Rare earth recycling: optimised management with automated Big Bag emptying

As part of its activity of recycling magnets and processing rare earths, our client was looking for a solution to automatically unload big bags of SWARF powder. This material, which is produced by grinding and machining permanent magnets based on neodymium iron boron (NdFeB) or samarium cobalt (SmCo), presents specific risks: flammability, fine dust and oxidability.

The main objective was therefore to guarantee safe unloading while ensuring total dust containment to protect operators and avoid any contamination of the production environment.

At the same time, the company wanted to fully automate the process of emptying the big bags in order to achieve a rate of 15 big bags per hour, while minimising the need for human intervention. It was also crucial to integrate a system for the disposal of empty big bags in order to optimise waste management and ensure fluidity of production.

To meet the customer's requirements in terms of safety, productivity and containment, Palamatic Process proposed the installation of an EF500 automated big bag emptying station, specially designed for the handling of sensitive and hazardous powders.

The EF500 is equipped with an innovative hydraulic gripper system incorporating two separate gripping devices. A first clamp allows the big bag to be handled and held firmly throughout the emptying process. A second clamp, equipped with claws, ensures the retention of the big bag after it has been completely emptied. These claws remain locked as long as the big bag still contains material and only retract once it has been completely emptied and positioned above the hopper of the baling press.

Emptying of the product is optimised by a big bag cutting blade mounted directly in the emptying hopper. This configuration allows for a clean and wide cut of the big bag fabric, thus ensuring a rapid and even flow of the powder.

In order to limit the spread of fine particles in the production area and to guarantee a healthy working environment for operators, the emptying station is fully enclosed and equipped with a dedusting line with several strategically distributed suction points. This system allows for homogeneous capture of suspended particles and maintains a clean and safe working environment.

To reach the rate of 15 big bags per hour, the station has been combined with a supply conveyor to store several big bags awaiting processing. This system guarantees continuous feeding and avoids any interruption of the production cycle.

At the outlet of the product hopper, a transfer screw has been installed to ensure the homogeneous delivery of SWARF powder to three processing reactors. This solution optimises the feeding of downstream equipment and guarantees a continuous flow without interruption.

The empty big bags are then automatically directed to a baler, located at the bottom of the hopper, near the emptying hopper. This device allows compacting up to 100 big bags into a single bale, thus considerably reducing the volume of waste and optimising its disposal.

Thanks to this turnkey solution, the customer now benefits from a fully automated process, without direct human intervention on the material, thus guaranteeing maximum safety for operators and a significant improvement in production efficiency.

The industrial equipment making up the installation with the advantages of the Palamatic Process solution. The installation set up is based on a combination of high-performance industrial equipment, specifically selected to meet the customer's requirements in terms of safety, speed and containment of fine powders.

• EF500 automated big bag emptying station: Equipped with a double hydraulic gripper system, this station ensures safe handling and optimised emptying of big bags. The first gripper picks up and holds the big bag during emptying, while the second, equipped with retention claws, stabilises the big bag after emptying before it is discharged to the baler.

• Big bag cutting blade integrated into the emptying hopper: This blade guarantees a clean and wide cut of the big bag fabric, optimising the flow of SWARF powder and limiting residues.

• Multi-point dust extraction line: To ensure a healthy working environment, the emptying station is fully enclosed and equipped with a dust extraction system with several strategically placed suction points. This system allows for uniform collection of the fine particles generated during emptying and prevents them from dispersing in the workshop.

• Transfer screw at the hopper outlet: To guarantee a continuous supply to downstream equipment, a transfer screw has been installed to convey SWARF powder homogeneously to three treatment reactors. This system ensures a constant and controlled flow, without accumulation or break in the load.

• Supply conveyor: In order to maintain an uninterrupted flow of big bags, a conveyor has been integrated upstream of the station to store and convey several big bags awaiting treatment. This system makes it possible to reach a rate of 15 big bags per hour without interruption.

• Baler at the bottom of the hopper: After emptying, the empty big bags are automatically directed to a baler, located at the bottom of the hopper near the emptying hopper. This baler compacts up to 100 big bags into a single bale, thus optimising waste management and reducing their volume.

Thanks to this turnkey installation, the customer benefits from a complete, automated and secure solution that meets the strictest standards for the handling and processing of rare earths in powder form.