Fast, reliable and flexible: the world of modern bulk weighing

by Ray Vrtiska, Vice President, Bulk Material Handling Sales Intersystems, USA

Bulk weighers are designed for continuous weighing of bulk material. The fast, reliable and flexible systems can provide an accuracy of 0.1 percent or better. Features of the computerised control system can include colour display, menu driven operation, a wide variety of printer options, programmable keys to operate other equipment, power-loss protection, manual backup controls, self-diagnostic and self-trimming.

Systems can also incorporate a RFID tag reader for automatic programming of rail cars and can interface with central control PLCs. The unit can be linked to a host computer and can also be used to update an existing weighing system.
Installation of factory-assembled systems is simple and quick. Intersystems factory-assembled bulk weighers are available from 1,000-100,000 BPH (2600 MTPH) and are prewired, preplumbed and preconfigured.

En-masse conveyor characteristics

Designed to be totally enclosed, the en-masse conveyor is equipped with roller chain and polyethylene flights that move inside and convey the material. Conveyors can be stainless steel, painted or galvanized housing. A variety of side and bottom abrasive resistant steel liners can be easily removed and replaced.
These conveyors can be installed with intermediate discharges for applications where you are going over more than one drop point. The electrically operated intermediate discharge diverts the material into a selected bin. Loading can be made at any point on the conveyor. Unloading is done through the intermediate discharge gates or at the end of the conveyor.
Intersystems en-masse conveyors are very adaptable and may be configured in a series of horizontal and/or inclined segments (up to 90 degree incline) with conveying capacity available from 20 to 1500 MTPH.

Self-cleaning conveyors

The Intersystems Kleen-Drag conveyor features en-masse capacity with cleanout that is superior to the typical round bottom or screw conveyor. This self-cleaning en-masse conveyor is designed especially to prevent ‘pockets’ of material inside the conveyor where an intermediate discharge is required. When changing materials (type, sort, grade), the conveyor helps to avoid partial mixing of current and subsequent materials.
The conveyor is equipped with self-cleaning, flush-mount intermediate gates to eliminate material nests as well as polyethylene flights to minimize carry-over. The tail section has a rounded shape that follows the path of the moving flights, providing a full sweep of the conveyor.

Enclosed belt conveyors

Enclosed belt conveyors require significantly less horsepower than a drag or screw conveyor. The increasing need to move materials in larger volumes and at faster rates makes reduced horsepower very beneficial. The enclosed design contains the dust emissions inside of the conveyor, eliminates cleanup of spillage around the conveying equipment and protects workers from moving parts. Conventional belts have been used for many years to move a variety of commodities, but they were never totally enclosed. Now you can enjoy the existing benefits of belt conveying plus improved sanitation in their operation.
The material is loaded onto the upper (working) section of the belt and moves along the conveyor. The lower section of the belt is for return (empty). Thus, the belt is both a carrier (carrying the materials) and traction (traction transmitting) element. Material loads through one or more inlets located on the conveyor. Unloading of the conveyor can be made at the end of the conveyor in the drive section (standard), in the middle of the conveyor, or with intermediate discharges. The enclosed belt can be designed for inclines or reversing applications.

The Intersystems way

The Intersystems enclosed belt conveyor offers a solution to the problems of dust emissions and spillage that exist with most conventional belt conveyors. Commodities are conveyed on a totally enclosed belt that runs on ‘spools’ and then returns on a slider bottom made of anti-static UHMW. Any carry-over of material is pulled back to the tail where a unique tail design reloads the material back onto the moving belt. The conveyors are equipped with spiral wing pulleys that reload carryover material back onto the top belt to eliminate build-up in the tail section.
Intersystems belt conveyors provide a carrying capacity up to 2,600 MTPH. Along the entire length of the housing, as well as at grain dust outlets, special reels support the belt and shape it as necessary for moving the material without carryover. Belts can be PVC, rubber or food grade.
Gravity screeners feature a lined internal by-pass, manual or electric control for the by-pass gate, service platforms and standard screens for corn, wheat and soybeans. A high-capacity internal by-pass saves the cost of building an external by-pass and saves height in installation.
The Intersystems 40,000 BPH Gravity Screener with a 60,000 BPH internal by-pass was developed in response to an industry demand for larger screening capacity and higher capacity throughput.


Sample selection

The process of extracting a sample and moving it to the collection cabinet can be performed automatically and fully controlled by the operator through the control system.
In-line automatic samplers provide representative sampling grain and any other free flowing material including liquid from gravity flow or from the discharge section of an enclosed-belt conveyor. Sampling is performed automatically at regular intervals or on command of the operator and the required amount of product is passed into a container for collecting samples. Excess sample is returned to the material stream.

Depending on the product characteristics and application, Intersystems can supply various models of crosscut and gravity samplers for operation in-stream with different slopes and capacities.
Truck probes allow for representative and repeatable sampling from trucks, rail cars, tubs, bulk-bags and other methods, avoiding dust and spilling of material. Standard construction for the truck probe stand, mast and boom is heavy carbon steel and all are equipped with a rugged hydraulic power unit. An automatic control system provides comfortable and quick sampling and transports the samples to the collection point for further classification.
Intersystems’ compartmentalised or core model probe assures uniformity of representative samples.

Gentle handling

Bucket elevators are designed for gentle material handling while carrying grain and other materials in a vertical direction. Bucket elevator assembly includes head, boot and elevator legs constructed of stainless steel, painted or galvanized housing. Material is passed through the boot hopper to the elevator buckets or is taken out of the bottom of the boot by the elevator buckets and carried up to the head section to discharge the buckets. Material is fed to the boot with the help of a conveyor or by gravity flow. In the elevator head, there is a rotating drum with buckets. The material transportation, primarily, is performed by buckets which are fixed to the elevator belt that is moving up inside the elevator legs.
Each Intersystems bucket elevator is equipped with NFPA compliant explosion panels on the top of the head as well as with a break mechanism to eliminate return movement of the elevator belt.


2 thoughts on “Fast, reliable and flexible: the world of modern bulk weighing

  1. Bulk material handling can generate a variety of production issues such as:
    Poor inventory control
    Poor flow rate control
    Conveyor safety
    Material quality contamination

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