What was the problem?

Our customer needed to increase its bulk out-loading capacity so that it could fill wagons faster and reduce waiting time at their animal feed mill in Darlington.

ISF was called in to convert the existing 40 tonnes per hour flake bin and out loading route to handle pellets and rolls that would fill the wagons at 100 tonnes per hour.

The process needed to include a sieve to ensure that the end customer was getting a good quality consistent product without contamination, however, the original process route had the sieve positioned after the bulk out loading bins, which restricted the throughput rate to the wagons.

What was the solution?

We visited the site to understand and discuss with the client the best way of solving the problem. The team then worked together to create a bespoke engineering solution tailored exactly to our customer’s needs.

To overcome the throughput restriction, because of the positioning of the old sieve, the plan was to remove it and install a new one before the bulk bins. This way the bins could be topped up steadily without affecting the speed that the wagons were being loaded at the end of the process.

To get the product to the sieve we installed a new chute from the top of the mill, down and through the roof that housed the out-loading bins. Using a crane, we installed the new sieve support steel by coming through the side of the building and then lifted the sieve, all supervised and coordinated by our own certified appointed person for crane lifting.

To enable the required throughput, we installed new electropneumatic slides valve to each of the twelve bins which discharged to a new 800mm wide chain & flight conveyor feeding a new belt and bucket elevator then finally the end chain & flight conveyor to load wagons.

The result

The customer’s throughput has increased significantly meaning the wagons are being filled in less than half of the original time.

Check out the great feedback we received from our customer below:

“Very pleased with the outcome of both the bulk out -loading arrangements, we are now filling bulk wagons four times faster than before and no longer have wagons waiting around for up to an hour to be filled”