WASHINGTON, NJ -- Chemicals producer BASF Corp. recently upgraded the packaging of surfactants with two key additions to its manufacturing plant. One was a purpose-built room designed for greater cleanliness and control in loading surfactants in drums or bulk bags prior to shipping. The other was installation of a rotating drum and bulk bag filler from Flexicon Corp., Bethlehem, PA, that automates the process and yields greater product output and quality control than the previous method of manual loading.

Surfactants are additives that reduce surface tension in liquids, making them easier to formulate and use in a range of consumer, industrial and healthcare products. BASF surfactants are formulated as liquids and then converted into powders. The materials are usually packaged in 55 gal (208 l) fiber drums and sometimes in 2000 lb (907 kg) bulk bags for shipment to product manufacturers.

Since many surfactants produced by BASF are for the personal care market, such as toothpaste, mouthwash, soap, shampoo and laundry detergent, their manufacture must meet rigorous quality standards. The plant is certified as ISO 9001:2000, is FDA regulated and conforms to Good Manufacturing Practices. Processes comply with U.S. Pharmacopeia (USP) and National Formulary (NF) guidelines. Hence, the need for a packaging operation that is accurate, efficient and capable of maintaining high levels of quality control, says Sherri Molomo, senior process engineer at BASF.

The loading room was designed to meet these needs. Molomo says the room is part of BASF's commitment to continuous improvement in operations and product quality. Its efficiency will help BASF expand production of USP and NF surfactants and share of the market, she adds.

Automation of the loading process also has safety and regulatory benefits. Prior to construction of the room and installation of the bulk bag and drum filler, containers were manually loaded. This meant that an operator had to move a drum to a weigh-filling station, operate a slide gate to fill it, check the weight and, if it exceeded the limit, adjust as needed. After filling, a drum was physically moved onto a pallet for transport to the shipping area. The process required multiple steps, took time, and exposed workers to possible injury from handling the drums, says Molomo.

To automate the process, BASF engineers worked with Flexicon engineers and PME Equipment Co., Flanders, NJ, to specify a Rear-Post Bulk Bag Filler that also has the capability to fill four fiber drums sequentially. An automated conveyor system now moves drums and bulk bags in and out of the filling station, and a rotary valve meters the required weight of material with a high degree of accuracy.

The bulk bag and drum filler installed in the loading room incorporates design features developed by both companies. BASF added a dust-collection system on the machine attached via flex-hose to contain particles that rise up during loading. The company also specified an Allen-Bradley PLC (programmable logic controller) to automate operations. The PLC communicates with a Mettler Toledo weigh-filler scale to regulate product flow and shut down the operation when a pre-set weight is reached.

An operator selects the appropriate product-loading program on the PLC and pushes a button to start the filling process. Surfactants are transported from the main plant to a vessel above the rotary valve, then gravity-fed into either a drum or a bulk bag.

When filling drums, the operator attaches the automatically rotating drum fill adapter to the Flexicon bulk filling station. Once the four drums have been positioned on the deck of the filling station, the operator presses a start-up button on the PLC and surfactant begins flowing. Each drum has a plastic lining into which the surfactant empties. When one drum fills, flow is interrupted while the diverter head indexes to fill the next drum in sequence. Once all drums are filled, the operator seals the liners, and puts lids on the drums. The drums are then transported via conveyor out of the purpose-built loading room into the shipping area.

When filling a bulk bag, an operator attaches the four bag straps to each corner of the loading frame, engages the bulk bag fill spout to the fill head utilizing an inflatable collar to provide a dust tight connection and puts the bag in a rubber bladder, which seals the surfactant in the bag after product is loaded, and acts as an extra layer of protection during transport. The frame raises to accommodate the height of the bag. The bag rests on a pallet atop the weigh-filler scale, which takes up about 25 sq. ft. (2.3 sq. m.) of floor space. The scale transmits weight data to the PLC, which automatically stops the flow of material when the correct weight of surfactant has been loaded. The bag is then closed and moved on the roller conveyor to the shipping area.

Molomo states that the automated loading process significantly enhances the surfactants packaging operation and increases operator productivity. Most importantly, though, is the improvement in operator ergonomics and safety, as well as elimination of operator involvement in the filling process. This has resulted in a more effective use of personnel. These benefits also mean less potential for contamination of surfactants during packaging.

In assessing the impact of the loading room and the Flexicon bulk bag and drum filler on operations, Molomo notes, "Our products have become better by using better tools."

1", 2", 3" & 4"- PVC or Corzan® CPVC

GENERAL DESCRIPTION

Two Proportional Flow Control Rates with One Valve: Hayward ProFile2 corrosion resistant, proportional control ball valves provide two linear flow curves; one for fast opening and one for slow opening. The percentage of flow through the valves with either flow curve is equal to the degree of opening. As the valves are opened or closed, the flow varies in direct proportion to the valve opening. This permits predictable, accurate control of the downstream flow rate with a 1/4 turn valve.

Unique Design "Characterized" Ball: These valves utilize a unique, patented ball with a special "characterized" opening that results in the linear flow rate change. Valves are shipped with the ball installed so that the smaller opening enters the flow first, creating the slow open rate. To switch to the fast opening rate, simply reverse the ball in the valve. With the larger opening first, the flow starts fast with slower, more controlled changes as the ball is turned to "full open".

Perfect With Positioners: Hayward ProFile2 Proportional Control True Union Ball Valves can be supplied with optional electric or pneumatic actuators with positioners for automated modulating service applications.

Never a Problem with Corrosion: Because of their all plastic construction, Hayward ProFile2 ball valves will never rust or corrode. They can survive corrosive environments and harsh weather conditions without the need for painting or expensive epoxy coatings.

• See Catalog Information

Features

• All Plastic
• Precise Flow Control
• True Union Design
• Accurate Proportional Control
• EPDM or FPM Seals
• Socket, Threaded or Flanged
• Two Year Warranty

Applications

• Methane Gas Recovery
• Fill Station Lines
• Lateral Take-Off Line
• Flow Control Flow Reduction in Systems with Oversized Pumps
• Control Flow From Tanks

About Hayward Flow Control Systems:

Hayward carries an extensive line of plastic valves including two-way and three-way true union ball valves, proportional control valves, pneumatic and electric actuated valves, pipeline strainers, basket strainers, and Y-strainers. In addition to our complete line of pneumatic and electric actuators that can be packaged together with our valve products, we also have actuator mounting kits, control systems/panels, bag filters, cartridge filters, in-tank filtration systems and high purity water and aggressive chemical filtration cartridges designed to meet today's demanding processing requirements.

Please click on the links to the right for more information or request a quote today!

BETHLEHEM, PA - A new combination bulk bag/drum filler from Flexicon Corporation features a fill head that pivots down for connecting empty bags at floor level, and a swing-arm-mounted chute for filling of drums.

The unit's Swing-Down^® fill head enables the operator to connect bag spouts and resume filling operations rapidly, eliminating the need to step over roller conveyors, strain to reach overhead connection points, or risk injury associated with operation of conventional bulk bag fillers, according to the company.

The patented device simultaneously lowers and pivots the fill head, stopping it in a vertically oriented position that places the bag inlet spout inflatable connection, inflator button, and four bag loop latches within an arm's length of an operator standing on the plant floor. This reportedly increases the safety and speed of connecting bulk bags, since the connection points of a conventional filler are beyond the reach of most operators, even when bags as short as 4 ft (1220 mm) in height are being filled.

A remote console or wall-mounted panel houses controls to raise and pivot the fill head into a locked, horizontal "fill position," automatically inflate the bag to remove creases, open a flow control valve or start a feed device, and stop the flow of material once a preset fill weight has been gained. Optional vibratory decks de-aerate and densify material in the bag at preset set points to create a solid, stable bag, ready for shipment.

Once bags are filled, the controller deflates the spout connection collar, releases the loop latches, and raises the fill head to fully disengage the spout, enabling the bag to exit the filler automatically on the roller conveyor.

The unit can be switched to drum filling mode in several seconds by positioning the swing-arm-mounted drum-filling chute under the fill head discharge port. The chute automatically rotates to deliver material to all four drums on a pallet.

The filler is constructed of carbon steel with durable industrial finish, or stainless steel finished to industrial, food, dairy or pharmaceutical standards, and is offered with material delivery systems integrated with upstream process equipment or other material source.

The company also manufactures Twin-Centerpost™ bulk bag fillers, rear post bulk bag fillers with non-pivoting fill heads, flexible screw conveyors, pneumatic conveying systems, bulk bag unloaders, bulk bag conditioners, bag dump stations, drum dumpers, weigh batching and blending systems, and engineered plant-wide bulk handling systems with automated controls.

Custom designed equipment unloads bulk bag, conveys material, filters and fills while saving time, increase safety and allow for a more throughput.

National Bulk Equipment custom configured a bulk bag handling system that will discharge the contents, convey the contents while filtering out the undesired portion of the bag contents and then fills a bulk bag on the receiving end of the equipment. Designed with many components that are integrated to achieve the desired results. The components include the Loop Retractor hanging mechanism, Bridgebuster Paddles, E3 bag spout untie module, Combo bag break hopper, Inclined cleated belt conveyor and bag filler on the receiving end. The Bulk Bag Unloader unit can be used to unload bags when suspended and positioned overhead by the integral hoist. Material flow is controlled by an iris mounted valve mounted above the untie box / break station. A belt conveyor receives product from the unloader at the crumbler device and is carried to an inlet transition above the sifter located on top of the filler. Bag filling weight is measured by a hang weigh type load cells.

Multisorb Technologies Inc. increased productivity at its new European facility for producing silica gel granule adsorption packets with an automated multi-line bulk solids handling system that simultaneously feeds four form/fill/seal machines. The system, under PLC control, consists of a bulk bag discharger, four flexible screw conveyors, and four feed hoppers gravity discharging material simultaneously to the form/fill/seal machines. Multisorb chose this layout over a simpler, lower capacity single line of flexible screw conveyors supplying the form/fill/seal machines one at a time.

The company selected mechanical over pneumatic conveying for gentle product handling to maintain particle size of 0.04 - 0.15 in (1-4 mm). A flexible screw conveyor's self-centering stainless steel spiral rotates within a UHMWPe (ultra-high molecular weight polyethylene) tube, providing clearance between the screw and tube wall for the silica gel particles to flow undamaged. The bulk handling system, which is expandable for future market growth, was designed, built and commissioned by Flexicon (Europe) Ltd.

Forklift loading of discharger frame

Granules arrive in 1-ton bulk bags, which are lined to prevent entry of moisture or oxygen that would affect the hygroscopic material. The entire conveying system is airtight, conferring the same benefit. A forklift operator attaches the bulk bag to four Z-CLIP™ bag strap holders on a bag-lifting frame, then maneuvers the forklift to secure the frame on a 12-ft (3.6 m) high discharger frame above the 8 cu ft (225 liter) capacity receiving hopper.

Bulk Bags discharge dust-free

The bulk bag/hopper interface consists of a manual Spout-Lock® clamp ring positioned above a pneumatically actuated Tele-Tube® telescoping tube, which facilitates dust-tight connections between bag spout and hopper, and automatically elongates the bag as it empties to promote flow and evacuation.

The telescoping tube pneumatically raises the clamp ring assembly allowing connection to the bulk bag spout, sealing the clean side of the bag spout to the clean side of the telescoping tube. It then lowers until the bag spout is pulled taut. Once the spout is untied, the telescoping assembly exerts continual downward tension on the spout, elongating the bag as it empties. The dust-tight seal between bag spout and clamp ring allows full-open discharge from the bag with no dusting.

From the hopper, a 20 ft (6m) long, 3-in (80 mm) diameter flexible screw conveyor, at a 45 degree angle, draws the material to 14 ft (4.4 m) height into the first of four 4.5 cu ft (130 ltr) capacity feed hoppers. Three 15 ft (4.5m) long, 3-in (80 mm) diameter flexible screw conveyors connect the feed hoppers horizontally in series. Each hopper gravity feeds material to an auger and form/fill/seal machine.

PLC control allows simultaneous filling of any combination of the four feed hoppers, dictating how much material fills a hopper by opening or closing a slide valve between the discharge of the flexible screw conveyor and hopper inlet. High and low level warning indicators on the hoppers and above each slide valve tell the control to stop or resume flow through the conveyors.

Expandable for future production

The system permits installing a parallel line of flexible screw conveyors to meet expanded production. The inlet on each of the four feed hoppers is offset so an additional flexible screw conveyor can discharge into a second inlet opposite the first.

Sorbent packets eliminate moisture and oxygen in final packaging of food, pharmaceuticals, chemicals, electronics, aerospace and other products. The Buffalo, NY-based company built the 22,000 sq ft plant to capture opportunities in Europe, Mid East and Africa, delivering product to BS (British Standards), MOD (British Ministry of Defense) and DIN (Deutsche International Normal) standard accreditations. The bulk solids handling system has been fulfilling production expectations and will allow higher productivity as the plant expands into different products for new markets.

Auxiliary Equipment

A basic Alar filter is an impressive piece of engineering with just its standard options. However, Alar manufactures each system to suit the customer's specifications that sometimes require auxiliary equipment. Alar supplies Auxiliary Equipment such as (but not limited to) the following:

Holding Tanks,

Alar filters operate in batches. Therefore, the current day's process water needs to be stored until the filter feed tank and/or treatment tank is ready to receive more water.Typically, the daily process water is strained of debris and fed into a holding tank. During the filtration cycle, the holding tank is used as a reservoir to retain incoming [untreated] wastewater.Holding tank capacities vary due to the volume of wastewater generated. It is recommended that the holding tank would be able to contain an entire day's volume.Alar manufactures Carbon Steel Holding Tanks ranging from 200 to 3,000 gallons. Alar can supply mixers, pumps, level controls, alarms, and electrical control panels.Alar is also an excellent source for Fiberglass (FRP) and Polyethylene (HDPE) tanks.

Super Sack Bulk Bag Unloading System

The filter aid bulk bags are supplied with lifting loops in all four corners. These loops are attached to the bag lifting frame hooks and by electric hoist are raised to clear the hopper. The hoist is mounted on a trolley. Therefore, the bag can easily be pushed into place over the center of the hopper. The discharge chute of the bulk bag is placed through an iris valve into the discharge box. The iris valve is then closed, the discharge chute untied, and the discharge box door closed. After opening the iris valve the bulk bag is now ready to dispense the filter aid into the hopper as needed. The hopper, in turn, feeds the lower end of the conveyor that discharges the filter aid to the mixing tank. When the desired amount is delivered, the iris valve is closed and conveyor is stopped.

Vacuum Pump Cooling Water Recirculation Systems

Alar uses vacuum pumps that are liquid cooled and require approximately six (6) gallons of water per minute for cooling. The Recirculation system will combine cooling water with filtrate water to keep the vacuum pump cool.

Filter Aid Economizers

The Filter Aid Economizer allows the system to conserve filter aid and extend operation time by controlling the knife advance in relation to the vacuum pressure being pulled on the filter.

Treatment Tanks

Most filtration or dewatering equipment requires liquid solid separation through chemical treatment. In most cases, the treatment is done in batches, and therefore, a treatment tank is necessary.Treatment tank capacities vary due to the volume of wastewater generated each shift. During the treatment cycle, a holding tank is used as a reservoir to retain incoming [untreated] wastewater until the treatment tank is empty. Holding tanks should have the capacity to contain an entire day's volume, whereas the treatment tank should contain the volume of at least one shift. Alar manufactures Carbon Steel Holding Tanks ranging from 200 to 3,000 gallons, and is an excellent source for Fiberglass (FRP) and Polyethylene (HDPE) tanks.Alar can custom design your treatment tank and provide accessory equipment such as: Mixers, mixer supports, level controls, automatic pH chemical addition systems (complete with make down tanks-mixers-pumps), automatic pH monitoring systems, filter feed pumps, and control panels. Our tanks can be stand-alone or skid mounted.The Alar Engineering Department employs mechanical, electrical, and design engineers that can custom build a system to match just about any tank specification.

Neutralization Systems

Neutralization of water requires pH adjustment. Neutralization is typically accomplished by using acidic and alkaline chemical treatment.Alar manufactures fully automatic neutralization systems that consist of a treatment tank with mixer and level controls, automatic pH chemical addition with make down tanks-mixers-pumps, automatic pH monitoring system, automatic filter feed pump, and control panel. The only man power required is to fill the treatment tank, fill two chemical tanks with water and chemicals, and press two push buttons on the control panel. The neutralization system is skid mounted on a structural steel base, pre-wired and pre-piped, for installation by others.The neutralization system operates as follows: If the treatment tank is empty, the holding tank wastewater is automatically pumped into the treatment tank. This pump will start and stop automatically until the treatment tank has reached a pre-determined treatment level. Then the chemical treatment cycle will begin.The wastewater is analyzed for pH concentration and the chemicals are automatically added in the proper amount, sequence, time and rate, under controlled agitation.

Chemical Treatment Systems (a combination of Neutralization Systems & Treatment Tanks)

There are two steps in the dewatering process:

1. Chemical Separation (pretreatment equipment)

2. Mechanical Separation (filtration equipment)

Alar manufactures the equipment for both processes.Most companies offer one filter and outsource the treatment system. Outsource typically means shipped loose or "piece-meal"; the customer will need to hire a contractor to interconnect the control cabinet, chemical feed tanks, treatment tanks, pH metering equipment, pumps, mixers, plumbing and electrical.Alar builds three filters that are often accompanied by custom designed Alar treatment skids. The treatment system is manufactured at Alar and shipped pre-piped, pre-wired, and mounted on a structural steel skid for easy disconnection and installation. A virtual "plug-n-play" operation.If your company already has a mechanical filter, then Alar can engineer and build a chemical separation system to meet the specific requirement of your wastewater and filtration equipment.Before building your treatment skid, Alar will bench test a sample of your wastewater (at no charge) to determine the best chemical solution.

Chemical Treatment System Operation

Wastewater is received and strained and then fed into a holding tank. During the treatment cycle, the holding tank is used as a reservoir to retain incoming (untreated) wastewater. If the treatment tank is empty, the holding tank wastewater is automatically pumped into the treatment tank. This pump will start and stop automatically until the treatment tank has reached a pre-determined treatment level. Then the chemical treatment cycle will begin.The wastewater is analyzed for pH concentration and the chemicals are automatically added in the proper amount, sequence, time and rate, under controlled agitation. If pH is not an issue for treatment, then flocculating and coagulating agents are metered in automatically.

Carbon Columns

The purpose of the Flex-O-Star Carbon Column is to remove residual color and organic material in the water coming from the vacuum pre-coat filter.Under normal operating conditions, one 200-225 pound charge will last four to five months before it needs replacement. This varies from installation to installation, due to different amounts of processed water and concentration of remaining contaminants.The carbon column is designed for an upward flow of filtrate. This carbon needs to be flooded at all times during the operation. The liquid is pumped into the bottom of the column, through the bottom filter screen. It then flows up through the carbon and out through the top filter screen.

Dissolved Air Flotation Systems (DAF's)

The DAF Clarifier is a wastewater clarification system that combines flotation and settling. This incorporates dissolved or inspirited air to aid in the flotation of fine solids, fats, oils, and greases. Its rectangular design uses less space, and the hopper shaped bottom facilitates easy removal and high concentration of settleable solids. Sludge collectors are provided, equally spaced on the traveling bridge to give complete coverage of the clarifier bottom. The bridge is also equipped with wiper blades that sweep the surface of the clarifier on each forward movement of the bridge. These wiper blades move the float to the incline plate and into the float discharge trough.

In-Line Polymer Injection System

Although polymers are not necessary for an Auto-Vac Rotary Vacuum Drum Filter, polymers enhance the filtering process and increase thru-put of the effluent; ultimately saving in the use of diatomaceous earth filter media.