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Big Bag Discharge Systems

As the bulk material handling industry expands and advances, the demand for efficient bulk material handling solutions has increased significantly over the past few decades. Among the various methods used to transfer and deliver dry bulk solids, Flexible Intermediate Bulk Containers (FIBCs), commonly known as big bags, remain one of the most popular and versatile options for handling granular and powdered materials. Big bag discharge stations are commonly referred to by a variety of names, such as big bag unloaders, bulk bag emptying systems, FIBC dischargers, FIBC unloaders, FIBC emptiers, super sack dischargers, container bag unloaders, container bag dischargers, super sack unloaders, and super sack emptiers.

These big bags offer various advantages, including ease of transport, storage efficiency, and cost-effectiveness. However, to maximize these benefits and ensure safe, efficient operations, well-designed big bag handling systems are essential. Polimak designs big bag handling solutions tailored to the specific needs of various industries. Proper system design helps prevent material loss, reduces dust emissions, and enhances overall productivity in bulk material management.
By using big bag discharging stations, different types of bulk materials can be handled, ranging from free-flowing granules like sand, grains, and fertilizers—commonly handled in the construction, agriculture, and chemical industries—to poorly flowing and sticky fine powders such as cement, flour, and clay—which are typical in building materials manufacturing, food processing, and ceramics. This versatility allows big bag discharging stations to serve a wide range of applications, meeting the challenges of each material type’s unique handling requirements.

Key Design Considerations for Bulk Bag Discharge Systems

The final design of big bag discharge systems depends on several important factors that address a wide range of application requirements, including:

• Type of Bulk Material: The physical properties of the material, such as flowability, moisture content, and abrasiveness, determine the necessary handling parameters.

• Big Bag Size: Variations in bag dimensions and weight capacity require customizable handling and support configurations.

• Discharged Medium: Whether the material is powder, granules, or a mixture affects the discharge mechanism and dust control measures.

• Downstream Equipment: The design must be compatible with conveyors, feeders, mixers, or other equipment receiving the discharged material.

• Discharge Speed: Operational throughput demands play a key role in selecting discharge methods and control systems.

• Environmental Aspects: Dust containment, emissions control, and compliance with environmental regulations are critical design considerations.

• Ergonomics: Ease of use, operator accessibility, and manual handling requirements ensure safe and efficient operation.

• Safety: Safety measures to protect workers from hazards such as dust exposure, mechanical injuries, and material spills should be integrated into the system design.

Careful evaluation of each of these factors allows big bag discharge systems to be tailored for efficient, safe, and reliable bulk material handling solutions.
Polimak's modular design of big bag discharging systems allows for easy configuration tailored to the specific needs of each application. In our standard models, the systems are designed with a frame and discharge hoppers, providing a reliable solution for general-purpose bulk material handling and discharge operations.

However, higher-level models provide a comprehensive solution within a single main frame. These systems integrate big bag discharging, product storage, dust collection, dosing, and conveying, all combined into one compact and efficient unit, tailored to the specific needs of the application.

Big bag discharge stations are also known by various other names, including big bag unloaders, bulk bag emptying systems, FIBC dischargers, FIBC unloaders, FIBC emptiers, super sack dischargers, container bag unloaders, container bag dischargers, super sack unloaders, and super sack emptiers.

Advantages and Key Benefits of Big Bag Discharge Systems:

• Enhanced Workplace Safety: Designed to minimize risks and protect operators from potential hazards during big bag handling.

• Effective Dust Control: Equipped with filter systems that ensure a dust-free air environment, improving air quality and reducing contamination.

• User-Friendly Big Bag Handling: Simplifies the process of loading and unloading big bags, reducing manual labor.

• Versatile Compatibility: Suitable for integration with a variety of conveying and storage systems, making it adaptable to different setups.

• Wide Range of Model Options: Available in multiple configurations to meet the unique requirements of diverse applications and materials.

• Easy Cleaning Procedures: Designed for straightforward cleaning, reducing downtime.

• Low Maintenance Requirements: Engineered with durable components that minimize the need for frequent maintenance and repairs.

• Robust Steel Construction: Built with rigid steel frames to ensure long-lasting durability and structural stability under heavy use.

• Advanced Filtration Systems: Incorporates filter mechanisms to effectively capture dust particles and prevent emissions during discharge.

Big Bag Discharging Applications

Silo Loading With Pneumatic Conveying System  

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Mechanical Conveying Systems For Silo Loading  

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Big Bag Discharging and Bag Filling Systems  

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Big Bag Discharge
  and Mixer Filling  

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Big Bag Discharging and Packaging System Feeding

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Big Bag Discharge, Dosing, Weighing, Batching Systems   

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Big Bag Discharge and Bulk Truck Loading Systems   

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Bulk Materials Handled by Big Bag Discharge Systems

Starch
   
Minerals
  
Coffee Powder
Spices
  
Limestone
  
Copper Oxide
Cement
  
Salt
  
Sugar
  
Sand
  
Calcium Carbonate
Alumina
  
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Our Engineering, Your Success… DISCOVER OUR PRODUCTS OUR PRODUCTS Explore our wide range of versatile bulk material handling machinery. Explore our wide range of versatile bulk material handling machinery. View all Rotary Valve A rotary valve, also known as an airlock feeder or airlock valve, is a piece of bulk material handling equipment used to […]

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OVER 40 YEARS OF SERVICE About Us Polimak is a leading engineering and fabrication company, specializing in bulk solids handling technologies for over four decades. Our wide range of versatile bulk material handling machinery is appropriate for value-added logistics as well as handling powders, granules and pellets in the food, chemical, plastics, minerals, and agriculture […]

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SHAPE THE FUTURE Career We are an internationally and rapidly growing dry bulk solids handling equipment and systems supplier which reckons that one of the key elements to success is acquiring a passionate, talented and diverse workforce. At Polimak, we work hard to establish an environment for our employees that delivers thought-provoking objectives, thus fostering […]

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These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
Installed below silos or hoppers, these valves are used for maintenance operations of equipment such as rotary valves, screw feeders, etc., that are positioned below the butterfly valve.
These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
In this design, the butterfly valve is sandwiched between two flanges. Rubber sealing at both faces of the valve provides a tight seal between the flanges and the wafer butterfly valve.
One side of the valve has a bolted flange connection, while the other side features a built-in short pipe designed for fixing a flexible sleeve.
These valves have bolted flange connections on both sides, making them suitable for installation on silos, hoppers, screw feeders, and similar applications.
Bulk tanker trucks or open trucks can be filled with powdered materials delivered within FIBC bags. These systems generally consist of bulk bag discharging station, mechanical or pneumatic conveyor and loading bellow. Big bag discharge station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.
Big bag discharge systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. The loading hopper of the weighing system should remain full during dosing and batching. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be employed to prevent dust emissions during hopper loading, especially for materials with high dust content.
Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks, etc. Bulk materials delivered in big bags must be transferred to packaging machines without interruption. The loading hopper of the packaging system should remain full during the filling and packaging process. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emissions during hopper loading, especially for materials with high dust content.
Mixer automation systems are used to mix dry bulk solids according to specific recipes. Raw materials delivered in FIBC bags can be transferred to mixing units through a combination of conveying equipment and bulk bag discharge systems. Depending on the type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag discharge stations can be manufactured with built-in dosing systems. The amount of raw material to be loaded into the mixer is automatically controlled with the help of a weighing and dosing system. Dust collectors can be used to prevent dust emissions during the mixer filling process.
Bulk material stored in big bags can be automatically filled into small bags. Big bag discharge systems come with optional built-in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper, providing a practical and cost-effective solution. Both big bag discharging and bag filling operations can be handled by a single, compact system. For higher bag filling needs, bag filling machines are installed near the bulk bag discharge stations. Pneumatic conveying systems or mechanical conveyors can be used to transfer bulk material from the FIBC bag discharge station to the bag or sack filling system.
Mechanical conveyors can be used for silo loading from big bag discharge stations. Screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to big bag discharge stations to fill silos. The selection of conveying equipment directly depends on the conveying distance, height, transferred material, and capacity. Bucket elevators are preferred for high silos, while screw feeders are preferred for shorter silos and short distances. The big bag discharge system can be installed on top of the silo for faster filling. In this case, rotary valves or butterfly valves are better choices as they provide simple flow control. Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some dust along with it. Vacuum fans and jet filters in dust collectors prevent dust emissions into the environment. The collected dust is sent back to the silo, thus preventing product loss.
Pneumatic conveying systems installed after bulk bag discharge units transfer bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, bulk bag discharge stations can be installed close to the warehouses, and pneumatic conveying systems are used to fill silos from long distances. This design reduces the need for forklifts and cranes for bulk material transfer on the production site and increases overall efficiency.

Pneumatic conveying systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Pneumatic conveying systems installed after bag dump units transfer bulk material through pipelines to fill silos. This configuration is ideal for applications requiring high transfer rates and long conveying distances. In production lines where raw materials are stored in warehouses far from storage silos, bag dump stations can be installed close to warehouses, allowing pneumatic conveying systems to transport materials over long distances. This design reduces the excessive use of forklifts and cranes for bulk material transfer within the production site, improving overall efficiency.

Pneumatic transfer systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on factors such as the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Mechanical conveyors can be used for silo loading from bag dump stations. In this configuration, screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to bag dump stations to fill silos. The selection of conveying equipment depends on factors such as conveying distance, height, material properties, and capacity. Bucket elevators are preferred for high silos, while screw feeders are ideal for shorter silos and short distances. Bag dump systems can be installed on top of the silo for faster filling. In such cases, rotary valves or butterfly valves are better choices as they provide simple flow control.

Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air inside the silo escapes to the atmosphere, carrying dust particles with it. Dust collectors equipped with a vacuum fan and jet filter capture airborne dust. The collected dust is returned to the silo, preventing product loss and ensuring a cleaner environment.
The inlet skirt is an optional feature designed to extend the lifespan of the flexible connector sleeve. Its upper portion is attached to the outlet port of the upstream equipment and extends down into the bin activator’s inlet port. The primary function of the inlet skirt is to serve as a protective shield, safeguarding the flexible connector seal from wear and damage.
A vibratory motor is externally mounted to the bin activator. When powered, the motor generates vibrations that facilitate a steady flow of dry bulk materials within the system. Depending on the application requirements, one or two vibratory motors can be installed externally.
To accommodate a bin activator, the cone of a silo must be shorter than usual, resulting in a wider outlet. A flange supplied with the bin activator is separately welded to the silo’s outlet, slightly above the opening, at the production site. Once installed, the vibrating bin discharger is securely bolted to the flange, ensuring a stable and reliable connection.
Special spring suspension links and an engineered polymer seal work together to create a flexible connection between a vibrating bin discharger and the equipment positioned above it.

The proper design and installation of the polyurethane seal prevent it from slipping off and ensure a secure seal, eliminating the risk of dry bulk material leakage. Additionally, the seal offers high stress resistance and long-term durability, withstanding stresses caused by motor vibrations, pressure conditions, and other operational factors.

Externally installed spring suspensions provide full resilience to the vibrations of the cone head. They ensure that the generated vibrations affect only the cone itself rather than the upstream equipment structure.
An internally tapered, conical-shaped baffle plate is positioned at the center of the bin activator’s diameter. The baffle is rigidly attached to the equipment body using structural steel components. It facilitates bulk material flow from upstream equipment by directly inducing vibrations into the material.

A secondary deflector plate reduces the weight of the bulk material in the lower portion of the bin activator by acting as a wedge beneath the material, directing it around the areas adjacent to the cone’s surface.

Polimak baffle plates are available in various configurations, including convex and cone plates, and in different angles (15°, 30°, 45°, or even 60°) depending on the flow characteristics of the handled bulk material and the specific application requirements.