The challenge

To safely pick up a specific stainless steel drum containing a powdery, clump-prone and potentially flammable product (hence the ATEX classification), lift it, tilt it 180° to empty the product into the integrated continuous crusher. The continuous crusher then breaks up the lumps in the product or crushes it to a defined size before it is transferred to reactors by a vacuum conveying system.

The machine therefore enables the cotrolled and low-dust emptying, processing (deagglomeration / crushing) and forwarding of powered products in a potentially explosive environment, typically in the pharmaceutical industry.

Solution for the customer

The solution presented offers the customer a sophisticated machine that has been specially designed for the sage and efficient handling of products, especially under demanding conditions. A key aspect is safe handling in potentially explosive atmospheres (ATEX). The machine id designed for use in ATEX zones 1/21 (gas/dust), which is a decisive advantage when processing combustible products, as the risk of explosion is significantly minimized. This is achieved through the use of electrically conductive components such as roller and cover tape, as well as consistent grounding of all relevant parts.

In addition, the focus is on improved product handling and quality. An integrated continuous breaker enables clumped products to be broken up directly during the emptying process. This ensures better flowability and a more homogeneous particle size for subsequent process steps. Controlled emptying in ensured by a 180° tilting process and connection to a vacuum pot, which enables targeted and low-dust product removal. The design as a pharmaceutical/cleanroom machine with smooth stainless steel surfaces (1.4301 / 1.4404 / 316 L in contact with the product), which are easy to clean and have small gaps filled with silicone to prevent product accumulation, underlines its suitability for hygienically sensitive environments.

Increased operator safety and ergonoics are also key features. Automatic lifting and tilting significantly reduces the manual strain on the operator when handling heavy drums weighing up to 150kg. Various safety devices, such as interlocks (for example, the continuous breaker only starts when the drum and vacuum pot are correctly positioned), emergency stop functions, overload protection, parking brakes, and a seat valve to prevent load drop, contribute to safe operation. The low-dust product transfer, achieved by connecting to a “suction machine” via the vacuum pot, also minimizes the operators's exposure to product dust.

The machine also offers significant advantages in terms of process efficiency and flexibility. Thanks to its mobility, it can be used at different locations, which allows for a high degree of flexibility in production planning. The combined operation potentially saves time and space compared to seperate devices. Repeatable positioning of the support arm at emptying height is ensured by the pneumatic setting device.

The process integration and control are well thought out. The vacuum pot serves as a defined interface to a vacuum conveyor for efficient product removal. At the same time, the machine has an independent control system that regulates both its own functions and the continuous breaker.

The robust and maintenance-friendly design rounds off the profile. High-quality stainless steels are used as materials. Detailed maintenance instructions, which provide clear instructions for maintenance, including disassembly of the continuous breaker, support a long service life and reliable operation. An automatic lubricator for the pivot bearing of the tilting drive also reduces manual maintenance.

In summary, the machine is a comprehensive solution for emptying and processing powdered products from drums. It combines safety, hygiene, ergonomics and efficiency, making it particularly suitable for use in the pharmaceutical industry and in potentially explosive environments.

Project photos