Liner Bag Filling And Unloading Systems

Polimak delivers complete, integrated solutions that assist bulk material producers at every stage of their logistics and warehouse operations. Our Liner Bag Filling And Unloading Systems are designed to optimize the three critical phases of bulk handling: loading, main carriage, and unloading.

• Loading: We provide specialized systems for dust-free, high-efficiency loading of bulk materials to bulk trucks, railcars, ships, or silos. Our loading solutions focus on safety, speed, and material preservation, helping producers maximize throughput and minimize environmental impact.

• Main Carriage: Polimak supports the secure and efficient movement of bulk goods across distances, offering solutions that integrate seamlessly with transportation infrastructure. Whether materials are moved by road, rail, or sea, our systems ensure stability, efficiency, and minimal product degradation during transit.

• Unloading: Our unloading solutions support rapid, dust-controlled discharge of bulk materials into silos, bulk trucks, or processing lines. Whether handling fine powders or abrasive granules, our systems are engineered to keep material integrity while ensuring safe, seamless transitions within your operation.

By covering each phase of bulk material handling with specialized equipment, smart control systems, and process expertise, Polimak helps its clients improve operational efficiency, reduce costs, and keep high standards of safety and sustainability throughout their supply chains.

PICTURE

Different components may be used in each application to meet specific operational requirements. Some of the key parts often found in our Liner Bag Filling And Unloading Systems are screw feeders, pump and motor assemblies, rotary feeders, and loading hoppers. These components help control the flow of materials, making sure they move smoothly and efficiently. They also reduce waste and prevent product spillage during the loading and unloading of bulk materials. These parts coordinate to provide a secure and consistent process for different types of bulk materials.

PICTURE

During the unloading process, the output spout of the liner bag is securely connected to the loading hopper of the system. The material discharged from the liner bag falls into the hopper, from where it is conveyed to the selected storage medium—such as silos—via a pneumatic conveying line. The entire operation is fully automated and can be monitored and controlled through the installed control panel, which allows for efficient and safe handling of the material during the transfer process.

1. Loading

You can choose the most suitable loading method based on your operational requirements:

• Loading directly from the plant process line

• Transferring material from a silo into a container through direct loading methods

• Loading bulk materials from a stockpile into a container

• Discharging bulk bags directly into a bulk truck

Polimak’s innovative technologies offer a wide range of loading solutions engineered to meet even the most demanding bulk material handling needs. Our systems are designed to ensure safety, sustainability, and efficiency across various industries.

Whether the transfer of dry bulk material is achieved through vacuum technology, mechanical conveyors, or custom-engineered equipment, Polimak delivers versatile and robust solutions that enable smooth, reliable, and dust-free handling of bulk solids. Our flexible solutions can be integrated seamlessly into new or existing facilities, enhancing productivity and minimizing downtime.

2. Main-Carriage

Once loaded, the product is transported using the most suitable logistics method—such as deep-sea container shipping, coastal (short-sea) transport, rail freight, or road haulage using standard container chassis. The choice of transport method is based on factors such as destination, cost-efficiency, and delivery timelines.

Polimak’s solutions enable you to transport bulk solid materials in standard ISO containers, offering a flexible, scalable, and globally compatible option for bulk logistics. This approach minimizes handling, reduces contamination risk, and ensures seamless integration with intermodal transport systems across road, sea, and rail.

3. Unloading

After arriving at the final destination, the product is safely unloaded using mechanical horizontal conveying systems, which ensure a smooth, controlled, and dust-free discharge process. Depending on the specific requirements of the customer and the conditions of the production site, unloading operations can be carried out in the following ways:

• Discharging the material directly from the container into a storage silo for later use or distribution.

• Discharging the bulk solid from the container directly into the next stage of the production process, enabling seamless integration with automated manufacturing or processing lines.

• Transferring the material from the container into a bulk truck, allowing for onward transport to other facilities, customers, or distribution centers.

Polimak’s unloading systems are engineered for sustainability, efficiency, and minimal material loss, maintaining optimal control during each phase of the bulk solids transfer.

The Critical Importance of Containerized Transport for Bulk Solids

Containerized transport provides numerous advantages for handling bulk solids in today’s fast-moving and complex supply chain management.


• Standardized and Flexible Solution

Containers offer a unified and adaptable logistics solution, allowing for smooth product transfer between various transportation modes, including ships, trains, and trucks.

• Standardized ISO containers support seamless integration with global logistics systems.

• This flexibility simplifies planning, reduces transit time, and enables efficient, uninterrupted material flow across supply chains.


• Enhanced Product Protection

Containerized transport ensures a secure, enclosed environment that protects bulk solids from external contaminants like dust and moisture.

• Minimizes the risk of contamination and degradation.

• Reduces material loss due to spillage or exposure.

• Essential for transporting sensitive, high-value, or food-grade materials.


• Reduced Handling and Operational Efficiency

By limiting the number of handling stages, container transport improves efficiency throughout the logistics process.

• Enables faster loading and unloading processes.

• Reduces labor and equipment costs.

• Decreases risk of product damage and increases overall productivity.

• Optimizes turnaround processes while driving down supply chain costs.

For industries aiming to transport bulk solids safely, efficiently, and cost-effectively, containers provide a smart and practical choice. Polimak offers advanced containerized transport solutions designed to optimize logistics, protect material integrity, and maximize operational efficiency at every stage of the supply chain.

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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.