Nick Basham, Magnum’s regional sales manager, sat down with our host and Magnum’s technical sales manager, Mike Abare, to take a deep dive into the fascinating world of packaging powders, pellets and flakes. Basham highlights how the peculiarities of material characteristics are not just trivial details but crucial determinants of packaging efficiency and product integrity.
It’s vital to understand the flow properties of these materials. It's not as simple as pouring water - these materials can behave unpredictably. Similarly, moisture sensitivity can drastically alter the effectiveness of packaging. Too much moisture can lead to clumping and degradation, turning your perfect pellets into a sopping mess. And let's not forget static charge, the invisible force that can cause materials to stick to the packaging, reducing efficiency and leading to waste.
But don’t stress or worry about these complexities. Our experts share practical strategies to help you navigate these challenges. They offer valuable insights into the art of pneumatic conveying and packaging, paving the way for you to optimize your processes. Learn how to effectively package powder, pellets and flakes as Nick and Mike take aim at better-integrated systems you can introduce to your manufacturing lines.
“Earlier this year, we opened our state-of-the-art testing facility in Lenexa, Kansas. We have dense and dilute phase conveying capabilities there, along with all our packaging machines,” says Nick. “It's a straightforward process. You'll fill out a test request form and send it to our test lab manager, Dave Wollenberg, letting us know your special material characteristics. We will then need a certain number of bags depending on the machine and the product that is going through. Then send us your product and we will test it for free.”
In the Case of Handling Molasses
In the feed industry, Magnum often handles specialty feeds containing molasses. This ingredient behaves differently from others and can significantly influence the packaging process. For instance, on the same machine and within the same plant, we might be packaging powder and minerals, then switching to granular ground corn, and finally to specialty feed, a blend of various products bound together by molasses.
The specialty feed might contain 10-15% molasses, and handling this molasses-rich product requires specific equipment design. Without the right approach, the molasses content can be a significant obstacle to an efficient packaging operation. In a feed mill dealing with such products, asking the right questions upfront is crucial. Understanding the most about all the products our customers handle prevents us from getting caught in a tight spot during installation, especially when we discover the presence of molasses in the product.
Handling molasses requires a deviation from our standard design. If we know a product contains molasses, we'll use a belt for feeding instead of a vibratory tray. We'll design our equipment to handle such materials differently. It's essential to have a wider open mouth on our packer's throat and ensure the chosen package suits the product's density.
The Bagging Experts
“While we don't claim to be bag experts, we pride ourselves on our packaging expertise,” Nick explains. “Our focus is on being a comprehensive solution provider to our customers, understanding their products, packages and the myriad variables they might present to us.”
Again, the focus always circles back to understanding the product itself - specifically, its unique characteristics that dictate what type of bag is required for packaging. As Nick mentioned earlier, while we're not bag experts, we are decidedly bagging experts. There is an extensive array of bag types: pinch-bottom bags, gusseted open-mouth bags, pillow-style bags, valve bags, bulk bags and more.
One day, we might be packaging small quantities, say two to ten ounces of coffee beans, in a diminutive package. The following day, we could be filling a valve bag with cement or grout from an entirely different packer style. We aim to concentrate on the customer's material and their objectives.
If the product is food grade, certain types must be packaged in a sealed bag, while others routinely go into valve bags. A valve bag, like one used for cement, has a small spout on the front and is usually exposed to the atmosphere. Sometimes, we place a food-grade product in a valve bag and ultrasonically seal the valve spout.
“Our expertise lies in understanding a broad spectrum of products and their characteristics, which equips us to guide our customers toward the optimal packaging for their operation,” Nick explains.
Common Concerns with Certain Powders
One of the significant concerns in packaging is the explosivity of certain powders. We understand vital parameters, such as the deflagration index (Kst) and maximum explosion pressure (Pmax), particularly concerning dust control. To handle this, all our equipment can integrate dust control, specifically in areas where the spout interacts with the bag.
For example, our APO fillers, which are open-mouth bag fillers utilizing an auger, are equipped with a hermetic seal on the bag. We achieve this by inserting an inflatable spout into the bag and inflating it to contain 100% of the dust when filled with a dusty product. Further, the filling process is designed to capture residual dust through a dust collection port at the top end of our filling spout. Understanding the product and its unique characteristics – in this case, its dustiness and potential explosivity – is always pivotal. Magnum is equipped to manufacture equipment that meets the safety standards of any plant.
The bulk density of certain products, particularly when they're aerated, can pose unique challenges in packaging processes. This is particularly true in settings like pneumatic conveying or a vertical drop, where products can become aerated. For example, products are transferred from a large bend and then dropped into a packaging bin. This action can aerate the product, causing filled bags to exhibit a water-like wiggle. In these instances, the powder itself takes on the material characteristics of water, transforming the otherwise static element into a dynamic, fluid-like substance.
“This is one of the many complexities of handling powders, so some companies shy away from them. But for us, we lean into these challenges,” Nick says. “One of the primary hazards in dealing with these powders is their high “fluid-ability,” which means we need to be able to extract the air from them while they're in the bag. To address this, we've developed a de-aeration probe that can be inserted into the bag to apply a vacuum to the product as it's being filled. This process helps to densify the product and ensures the proper amount can be fit into the selected bag size.”
It's clear that when handling powders, isolating your product from moisture becomes a key factor. A nitrogen blanket can be beneficial unless the product requires a specific moisture content. Alternatively, you may consider a warm air blanket depending on the product's unique requirements. It's essential to shield the product from moist air or any condensation induced by temperature changes. Such preventative measures not only safeguard the quality of the product but also ensure a consistent packaging rate for your production. This commitment and attention to detail are vital for achieving optimal packaging outcomes.
Dealing with certain materials, such as pigments, can be challenging due to their sticky nature and fluid-like behavior. As experts in this field, we must understand and acknowledge the limits of our capabilities. Knowing our strengths and weaknesses improves our services and provides the utmost value to our customers.
When a client approaches us with a product we know we cannot handle or package effectively, we must be honest about our limitations. We'd instead recommend another expert who can provide a more suitable solution than compromise on our service quality. Our prime focus is always on the product and the customer's needs, not just selling our system for the sake of it.
We will delve deeper into recognizing failure and addressing faults in the coming episodes. Understanding specific products and their handling capabilities is beneficial for us and equally, if not more, valuable for our customers. Keeping our focus on the product rather than just the equipment, we strive to deliver the best possible outcomes for every project we undertake.
Listen to Nick's podcast episode.
Magnum Systems podcast series, AIM!
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