Course of MT- 362 Material Handling Lecture # 6. Batch Feeding and Weighing Systems: The manufacture...

Course of MT- 362Material Handling

Lecture # 6

Batch Feeding and Weighing Systems:• The manufacture of any blended product typically involves the

intermediate process steps of transfer and weighing or batching of individual ingredients based upon their weight percentage in a blend. Depending on this percentage, materials are categorized as majors, minors and micros.

There are two principle batching methods for weighing and feeding bulk materials:

1. A Gain-in-Weight (GIW) batching station includes volumetric metering devices, such as screw feeders or valves, that deliver the product to a hopper on load cells. GIW batchers for the major ingredients.

2. The Loss-in-Weight (LIW) batching system employs gravimetric feeding devices, such as loss-in-weight screw or vibratory feeders, which are mounted on individual load cells or scales. LIW feeders for the micros and minors.

Material Feeding and Metering Devices


Gravimetric Feeders:In gravimetric feeding, dry bulk material or liquid is fed into a process at a constant weight per unit of time. Consistent control and complete monitoring are possible. In principle, gravimetric feeding combines monitoring of the feeding process with a feedback loop that enables accurate material control.For example spice industries, glass bottle making industries Volumetric Feeder:

volumetric feeding is the simplest, most economical feeding solution available. Bulk material is held in a hopper and constantly fed into a process per unit of time. Although there is no weight feedback to assure feeding accuracy over time, this may not be a concern for materials with consistent bulk density.For example Beverage industries.


Continuous Feeders:In a continuous process, all equipment components related to the required unit operations function as a single system and are designed to operate 24 / 7, except for periods of required maintenance. This increased equipment utilization.


• Centerboard feeder-shaped to match part,-dips and then rises -through parts to selectpart, - which then slides into feed groove

• Reciprocating feeder

Either hopper or tube reciprocates to obtain, orient,and feed items

CHUTE: a sloping channel or slide for conveying things to a lower level


- Blade, with edge shaped tomatch part, rotates throughparts, catching thoseoriented correctly. Partsslide on contour of blade toexit onto feeder rail

• Rotary centerboard feeder


• Escapement feeder- Escapement is weightedor spring-loaded to stoppart from leaving trackuntil it is snared (trapped)by the work carrier. Slopeof track feeds next partinto position

• Lead screw feeder-Parts stack up behind the screw- Rotation of screw feeds parts withdesired separation and timing.


Hopper

Motor

Screw

Adjustmentmechanism

Supports

Outlet

Vehicle bulk conveyor systemsSuch systems consist of conveyors that can be moved easily so that they can be used for loading and unloading of bulk material from vehicles like

TrucksRailsAircrafts

Consists ofConveyer systems (belts, rollers etc.)Driving mechanism (motor, gears, pulleys etc.)Control cabinet (electronics, sensors, transducers etc.)Transportation modes (wheel carriages, trucks etc.)

Vehicle bulk conveyer systems

Conveyer system

Electronics

Controls cabinet

Drive mechanism

Transportation mode

Vehicle bulk conveyer systems

Marine Bulk Material Handling

Marine handling equipments

• Those equipments which are used for handling of material related to sea or ocean• These may include transportation to or from

Directly from sea From islandsShipsPorts

Products associated with marine may includeMining (coal, iron, sulfur, etc.) Import export bulk materials (grains, wheat, etc.)Chemical plants (chemical processing)Petroleum productsFood products


Material handling equipments is performed by

CranesConveyers Elevators Rails ContainersLifters


Different stages in marine material handling

Loading/ unloading Stacking

Conveyers Reclaimers

Wagon loading

• Bulk material loading to ships



• Loading/ unloading


• Stacking

• Reclaimers


• Conveyers


• Wagon loading


Packaged material handling

• Packaged materials are those materials that can be easily packed in single units

• Few examples are– Food items– Medicines – Glassware– Industrial products– Electronics


• Pallets and palletizing operations– These are unit load formation equipments– The objective is to use recyclable material for the product

containers– Such material handling consist of

• Boxes• Cartons • Crates • Totes• Bags • Packets


• Pallets – Pallets are probably the most common platform for moving unit

loads. – Perhaps the most obvious area of concern associated with the

use of pallets today involves cost and quality – Poor quality pallets annually cost industry billions of dollars in

the form of • Product damage, • Lost productivity, and • Damaged handling


• Pallet construction– A pallet consist of

• Top deck/ slat• Bottom deck/ slat• Blocks• Stringer board (support/ connector)• Guide ways for fork lifter forks• Guide ways for hand-trucks forks


• Pallet construction– Size of pallet is specified by its depth (i.e., length of its

stringers or stringer boards) and its width (i.e., length its deck-boards)—pallet height (typically 5 in.) is usually not specified

– 48 × 40 in. (1200 × 1000 mm) pallet is most popular in the US, because its compatibility with railcar and truck trailer dimensions; e.g., the GMA (Grocery Manufacturers of America) pallet is four-way and made of hardwood

– 1200 × 800 mm “Euro-Pallet” is the standard pallet in Europe

– Single-face pallets are sometimes referred to as “skids”


• Pallet material– A key decision affecting the overall life cycle cost of pallets is the

materials used in their manufacture– The pallet materials include

• Wood• Pressed wood fiber• Corrugated fiberboard• Plastic • Metal

Corrugated : a material shaped into a series of parallel ridges and grooves so as to give added rigidity and strength


Wooden palletsCorrugated fiberboard


Pressed wood fiber pallets


Plastic pallet Metal pallet


• Advantages of using different material pallets– Wooden pallets are sold each year than any other type due to

the versatility, low cost, biodegradability and recyclability of this material

– Pressed wood fiber is a combination of wood fibers and organic resins which eliminates the need for nails and enables the molding of pallets into more space efficient designs


• Advantages of using different material pallets– Disposable, corrugated fiberboard pallets can be made of

recycled paper materials and provide a light weight, low cost alternative for one way shipping when loads do not need to be stored outdoors

– Durable plastic and metal pallets may provide the low cost alternative over the full pallet life cycle despite their high initial cost

• Both of these materials are recyclable, can be sanitized for clean applications, and can be used in the most demanding applications


• Palletizing – It is the process of stacking the product to

form a unit load– Palletizing operation may be through the

following methods• Manual • Automated /robotic


• Manual palletizing


• Automated/ robotic method


• Pallet positioner – It is a tool which fulfills the ergonomics requirements of an

operator– It consist of a turn-table, drive mechanism, damping system and

control device– It can be operated

• Manually• Hydraulically • Motorized

Ergonomics (or human factors) is the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design in order to optimize human well-being and overall system performance.

Packaged material handling• Pallet positioner

Course of MT- 362 Material Handling Lecture # 6. Batch Feeding and Weighing Systems: The manufacture...

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