Case Studies (copy 3)

Case Study: Discharging and dosing in one step with SoliValve®100

In the field of internal raw material transport and specifically in bulk handling technology, recurring questions arise: How can we gently and safely introduce or discharge our products into the process? How can smooth transport between different processing stages be ensured? How should various types of containers, such as Big Bags, barrels, containers, or sacks, be handled? How can raw materials be transported dust-free and unmixed? These questions need to be addressed both for new projects and for existing systems. The increasing demands in the pharmaceutical, chemical, and food industries also pose challenges even for the transport of non-harmful substances. It is crucial, among other things, to avoid cross-contamination and ensure product purity. These industrial developments are the main drivers of innovation.

A comprehensive project for a well-known manufacturer of minerals and vitamins included systems for bulk handling, such as sack dumping, as well as systems for closed automatic filling and partial emptying of containers. The customer’s main requirements included:

  • Process in Hygienic Design
  • Prevention of product contamination
  • Prevention of contamination of the production facility
  • Reduction of pre-mixes
  • Drying of the production facility
  • Containment process to protect the product

The Core: Solivalve Double Cone System

The Solivalve double cone system enables fully automated, contamination-free, and closed discharging and dosing of low-hazard bulk materials, specifically powders with an OEL value of 10 to 100 µg/m³. The universal passive Solivalve design allows for the filling and emptying of Big Bags, containers, barrels or sacks using a single docking unit. This avoids the need for expensive and complex double shut-off valves.

The double cone system is fully automated, eliminating the need for manual steps to connect or disconnect containers. The control of the active cone allows for product dosing directly from the container. Partial discharges are always possible. The system is dust-tight. The dosing algorithm ensures precise positioning and opening of the double cone, as well as activation of a high-frequency vibrator. This results in accurate and repeatable dosing. Depending on the scale, a dosing accuracy of 0.5% can be achieved (Solivalve 100). One of the greatest advantages of the system is maintaining containment. Powder transfer is completely dust-tight. After an SMEPAC test of the double cone system with lactose conducted by an independent test laboratory, an OEB 5 value (<1 µg/m³) was defined (Solivalve 100). Extensions such as CIP concepts or inertization are always possible.

Micro-Ingredient Dosing with Active-SoliValve®

In developing this system, the goal was to reduce the number of pre-mixes purchased annually while achieving greater variability and flexibility in the produced recipes. Raw materials are categorized into families: minerals and vitamins. Each material has a specific usage point with a total of 22 containers: a sack dumping station with an integrated dust removal unit and an integrated storage hopper below. Barcode scanning ensures traceability of the material and prevents handling errors when dumping sacks of raw materials.

Each storage hopper is equipped with a passive SoliValve®. A mobile cart with one or two active SoliValves® moves under all storage containers. Once the Active-SoliValve® is positioned under the selected raw material, it is automatically lifted to dock with the Passive-SoliValve®. The material weighing is done according to the target weight. For weights under 10 kg, the ingredient is weighed in a 25-L container on a digital weighing platform with a readability of 1 g, ensuring accuracy of 1% for weights starting at 160 g. For weights over 10 kg, 90 to 95% of the material is directly transferred into the collection container under the weighing container, and the last 5-10% is weighed precisely in the weighing container before being emptied into the collection container. The dosing time is approximately 2 to 5 minutes for weights ranging from 160 g to 150 kg.

Once the batch is prepared, it is discharged into a catch funnel using a SoliValve 250 system, which pneumatically transfers the powder into a wet mixer. The active unit docks through an opening in the bottom.

Benefits:

  • Fully automated and traceable formulation system
  • Extremely large weighing range with the same dosing device: the SoliValve
  • Ultra-clean processing facility due to the high containment capabilities of the Alpha-Beta coupling system between the active and passive components
  • Vertical dosing system that negates the risk of product degradation typically caused by horizontal screw conveyor systems

 

SoliValve®100
Mixture Composition
Docking at the floor
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