Closed vehicle loading bellows are used for loading tanker trucks, barges, and ships. Equipped with sealed containers, they ensure a safe and dust-free filling process.
• Sealed Discharge Design:
Polyurethane-coated discharge cones are used to tightly seal the vessel inlet, effectively eliminating dust escape during the loading process.
• Air Evacuation System:
Once the loading process begins, a built-in vacuum fan removes the air from inside the container, improving the flow rate of the material being discharged.
• Dust Collection Mechanism:
The extracted air is directed through a dust collector, where filter units collect airborne dust. The cleaned air and particles are returned into the tanker using pulse jet valves controlled automatically.
• Level Monitoring:
A sensor positioned at the bottom of the loading bellow monitors the rising material level inside the tanker and sends a stop signal once the container is full.
• Flow Completion Delay:
After the filling is complete, the system briefly pauses to allow the remaining product to settle and any residual dust to be captured through the dust collector.
• Automatic Retraction:
After the loading process is finished, the bellow automatically retracts to its top standby position, preparing the system for the next operation.
• Weighing System Integration:
For applications requiring accurate loading amounts, truck weighing scales can be connected to the loading system.
• Automatic Flow Control via Weighing Signal:
Once the target weight is reached, the scale sends a signal to the control panel, which automatically stops the product flow.
Tanker Loading Bellows
Bulk tanker loading bellows provide a sealed and efficient solution for loading powdered and granular bulk solids into tanker trucks without generating dust. These systems ensure a smooth and controlled transfer of free-flowing dry materials, including powders and granules, from various sources such as silos, hoppers, containers, and screw feeders directly into tanker trucks. Designed to maintain product integrity and minimize environmental impact, tanker loading bellows are essential components in industries handling bulk solids that require clean and safe loading processes.
Open Vehicle and Stockpile Loading Bellows
• Application Areas:
Open vehicle and stockpile loading bellows are used for loading bulk materials into open spaces such as flatbed trucks, ships, and stockpiles.
• Flexible Dust Containment:
A flexible dust skirt located at the bottom of the loading bellow provides a sealed containment area to prevent dust from escaping during discharge.
• Dust Collection System:
Any fugitive dust generated during loading is captured by a vacuum dust collection system, preventing dust from spreading to the environment.
• Dust Recycling:
Captured dust is returned back to the product stream, minimizing material loss and waste during loading.
• Level Monitoring:
Built-in level sensors monitor the product level below the loading bellow to ensure smooth operation and safety.
• Automated Retraction:
As the product level rises, the loading bellow automatically retracts upwards, maintaining clearance for continuous and efficient discharge.
• Discharge Valve Closure:
Once the loading process is complete, the product discharge valve positioned above the bellow closes to stop material flow.
• Flow Completion Delay:
The system waits for a few seconds after closing the valve to allow residual product flow to finish and to collect remaining dust through the dust collector.
• Automatic Standby Position:
After the loading process is fully completed, the bellow automatically retracts to its top standby position, ready for the next loading cycle.
Open Truck Loading Bellows
Open truck loading bellows offer a reliable and dust-free solution for loading powdered and granular bulk solids into flatbed open trucks. These systems enable the efficient and controlled transfer of free-flowing dry bulk materials, such as powders and granules, from various sources including silos, hoppers, containers, and screw feeders directly into open trucks.
Designed with a built-in flexible dust skirt, the bellows effectively contain dust within the loading zone, preventing emissions from escaping into the surrounding environment.
Open truck loading bellows are widely used in industries where environmental safety and product integrity are critical, ensuring clean, efficient, and safe loading operations in open-air settings.
Ship Loading Bellows
Ship loading bellows provide an effective and dust-free solution for loading powdered and granular bulk solids into dry bulk carrier ships. These systems enable the efficient and controlled transfer of free-flowing dry bulk materials, including powders and granules, from a variety of sources such as silos, hoppers, containers, and screw feeders directly into ships.
Equipped with a built-in flexible dust skirt, the loading bellows contain dust within the immediate loading area, preventing emissions from escaping into the port environment. Ship loading bellows are essential in industries focused on bulk material transport, helping to maintain product quality while ensuring compliance with environmental regulations and minimizing pollution during the ship loading process.
Stockpile Loading Bellows
Stockpile loading bellows offer a reliable and dust-free method for discharging powdered and granular bulk solids onto stockpiles. These systems enable the efficient and controlled transfer of free-flowing dry materials, such as powders and granules, from silos, hoppers, containers, and screw feeders directly to the designated stockpile area.
Equipped with an integrated flexible dust skirt, the bellows effectively contain dust within the loading zone, minimizing environmental impact and maintaining a clean worksite. Stockpile loading bellows play a critical role in bulk material handling operations, ensuring efficient, safe, and environmentally responsible stockpile management.
Combined Loading Bellows for Tanker Trucks and Open Trucks
Combined telescopic loading bellows provide a versatile and dust-free solution for loading powdered and granular bulk solids into both tanker trucks with closed containers and flatbed open trucks. These systems ensure efficient and controlled transfer of free-flowing dry bulk materials, such as powders and granules, from silos, hoppers, containers, and screw feeders directly to various truck types.
The design is equipped with both a flexible dust skirt and a polyurethane-coated discharge cone within a single loading bellow, effectively containing dust emissions and ensuring environmental safety during the loading process. This dual-functionality makes combined loading bellows ideal for facilities handling a mixed fleet of vehicles, enabling seamless transitions between open and closed loading operations without the need for multiple loading systems.
Combined telescopic loading bellows are particularly useful in industries with diverse logistics requirements, such as cement plants, chemical processing, and agricultural bulk handling.
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.
