Chain tube conveyor feeding a Flowmatic 04 Big Bag filling machine with cocoa powder

The agri-food manufacturer, specialising in cocoa processing, is looking to optimise its powder transfer and packaging process.

The main objective is to improve the feed to its big bag packaging machine while ensuring efficient management of space constraints and safety requirements associated with the ATEX 21/22 zone.

The specific requirements of the project include:

• Optimised transfer of cocoa powders: ensuring a constant and controlled flow from a buffer hopper to the big bag packaging machine, while preserving the physical characteristics of the product.
• A system adapted to space constraints: integrating a tubular chain conveyor that allows vertical elevation and a small footprint.
• Compliance with ATEX standards: guaranteeing maximum safety in an ATEX 21/22 classified environment, where the presence of flammable dust requires certified equipment.
• Extraction and regulated feeding: the integration of a rotary valve ensures a controlled flow of product to the conveyor, thus avoiding flow variations and the risk of blockages.
• Minimised product retention: optimised equipment design to limit powder residues in the transfer system.

The manufacturer is therefore looking for a robust, simple solution that guarantees continuous and consistent feeding.

To meet the manufacturer's requirements, Palamatic Process designed a solution incorporating a tubular chain conveyor to transfer cocoa powder from a buffer hopper to a big bag filling machine.

Mechanical transfer was chosen over pneumatic transfer due to the characteristics of cocoa powder.

This very fine product is sticky, which could cause clogging of the pipes in a pneumatic system and reduce the transfer flow rate.

The tubular chain conveyor was therefore chosen for its ability to scrape the inner walls of the pipes, thus limiting material deposits and ensuring a constant flow.

The key elements of the solution implemented are:

• A 7-metre-long chain tube conveyor with a 4.3-metre elevation, enabling vertical transfer of the product in a small space. This system limits the formation of deposits and ensures efficient extraction of the cocoa powder.
• A PE 250 rotary valve positioned at the hopper outlet to ensure regular feeding of the conveyor, thus avoiding flow variations and risks of clogging. The valve is made of stainless steel to guarantee optimal resistance to the abrasive properties of cocoa powder.
• A design adapted to ATEX requirements with equipment compliant with zones 21 and 22, incorporating certified components to prevent any risk of ignition of suspended dust.
• An optimised automation system for smooth management of the production flow, with control sensors ensuring continuous monitoring of the conveyor and rotary valve.

Thanks to this configuration, the Palamatic Process solution provides controlled feeding of the big bag packaging machine, smooth transfer of the product and a significant reduction in maintenance thanks to a design that promotes low material retention.

The installation is based on equipment specifically selected to ensure efficient and safe transfer of cocoa powder while complying with space and ATEX safety requirements.

1. Tubular chain conveyor

Technical characteristics:

• Length: 7 metres
• Elevation: 4.3 metres
• Track type: S-shaped
• Mass flow rate: 2,500 kg/h (for a density of 0.65 kg/l)
• Material: 304 stainless steel
• Drive: 400V, 50Hz, IP55 gear motor

Advantages:

• Ensures smooth mechanical transfer, limiting product degradation.
• Scraping of the internal walls of the tube, reducing powder retention and the risk of clogging.
• Suitable for fine and slightly sticky products, unlike pneumatic systems.
• Can be integrated into ATEX zones 21 and 22 with a specific design.

2. PE 250 rotary valve

Technical specifications:

• Inlet/outlet diameter: Ø250 mm
• Total height: 450 mm
• Litres per revolution: 19 L
• Maximum rotation speed: 30 rpm
• Material: 316 stainless steel body, 316L stainless steel rotor
• Motorisation: IP55 gear motor, speed 16/23 rpm, power 0.37 kW

Advantages

• Ensures a smooth and regulated feed to the conveyor, without jamming.
• Limits the risk of blockages or jams by managing the flow evenly.
• Stainless steel construction ensures high resistance to abrasive products and easy cleaning.

3. Automated management system

Components:

• Rotation control sensors and chain offset sensors on the conveyor.
• Frequency variator for precise adjustment of the conveyor speed.
• Integration with a supervision system for real-time process monitoring.

Advantages:

• Secure operation with alerts in the event of anomalies (misalignment, overload, loss of rotation).
• Optimised production flow according to the requirements of the big bag packaging machine.
• Reduced manual intervention thanks to centralised and automated control.

The integration of this equipment makes it possible to meet the manufacturer's requirements precisely, guaranteeing a transfer process that is safe, efficient and compliant with ATEX regulations.

Thanks to the tubular chain conveyor, the manufacturer benefits from a transport system that is robust and suitable for fine and slightly sticky powders, avoiding the clogging problems encountered with pneumatic transfer.

The solution implemented ensures:

• A controlled and constant flow of cocoa powder, avoiding any interruption in the packaging process.
• Perfect adaptation to space constraints, with a vertical transfer solution that optimises the available space.
• Reduced losses by minimising material retention in the ducts, thus facilitating cleaning and production changes.
• ATEX compliance with certified and secure equipment, guaranteeing a working environment that meets regulatory requirements.
• An optimised process thanks to advanced automation, reducing maintenance interventions and increasing overall productivity.

By integrating proven technologies adapted to the specific characteristics of the product being handled, this installation enables the manufacturer to improve its operational efficiency while making its handling operations safer.

The choice of mechanical transfer by tubular chain conveyor ensures increased durability and reliability, while limiting operating and maintenance costs.

Thanks to this tailor-made solution, the manufacturer now has a high-performance, long-lasting system that guarantees smooth, safe production that complies with the quality requirements of the food industry.

Palamatic Process is thus supporting its customer in a process of continuous improvement by offering an innovative solution that is perfectly integrated into its industrial process.