Within our case studies section, you will find a range of case studies that feature our product range and illustrate the various methods we use to successfully handle and move a vast array of ingredients. You can search case studies either by product, by industry or by material.
A dairy company producing an anhydrous milk fat blend with sugar for ice cream, chocolate & other confectionery wanted to unload sugar from bulk bags and transfer it to two blenders. Spiroflow supplied a bulk bag unloader with two flexible screw conveyors leading from the outlet to each of two blenders.
Spiroflow supplied two (2) bag dump stations with bag compactors, two flexible screw conveyors to deliver constituents to weigh hoppers, two metering screws to discharge weighed materials at a metered rate into a sifter & a third flexible screw conveyor to transfer the sifted premix for final mixing/conditioning.
Solutech needed to load batches of sugar from bulk bags into a series of liquor tanks. Spiroflow mounted a bulk bag unloader on a wheeled frame complete with an integral flexible screw conveyor. The conveyor outlet is fitted with a fan to prevent the ingress of moisture.
The original bulk bag discharging arrangements for the 11 ingredients used to manufacture Skretting's fish food was a production bottle neck. One Spiroflow Bulk Bag Discharger specifically designed to operate in a low headroom area has solved the problem!
Carroll & Meynell make transformers for the construction industry. Each one is filled with sand which is then sealed in place. The handling of the sand was a production bottle neck solved by a Spiroflow bulk bag unloader, flexible screw conveyor & distribution system.
Waste Recycling Group needed a Bulk Bag Discharger to empty single bags and a method of transferring alkaline powder to a blending tank where acidic liquors are neutralized. A Spiroflow single trip Bulk Bag Discharger and Aero Mechanical Conveyor are successfully used for this application.
AMCOL Minerals required a Bulk Bag Discharger to meter out a difficult to handle, highly moisture sensitive chemical and protect it from the atmosphere. The challenge was satisfied by a Spiroflow Bulk Bag Discharger including load cells, pinch bars and bag massagers.
This customer needed to dump material from 20 lb bags as well as bulk bags without any escape of explosive dust into the atmosphere. All electronics on the discharge station had to be NEMA 7 compliant. We supplied a Bulk Bag Discharger with an integral bag dump station and dust collector.
A change in potato powder production & handling at Premier Foods called for bulk bag unloaders & conveying systems. We supplied two bulk bag unloaders & four flexible screw conveyors to deliver ingredients to the packing lines. A fifth conveyor returns perfectly good product, recovered from any ‘out of spec’ packaging, for repackaging.
Choosing key ingredients delivered in bulk bags, Gem Pack Foods had to discharge several products and deliver each to the appropriate feed points of their packing machine. Spiroflow’s solution was a bulk bag unloader with a flexible screw conveyor and a vacuum conveyor. Each conveying system is mobile making change-over quick and easy.
Innospec replicated their application at another plant making chemicals for personal care products. The main ingredient is delivered in bulk bags. Spiroflow supplied a bulk bag unloader with an integral flexible screw conveyor to supply the reactor. 55 lb/25 kg bags of catalyst are added through the unloader’s access doors.
Tetley improved Decaffeinated Tea handling through delivery in 1,100 lb bulk bags instead of 55 lb bags. Bags are delivered two high on each pallet. Although forklifts deliver pallets to the discharger, we supplied a Bulk Bag Discharger complete with a bag hoist, releasing the forklift for other duties while the two bags are emptied.
Increased demand caused Dekura to expand capacity at their factory, where they had a pneumatic conveying system in place. Their pneumatic conveying was expensive to run, fairly noisy & required a filtration system. For the expansion, Spiroflow supplied ten (10) flexible screw conveyors, two (2) bulk bag unloaders, two (2) rigid bin unloaders, three (3) bulk bag fillers and a fountain blender.
Mineral clay in 2,200 lb Bulk Bags is repackaged into 3 lb and 4.5 lb pouches. The challenge was to discharge fragile mineral clay granules and deliver them, undamaged, to the pouch filler. A Spiroflow Bulk Bag Discharger, discharges onto a vibrating tray, feeding a bucket elevator and does the job just fine!
United Utilities add powdered activated carbon (PAC) to water drawn from reservoirs to neutralize a naturally occurring organic compound which gives untreated water a harmless yet undesirable earthy taste & smell. As an approved supplier to United Utilities, Spiroflow supplied the PAC dosing systems required.
‘Adblue’, urea prills dissolved in hot, high purity water, is used in trucks to reduce air pollution from exhaust gases. A bulk bag unloader, with integral bag hoist, empties prills from bulk bags where they are then conveyed to the top of the mixing tank with a 56 ft (17m) long flexible screw conveyor.
A chemical, used in paint manufacturing was delivered in 220 lb (100 kg) bags causing back problems to operators. Switching to one ton bulk bags required a bulk bag unloader. Spiroflow supplied a special unloader ‘shoe-horned’ into limited space complete with roof mounted bag hoist - given the mezzanine floor could not support forklift trucks.
A leading chemical company required a Bulk Bag Discharger with a loss-in-weight metering feeder. The customer required the Discharger to have a maximum height of 9 feet when operational and be capable of collapsing down to within a height and a width of 6.5 feet to facilitate movement around the plant. We rose to the challenge!
A manufacturer of construction industry products required a reliable replacement for an existing materials delivery system. Additives arrive in bulk bags, up to 1.8 tons, or 50 lb bags. Our solution included two Bulk Bag Dischargers and two Aero Mechanical Conveyors. One of the Dischargers has an integral Bag Dump Station.
A manufacturer of cement products needed to discharge 5 components from 3,000 bulk bags for delivery to either of two mixers. Spiroflow supplied five (5) loss-in-weight bulk bag unloaders with metering feeders to transfer constituents into a horizontal aero mechanical conveyor. This feeds a second vertical aero mechanical conveyor which lifts materials to the ‘wet’ or ‘dry’ mixer.
Jowat Adhesives required a totally enclosed, dust-tight Bulk Bag Discharger/Bag Dump Station. We custom designed our discharger to their exact specifications. The unit accepts two sizes of bulk bags and incorporates a bag dump station too. According to the company, it has been operating 24/7 and performing flawlessly.
Jacob’s Bakeries have used a bulk bag unloader & flexible screw conveyor to load oat flour into a mixer, via a storage silo, for 14 years - trouble-free! To produce other products in the same mixer, they are required to load alternative flours directly into the mixer. An additional flexible screw conveyor has been installed to achieve this.
Just Trays’ new casting machine doubles output of shower trays. With their previous machine, any difficulty in discharging materials was solved by bumping bags up & down on the hoist that supported them during discharge. Spiroflow supplied two (2) low headroom bulk bag unloaders. One, for calcium carbonate beads, was furnished with bag massagers to promote flow from compacted bags.
As the bags are unloaded from ships, our customer wanted to transfer the chemical contents of bulk bags directly into road transportable ISO Tanks. We built a bulk bag unloader, with a high capacity rigid screw conveyor, into a mobile frame. A partial enclosure offers some protection from rain & sea-spray.
Faced with growing demand, Everbuild, manufacturer of building sealants, adhesives & fillers, installed a new mixer alongside an existing machine. They then needed to load bulk materials & minor additives into both mixers. Spiroflow supplied a loss-in-weight bulk bag unloader to dispense accurate quantities. Minor additives, are loaded through an adjacent bag dump station.
At another factory, our customer used a Spiroflow bulk bag unloader & flexible screw conveyor to transfer bread crumbs from bulk bags in the warehouse, through a wall, to the high-hygiene production area. The system worked so well that they duplicated the same application at their expanded North West site.
Nynas’ original asphalt plant needed upgrading. The joints and bends of the pneumatic conveying system were wearing out. It also needed a sizeable filtration system which had environmental implications. Spiroflow Aero Mechanical Conveyors transferring materials from Bulk Bag Dischargers have proven to be an effective replacement and eliminated the environmental issues.
Thomas Dudley Ltd, a manufacturer of commercial bathroom fixtures, wanted to make production efficiency as well as health & safety improvements in their plant. They specifically wanted to eliminate hand weighing & manually loading resins. Spiroflow provided a low headroom bulk bag unloader & a flexible screw conveyor to feed resin to a continuous casting machine.
Ejector specialist Transvac Systems Ltd worked with Spiroflow to develop a containerized dosing system inside of a 20 ft (6m) ISO container. The entire solids additive handling system, the dosing ejector, associated controls, safety & alarm systems operate within the mobile space.
Unifi, developer and producer of REPREVE® recycled fiber, creates plastic flake from the millions of plastic water bottles used every day. Spiroflow helped them develop a line to fill & recirculate plastic flake into large mixing silos & also convey flake onto the next step in their manufacturing process. This system included a box dumper, two (2) bulk bag unloaders, five (5) flexible screw conveyors, four (4) aero mechanical conveyors, a hopper & a comprehensive custom control panel.
Although the materials listed are traditionally handled manually, in a modern pulp and paper plant they are normally handled in Bulk Bags (FIBCs). Due to the large quantities used, bulk bags are replacing 50 lb. bags. Spiroflow's material handling systems help pulp and paper companies reduce dust, reduce cost & increase operator safety.
Spiroflow offers a complete system for accurately discharging and metering dry water treatment chemicals. Many of the products used for pH control, such as hydrated lime, activated carbon and soda ash are now delivered in one ton bulk bags. Spiroflow is recognized worldwide as a leading manufacturer of bulk bag unloaders, as well as flexible screw conveyors, which have been used in the water treatment industry for many years for metering and conveying from silos.
Spiroflow has developed a bulk bag discharge system which provides a proven solution for handling titanium dioxide and other poor flowing, cohesive products, which tend to bridge in hoppers, cause smearing of conveyor tubes and generally create production nightmares for process engineers.
Aero mechanical and center-less screw conveyors are widely used for filling road tankers and can be mounted on mobile frames for ease of use. Spiroflow offers bulk bag (FIBC) or rigid bin discharge stations as an integral part of tanker and rail car loading systems. A high level probe in the discharge spout insures automatic conveyor shut-off once the tanker section is filled.
Spiroflow’s bulk bag unloader/flexible screw conveyor systems have been designed to handle sensitive products in controlled environments. They are particularly suitable for those products where the highest levels of sanitation and the lowest degrees of cross contamination must be maintained during handling such as: meat, poultry, dairy, food, pharmaceutical, fine chemical, pigments/dyes and catalysts.
Spiroflow has provided a mobile bulk bag unloader with an integral flexible screw conveyor to handle aluminum oxide for Metaref, a division of Walther Trowal. The company approached Spiroflow to review the material handling aspects of their ceramic chip manufacturing process. These chips are available in various shapes & sizes & are used in the deburring, fettling & polishing of metal & ceramic castings.
Spiroflow worked with Access Security Products Ltd. to resolve a powder handling problem with a proprietary cement mixture used in their manufacturing process. The material is a fine powder, which arrives by container quite compacted, has very poor flow characteristics bridges easily, is very abrasive & readily absorbs moisture. Spiroflow installed a bulk bag unloader fitted with dual flexible screw conveyors. The flex screws deliver the cement powder to two (2) aero mechanical conveyors that fill an outdoor silo about 40 ft (12m) outside of the building.
North Carolina based Colony Gums provides the finest quality gums & stabilizers to the food, pharmaceutical & chemical industries. They turned to Spiroflow to increase their conveying capabilities. They now have two side by side powder handling systems that deliver a conveying rate of 20,000 lb/hr (9 tph), with improved productivity, additional safety features, a cleaner environment & reduced product waste.
Spiroflow loss-in-weight bulk bag unloaders are ideal for the dosing of powders used in the manufacture of white goods. High levels of dust containment maintain a hygienic atmosphere while accurate dosing ensures a consistent mix of product is maintained for every batch.
Spiroflow’s patented spout closure bars are a multi-functional feature available on Spiroflow Bulk Bag Discharge systems. They allow processors to: • Open bulk bags in a totally enclosed and dust-free manner • Partially empty, re-tie and remove bulk bags • Release batches from a bulk bag by weight or by volume
The build-up of static electricity is a serious safety issue in many modern processes where powders are handled. How a material flows, its conductivity and the atmosphere where it is processed have an effect on static build-up potential. Spiroflow has developed powder handling equipment where static grounding materials and controls are an integral part of the design.
To reduce manual handling & associated costs, pharmaceutical manufacturers have increasingly adopted large containers such as rigid IBCs for the delivery of mixed materials to tableting lines. Spiroflow has developed dedicated equipment to enable material to be conveyed automatically from a rigid IBC to pharmaceutical tableting lines or other process machinery.
Spiroflow has provided Hexion with a safer more reliable solution for conveying hazardous, explosive hexamine in their Acme, NC plant. They replaced another supplier’s flexible screw conveyors with Spiroflow’s bulk bag discharger and Dynaflow® chain drag conveyor. The new system has yielded a much safer, cleaner and more productive process solution for Hexion.