How do you introduce dusty bulk materials into a manufacturing process when you have strict hazardous area requirements? That’s the challenge faced by one of Australia’s largest industrial coatings manufacturers when they were constructing a new facility for water-based paint production. They needed a conveying solution that could handle thickening agents safely and efficiently while eliminating manual handling risks and controlling dust emissions.
Industrial coatings manufacturing challenge: safe handling of dusty thickening agents
The company produces 22-24 million litres of paint annually across various technologies. Their new facility was designed around mixing vessels ranging from 3,000 to 10,000 litres per batch. A critical component of their material handling for the paint production process involved adding Natrosol Plus, a free-flowing, dusty powder. The material is used as a thickening agent and provides rheology control for smooth finishes and enhanced splatter resistance.
The challenge was introducing this material from 25 kg bags into the top of a hot mix tank. The materials needed to be conveyed vertically, approximately four metres, with a target throughput of 3,000 kg/h. Strict safety standards for Zone 22 hazardous area compliance were required to mitigate the risk of combustible and flammable dusts.
A traditional set-up would have required operators to:
- Deliver bags to a mezzanine level
- Manually tip materials directly into elevated tank inlets
- Work in potentially hazardous conditions with dust exposure
- Deal with material spillage and extensive clean-up requirements.
The facility management wanted a complete, ready-to-install system for fast and efficient commissioning. The new bulk material handling equipment needed to improve safety and working conditions in the new plant, including:
- Removing the need for mezzanines and manual tipping into elevated tanks
- Introducing an ergonomic bag tipping station to eliminate manual handling injuries from awkward lifting and access
- Providing fully enclosed and safe conveying into heated mixing vessels
- Controlling dust emissions during material transfer by preventing dust release
- Integrating with existing dust extraction systems to capture airborne particles
- Ensuring Zone 22 hazardous area compliance
- Minimising material loss and reducing clean-up requirements from spillage at the tank inlet.
The company set about evaluating multiple suppliers offering aero-mechanical conveyor (AMC) and screw conveyor systems for their new paint manufacturing operation.
Moving to a purpose-built vertical conveyor solution
Following detailed consultation and solution modelling, the facility selected a Floveyor aero-mechanical conveyor system specifically designed for their industrial coatings application. The company had used Floveyor equipment in the past, so they were familiar with the high-quality, durable and reliable conveyor solutions.
Why the Floveyor AMC was selected over screw conveyor alternatives
Floveyor’s AMC offered several advantages over traditional screw conveyor systems for this vertical conveying application:
- Fully enclosed system controls dust, prevents contamination, and ensures safe transfers at any elevation
- Gentle material handling maintains product integrity without degradation
- 100% batch transfer capability with minimal residual material
- Low energy consumption compared to pneumatic alternatives
- Minimal maintenance requirements, with reduced consumable costs
- Compact footprint suitable for the facility’s space constraints.
Choosing the Floveyor Endura product range
The Floveyor Endura range is engineered for continual use in harsh industrial environments. It met all the conveying requirements for handling difficult and potentially hazardous bulk materials commonly used in additive and chemical processing.
The Endura system’s robust construction and reliable performance made it ideal for the demanding conditions of industrial paint manufacturing, where consistent operation and minimal downtime are critical for maintaining production schedules and product quality standards.
Comprehensive turnkey solution
Floveyor’s complete aero-mechanical conveying system for powder handling in paint manufacturing included:
- Small bag dump station with ergonomic design for safe material introduction
- Endura F3 capable of 4-metre elevation change
- Zone 22-compliant electrical system delivered as a turnkey solution
- Integration capabilities with existing dust extraction systems.
Custom conveyor design addresses facility constraints
The new industrial coatings manufacturing facility presented specific challenges that required a tailored approach. The implemented system transformed the material handling process for Natrosol Plus and similar thickening agents used in paint production.
Streamlined four-step process:
- Position material: 25 kg bags are placed at the ergonomic bag dump station
- Controlled introduction: Material flows into the enclosed hopper with integrated dust control
- Gentle vertical conveying: The AMC transports material vertically four metres to the heated mixing vessel
- Precise discharge: Material is delivered directly into the hot mix tank through a controlled outlet.
The fully enclosed system ensures dust-tight operation while the conveyor’s gentle action maintains the integrity of the thickening agent throughout the transfer process.
Industrial coatings facility achieves operational excellence
Floveyor’s Endura F3 solution delivered major advantages across multiple operational areas:
Enhanced safety performance
- Eliminated manual handling risks associated with carrying heavy bags and manually tipping them
- Removed dust exposure through fully enclosed conveying system
- Integrated dust control, preventing airborne particle release
- Achieved Zone 22 compliance for safe operation in hazardous areas
Improved production efficiency
- Achieved target throughput of 3,000 kg/h for consistent batch processing
- Reduced material loss through 100% batch transfer capability
- Minimised clean-up requirements with enclosed, spillage-free operation
- Streamlined workflow, allowing operators to focus on other production tasks
Operational benefits
- Low maintenance demands with minimal consumable costs
- Energy-efficient operation compared to pneumatic alternatives
- Reliable performance with consistent material delivery
- Easy integration with existing plant systems and dust extraction.
Winning the tender: Floveyor’s local manufacturing advantage
The project was awarded to Floveyor, in part, because they were the only locally manufactured vertical conveyor solution in Australia. This provided several strategic advantages for the new facility.
- Reduced lead times: Local manufacturing shortened delivery schedules, which was critical for new facility commissioning timelines, and reduced transport costs compared to imported alternatives.
- Responsive support: Being able to communicate in the same time zone, and having an established local partner network, ensured fast, reliable service when needed.
- Competitive economics: Competitive capital costs that were particularly cost-effective for short conveying distances common in paint manufacturing applications.
- Proven technology: Demonstrated ability to handle a diverse range of powders and granules, and deliver 100% batch transfers, reducing product loss and clean-up requirements.
- Energy-efficient: Extremely low energy usage reduced operational costs and contributed to a total lower cost of ownership.
Vertical conveyor technology for your industrial coatings and paint manufacturing operation
Modern industrial coatings and paint manufacturing facilities require conveying solutions that balance safety, efficiency, and regulatory compliance. Aero-mechanical conveyors from Floveyor offer proven advantages over traditional screw conveyor systems for vertical applications, particularly when handling dusty materials like thickening agents and rheology modifiers.
Key considerations for industrial coatings manufacturers include:
- Hazardous area compliance for safe operation with solvent-based and water-based paint systems
- Dust control integration to meet environmental and workplace safety requirements
- Gentle material handling to maintain product quality and batch integrity
- Ergonomic design to reduce manual handling risks, injury, and operator fatigue
- Flexible installation to accommodate existing facility constraints.
If you’d like more information about Floveyor’s capabilities for industrial manufacturing applications, get in touch. We’re happy to discuss your requirements and can work with you to develop a safe, efficient powder handling system for your operation.