Issue link: https://www.e-digitaleditions.com/i/1388570
July 2021 / 55 C hemicals producer BASF Corp. installed a rotating drum and bulk bag filler from Flexicon Corp. that yields greater output and quality control than the previous method of manual loading. BASF surfactants are usually packaged in 55 gal (208 l) fiber drums and sometimes in 2000 lb (907 kg) bulk bags for shipment to product manufacturers. Previously, an operator moved a drum to a weigh-filling station, operated a slide gate to fill it, checked the weight and, if it exceeded the limit, adjusted as needed. After filling, a drum was physically moved onto a pallet for transport. To automate the process, BASF specified a Flexicon 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. An operator selects an appropriate product-loading program on the PLC and initiates a filling cycle with a push button. 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, which are conveyed to 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 scale COMBINATION BULK BAG AND DRUM FILLER HANDLES SURFACTANT AT BASF 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. The automated system minimizes operator involvement, increases productivity and improves safety, while reducing the potential for product contamination during packaging. Flexicon Corporation 1-888-353-9426 sales@flexicon.com www.flexicon.com CASE HISTORY ADVERTISEMENT PLC communicates with weigh-filler scale to regulate product flow into each drum and shut down on reaching a pre- set weight. Four drums await filling as four are about to exit the room. System improves product output, worker safety, and quality control. Pallet of four drums is conveyed into purpose- built loading room where they are filled by rotating drum/bulk bag filler. Automated drum filler utilizes an index- ing diverter head to fill four 55 gal (208 liter) drums sequentially with surfactant powder gravity feeding from rotary valve at top. System can also be configured for loading 2000 lb (907 kg) bulk bags.