Common Challenges You May Enounter

PRODUCT NON-UNIFORMITY

Lot to lot consistency is critical when you are batching. In a continuous process, absolute steady state operation is the goal.  Depending on your industry, challenges may include too many fines, departure from texture and colour standards, variance in appearance and poor product performance. Product non-uniformity can result in process inefficiency, customer complaints, product recalls, increased warranty issues and loss of accreditation. Transporting bulk materials to the next process and then accurately metering them without any product segregation or damage will contribute to consistent batches, dramatic reduction of lot to lot variances and rock solid operation.

PRODUCT SEGREGATION

In any quarry, larger rocks roll away from a pile farther than small rocks do. Similarly, when making snack foods, ground pepper is frequently the last ingredient to exit the hopper. DI3’s experience anticipates these problems in new designs and can help you to avoid the problem altogether. We also have the solutions to immediately resolve any existing bulk solids handling problems you may have. 

FLOW STOPPAGE / POOR FLOW

Most plants have silos or hoppers that bear scars from sledge hammers used in a futile effort to promote flow. DI3 can offer standard designs that will completely eliminate any bottleneck. Once on site, DI3 can then examine your handling process so that your entire line may be optimized.

PRODUCT ATTRITION OR DEGRADATION

Handling stabilized coal, potash granules or fertilizer prills demand that the materials must not be abused. The creation of sub-sized product, dust or any appearance "issues" must be avoided. DI3 offers designs that address these matters and the process improvements frequently pay for themselves within months.

FLOODING AND STARVATION

Two extremes of bulk solids handling involve the absence of flow or its opposite, a wild, uncontrolled discharge from storage. DI3 offers a full range of extraction and control components that ensure the uniform and controlled withdrawal of bulk materials as well as the accurate and reportable monitoring of your process.

BATCHING VS CONTINUOUS PROCESS

DI3 is experienced with all manner of batching and continuous discharge designs as it offers both volumetric as well as gravimetric systems. These designs will allow you to optimize your bulk materials process and confirm that you have satisfied compliance to your industry standards as well as any legislated obligations.

RATHOLING

Ratholing, as the name implies, occurs when a stable, vertical flow channel empties out, similar to a tunnel that a rat may dig. A common enough occurrence, however it is not necessarily an easy one to solve unless you know the root causes of the problem. This condition and its consequences can vary from nuisance to catastrophic. DI3 has solutions tailored to address this showstopper. As you explore remedies to this problem, material testing and if needed, full scale lab evaluation is available to minimize any project risks.

CROSS CONTAMINATION

Cross contamination is a serious matter. Nut and lactose free obligations parallel flavour and colour transfer issues. Simple, straight forward material handling systems can eliminate process contamination and DI3 has the experience and product designs to allow you to get the job done right the first time.

CHARGING A MELT-SHOP TREATMENT LADLE

Safely pulling ferrous materials from a stockpile and then placing them into a ladle requires full control. To avoid pulling the pile apart or perhaps spreading the material across the workspace with a faulty magnet, DI3 can help configure a lifting magnetic system to exactly suit your application.  

PIPE WEAR

Dilute-phase conveying systems, which rely upon a blower or a vacuum pump, trade off lower capital costs at the expense of energy consumption, product attrition and extremely high rates of wear in the transfer pipes and downstream valving.

DI3 can examine your present material handling system and offer long-life components to replace troublesome double-set butterfly valves and diverter gates. The installation of a dense-phase system will eliminate the above shortcomings.

VALVE FAILURES WITH SLURRIES AND ABRASIVE MATERIALS

If your application involves acidic, abrasive or hot slurries, or abrasive bulk solids, Macawber's dome valve can eliminate failures associated with traditional valving.

HOUSEKEEPING ISSUES, SPILLAGE AND DUST

DI3 has the insight to offer innovative solutions to address these handling issues. Sanitary, health and dust explosion concerns are addressed and satisfied with designs exactly suited to the task.

The VAC-U-MAX product line includes a full range of portable and central industrial vacuum cleaning units and systems, engineered for specific applications that address issues like worker exposure to dusts, chemical compatibility, flammability and combustibility.  VAC-U-MAX offers NFPA-compliant continuous-duty industrial vacuum cleaning equipment for fine powders and combustible dusts with continuous bagging options eliminate fugitive dust clouds and operator exposure to dusts.

 

DI3 CAN HELP YOU IDENTIFY THE CAUSE AND CORRECT THESE AND OTHER BULK MATERIAL HANDLING ISSUES!


What They Say

WE CAN PROVIDE

  • Electromechanical Vibratory Feeders
  • Impactors
  • Roll Crushers
  • Size Reduction Equipment
  • Vibratory Tube Conveyors
  • Cross-belt Separator
  • Gravimetric Feeders
  • Dome Valves
  • Diverter Valves
  • Magnetic Drums
  • Volumetric Feeders
  • Industrial Vacuum Cleaning Systems
  • Magnetic Separation Systems
  • Magnetic Lifting Systems
  • Air-powered Vacuum Cleaner
  • Dense Phase Pneumatic Conveyors
  • Over-the-belt Magnets


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DI3 – BULK MATERIAL HANDLING SOLUTIONS FOR ONTARIO, CANADA
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