Polimak Big Bag Discharge Systems can be equipped with a wide range of accessories to suit various operational needs. Configurations may include side pistons, massaging system, weighing system, cutting knives, lump breaker, automation system, and more. These accessories enhance the functionality and adaptability of the big bag discharge systems.

This accessory is designed to securely hold bulk bags in place while absorbing movement and reducing stress on the system during material discharge.

Operation of this unit is as follows: Big bag hanging units are mounted on upper frames to support big bags delivered by overhead cranes or forklifts. A lifting cross is positioned over the big bag, and the bag’s handles or straps are attached to the hooks on the cross. The entire assembly is then lifted and placed onto the top frame hanging unit. A spring and damper mechanism applies upward force to the lifting cross. As the raw material begins to discharge, this mechanism gradually lifts the big bag, assisting in the complete and consistent flow of the material. The strength of the springs and dampers can be adjusted based on the weight or bulk density of the raw material.

Additional equipment can be installed to enhance material flow during discharge. Side pistons gently massage the big bag, while a vibration motor can be added to further increase unloading speed.

Side pistons are optional pneumatic devices mounted on the side frames of the big bag discharger, designed to assist with the unloading of bulk materials. These massage cylinders apply controlled side pressure to the big bag, helping to break up compacted material and restore flow, especially in cases where stored materials have settled or hardened during storage. Unlike vibration systems, which can sometimes worsen compaction, the massaging action of side pistons provides a more targeted and gentle method for promoting consistent discharge.

There are several adjustable parameters, including piston stroke length, movement speed, and operating intervals. All of these can be precisely controlled via the discharger’s built-in control panel, allowing the system to be optimized for various material characteristics and flow requirements.

The pneumatic big bag massaging system is equipped with a specially designed platform consisting of two independently moving surfaces, each connected to pneumatic pistons. These surfaces periodically press against the lower sides of the big bag, applying a controlled force that gently kneads and loosens the compacted material inside. This massaging action directs the bulk material towards the outlet spout, improving material flow and reducing the risk of blockages.

The system is ideal for bulk solids that tend to bridge, clump, or settle during storage, such as powdered chemicals, food ingredients, or plastic pellets, ensuring a more consistent and efficient discharge process.

A built-in storage silo is an integrated container installed under the big bag discharge platform to collect and store discharged material. The unloaded material is transferred straight into the silo for temporary storage and later use. With this configuration, there is no need for separate storage silos or additional conveying equipment connected to the big bag discharge system. In this unit big bags can be fully emptied and removed efficiently in a single operation.We provide a range of silo capacities to suit varying raw material consumption requirements.

Level sensors are installed in the silo to monitor the product level during the entire operation. These sensors provide real-time data to ensure accurate tracking of material quantity. If the product level falls below a certain threshold, an alarm signal is generated to alert operators.

Flow aids, such as air jets or vibrating bin activators, are available as optional features for the silos. These equipment help to improve material flow and prevent clogging or bridging inside the silo.

For products with high dust content, such as powdered chemicals or fine minerals, dust collection systems are connected to both the big bag discharge stations and storage silos. These units help maintain a clean working environment and reduce airborne dust during material handling.

Dust emissions typically occur during key stages of the unloading process, including the cutting or untying of bag spouts, the flow of product from the bag, and the removal of empty big bags. To effectively contain and control these emissions, a dust collection system at the big bag discharge station is essential. This system helps ensure a cleaner working environment, protects operator health, and prevents contamination of nearby equipment and materials.

An integrated dust collection system consists of a vacuum air source, a jet filter with a built-in fan, and a reverse pulse jet cleaning mechanism. Vacuum air supplied by the dust collector captures any dust in the area. The collected dust is automatically returned to the big bag discharging unit, preventing product loss. The vacuum air is cleaned using the reverse pulse jet system before being safely discharged outside.

A big bag weighing system can be integrated into the discharge station to ensure precise monitoring and control of raw material usage. This system is especially useful for processes that require accurate dosing, inventory management, or automated control. The big bag discharge station is equipped with high-precision load cells mounted on the main frame, enabling continuous measurement of the big bag’s weight. Real-time weight data is displayed to the user, providing instant feedback on the remaining material. Additionally, the system can transmit signals to external PLC automation systems or coordinate with other equipment connected to the big bag discharger, supporting seamless integration into larger production processes.

An iris valve can be installed on the big bag discharge system to provide precise control over material flow during unloading. The big bag’s discharge spout passes through the valve. The valve can be operated manually via a handle. Alternatively, it can be operated automatically using a pneumatic piston.

The iris valve allows for full closure, full opening, or partial adjustment, giving operators flexible control over the unloading speed. This makes it especially suitable for applications requiring careful dosing or controlled discharge of sensitive or fine materials.

Optional cutting blades can be installed in the center of the big bag platform’s rubber seal to enhance the unloading process. When a big bag is placed on the platform, these blades quickly and efficiently cut the bag, creating an opening that allows the product to flow out faster. This addition helps improve operational efficiency by reducing unloading time and minimizing the need for manual intervention.

Bulk bag cutting equipment is preferred in applications requiring high transfer rates to ensure fast and efficient material flow. It is generally used for products like food powders, chemical powders, and plastic pellets where rapid discharge is needed.

To streamline and optimize bulk material handling, big bag automation systems offer comprehensive control over the entire discharge process. The system integrates various components such as the vibration motor, iris valve, massaging system, hoist, dust collector, big bag weighing system, and conveying system.

There are mainly two types of automation systems used depending on the complexity and configuration of the big bag discharge station. For simpler units, a small manual-controlled electrical panel may meet the requirements. However, for stations equipped with multiple accessories, PLC-controlled automation panels are preferred. These PLC units can also manage other material handling systems connected to the bulk bag discharge station, such as screw feeders, pneumatic conveying systems, rotary valves, etc.

Optional reporting functions can generate daily, monthly, and annual reports. PLC-controlled systems also integrate with other SCADA, PC, and PLC systems within the production plant, enabling improved handling and monitoring of the entire production process.

A built-in sack discharger is an optional equipment integrated into the big bag discharge hopper to efficiently handle bulk materials delivered in small bags or sacks. It is especially needed when small quantities of additives or ingredients need to be fed into the system alongside bulk materials. This unit provides a convenient and safe way to introduce these smaller bags directly into the discharge area without interrupting the main process.

The sack discharger is typically installed as a tipping unit on the side or top of the big bag discharge hopper. When an operator needs to add material from small bags, the sack is installed into the tipping unit’s opening. The operator then tips or empties the contents through the inlet, allowing the material to fall directly into the same discharge zone as the bulk material. This unit streamlines the feeding process, reduces handling time, and minimizes dust or spillage during transfer.

Bulk solids stored in FIBC bags for extended periods often become compacted due to their own weight and exposure to moisture in the environment. This compaction can lead to the formation of large, hard lumps that make smooth material flow difficult. Common products prone to compaction and lump formation include powders such as cement, flour, powdered chemicals, and granular materials like fertilizers and plastic resins.

These lumps must be broken down before the material enters downstream equipment to ensure efficient processing. Lump breakers are therefore installed beneath big bag discharging systems to crush and break up oversized particles, preventing blockages and damage to conveyors, feeders, or mixers further along the production line. This helps maintain consistent flow, reduces downtime, and improves overall operational efficiency.

A screening system is often incorporated into the big bag discharge process to maintain product quality and protect downstream equipment. A screen is used to prevent oversized particles from entering the production line, ensuring that only appropriately sized material passes through. These screening systems are generally installed at the discharge point of the big bag discharger unit, where they effectively separate unwanted large particles before the material continues through the process.

Depending on the bulk material properties and acceptable particle sizes, different types of screens can be installed. Vibrating screens are among the most commonly used screen types in bulk material handling.

Ensuring product purity and protecting sensitive equipment from damage are critical concerns in many bulk material handling industries. Foreign materials in bulk solids, especially metallic contaminants, can cause serious issues in production processes, leading to equipment failure, product recalls, or safety hazards.

Magnetic separators are used to detect and remove metallic particles from bulk solids, safeguarding both the product and the machinery. These metal detectors and separators can be installed at the outlet port of big bag discharger systems to effectively prevent contamination. They are used in industries such as food processing, pharmaceuticals, chemicals, and plastics, where even small metal fragments can compromise product quality and safety.

Polimak designs and manufactures food-grade big bag dischargers tailored to meet the strict hygiene and safety requirements of the food industry. All surfaces that come into contact with food materials are made from food-grade materials such as stainless steel and silicone to ensure durability and prevent contamination. The equipment is carefully designed and manufactured to eliminate any risk of bacterial growth, with smooth surfaces and hygienic construction methods. Additionally, filter bags, valves, and other components are selected from certified food-grade suppliers to guarantee compliance with industry standards. This precise engineering ensures that Polimak’s food-grade big bag dischargers provide safe, reliable, and efficient handling of food products.

Working with explosive and flammable raw materials in hazardous environments demands careful design and manufacturing of big bag discharge systems to ensure maximum safety. In dry bulk material handling processes, risks such as overheating, gas or dust leakage, static electricity, and electrical spark generation must be carefully controlled and prevented to ensure safe operation.

Polimak provides ATEX-certified and Ex-proof equipment specifically engineered to meet these strict safety requirements. These systems are widely used in industries such as chemical manufacturing, pharmaceuticals, mining, and grain processing, where materials like powdered metals, solvents, fertilizers, and grain dust present significant explosion hazards. Polimak’s solutions include robust safety features and compliant designs to help protect personnel, equipment, and facilities in demanding hazardous environments.

The design of big bag discharge stations can vary depending on the type of bulk material being handled. Additionally, the construction materials are selected based on the specific requirements of the application.

• Stainless Steel: Made from either AISI 304 or AISI 316, it is preferred for food materials, additives, PVC, polypropylene, polyethylene, PET, HDPE, LDPE, painting materials, and similar products.

• High-Carbon Steel and Manganese Alloys: Used for abrasive materials such as arc furnace dust, perlite, quartz, silica sand, and fly ash.

• Standard Steel: Applied in general-purpose applications like cement, calcium carbonate, and activated carbon handling.

Polimak designs big bag discharge systems with a focus on machine safety, ensuring full compliance with human and environmental safety regulations. All of our systems and equipment are designed and manufactured to meet the highest standards of safety, quality, and reliability. This ensures that every necessary precaution is taken to prevent workplace accidents during big bag handling operations. The equipment is equipped with various safety features such as mechanical and electrical locks, emergency stop buttons, and alarm systems that activate under dangerous conditions such as unexpected bag failure, overloading, or system malfunctions. These measures protect operators from potential hazards such as crushing, falling bags, or electrical faults, creating a safer working environment and minimizing the risk of injury or damage.