A combination ‘Spiroflow’ Bulk Bag Discharger and Sack Tip Station, with integral Conveying System, was chosen by Everbuild Building Products Ltd of Leeds because it can handle the wide range of the bulk components and additives used in the manufacture of their comprehensive range of building sealants, adhesives, and fillers for both the Professional and DIY trades.
As a company, Everbuild are experiencing meteoritic growth due to their innovative nature, extensive product range and the outstanding performance of their products – all backed by support services second to none. Today they are the UK and Ireland’s largest independent manufacturer of sealants, adhesives, fillers and building chemicals. The Leeds factory is a massive 250,000 square feet, employing some 230 people, producing a vast array of products including close to 750,000 cartridges of sealant a week.
To meet the growing demand, earlier this year, Everbuild installed a new twin shaft mixer alongside an existing machine. Operations Manager, Lisa Broadhead, then set about identifying the means to load bulk materials and minor additives into both mixers and, at the same time, taking the opportunity to improve working conditions by reducing manual handling and dust emissions.
The materials charged into the mixer during the production of Everbuild’s acrylic sealants, fillers and mastics, range from chalk based compounds to glass beads and includes Titanium Dioxide which, as anyone involved in powder handling knows, is notoriously difficult to handle. It was the tests on a range of materials, including Titanium Dioxide, at Spiroflow’s Test Centre that convinced Lisa Broadhead that their equipment could do the job. The tests also confirmed that the performance of Spiroflow’s Bulk Bag Discharger and Conveyors was more than adequate to meet the speed at which the mixers needed to be loaded. As Lisa Broadhead confirms, “We can’t have one mixer standing idle whilst we wait for the other to be filled”.
The equipment supplied to Everbuild is a model T3 Bulk Bag Discharger working in conjunction with a Sack Tip Station, Flexible Screw Conveyor, Aero-Mechanical Conveyor and a feed chute system. The bulk materials are delivered to Everbuild in 1,000 kg bags. The model T3 Bulk Bag Discharger has a load cell arrangement that is specifically designed to discharge accurate quantities. The optional pinch bars fitted to the Discharger supplied to Everbuild enable the neck of partially discharged bags to be tied-off and removed once the required amount has been unloaded from them. Discharged materials are conveyed by a short Flexible Screw Conveyor into the collection hopper below the adjacent Sack Tip Station. An agitator is installed above the inlet to the Flexible Screw Conveyor to ensure that difficult materials are prevented from bridging across the inlet. In similar vein, the Bulk Bag Discharger has paddle massagers ready to encourage the flow of materials from Bulk Bags that have become compacted or which contain otherwise difficult to discharge materials. A keynote feature of all ‘Spiroflow’ Bulk Bag Dischargers is their spring-loaded bag support arms that rise as material is discharged to ensure minimum residue.
Minor additives, supplied to Everbuild in 25 Kg bags, are loaded manually via the Sack Tip Station. This is furnished with a dust hood and plastic strip curtain. The cabinet is connected to Everbuild’s central filter system which ensures dust emitted from bags, as they are opened, is drawn away from the operator.
From the hopper below the Sack Tip Station material, emptied from 25 kg bags and from the Bulk Bag Discharger, is conveyed by a ‘Spiroflow’ Aero-Mechanical Conveyor some 5 metres vertically so that it can be dropped into either of the two mixers. A gravity diverter valve controls the flow of material into either of two feed tubes below the outlet of the Aero-Mechanical Conveyor. Spiroflow’s Aero-Mechanical Conveyors have proven particularly successful at conveying materials such as Titanium Dioxide. The high speed rope and disc assembly carries materials in an airstream which prevents any compacting or sticking during conveying. In addition, they offer ‘total transfer’, an essential attribute when handling pre-weighed batches of materials.
Controls for the system were designed and manufactured in-house by Spiroflow. Such controls can be designed to include touch-screen driven recipe systems and can interface with other PLC control systems in a production environment.
In conclusion, Lisa Broadhead confirms, “I am really happy with the Spiroflow equipment. So are the operatives. It handles all of our materials. The controls are great. Now we can weigh batches of material very accurately”.
For details about Everbuild’s comprehensive range of sealants, adhesives, fillers, tapes and building chemicals go to www.everbuild.co.uk.
For more information about ‘Spiroflow’ Bulk Bag Dischargers, Sack Tip Stations, Flexible Screw Conveyors and Aero-Mechanical Conveyors and also about their ranges of Bulk Bag Fillers, Tubular Drag Conveyors, Pneumatic Conveyors and Vacuum Conveyors too, visit their web site at www.spiroflow.com or call them on +44 (0)1200 422525 to discuss your specific requirements.