Bulk Material Handling Systems

Bulk material handling systems are essential in any process involving the transfer, storage, or processing of bulk solids. Polimak designs and manufactures these systems to meet the unique requirements of each industrial application, ensuring the delivery of advanced solutions for even the most demanding challenges.

Engineered for efficiency and reliability, our bulk material handling systems play a fundamental role in storing, transporting, feeding, and supplying bulk solids to processing units. Polimak’s solutions are designed to handle bulk materials in powder and granular form—optimizing workflow, enhancing productivity, and ensuring consistent material flow throughout the production cycle.

Polimak delivers expert solutions across various industries, built on the expertise of a highly skilled team with decades of experience in the design, production, and installation of bulk material handling systems. From initial design to commissioning and full-scale operation, every phase of a bulk material handling project plays a critical role in meeting performance targets, maximizing efficiency, and upholding safety requirements.

Polimak’s team of experienced and solution-oriented engineers specializes in developing industrial solutions that prioritize both safety and reliability. Developing a high-performing bulk material handling system involves evaluating a broad spectrum of variables that affect operational efficiency. These include the physical and chemical properties of bulk materials—such as bulk density, particle size, angle of repose, flowability, moisture content, corrosivity, and minimum ignition temperature—as well as conveying capacities, storage requirements, process constraints, and compatibility with existing or connected equipment.

In addition to technical specifications, process safety and occupational health are central to every engineering decision we make. Our commitment to these principles ensures that each solution we deliver meets not only functional expectations but also the highest safety and compliance standards.

Polimak brings over 40 years of experience in the bulk solids handling industry, establishing itself as a trusted solution provider. Our strength lies in continuous research and development, application-specific design, advanced engineering, quality manufacturing, flexible production capabilities, and comprehensive after-sales support. This enables us to develop tailored solutions, ranging from individual equipment supply to complete turnkey system installations, while maintaining fast response times and problem-free application. Our operational structure is flexible, allowing us to meet the unique needs of our clients quickly and efficiently, regardless of project size or complexity.

Bulk Material Conveying Systems

Dry bulk materials in powdered or granular form are generally received via trucks, ships, or trains and are processed using bulk material handling systems designed specifically for the efficient movement and control of such materials. Bulk solids conveying systems are key components in transporting dry materials efficiently and sustainably throughout the processing line.

Bulk solids handling systems rely on various conveying technologies, including screw conveyors, pneumatic conveyors, belt conveyors, and other related equipment. These equipment ensure the safe, consistent, and efficient transfer of materials from one point to another within industrial processes.

Polimak’s bulk solids conveying systems are engineered to provide environmental-friendly, fast, and reliable material transfer across a wide range of industries and applications. These systems are used in a variety of operations, including:

• Transferring bulk solids from sacks or bags into storage silos,

• Conveying materials from bulk bag unloading stations to intermediate storage containers,

• Feeding production lines from silos, hoppers, or bins,

• Discharging materials from silos into packaging lines or processing machinery,

• Transporting dry bulk materials across different stages of production with minimal loss and dust generation.

Each system is designed to meet specific operational requirements, taking into account material characteristics, flow rates, layout constraints, and integration with existing equipment. Polimak provides efficient and accurate conveying systems for materials such as food ingredients, chemicals, minerals, and cement, improving both productivity and safety.

Bulk Material Loading Systems

Polimak bulk material loading systems are designed to load dry bulk solids into various containment units such as bulk trucks, ships, storage silos, and other related vessels or storage facilities. At production sites, dry bulk materials are commonly loaded using bulk material loading systems, which facilitate the safe, dust-free, and efficient transfer of materials for transportation to their point of use.

Polimak designs and manufactures a wide range of bulk loading systems to meet different industry needs and material types. Our product portfolio includes mobile bulk truck loading systems, ship loading systems, stockpile loading systems, big bag (FIBC) loading systems, tanker loading systems, hopper loading systems, and more.

These loading systems are engineered for flexibility, high capacity, and minimal material loss. They can be integrated with dust collection units, flow control mechanisms, and automation features to ensure clean operation, compliance with environmental regulations, and enhanced operator safety. From handling fine powders to coarse granules, Polimak’s bulk loading systems are tailored to meet specific operational requirements across industries such as cement, food, chemicals, mining, and agriculture.

Bulk Material Storage Systems

Safe and efficient storage of powdered and granular dry bulk materials is critical across a variety of industrial operations, including food processing, chemicals, pharmaceuticals, cement manufacturing, mining, and agriculture. Bulk material handling systems must include secure storage facilities to hold materials until they are needed for processing or distribution.

Polimak’s wide range of bulk material storage solutions include silos, hoppers, and bins, and offer the flexibility to store both large and small volumes of dry bulk solids. Designed with space efficiency in mind, our storage systems minimize ground footprint while preventing contamination and ensuring the integrity of stored materials.

Polimak’s storage systems are engineered to promote optimal material flow, reducing risks of blockages, bridging, or other types material degradation, and enabling smooth, consistent feeding into downstream processing units. Equipped with advanced equipment, such as aeration systems, level monitoring, and controlled discharge mechanisms, our storage solutions enhance operational reliability and safety.

Polimak’s storage systems can be customized to handle food ingredients, chemicals, minerals, and other dry solids, tailored to specific material characteristics, environmental requirements, and production demands. This customization helps maximize efficiency and protect product quality throughout the supply chain.

Bulk Material Discharge Systems

Bulk material discharge systems are essential for managing the controlled release of dry solids from storage units such as silos, hoppers, tanks, and containers. These systems ensure consistent and reliable material flow, preventing common challenges like clogging, bridging, rat-holing, and material degradation, which can compromise product quality and disrupt process continuity. The behavior of dry bulk solids during discharge can vary significantly depending on material characteristics such as particle size, moisture content, cohesiveness, and flowability. As a result, discharge systems must be carefully selected and customized to suit the specific properties of the material being handled.

Effective, reliable, and sustainable discharge systems are not just operational necessities, they are also vital to the overall performance of bulk handling systems. The design and efficiency of these systems have a direct impact on downstream equipment, influencing everything from flow regulation and metering to the timing and safety of the entire process. Properly engineered discharge systems help minimize downtime, reduce manual intervention, and ensure seamless material transfer across all stages of production. Discharge systems with the right configuration support operational efficiency, environmental safety, and long-term cost savings across industries such as food processing, cement, chemicals, pharmaceuticals, mining, and agriculture.

Polimak offers a comprehensive range of bulk material discharge solutions tailored to meet the specific needs of various industries handling dry bulk solids. Our extensive portfolio includes a wide range of systems such as silo discharge systems, mixer discharge systems, tank discharge systems, big bag (FIBC) discharge systems, octabin discharge systems, bag dump stations, bulk truck unloading systems, tanker unloading systems, liner bag container unloading systems, and storage hopper discharge systems.

By combining advanced engineering with customization capabilities, Polimak’s discharge systems help optimize process continuity, reduce downtime, and enhance overall operational performance across industries such as food processing, chemicals, mining, cement, and agriculture.

Bulk Material Dosing Systems

It is essential in many industrial applications to develop accurate formulations that take into account the specific physical and chemical properties of bulk solids. These formulations are critical in order to dose multiple components accurately and produce a consistent, high-quality end product. Bulk material dosing systems designed and manufactured by Polimak play a vital role in these processes, enabling precise and repeatable measurement and delivery of materials into the production line.

Dosing accuracy is a critical factor for maintaining product consistency, meeting quality standards, and ensuring process efficiency. This is especially important in the case of dealing with sensitive formulations or high-throughput operations. Bulk material handling systems generally integrate gravimetric (weight-based) or volumetric (volume-based) dosing technologies to ensure accurate bulk material delivery. These systems can be combined with pneumatic conveying systems to transport materials directly into mixers, reactors, or packaging lines.

Our innovative and efficient dosing systems meet the diverse needs of industries such as food processing, chemicals, plastics, construction, and pharmaceuticals, offering reliable and precise solutions for handling a wide range of bulk materials. Our solutions can be configured for batch or continuous operation and they are tailored to handle materials with varying flow properties, particle sizes, and densities. Whether managing micro-ingredient dosing or large-volume feed rates, Polimak ensures reliable performance, precise control, and seamless integration into existing process automation systems.

Turnkey Bulk Material Handling Systems

Polimak provides turnkey bulk solid handling systems that manage every stage of the process, from raw material intake to final product output. These integrated solutions combine all essential equipment to create a seamless, efficient workflow that enhances productivity and ensures consistent performance throughout the production line.

Our comprehensive solutions integrate equipment for bulk solids loading, filling, discharging, conveying, mixing, dosing, feeding, and weighing. These components work together to create a fully automated and efficient production line.

Polimak draws on its expertise in design, manufacturing, installation, and commissioning to deliver end-to-end services tailored to the unique requirements of a wide range of industries. Our integrated approach ensures seamless system compatibility, optimized performance, and reduced project timelines—all from a single, trusted supplier.

Whether you require a new production line or upgrades to existing systems, our turnkey solutions provide reliability, scalability, and precision to meet your operational goals.

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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.