overhead joist, tank rim or
any other solid structure.
Friable materials
The conveyor tube may be
routed through small openings
in walls or ceilings. BEV-CON
conveyors are also available on
frames with masts and castors
for in-plant mobility.
Products that pack, cake,
smear or plug
A wide variety of conveyor
tubes, motor drives, hoppers,
and bag dump dust collectors,
in a range of sizes, shapes and
materials, enables Flexicon to
custom build a BEV-CON
conveyor to your specific
requirements.
BEV-CON conveyors are
available in carbon steel with
durable industrial finishes, or
stainless steel designed and
constructed to industrial, food,
dairy and pharmaceutical
standards.
This BEV-CON conveyor is
equipped with a highly specialised
flexible screw matched to material
characteristics and other
application requirements.
BEV-CON Conveyors can
transport difficult-to-handle bulk
materials vertically, horizontally
or at any angle. This low-incline,
mobile configuration is designed,
constructed and finished to dairy
standards, and allows dust-free
connections to upstream as well
as downstream equipment.
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PNEUMATI-CON® Dilute Phase
Pneumatic Conveying Systems
Flexicon’s PNEUMATI-CON®
dilute phase pneumatic
conveying systems range
from single-point “up-andin” installations to crossplant systems with multiple
pick-up and discharge points
and automated controls,
satisfying an exceptionally
wide range of bulk
conveying applications.
All are custom-engineered
and fully integrated with
other Flexicon equipment
and systems, and your
new or existing process.
PNEUMATI-CON dilute phase
pneumatic conveying systems
move bulk materials that are
suspended in an air stream
that is introduced by a positive
pressure blower upstream of
material intake points, or by
a vacuum pump that removes
air from the system downstream
of material discharge points.
Material is separated from the
conveying air at the use point,
then discharged on a batch
basis via butterfly or slide gate
valves, or continuously via
rotary airlock valves.
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Positive pressure systems
Vacuum systems
Positive pressure dilute phase
pneumatic conveying systems
are typically employed to convey
bulk materials from a single
source to one or multiple
destinations, over longer
distances and with greater
capacity than possible using
vacuum systems.
Vacuum dilute phase pneumatic
conveying systems are generally
employed for transporting
material from multiple sources
such as storage vessels, process
equipment, trucks and railcars,
to individual or multiple
destinations. Unlike positive
pressure systems, vacuum
systems allow easy pick-up of
materials from open containers
using wands, and do not impart
heat to the material. Since
vacuum systems offer superior
leak containment, they are
often specified on the basis of
cleanliness, particularly when
handling hazardous materials.
These systems utilise a positive
displacement blower with single
or multiple downstream material
entry points, each of which
meters product into conveying
lines by means of a rotary
airlock valve that maintains the
pressure differential between the
ambient atmosphere and that of
the conveying line. Material and
air blown through the line exit
at single or multiple use points
where they are separated by
means of a filter receiver or
cyclone separator, or fed directly
into process vessels that are
vented to downstream dust
collection devices.
Pressure systems offer higher
efficiency than vacuum systems,
can convey over longer distances,
and can blow directly into
process and storage vessels
without the use of a rotary
airlock valve.
Negative pressure is created
by a positive displacement
vacuum pump located at the
downstream end of the system.
Material typically enters the
system via upstream rotary
airlock valves, hand-held
pick-up wands, and non-flowthrough/flood-feed pick-up
adapters, and exits the system
through filter receivers or
cyclone separators that separate
the material from the conveying
air directly above process
equipment, surge hoppers,
storage vessels or other
discharge points.
In addition, vacuum conveying
is suited to direct feeding of
blenders, reactors and other
enclosed process vessels that
are put under vacuum by a line
terminating at a downstream
bag house or other dust
collection device, eliminating
the need for individual filter
receivers or cyclone separators
above each discharge point.
Easy conveyor line routing
Wide capacity range
Since conveyor lines can be
routed vertically and in any
horizontal direction, over short
or long distances, through
small holes in walls or ceilings,
Flexicon PNEUMATI-CON®
systems are easy to integrate
into production environments
in which process equipment and
other obstacles often exist, while
consuming minimal floor space.
With a PNEUMATI-CON
conveyor, capacity can range
from several kilograms to tens
of tonnes per hour, feeding
any destination from small
packaging lines to silos and
railcars. Moreover, excessive
fluctuations in the feed rate—
resulting in overloading or
underloading—will not
damage the system.
Total evacuation
Diversity of products
handled by one conveyor
PNEUMATI-CON systems fully
evacuate the vessel being
discharged and the conveyor
line itself, minimising crosscontamination of multiingredient systems. Complete
transfer of material also ensures
that individual and consolidated
batch ingredients reach their
destinations accurately by
weight, maximising quality
while minimising waste.
This Silo Vent is essentially the
upper section of a filter receiver
that can be mounted atop an
existing silo or other large vessel,
into which material can be
conveyed.
Powders having wide ranging
bulk densities, as well as flakes,
pellets, capsules, tablets and
other friable materials, can be
handled by a single Flexicon
pneumatic conveyor, providing
the flexibility needed to
transport multiple ingredients.
(See “Materials,”page 4.)
A complete range
of pneumatic system
components
Flexicon provides any and
all components necessary to
configure your PNEUMATI-CON
system including:
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PNEUMATI-CON filter receivers
incorporate numerous design and
construction innovations offering
unsurpassed separation efficiency
across all capacity ranges.
Low-capacity units (above) are
commonly positioned above
packaging lines or smaller process
equipment, while mediumcapacity units (right) are utilised
above storage vessels and process
equipment such as blenders and
bulk bag fillers.
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Pressure blowers and vacuum
pumps with integral sound
enclosures with separate
cooling fans, and easyaccess maintenance points
Rotary airlock valves in all
popular designs and sizes
Flex-tube diverters, wyediverters, plug diverters
and other line diverter
configurations
Filter receivers for low- to
high-capacity applications
Cyclone separators for lowto high-capacity applications
Gain-in-weight and loss-ofweight batching systems
Dust collectors and bin vents
Controls and electrical
equipment
Hand-held pick-up wands
Silos, day bins and other
storage vessels
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Material discharge methods
Material intake methods
Material typically exits pressure and vacuum pneumatic
conveying systems via filter receivers, cyclone separators,
or fill/pass valves, or discharges directly into process
or storage vessels.
Pressure and vacuum conveying systems commonly utilise
rotary airlock valves to introduce material to the air stream.
Hand-held wands and non-flow-through (flood-feed) pick-up
adapters can be utilised with vacuum systems.
Filter Receivers
Flexicon filter receivers separate
solids from the air stream using
filter media and gravity, and are
generally specified when materials
contain smaller particles that are
prone to dusting and/or when dust
containment is a primary requirement. They are normally located
above material use points, and
employ reverse-pulse jet filter
cleaning to dislodge accumulated
dust from filter surfaces, allowing
continuous and efficient separation
of material from the air stream.
Cyclone Separators
Cyclones separate solids from
the conveyor air stream using
centrifugal force and gravity,
and are typically specified when
materials are comprised of larger
particle sizes that are not prone
to dusting. Although filters
are uncommon, they can be
incorporated as a secondary
means of capturing airborne solids.
Fill/Pass Valves
Fill/pass valves are commonly
used to discharge material directly
into individual or multiple process
vessels and/or to deliver it to several
destinations along a common
conveying line. Downstream of the
last fill/pass valve, the conveying
line is normally routed to the
original material source point
or into a dust collection device.
Rotary Airlock Valves with FlowThrough Pick-Up Adapters
(Pressure and vacuum systems)
Rotary airlock valves with flowthrough pick-up adapters can be
utilised in pressure and vacuum
systems for both controlled metering of material into the conveying
system, and maintaining the
pressure differential between
the conveying system and
ambient atmosphere.
Wands
(Vacuum systems)
Hand-held pick-up wands
plumbed to vacuum conveyor
lines with flexible hose are used
to vacuum material from hoppers,
drums, paper bags, barrels or
other containers.
Non-Flow-Through (flood-feed)
Pick-Up Adapters
(Vacuum systems)
Material can be introduced into
vacuum conveyor lines via nonflow-through (flood-feed) pick-up
adapters, which are typically used
at pick-up points where lower
volumes of material are fed
manually.
Directly Into Process Vessels
Both pressure and vacuum systems
can feed material directly into
blenders, reactors and other
enclosed process vessels that
are vented to a downstream bag
house or other dust collection
device, eliminating the need
for individual filter receivers.
Material pick-up points, clockwise from top left, include hand-held
pick-up wand, rotary airlock with flow-through adapter, non-flow-through
pick-up adapter, and rotary airlock with flow-through pick-up adapter.
12
Enclosed system
prevents contamination
Mobile and custom
configurations
Totally enclosed and dust-free,
a PNEUMATI-CON® conveying
system prevents contamination
of the product and plant
environment, allowing safe
transfer of contaminationsensitive materials including
dusty and hazardous products.
Self-contained Flexicon
PNEUMATI-CON conveying
systems complete with feed
hopper and/or pick-up wand,
blower unit, filter receiver and
control package, are available
pre-engineered and configured
on castor-mounted frames
for in-plant mobility.
High reliability and ease
of maintenance
Flexicon PNEUMATI-CON
systems feature easy-tomaintain filter receivers with
access doors and inspection
ports, as well as rotary airlock
valves with optional rotor
support bars for easy access,
cleaning and inspection.
Designed, constructed and
finished to industrial and
sanitary standards
PNEUMATI-CON conveying
systems are available in carbon
steel with durable industrial
finishes, or stainless steel
finished to standards required
for industrial, food, dairy and
pharmaceutical applications.
Available upgrades include
quick-access and quickdisconnect fitments.
This modular vacuum receiver
features a rugged clamp-together
design that facilitates rapid
disassembly for filter maintenance
and cleaning. Whereas conventional
filter receivers employ multiple
smaller elements, it employs a
single, large diameter filter cartridge,
and offers an ideal solution for
low-throughput-rate, short-distance
pneumatic conveying applications.
Unlike filter receivers, cyclone separators require no filters to separate solid
particles from the gas stream, instead
relying on cyclonic action alone. An
air stream containing material enters
the separator at a tangential angle
and is spun rapidly, creating a circular flow that imparts centrifugal force
to the particles which strike the wall
of the cyclone and fall through a
bottom outlet, into a process vessel.
13
Bulk Bag Dischargers
Dust-free loading, untying, retying and removal of bulk bags
Broad model range
satisfies general to
specific requirements
Revolutionary advances
overcome limitations of
outdated designs
Flexicon bulk bag dischargers
are offered in numerous frame
configurations for loading and
unloading of bulk bags using
a powered hoist and trolley or
a forklift. Specialised models
include split frames for forklift
loading of bags in low
headroom areas, half frames
for suspending bags during
discharge using a forklift,
hoistable frames for lifting
the entire bulk bag discharger,
continuous loss-of-weight
dischargers for uninterrupted
feeding directly from bulk
bags, and other applicationspecific designs.
Just as bulk bags changed the
way you stored and shipped
bulk material over the last
decade, so will these bulk bag
dischargers revolutionise the
way you load, untie, retie,
remove and collapse bulk
bags in the future.
No longer must your operators
reach through cramped access
doors and awkward glove
boxes, struggle to retie partially
empty bags, clean up spillage
after disconnections, dislodge
products from dead spots or
flatten bags manually.
Patented SPOUT-LOCK™ clamp ring eliminates dust
during untying, discharge, bag collapse and removal
The SPOUT-LOCK™ clamp
ring creates a high-integrity,
sealed connection between the
clean side of the bag outlet
spout and the clean side of the
telescoping tube. This prevents
contamination of the product,
while eliminating the plant
Model BFF Bulk Bag Discharger
(Forklift loading)
Shown with the following options: FLOW-FLEXER™ bag activators,
POWER-CINCHER™ flow control valve, SPOUT-LOCK™ clamp ring,
TELE-TUBE™ telescoping tube, and hopper with non-flow-through
pick-up adapter for multiple pneumatic conveying lines.
14
contamination that occurs
when falling material displaces
air and dust from the hopper.
The clamp ring is fully
accessible and manually
operated using quick-release
handles for rapid and safe, yet
secure, bag spout connections.
Cantilevered I-beam with electric
hoist and trolley allows positioning of
bulk bag without the use of a forklift.
Performance never
before possible
You can eliminate the
drawbacks of outdated
designs—while dramatically
improving convenience,
safety and cleanliness—with
Flexicon’s latest generation
of bulk bag dischargers. The
heart of the new design is a
bag spout interface that not
only creates a dust-tight seal,
but promotes material flow
and total evacuation. It also
allows easy retying of partially
empty bags, and can collapse
empty bags—free of spillage
and dust.
Patented Z-CLIP™
bag strap holder
allows fast, easy
and secure
insertion and
removal of
bag straps.
POWER-CINCHER™
flow control valve
cinches the bag
spout concentrically.
Frames are offered
in carbon steel with
durable industrial
finishes or in stainless steel designed
and constructed
to industrial, food,
dairy or pharmaceutical standards.
BAG-VAC™ dust
collector creates
negative pressure
when piped to
sealed system,
collapsing empty
bags prior to tie-off
and removal.
SPOUT-LOCK
clamp ring eliminates
dust during untying
and discharge.
Pneumaticallyactuated FLOWFLEXER bag
activators promote
positive material flow.
Operators are
protected from
falling bags by
four safety frame
crossmembers, and
four guard plates.
Patented TELE-TUBE™ telescoping tube prevents
dead spots and promotes flow
The TELE-TUBE™ telescoping
tube raises the SPOUT-LOCK™
clamp ring for connection to
the bag spout, then lowers,
applying continual downward
tension. As a result, the spout
is kept taut at all times,
preventing excess spout
material from bulging
outward (creating dead
pockets) or falling inward
(creating flow restrictions).
Works in conjunction with
SPOUT-LOCK clamp ring and
FLOW-FLEXER™ bag activators
(see page 17) to promote
material flow and total
evacuation.
Hopper is available
with hinged lid for
manual dumping or
clamped lid (shown)
for rapid wash-down.
TELE-TUBE
telescoping tube
prevents dead
spots and
promotes flow.
A wide variety of
hopper designs connect
to processing equipment, pneumatic or
mechanical conveyors.
Model BFC Bulk Bag Discharger
(Electric hoist and trolley loading)
Shown with the following options: FLOW-FLEXER bag activators,
POWER-CINCHER flow control valve, SPOUT-LOCK clamp ring,
TELE-TUBE telescoping tube, BAG-VAC dust collector, and hopper
with adapter for flexible screw conveyor.
15
Total dust containment with
BAG-VAC™ dust collector
The high-integrity connection
between bag outlet spout and
discharger creates a sealed
system that can be vented
through a filter sock to a central
dust collection system, or to
an optional BAG-VAC™ dust
collector. Actuating the BAGVAC dust collector creates
negative pressure within the
sealed system to collapse empty
bags prior to retying, eliminating
dust commonly emitted when
bags are flattened manually.
In addition, the BAG-VAC dust
collector vacuums any particles
trapped in spout creases during
disconnect, eliminating the need
for awkward access ports. Where
absolute spillage containment
is essential, an optional double
wall version of the TELE-TUBE™
telescoping tube draws errant
particles into the dust collector
through an annular gap that
encircles the bag spout seal.
Leak-proof retying of spouts
with POWER-CINCHER™ flow control valve
Unlike opposing bars that pinch
the spout of partially empty
bags from two sides, the
patented POWER-CINCHER™
pneumatically-actuated flow
control valve contains a series
of curved, articulated stainless
steel rods that cinch the spout
concentrically on a horizontal axis
for easy tie-offs, and vertically
in a tight zigzag pattern to
prevent leakage of even the finest
powders. It also resists jamming,
breaking and leaking, and allows
full-open discharge from bag
spouts of all popular diameters.
This BFC Series Bulk Bag
Discharger is equipped with a
small surge hopper that directs
material into the throat of a
variable speed rotary airlock
feeder for volumetric or gravimetric
metering into positive- or negativepressure pneumatic conveyor lines.
Flexicon Bulk Bag Continuous Lossof-Weight Dischargers feature an
activated surge bin and flexible
screw conveyor, allowing continuous
loss-of-weight (gravimetric) feeding
directly from bulk bags. System
software switches to volumetric
mode during bag changes.
Conventional iris valves
also available
When a sealed connection is
unnecessary, iris valves are
recommended. To operate, the bag
outlet spout is pulled through the iris
valve which is then closed around the
spout, preventing material flow. The
spout can then be untied, the access
door closed, and the valve released
slowly, reducing uncontrolled bursts
of material into the hopper and dust
into the plant environment.
This Half Frame Bulk Bag
Discharger offers total dust
containment at low cost by
eliminating upper frame components
to lift and/or position the bag,
instead relying on the user's forklift
or plant hoist to suspend the bag
above the unit during operation.
16
Flexicon’s Hoistable Bulk Bag
Discharger features a bag-lifting frame
that allows one operator to replace
bulk bags using an overhead crane,
and/or to hoist the entire unit from
a single lift point—with or without
bulk bag in place—to weighing,
processing and storage areas.
Multi-purpose intake chute and manual
dumping station
The Multi-Purpose Hood allows
automatic discharging from
bulk bags as well as manual
emptying from sacks, drums
and other containers. Available
as an option on both BFC
and BFF Series dischargers,
it can operate with an optional
dust collector to prevent
contamination of the product
and plant environment.
Poor-flowing, nonfree-flowing and/or
compacted materials
will not fall through
the bulk bag discharge
spout consistently,
often “rat-holing”
or bridging as
shown above.
At timed intervals,
FLOW-FLEXER™
bag activators raise
and lower opposite
bottom edges of bulk
bags, promoting
material flow into
the discharge spout.
Extra-wide receiving
cups and backstops
maximise the operator’s
target area.
Fork tips slide easily and
securely into full-length
rectangular sleeves, unlike
frames having separated
forklifting points.
Z-CLIP™ bag strap
holders offer the fastest,
most secure way to
connect bag straps
to the lifting frame.
Round frame rails are
easy to locate into
receiving cups, and
slide into position.
As the bag empties,
the stroke of the
FLOW-FLEXER bag
activators increases,
raising the bottom of
the bag into a steep
“V” shape, while
POP-TOP™ extension
devices stretch the
bag into a cone
shape, promoting
complete discharge.
This Split-Frame Bulk Bag Discharger accommodates bulk bags and—
with upper frame removed—rigid totes. The removable top frame can
also be lowered to the plant floor for connection and disconnection of
bag loops, significantly reducing ceiling height requirements.
BFF Series Bulk Bag Discharger
(Forklift loading)
Shown with the following options: FLOW-FLEXER bag activators,
POP-TOP extension devices, Multi-Purpose Hood and manual dumping
station, Flexicon flexible screw conveyor, and load cells for automated
loss-of-weight weigh batching directly from bulk bags.
17
Bulk Bag Conditioners
Loosen solidified bulk solid materials
Flexicon Hydraulic Bulk Bag
Conditioners loosen bulk solid
materials that have solidified
during storage and shipment,
enabling bulk bag dischargers
to discharge the material
through bag spouts. These
conditioners are ideal for bulk
bags containing hygroscopic
chemicals, certain types of
spice blends, heat-sensitive
products, and other materials
prone to solidifying to the
point at which pneumaticallyactuated flow promotion
accessories integral to bulk
bag dischargers are inefficient
or completely ineffective.
Flexicon Hydraulic Bulk
Bag Conditioners utilise two
hydraulic rams with specially
contoured end plates that press
opposing sides of bulk bags to
loosen the contents of the bag,
and accommodate bulk bags
of all popular sizes.
Stand-Alone Hydraulic Bulk Bag Conditioner
The Flexicon Stand-Alone
Hydraulic Bulk Bag Conditioner
is equipped with the abovementioned hydraulic rams, as
well as an optional hydraulicallyactuated, variable-height
turntable that allows in-frame
bag rotation, and conditioning
of bulk bags at varying heights.
The number and pressure of
hydraulic ram actuations, the
height of the turntable, and the
number of 90-degree rotations
are user adjustable to achieve
maximum effectiveness and
efficiency.
The conditioner is enclosed on
four sides for operator safety
and includes full-height doors
that are interlocked to disallow
operation of the system when
the doors are open. The
controller and hydraulic pump
of the system, which can be
mounted on the exterior of the
safety cage or remotely,
require only an electrical
power connection for operation.
Integral Bulk Bag Conditioner-Discharger System
The Flexicon Bulk Bag
Conditioner-Discharger System
eliminates the time, labour and
equipment needed for separate
loading of bulk bags into a
stand-alone conditioner.
The design also consumes
significantly less floor space
than two separate pieces of
equipment and requires less
material and labour to construct,
reducing initial cost.
The number and pressure
of hydraulic ram actuations
are user adjustable, but unlike
stand-alone conditioners, the
Conditioner-Discharger System
utilises its electric hoist to
raise and lower the bag for
conditioning at varying heights.
18
The conditioner’s controller and
hydraulic pump can be mounted
on the exterior of the discharger
or remotely. Optional safety
interlocks disallow operation
of the conditioner when the
discharger’s doors are open.
(See Bulk Bag Dischargers
section pages 14-17, for
features on bulk bag
discharger aspect
of system.)
Bulk Bag Fillers
Three designs satisfy the entire range of bulk bag filling requirements without compromise
Flexicon offers three bulk bag
filler configurations, each of
which is engineered to deliver
optimum performance across
specific capacity ranges with
maximum cost effectiveness.
Flexicon’s TWIN-CENTREPOST™
filler (bottom right), satisfies
low- to medium-capacity filling
requirements and/or sanitary
applications where frequent
wash-down or compliance
with USDA Dairy standards
is required.
STANDARD FEATURES INCLUDE:
■
■
■
■
■
Rugged TWIN-CENTREPOST,
REAR-POST or SWING-DOWN
configuration
Forklift fill head height
adjustment to accommodate
all popular bag sizes
Inflatable collar to hold and
seal the bag inlet spout
Pneumatically retractable bag
strap hooks for quick, positive
strap release
Vent port for air displacement
and dust control
OPTIONAL FEATURES INCLUDE:
■
■
■
■
■
Accurate weigh scale system
with automated control
Automated vibratory
densification/deaeration
system to stabilise the bag
Inflator to expand empty bag
and liner, and remove creases
prior to filling
Pneumatically-actuated material
flow control valve
Custom controls for integrated
material feed system
■
■
■
■
■
Drum/box filling conversion kit
Powered fill head height adjustment (REAR-POST and SWINGDOWN fillers only)
Powered or gravity roller
conveyor for bulk bag staging
and removal
Forward-travelling, rear bag
strap hooks (REAR-POST
fillers only)
Pallet-jack accessible base
Material delivery systems
Flexicon’s latest bulk bag filling
innovation is the patented
SWING-DOWN™ filler (page
20). Designed for medium- to
high-capacity applications, this
revolutionary design brings the
fill head to the operator at floor
level for faster, safer and easier
bag connections.
The REAR-POST filler (page
21, bottom left) is intended
for medium- to high-capacity
applications requiring passthrough conveyors and/or
powered fill head height
adjustment.
Flexicon will custom engineer
an automated delivery system
according to your specific
bulk material and process
requirements. Whether your
system must integrate with
new or existing upstream
equipment, elevate non-freeflowing materials, or prevent the
surging of free-flowing materials
from elevated storage vessels,
Flexicon offers precisely what
you need to keep your filler
well fed:
■
■
Each of these designs satisfies
a distinct range of bulk bag
filling applications, and is
available with performance
enhancements to meet your
individual requirements with
extreme cost effectiveness.
From basic, low-cost fillers
to automated, high-capacity
systems and everything in
between, Flexicon offers
precisely what you need
for bulk bag filling success.
■
■
■
Flexible screw conveyors
Pneumatic conveyors
Controls and weighing
systems
Conveyor and feeder inlet
adapters to interface with
material sources
Surge bins and other storage
vessels for overhead material
delivery
(For sanitary Bulk Bag Fillers
see page 24.)
TWIN-CENTREPOST™ Bulk Bag Filler
Flexicon TWIN-CENTREPOST Bulk Bag Fillers feature a frame design that
is exceptionally simple, strong and stable, and economical to fabricate. It
is the first bulk bag filler designed, constructed and finished to industrial,
food, dairy and pharmaceutical standards, and is recommended for
applications requiring low- to medium-capacity filling and/or rapid,
thorough wash-down.
19
Revolutionary SWING-DOWN™ Fillers
Brings fill head to operator for floor-level bag connections
Flexicon’s latest innovation in
bulk bag filling features a pivotdown fill head that enables the
operator to connect empty bags
at floor level and resume filling
operations rapidly, eliminating
the need to climb steps, strain
to reach overhead connection
points, or risk injury associated
with operation of conventional
bulk bag fillers.
The SWING-DOWN™ filler
simultaneously lowers and
pivots the fill head, stopping it
in a vertically-oriented position
that places the bag inlet spout
inflatable connection, inflator
button, and four bag loop
latches within one arm’s length
of an operator standing on the
plant floor. Bringing the fill
head to the operator in a
vertical position at floor level
can significantly increase the
safety and speed of connecting
bulk bags, since the connection
points of a conventional filler
are beyond the reach of most
operators, even when short bags
are being filled. For example,
the connection points for bulk
bags of only 122 cm in height
are approximately 213 cm
above the floor, considering
the height of a roller conveyor
and the length of bag loops in
addition to the height of the
bulk bag.
An operator is connecting a bag
spout to the vertically-oriented bag
connection frame at floor level.
As the entire fill head rises, the
bag connection frame is pivoting
to a horizontal position.
The bag connection frame has
pivoted to horizontal position,
the fill head is raised to “bag fill”
position, and the bag has inflated
to remove creases.
The design also eliminates the
danger of repeatedly stepping
onto and over roller conveyors
to access rear bag hooks and
spout connection collars, and
of standing on the conveyor
and bending over with head
and arms inserted beneath
operational fill head components
to pull bag spouts upward over
inflatable collars while reaching
for bag inflator buttons.
An innovative latch mechanism
automatically resets the latch
after releasing the bag loops,
and re-positions it as the fill
head pivots into a vertical
position, enabling the latch to
receive bag loops easily inserted
by an operator and to re-latch
automatically, securing the bag.
A remote console or wallmounted panel houses controls
to raise and pivot the fill head
into a locked, horizontal “fill
position,” automatically inflate
the bag to remove creases,
open a flow control valve or
start a feed device, and stop
the flow of material once a
preset fill weight has been
gained. Optional vibratory
decks deaerate and densify
material in the bag at preset
set points to create a solid,
stable bag, ready for shipment.
Once bags are filled, the
controller deflates the spout
connection collar, releases the
loop latches, and raises the
fill head to fully disengage the
spout, enabling the bag to exit
the filler automatically on the
roller conveyor.
Combination SWING-DOWN Bulk Bag
and Drum Filler
Flexicon’s patented SWING-DOWN Bulk Bag Filler represents a total re-think
of the bulk bag filling process, allowing operators to connect empty bags at
floor level. The model above is equipped with an optional swing-arm-mounted
drum filling chute which automatically rotates to deliver material to all four
drums on a pallet.
20
REAR-POST and TWIN-CENTREPOST™ Fillers
Low- to high-capacity configurations
Basic units to fully
automated, high capacity,
feeder/filler systems
For fast, accurate, and stable
weigh-filling of small to large
volumes of free- and non-freeflowing bulk materials, Flexicon
bulk bag fillers are offered in
two configurations: with load
cells which measure weight
gain of the bulk bag filler
(below) and with weigh hoppers
suspended above the bag filler
(right) allowing simultaneous
recharging of the hopper
and replacement of the bulk
bag to achieve high filling rates.
Flexicon’s Low Profile Bulk Bag
Filler allows removal of loaded
bags using a pallet jack,
eliminating the need for a forklift.
Inflatable collar
holds and seals
bag inlet spout.
Air displacement outlet for connection to
filter sock, cartridge filter, or dust collector.
(Hidden by discharge spout assembly)
Pneumatically
retractable bag
hooks partially
suspend bag
during filling
for superior bag
shape, stability,
and utilisation
of capacity. Bag
straps are released
manually, or
automatically
upon completion
of filling cycle.
Load cells with
overload protection
transmit weight-gain
information to the
system controller.
Bag inflation blower
removes creases
and pre-shapes
bag, allowing
material to fill
corners for
maximum bag
stability during
shipment. (Also
available with plant
air connection)
Manual fill head
height adjustment
accommodates all
popular bag sizes.
Powered height
adjustment also
available.
This TWIN-CENTREPOST™ frame
can be forklifted onto an allpurpose plant scale, eliminating
the cost of load cells and controls.
Electric or pneumatic
vibratory deaeration/
densification deck with
high amplitude/low
frequency motion.
Inflatable air mounts raise
deck and isolate vibration.
Patented TWIN-CENTREPOST
Bulk Bag Fillers are available
in industrial, food, dairy and
pharmaceutical standards.
(See “Sanitary” page 24.)
REAR-POST Bulk Bag Filler
Flexicon REAR-POST Bulk Bag Fillers feature a cantilevered fill head that
provides three-sided access preferable for “pass-through” conveying using
a roller conveyor. It also offers powered fill head height adjustment as an
option, allowing rapid raising and lowering of the fill head to accommodate
bags of varying heights, without the use of a forklift.
21
Bag Dump Stations
Reverse-pulse filter cleaning for continuous operation
Collect dust efficiently
Flexicon bag dump stations
collect dust generated when
dumping powder and bulk solids
from bags, boxes, drums, and
other containers, and return
the material to the hopper.
The system reduces material
waste and eliminates the
need to clean a remote dust
collection site, while protecting
workers and preventing plant
contamination.
All units feature a high-velocity
vacuum fan which draws
airborne dust away from the
operator through two cartridge
filters which are sized according
to the application.
the cartridge filters, causing
dust build-up on the outer filter
surfaces to fall into the hopper.
Because the filters are blasted
alternately at timed intervals,
operation of the dust collection
system is both continuous and
efficient.
Tailored to your process
The hoppers of Flexicon manual
dumping stations are available
in various configurations for
simplified connection to
pneumatic conveyor lines,
flexible screw conveyors, and
virtually any process equipment.
All units are available in carbon
steel with durable industrial
finishes, or in stainless steel in
industrial or sanitary finishes.
The hoppers of Flexicon Bag Dump Stations are offered with outlets
configured for: (left to right) direct connection to process equipment, flexible
screw conveyor charging adapters, rotary airlock valves with flow-through
adapters, and non-flow-through pick-up adapters for multiple conveying lines.
To operate, the hopper lid is
opened, the vacuum fan is
activated, and material is
dumped through the hopper
screen. Airborne dust in the
vicinity of the hopper opening
is drawn into the dust collector,
protecting workers, preventing
plant contamination, and
reducing material waste.
An automatic reverse-pulse
filter cleaning system employs
timer-activated solenoid valves
to release short blasts of
compressed plant air inside
ATEX
Compliant
Two cartridge filters are accessed
easily by removing the interior
baffle, and replaced rapidly using
quick-disconnect fittings.
22
Explosion-Proof Bag Dump Station
This dust-free Bag Dump System integrates a receiving hopper,
dust collector, bag compactor and flexible screw conveyor on a
castor-mounted frame with hinged operator platform. An explosionproof electrical system allows the unit to handle flammable as well
as hazardous and non-hazardous materials throughout the plant.
Drum Tippers
Open or sealed transfer of solids from drums to process equipment
Flexicon “lift-and-seal” drum
tippers (top right and bottom
left) and “open chute” drum
tippers (bottom right)
accommodate all popular drum
sizes and are available in carbon
steel with durable industrial
finishes, or in stainless steel
with material contact surfaces
finished to industrial, food or
pharmaceutical standards. All
models can discharge directly
into process equipment or into
hoppers equipped with outlets
for connection to Flexicon
flexible screw or pneumatic
conveyors, or to other process
equipment.
Lift-and-seal drum
tippers eliminate dust
Flexicon lift-and-seal drum
tippers enable you to load,
seal, tip and discharge drums
with no dusting, bringing a new
level of cleanliness and efficiency
to an age-old task. A hydraulic lift
automatically forms a dust-tight
seal between the drum lip and
the discharge cone. The assembly
is tipped hydraulically causing the
cone to mate with the gasketted
receiving ring that is fitted to
existing process equipment or
the lid of an optional Flexicon
hopper, eliminating the need for
connecting sleeves and clamps.
(Optional hopper shown with
Flexicon flexible screw conveyor
adapter. Also available with
universal flanged outlet or
Flexicon pneumatic pick-up
adapter.)
Open chute drum
tippers offer simplicity,
ease of cleaning
Flexicon open chute drum
tippers offer an economical
method of discharging from
drums when dust generation
is not a concern. The drum lift
assembly is raised hydraulically
until material discharges from
the drum, down onto the chute,
and into a receiving vessel. The
smooth, wide-diameter product
chute allows unobstructed
discharge of free-flowing
materials as well as non-freeflowing products containing
large agglomerates. It is also
fully accessible and free of
crevices, allowing rapid,
thorough cleaning. (Optional
hopper shown with Flexicon
non-flow-through pneumatic
pick-up adapter. Also available
with universal flanged outlet or
Flexicon flexible screw conveyor
adapter.)
Flexicon’s Bulk Filling System with High-Lift Drum Tipper allows drums to
be loaded at floor level, sealed against a discharge cone, elevated and
tipped, mating the cone spout to a receiver on the filling machine’s surge
hopper lid. The spout’s slide gate valve opens to fill the hopper with no
dusting, while pails are indexed, filled by weight, then conveyed to a
second scale for check weighing.
23
Sanitary Construction and Finishes
Virtually all Flexicon equipment
is available constructed and
finished to meet food, dairy and
pharmaceutical requirements
of industry associations and
governmental agencies
worldwide.
Flexicon sanitary equipment can
be constructed almost entirely
of 304 or 316 stainless steel
and finished to Flexicon sanitary
standards, or customer-specified
requirements. Product contact
areas include continuous welds,
ground smooth and flush with
adjoining walls, with available
finish levels up to mirror finish.
Sanitary Flexible Screw Conveyors are
totally enclosed, preventing plant and
product contamination. The inner screw
connects to the motor drive beyond the
material outlet, eliminating material
contact with bearings. Allows flushing
of smooth interior, or rapid, tool-free
disassembly. 3-A Dairy Certified.
Sanitary Pneumatic Conveying Systems
offer optional airlock valves with rotors
that slide-out for tool-free wash down,
filtration of conveying air, top-removal
filtration elements, machined ferrules
and clamps for conveying line couplings,
and other easy-access features that
permit rapid inspection and cleaning.
Sanitary Bulk Bag Dischargers create
a dust-tight connection between the
clean sides of the bag spout and the
equipment, vacuum displaced air/dust
and collapse empty bags dust-free.
A USDA-accepted POWER-CINCHER™
flow control valve allows dust-free
retying of partially empty bags.
Sanitary Weigh Batching Systems and
other engineered systems integrate
sanitary equipment and employ
dust-tight connections, preventing
product and plant contamination.
The sanitary bulk bag discharger,
flexible screw conveyors and weigh
hopper of this batching system
allow rapid, thorough wash down.
Sanitary SWING-DOWN™ Bulk Bag
Fillers offer stainless construction
with continuous ground and polished
welds, and a fill head that pivots
away from its support structure,
providing unrestricted access for
thorough wash down, bringing
unprecedented safety, productivity
and cleanliness to bulk bag filling.
Sanitary TWIN-CENTREPOST™
Bulk Bag Fillers are the first fillers
to receive USDA acceptance. They
provide a dust-tight, inflatable
bag spout seal, a feed chute airdisplacement port for dust-free
filling, and four-sided access for
easy operation and rapid wash
down.
Sanitary Bag Dump Stations with
optional dust hoods on rocker arms
raise the hood for easy separation and
wash down of the gasketted seam—
and for removal and wash down of the
interchangeable dump screens. Dust
collection prevents contamination of
personnel and plant environment.
Sanitary Lift-and-Seal Drum
Tippers allow loading, sealing,
tipping and discharging of drums
with no dusting by forming a dusttight seal between a drum discharge
cone and a gasketted receiving
ring fitted to existing process
equipment or the lid of a hopper.
Sanitary Tote Tippers form a dusttight seal between the tote rim
and gasketted discharge chute.
Constructed of stainless steel with
continuous ground and polished
welds, these units provide
unrestricted access and IP65 panels
for rapid, thorough wash down.
Wash down control enclosures
and motors allow fast, thorough
wash down using steam,
cleaning solutions and high
pressure water, with no
adverse effect on equipment.
Sanitary designs
Beyond requisite sanitary
construction and finishes,
Flexicon equipment offers
innovative design features—
many patented—that enable
food, dairy and pharmaceutical
processors to minimise washdown time, eliminate crosscontamination between
changeovers, eliminate plant
contamination and verify
cleanliness—and do so rapidly,
efficiently and safely.
24
Weigh Batching and Blending Systems
Virtually any bulk material, from any upstream source, to any downstream destination
Whether you are sourcing
material from bulk bags, silos,
manual dumping stations,
process equipment or all of the
above, weigh batching one
ingredient or 50, blending your
recipe, filling containers, and/or
delivering it to process vessels,
packaging lines, or any other
destination, Flexicon has the
comprehensive selection of
equipment you need for a
total weigh batching solution.
From individual loss-ofweight bulk bag weigh batch
dischargers to automated gainin-weight batching/blending
systems integrated with your
upstream and downstream
equipment, Flexicon offers you
the entire range of specialised
equipment—and the engineering
talent—required for a smooth
start-up and efficient
performance.
Equally as crucial to your weigh
batching success is the proven
ability of Flexicon equipment
to move your material—at high
rates for fast batching cycles
and at steady trickle-feed
rates for highly accurate
weighments—and to deliver
recipes with no separation
of blended materials and
no exposure to potential
contamination.
Flexicon’s Self-Contained, Gain-in-Weight Batching and Blending
System conveys bulk ingredients from multiple upstream sources,
weigh-batches, blends and discharges the material into a surge
hopper, and transports it to a TWIN-CENTREPOST™ Bulk Bag Filler.
The system is offered with Flexicon Flexible Screw Conveyors (shown)
or Flexicon Pneumatic Conveying Systems.
Flexicon’s Bulk-Bag-to-Rigid-Tote
Weigh Batching System seals
against the clean side of the bag
spout, elongates the bag for total
evacuation, and allows dust-free
retying of partially empty bags.
A low-profile de-lumping device
breaks up agglomerates as a
gravimetric feeder loads accurately
weighed batches into rigid totes.
Whether your ingredients are
free-flowing pellets, powders
that pack, bridge or smear,
products that fluidise, or blends
prone to separation, Flexicon
can move them positively,
weigh them accurately, and
deliver them in prime condition.
This Automated Weigh Batching System conveys material from Flexicon bulk bag dischargers via Flexicon flexible screw
conveyors to a weigh hopper mounted on load cells at mezzanine level. Weighed batches are automatically discharged
through a rotary airlock valve into a Flexicon Pneumatic Conveying System, transporting the pre-weighed batch to a blender.
25
Gain-in-Weight Batching Systems
Simple or sophisticated
batch control
Flexicon Gain-in-Weight Batching
Systems convey bulk ingredients
mechanically or pneumatically
from any location to a central
receiving vessel which is mounted
on load cells. The receiving vessel
can be a hopper positioned
above a blender, reactor, or
other process equipment, or
it can be the equipment itself.
When the batch sequence
is initiated by a manual start
button or automated signal, a
programmable controller activates
the first flexible screw conveyor
or rotary airlock valve to begin
loading the first ingredient into
the receiving vessel at maximum
feed rate.
Load cells transmit weight gain
information to the controller
which steps-down the feed rate
to trickle prior to reaching the
the target weight, for greater
accuracy. The controller stops the
flexible screw conveyor or rotary
airlock valve immediately before
the target weight is reached to
compensate for material in-flight.
This Gain-in-Weight Batching System allows automated weighing
of a major ingredient supplied in bulk bags, and a minor
ingredient dumped manually. The central weigh hopper’s load
cells transmit weight gain information to a controller that starts
and stops the conveyors to weigh each material in sequence,
and actuates a slide gate valve to discharge the weighed batch.
26
Flexicon mechanical (above) and pneumatic (below) Gain-in-Weight Batching Systems
can transport material from silos, manual dumping stations, process equipment, bulk
bags, or any other source to a weigh batching hopper, a blender, or other downstream
equipment mounted on load cells.
This turnkey, Gain-in-Weight Batching System conveys material from four Flexicon
bulk bag dischargers to a weigh hopper which discharges into a blender. During the
blending operation, a subsequent batch is being weighed by the hopper, thereby
reducing cycle times. In this case, blended batches are discharged directly into
shipping containers.
Loss-of-Weight Batching Systems
Simple or sophisticated
batch control
Flexicon bulk bag Loss-of-Weight
Batching Systems consist of
a Flexicon bulk bag discharger
mounted on load cells which
measure weight loss of each
discharger during the batching
cycle and transmit the
information to a system controller.
The batch sequence is initiated
by a manual start button or
automated signal.
As the conveyor unloads material
at maximum feed rate, the load
cells transmit loss-of-weight
information to the controller
which reduces the feed rate
to trickle immediately prior
to stopping the flexible screw
conveyor or rotary airlock valve
once the target batch weight
has been unloaded. System
software permits mid-batch
bag changes.
Multiple weigh batch dischargers
can each convey a different
ingredient to a central discharge
point such as a hopper, blender,
reactor, or other process
equipment.
Loss-of-Weight Batching Systems discharge one or more bulk
bags while weighing the material and conveying the batch directly
to a common hopper, blender, conveyor, shipping container, or any
process vessel—automatically and accurately. Load cells transmit
the amount of weight lost to a controller, which stops the conveyor
once the target batch weight has been reached.
Flexicon mechanical (above) and pneumatic (below) Loss-of-Weight Batching
Systems transport material from one or more bulk bags to a common hopper,
blender, conveyor, shipping container, or any process vessel.
This Loss-of-Weight Batching System conveys material from two Flexicon bulk bag
dischargers into a filter receiver which discharges into a blender. The manual bag
dump station allows the addition of pre-weighed minor ingredients to the batch.
27
Digital Programmable Controls
Maximise Productivity of All Flexicon Equipment and Systems
All Flexicon equipment, from
basic conveyors to sophisticated
plant-wide process systems,
are offered with digital
programmable controls,
including:
■
Programmable Logic
Relays (PLRs)
■
Programmable Logic
Controllers (PLCs)
PLR-based controls packages
are generally employed on
individual equipment to monitor
and control basic to semisophisticated functions. The
PLR eliminates the need for
analog timers and mechanical
relays, offering numerous
benefits, and can be utilised
as an economical substitute
for a full PLC in less complex
equipment systems.
PLCs, which generally offer a
greater number of input/outputs
and more processing power,
are typically employed to
monitor and control more
sophisticated equipment
systems such as multiple
ingredient weigh batching/
blending systems, larger
pneumatic conveying systems
and integrated engineered
systems including multiple
equipment types.
The Controls Department
customises individual equipment
as well as systems for maximum
productivity according to each
customer’s bulk handling
requirements by integrating
full-scale fabrication capabilities
with state-of-the-art control
technologies:
Panel assembly area of Controls Department
28
Electrical engineers programming digital controls to customise equipment
automation.
■
Easy-to-operate interfaces,
from push buttons to humanmachine-interfaces (HMIs)
with touch screens and
graphic representations
of equipment inputs and
outputs, all customised
by application
■
100% Bench testing to
ensure proper monitoring
and control functions using
actual inputs/outputs such
as simulated scale systems,
various types of sensors and
electric motors
■
Advanced exchange of
process data between
equipment controls and the
customer’s plant-wide process
control programme such as
downloading of weigh batch
recipes and other operational
parameters to plant floor
equipment, and uploading
of weight deviations, alarm
signals and any type of
feedback required for
plant optimisation
■
Components that are logically
configured and labelled for
easy-to-follow troubleshooting
by plant personnel
■
IP65 and Explosion Proof
control panels
Plant personnel can download
programmes to start, stop, slow,
speed-up, delay, advance or
cycle equipment functions.
Programmable Logic Relays Outperform Analog/Mechanical Controls
Flexicon controls utilise
programmable logic relays
(PLRs) instead of hard relays,
reducing the cost, size and
potential failure associated
with mechanical controls, while
adding digital programmability
to even the most basic Flexicon
equipment.
■
Essentially PLCs in miniature,
PLRs replace physical relay logic
with digital programmable logic,
offering a range of significant
advantages over mechanical
controls including:
■
Multi-function capability:
A single PLR can perform
numerous functions such
as counting, sequencing,
timing and real-time clock
operations, expanding the
capabilities of Flexicon
equipment without increasing
the cost or complexity of its
controls.
■
Programmability:
Logic can be modified
quickly and easily since there
is no need to add or replace
components such as physical
relays and timers. Based
on feedback from existing
level sensors or upstream/
downstream equipment for
example, the PLR’s timing
programme can be fine tuned
to start, stop, slow, speedup, delay, advance or
cycle equipment functions
according to individual
processes and material
characteristics. No physical
modifications to the panel
may be necessary, even if
additional sensors or other
signals are added to the
process. In many cases,
reprogramming the PLR
is as simple as setting a
thermostat, and can be
accomplished by an operator
having little or no expertise.
■
Lower component and
assembly costs:
Since the PLR replaces
numerous components,
the overall number of
electrical components is
lower, reducing assembly
costs as well as material
costs in many cases.
■
Reduced number and
size of panels:
One PLR can replace
numerous electrical
components, significantly
reducing panel size
requirements. Due to
its number of inputs and
outputs, a single PLR can
also consolidate controls from
multiple pieces of equipment
such as flow promotion
devices, dust collectors
and conveyors, eliminating
the need for sub panels
while streamlining installation
of the system.
■
Increased reliability and
decreased parts inventory:
PLRs eliminate the potential
failure and maintenance
associated with hard
relays, timers and other
components, and eliminate
the need to stock these
individual components.
Should a PLR fail, an
operator can replace it,
download the programme,
and resume operation
with minimal downtime.
Field serviceability:
PLRs simplify troubleshooting
by plant personnel, and allow
emailing of programmes
to and from the Flexicon
Controls Department for
troubleshooting, reinstallation
and/or customisation of
programmes.
Flexicon offers IP65 (shown with
optional purge kit) and Explosion
Proof control panels.
One PLR (foreground) can eliminate the need for multiple components,
increasing programmability and reliability, while reducing initial cost
and maintenance.
29
Worldwide Engineering, Testing,
Manufacturing and Field Support
and equipment that complies
with certifications required by
governmental and industry
associations for chemical,
food, dairy and pharmaceutical
applications—both nationally
and internationally.
Flexicon is an international
organisation with administrative,
engineering and manufacturing
capabilities on four continents,
and an extensive worldwide
network of applications
engineers, authorised
representatives and field
support technicians to serve
you—a unique consolidation
of bulk handling specialists
with 1000+ years of combined
experience.
Testing facilities
Flexicon’s design engineering
staff devises efficient solutions
to the most unusual problems
with highly custom equipment,
basing solutions on unique
customer requirements, not
merely on existing product
line offerings. This approach
provides each customer with
the most efficient solution to
his or her individual problem,
and endows Flexicon with a
depth and breadth of bulk
handling experience unequalled
by any other comparable
manufacturer in the world.
At the local level, Flexicon
personnel provide the
knowledge and resources
needed to satisfy the diverse
requirements of individual
process plants country-bycountry, while providing the
worldwide infrastructure, longterm vision, stability and single
source capability required by
multi-national organisations.
An extensive research
and development programme
continually sets new standards
for bulk handling equipment
performance with entirely new
designs, product improvements
Flexicon’s worldwide testing facilities simulate full-size customer
equipment and systems, verify performance prior to fabrication,
demonstrate newly constructed equipment for visiting customers,
and study the performance of new designs.
Test lab equipment for pneumatic bulk handling systems includes
a comprehensive range of blowers, vacuum pumps, filter receivers,
cyclone separators, inlet/discharge adapters and valves, and conveyor
lines in a wide range of diameters and lengths, as well as bulk bag
dischargers, bulk bag fillers, manual dumping stations and other
equipment designed to interface with pneumatic conveyors.
Mechanical bulk handling test lab equipment includes flexible
screw conveyors in a comprehensive range of diameters, lengths
and screw configurations, as well as bulk bag dischargers, bulk bag
fillers, manual dumping stations and other equipment designed to
interface with mechanical conveyors.
30
Flexicon products are manufactured on four continents,
and marketed through an extensive network of representatives
throughout Europe, Australia, New Zealand, Southeast Asia,
Africa and North/Central/South America.
AUSTRALIA (SYDNEY)
AUSTRALIA (BRISBANE)
FLEXICON (EUROPE) LIMITED
89 Lower Herne Road
Herne, Herne Bay
Kent CT6 7PH
UK
Tel: +44 (0)1227 374710
Fax: +44 (0)1227 365821
E-mail: sales@flexicon.co.uk
Web: www.flexicon.co.uk
FLEXICON CORPORATION
(AUSTRALIA) PTY LIMITED
Unit 2/7 Sefton Road
Thornleigh, NSW 2120
Australia
Tel: 1 300 FLEXICON
(1 300 353942)
Tel: +61 (0)2 9484 2083
Fax: +61 (0)2 9484 1283
E-mail: sales@flexicon.com.au
Web: www.flexicon.com.au
FLEXICON CORPORATION
(AUSTRALIA) PTY LIMITED
78 Westgate Street
Wacol, QLD 4076
Australia
Tel: 1 300 FLEXICON
(1 300 353942)
Tel: +61 (0)7 3879 4180
Fax: +61 (0)7 3879 4183
E-mail: sales@flexicon.com.au
Web: www.flexicon.com.au
SOUTH AFRICA
USA
ADDITIONAL WEBSITES:
FLEXICON AFRICA (PTY) LTD.
PO Box 10450
Linton Grange
Port Elizabeth 6015
South Africa
Tel: +27 (0)41 453 1871
Fax: +27 (0)41 453 1670
E-mail: sales@flexicon.co.za
Web: www.flexicon.co.za
FLEXICON CORPORATION
2400 Emrick Boulevard
Bethlehem, PA 18020-8006
USA
Tel: +1 610 814 2400
Fax: +1 610 814 0600
E-mail: sales@flexicon.com
Web: www.flexicon.com
FRENCH LANGUAGE
www.flexicon.fr
W-0433
UK
GERMAN LANGUAGE
www.flexicondeutschland.de
SPANISH LANGUAGE
www.flexicon.es
®
©2002-2009 Flexicon Corporation. FLEXICON Corporation has registrations and pending applications for the trademark FLEXICON and other FLEXICON Corporation trademarks throughout the world.
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