An Australian producer of plasterboard and other high-performance construction industry staples had been using Floveyor conveyors to help with their bulk materials transfer. As their business changed, they needed to reconsider the best way to manage their bulk materials handling. Floveyor process line technology was part of the new solution.
The manufacturing company had been using two Floveyor Endura F3s to convey gypsum and vermiculite for plasterboard production for more than 30 years. The fully enclosed Floveyors were originally purchased to provide high-speed, contained and dust-free transfer for both handling systems.
Soaring production levels prompt a rethink
The company faced challenges on two fronts – soaring production levels and a switch from clay to fly ash. This presented an opportunity to address the inefficiencies caused by bottlenecks and dust containment in their bulk materials handling. They wanted to streamline the loading process of the day bins which relied on a combination of forklift and manual applications.
Because their existing screw conveyors proved to be incompatible with the rapid flow of aerated fly ash, they also needed a new conveying solution.
Process line technology needed an upgrade
After experiencing a quarter century of Floveyor reliability and low maintenance costs, the company wanted to continue experiencing the same benefits. Floveyor proposed two options which were modelled in 3D software to ensure the new recommendations would integrate easily with the existing plant and they wouldn’t experience any access restrictions when installed.
The proposal was accepted, followed by the installation and commissioning of process line technology modifications:
- An integrated electric hoist was installed to eliminate the use of forklifts when loading the vermiculite process line. Bulk bags delivered to the hoist by pallet trucks were already operating in the area.
- An enclosed support hopper was mounted to the hoist frame, with an access door and extraction to interface with the existing hopper and minimise dust.
- A vibrator was fitted to the support hopper to reduce operator intervention for the agitation of the product flow.
For the fly ash process line, the same approach of bulk bag handling was taken and a new Floveyor F3 was installed to replace existing screw conveyors.
- The F3 Floveyor was installed to transfer product from floor level to a silo. The F3 was fitted with an ASF screw feeder to prevent surges and regulate the flow of aerated fly ash.
- Existing plant dust extraction was integrated into the system, which reduced operator exposure to the very light and dusty material when accessing the bulk bag outlets.
Purchasing additional Floveyors improved plant efficiency
This new phase of a longstanding partnership with the manufacturing company helped solve two industrial conveying problems which had threatened to compromise the efficiency of their operations at a time of significant production increase.
Floveyor installed and commissioned new equipment with minimal downtime and a smooth handover.
Implementing conveyors from the Endura range with additional process line technology has made the operation cleaner, quicker and safer. It has also reduced front-end manual handling and labour requirements while freeing up the forklift for use at the end of the manufacturing process.
Floveyor conveyors continue to exceed performance expectations in plant, for the flow of gypsum and vermiculite.
Find the right process line technology for your plant
If you want to improve your plant operation, Floveyor Process Line Technology is designed and manufactured to maximise conveyor efficiency for better powder handling.
You can request an online quote and get started on transforming your own bulk material handling operation.