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Bulk Materials Storage
& Conveying
Pneumatic Conveying and Handling Systems for
the Food, Plastics & Chemical Industries
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BULK MATERIALS STORAGE & CONVEYING
Conveying
& Weighing
Intermediate
Storage & Transfer
Bulk Silo
Storage & Transfer
Process Lines
Road Tanker
Delivery
PLC Control
& SCADA
Major and Minor
Additives & Transfer
A TYPICAL STB BULK MATERIALS HANDLING SYSTEM
CONTENTS:
Introducing STB Engineering
Pneumatic Conveying Regimes
Conveying:
Dilute Phase Conveying
Medium Phase Conveying
Pulse Phase Conveying
Pulse Flow Conveying
Dense Phase Conveying
Products:
Storage Silos & Discharge Systems
Bulk Materials Weighing & Feeding
Big Bag & Sack Handling
Solutions for Industry:
Food
Plastics
Chemicals, Minerals & Pharmaceuticals
Project Management & Technical Services
Test House & Alan Yorke RotoMachinery
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BULK MATERIALS STORAGE & CONVEYING
Welcome to STB Engineering
ABOUT US:
STB Engineering was founded in Stroud in
1969, pioneering the development of
Dense Phase conveying technology and
silo manufacture. The company soon
established itself as the UK’s leading Bulk
Materials Handling and Pneumatic
Conveying Specialists.
STB is supplier of choice to some of the
major Blue Chip PLC Companies in the
Plastics, Food, Chemical, Mineral and
Pharmaceutical industries.
We are an ISO 9001 Quality Assured
Company and are proud to have been
awarded Supplier of the Year by a well
known blue chip company.
WHAT WE DO:
STB offer a total end to end in house
solution giving you one point of contact
and a system tailored to suit your specific
application.
• Pneumatic conveying systems
(Dilute and dense phase)
• Weighing and feeding
• Storage and discharge
• Big bag and sack handling
• Control systems
• In House: Project design and
management, manufacture, installation
and commissioning
OUR PEOPLE:
Our engineers have many years
experience and a thorough understanding
of our customers' process needs and
objectives.
We have a programme of continuous
product development and improvement
which has kept us at the forefront of the
bulk materials handling industry for 40
years.
STB’s success is the result of combining
innovative and cost effective design
concepts with the highest quality of
engineering technology, all brought
together by having the advantage of
decades of in house engineering design
and manufacturing experience.
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BULK MATERIALS STORAGE & CONVEYING
Pneumatic Conveying Regimes
GRAPHICAL VIEW
CONVEYING METHOD
SPEED (M/S)
CONVEYING PRESSURE
Dilute / Lean Phase: For most products in powder,
18 - 35 m/s
Pressure System
flake or granular form. Particles are fully suspended
up to 1 bar.
in the air stream. Positive pressure - blowing system,
Vacuum System
negative pressure - vacuum system.
up to 0.5 bar.
Medium Phase / Low Velocity: For most products
8 - 18 m/s
Pressure System
in powder, flake or granular form. Particles are
up to 1 bar.
partially suspended in the air stream with a bed
Vacuum System
of moving material.
up to 0.5 bar.
Pulse Phase: For cohesive powders. Plugs of
4 - 10 m/s
material fill the entire cross section of pipe, an
Pressure System
up to 4 bar.
air knife injection system breaks up the plugs and
reduces the risk of complete pipe plugging.
Pulse / Dune Flow: For regular granular products.
4 - 15 m/s
Product flows in a pulse or wave. The air stream is
Pressure System
up to 2 bar.
precisely controlled using an intelligent PLC
monitoring system.
Dense Phase: For fluidizable powders and fine
4 - 10 m/s
granules. Conveying with high product to gas
Pressure System
up to 4 bar.
ratio. Takes advantage of the fluidisation and air
retention of certain materials.
PHASE DIAGRAM:
Pressure (bar)
4 bar
3 bar
Dense Phase
2 bar
Pulse Conveying
1 bar
Unstable Area
Dilute Phase
Medium Phase
0 bar
0 m/s
10 m/s
20 m/s
30 m/s
40 m/s
Air Velocity (m/s)
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BULK MATERIALS STORAGE & CONVEYING
Conveying :
BLOWING SYSTEMS:
The simple positive pressure or ‘Blowing’
system is the most elementary of all the
pneumatic conveying systems with the
product being totally suspended in the air
stream. These systems generally comprise
a blower or fan delivering air into the
pipeline, a feed device to entrain the
product into the conveying air and a filter
or air separator to remove the product
from the air at the receiving hopper.
• Conveying pressures up to 1.0 barg.
• Low product / air ratio, generally up
to 15:1.
• Conveying velocities 18 to 35 m/s.
• Complex systems conveying to multiple
delivery points possible using diverter
valves.
• Closed loop conveying and low velocity
conveying systems.
VACUUM SYSTEMS:
Negative pressure or vacuum transfer
systems generally comprise similar
equipment to the positive pressure
system. Vacuum systems have an
advantage that any system leakage is
inward, so the escape of dust into the
atmosphere is much reduced.
• Conveying pressures to -0.5 barg.
• Low product / air ratio, generally up
to 15:1.
• Particularly suitable for conveying from
multiple sources to a single point.
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BULK MATERIALS STORAGE & CONVEYING
Conveying :
Medium Phase conveying is where the air
volume / air velocity is reduced and the
concentration of the product to air is
increased.
The particles stream moves towards its
saltation velocity - the point at which
particles begin to drop out of the air
stream and start to form a moving bed of
material in the base of the conveying pipe.
Air velocity can be controlled via an
intelligent speed control system
controlling the blower output. Most of the
particles travel in suspension at low
velocity above the moving bed of material.
Conveying :
The pulse pump was
developed as an efficient
solution to the problems of
pneumatically conveying
cohesive powders.
The pulse pump separates the
product into discrete ‘plugs’ of
powder and air in the pipeline.
It does this by using an air knife
system, enabling the product to
be easily transported, with the
product sliding through the
pipeline rather than particles
being fully suspended in the air
stream.
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The pulse pump enables the following
gains to be made:
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•
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•
•
High product / air ratios of up to 500:1.
Smaller pipelines can be used.
Low conveying velocities.
Reduced pipeline wear.
Reduced product degradation.
Low air volumes, reducing receiving
vessel air filter size.
• Low air consumption, hence reduced
operating costs.
• Conveying rates up to 10 tonne/hr
• System can be arranged for continuous
operation.
• Conveying pressures up to 1.0 barg.
• Medium product / air ratio, generally
15-30:1.
• Suitable for fragile or friable materials.
• Conveying velocities 8-18 m/s.
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BULK MATERIALS STORAGE & CONVEYING
Conveying :
Pulse Flow or Dune Flow conveying is
used to convey regular granular products
that need to be handled gently.
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•
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•
Conveying pressures up to 2.0 barg.
Product / air ratio 20-100:1.
Suitable for fragile or friable materials.
Conveying velocities 4-15 m/s.
Transfer rates up to 20 tonne/hr can be
achieved and conveying velocities as low
as 4m/s.
Product flows in a pulse or wave over a
moving bed of materials. The air stream is
precisely controlled using an intelligent
PLC control system that monitors the
product flow path, conveying air velocity &
pressure and carefully regulates the
system to maintain the pulse flow
condition.
Conveying :
The dense phase pump is a batching
system designed to pneumatically convey
free-flowing powders in a fluidised state.
The vessel is charged with product and
fluidising air is introduced through a
porous membrane. On opening the
discharge valve, fluidised product enters
the pipeline and is transported to the
receiving vessel, with the product sliding
through the pipeline rather than particles
being fully suspended in the air stream.
The dense phase pump enables
the following gains to be made:
• Product / air ratios of up to
150:1 can be achieved.
• Smaller pipelines can be used.
• Lower conveying velocities.
• Reduction in pipeline wear.
• Reduction in product
degradation.
• Conveying rates up to 10
tonne/hr.
• System can be arranged for
continuous operation.
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BULK MATERIALS STORAGE & CONVEYING
Products :
STB can provide creative solutions for
bulk materials storage, feed and discharge
problems.
Systems include:
• Silos, process vessels, hoppers and bins
in carbon steel, stainless steel and
aluminium.
• Discharge devices engineered to suit
the product and applications.
• Feeding and conveying systems including:
screw conveyors, belt and bucket
conveyors, rope and disc, air slide
conveyors, vibratory conveyors and
feeders.
Our design and build expertise combined
with high quality of finish has led to our
customers coming back to us time and
time again.
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BULK MATERIALS STORAGE & CONVEYING
Products :
STB's wealth of experience in
providing weighing and feeding
systems ensures the correct
system is installed to achieve
the most cost effective and
technically assured results.
• Volumetric feeders and
dosing screws.
• Silo weigh systems.
• Process weigh hoppers and
batch weighing.
• Loss in weight systems,
gravimetric feeders.
• Automated weigh and feed
control.
• Mechanical handling and
conveying systems.
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BULK MATERIALS STORAGE & CONVEYING
Products :
FIBC - BIG BAG HANDLING:
STB have designed a technically advanced
range of big bag discharge and filling
systems. Each system provides a means of
safe handling 1 tonne big bags with dust
free discharge and filling.
Big Bag Discharge Systems
• Various discharge aid systems to suit
products.
• Bag loading by fork truck, beam hoist or
column hoist lifting
• Weighing systems
Big Bag Filling Systems
• Adjustable height frames
• Inflation grip / bellows or manual clamp
to hold the spout
• Vibrating table for product compaction
• PLC weighing systems
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SACK HANDLING:
Our range of sack tipping stations provide
a safe, dust free method of manually
emptying bags and sacks containing
powders and granules.
Systems typically include:
• Dust extraction using reverse jet dust
filters with fan - this provides a through
draught of air, ensuring any dust from
the sack is drawn up into the sack tip
unit and away from the operator’s face.
• Level probes for contents control and
impact vibrators, aeration and stirrers
for clean discharge.
• Dosing and feeding devices.
• Weighing systems and controllers.
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Industries :
The food industry is constantly demanding
higher levels of hygiene and efficiency.
Our solutions provide high quality bulk
handling systems that meet or exceed our
customers specifications and expectations.
Our experience encompasses many types
of food, including:
• Rice, wheat, maize, soya and grain.
• Flake, bran and pellets.
• Rusk, bread and cereals.
• Flour, gluten and starch.
• Sugar, salt and additives.
• Powder, custard, milk, whey, potato, etc.
• Animal and pet food products.
Above: Silo installation including cooler for
chilling of rusk for well known brand of
sausage manufacturer.
Left: Feeding and weighing system for a major bakery
company manufacturing cakes and pastries. The system
is designed to discharge into mixing bowls with high
accuracy, with the benefit of eliminating manual
handling of sacks.
Above & Right: Solution for handling of wet flake by
Teflon coating of pneumatic conveying pipework and
components.
Above: Low velocity conveying system for
the gentle handling of tea blending
system.
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Industries :
For plastics and bulk polymer industries
we offer expertise in system solutions for
handling many types of polymer, both
granular and powder, as well as many
additives - for example we have installed
over 70 PVC mixing plants and our
pneumatic conveying systems feed
hundreds of extruders and moulding
machines.
Our systems are designed to offer cost
reduction and greater safety of operation.
Solutions are fully compliant with the
requirements of the industry.
STB offer recipe control PLC systems to
enable complete automation of ingredient
feeding systems including the weighing,
feeding and transfer of multiple ingredients
and transfer to mixers and process lines.
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Systems can include:
• Blending, mixing and pulverising systems.
• Additives handling: TiO2, fillers, colours,
blowing agents, stabilisers.
• Weighing: batch, loss of weight,
continuous, gravimetric.
• Big bag and sack handling systems.
• Accurate dosing and feeding.
• Blending cones and anti-seg silos.
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Industries :
CHEMICALS:
Some products can be hazardous and
require special care and handling:
• Explosion hazards.
• Dust control.
• Environmental protection.
• Cross contamination control.
STB provide full ATEX compliant systems.
We are proficient in dealing with dust
control using primary and secondary
filtration systems with intelligent
monitoring for control and environmental
protection.
MINERALS:
STB has extensive experience with
mineral storage, handling and conveying
systems including:
• Powder storage dosing and feeding.
• Slurry make up and mixing tanks.
• Lime, PAC, cement, coal, sand and ash
handling.
PHARMACEUTICALS:
STB specialise in the design and
implementation of systems according to
validation norms and GMP/GAMP
guidelines. Important issues are
encompassed including FDA certification
of materials, ease of cleaning, minimum
production downtime and operational
safety.
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BULK MATERIALS STORAGE & CONVEYING
Project Management
TOTAL PEACE OF MIND:
STB has many years’ experience of project
managing major installations from concept
through to commissioning.
MECHANICAL ENGINEERING:
Once an order is placed, we produce an
integrated project timetable, liaising with
all parties, including the customer, subcontractor and suppliers. We then manage
the implementation of the plan to ensure
agreed deadlines and specifications are
met, taking into account all the relevant
norms ATEX, CDM, etc.
Structural engineering is carried out using
AutoCAD, Solidworks, etc.
ELECTRICAL ENGINEERING:
One very important part of installation is
the process control system. Our team of
electrical engineers can provide total
solutions to include:
• Electronic hardware.
• Software.
• PLC control.
• Operator interfaces & SCADA systems.
• Interfacing with plant control systems.
In many installations, minimising downtime
of existing plant is paramount. STB has
considerable expertise in this area, having
installed many new systems within existing
plants with zero production loss.
Technical Services
SERVICE, MAINTENANCE &
BREAKDOWNS:
• Its is STB’s policy to offer fast responsive
and effective support when it comes to
breakdowns, service and maintenance.
• Our ability to respond quickly with
effective support is highly valued and
over the last 40 years has led to our
existing customers returning to us with
ongoing repeat business.
• We are firm believers that after sales
support and service forms an integral
part of the equipment we supply.
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• Whatever your needs - mechanical,
electrical, supply of parts or on site
maintenance work - our service team is
here to offer technical advice and swift
response to your service calls.
PLANT UPGRADES:
We can carry out modifications to your
plant to meet your changing operational
requirements or to comply with new
legislation. All work is carried out
efficiently and effectively, with minimal
disruption to your plant.
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BULK MATERIALS STORAGE & CONVEYING
STB Test House
STB TEST RIG
TESTING:
Our test facilities allow us to trial new
materials under a wide variety of
conditions. This enables us to optimise
system design, utilising our experience in
dense phase, pulse phase, dilute phase and
vacuum systems to successfully handle
even the most friable and delicate
materials.
REASONS FOR TESTING:
We often find that materials, although
similar in particle size and bulk density, will
have differing conveying properties. We
therefore test such materials thoroughly, in
order to gain an understanding of what is
the most effective and efficient means of
handling and transporting the material.
Filter
Receiver 1
Filter
Receiver 2
Up to 120m
Conveying Line
Dense
Phase Pot
Dilute
Phase Pot
Roots 1 Bar Blower
Siemens PLC
Control System
6 Bar Compressor
Rotary Valve
Such variables include:
• Particle size and shape distribution
• Cohesiveness
• Moisture content
• Pipeline length - vertical or horizontal
• Pipe bend radius
Air Control
Testing of materials will result in
correctly determining:
• Pipeline diameter
• Vessel sizing
• Compressor size
• Filter size
• Conveying velocities
Alan Yorke :
In 2006 STB Engineering Ltd acquired the
business Alan Yorke – manufacturers of
Roto Machinery. As a consequence, STB
can now offer a complete turnkey solution
to the Rotational Moulding Industry. This
includes specialist materials handling
systems for accurately dispensing weighed
amounts of materials into the actual
mould prior to it entering the oven, as
well as the rotational moulding machine.
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BULK MATERIALS STORAGE & CONVEYING
SERVING THE PROCESS INDUSTRIES:
This is a sample list of some of our
customers, for a more comprehensive
reference list please contact us.
FOODS
PLASTICS
CHEMICALS & MINERALS
PHARMACEUTICALS
STB Engineering Ltd.
Toadsmoor Road, Brimscombe,
Stroud, Gloucestershire. GL5 2UF.
Tel: +44 (0)1453 885353
Fax: +44 (0)1453 886824
Email: sales@stbengineering.com
Web: www.stbengineering.com
Advanced Elastomer
AGRA Birwelco
APV
Batchelors
Birds Eye
Bowmans
Bowater
BP
Brooke Bond
Cadbury
Caradon
CEGB
Coal Board
Coca-Cola
Courtaulds Engineering
Dairy Crest
Doeflex
Dow Corning
Eli Lilly
GEA Niro
GE Plastics
GlaxoSmithKline
Heinz
Hepworth
Huntsman Chemicals
Hydro Polymers
ICI
Imerys
Ineos
Johnson & Johnson
Kerry Ingredients
Kingspan
Kraft Jacob Suchard
Lafarge
Lyondell Basell
Macfarlan Smith
Marley
Master Foods
Matthew Hall
Müller
Nabisco
Nestle
Northern Foods
Pilkington
Polypipe
Premier Foods
Proctor & Gamble
Prysmian
RHM
South West Water
Tate & Lyle
Unilever
Weetabix
Zeneca
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