ISL Technologies; manufactures IBC Systems (Intermediate Bulk Container) as a unique way of handling powders and granular materials for different usages such as storage, screening, blending packaging, etc., and many more applications. For use in various industries, including those involving chemicals, food, nutraceuticals, medicines, and many more, they are made of either stainless steel or polyethylene and invented in either round or square shapes with various size alternatives. Our IBCs are made to be stackable and blendable for optimal and precision benefits. IBCs are used as transport containers or in process handling. They can easily be identified as batch production vessels for traceability and are designed for a reliable, flexible production process.
IBCs are popular today because they have an indefinite life unless exposed to certain chemical erosions. Due to the properties of stainless steel, it is an ideal corrosion-resistant and stain-resistant material that will withstand long-term exposure to the environment. Stainless Steel IBCs are designed and built to last for years. The IBC frame is fully equipped with stacking pads (for stacking IBCs), and its support structure can move fork trucks in both directions. Stainless steel IBCs can be either round or square, depending on the customer’s preference and the product’s characteristics.
Polyethylene IBCs are competitively priced! The cost of replacing the plastic molding can be as competitive as a weld repair on stainless steel IBC. This is particularly so if the internal of stainless steel IBC is ground/polished. If it is a total replacement, polyethylene IBCs are lower priced too.Bin lid and body can be made in standard natural, colored, or black conductive medium-density polyethylene (MDPE). Other non-material contact parts like support base, frame, and clamp flange can be in stainless steel or mild steel. IBC frame completed with stacking pads (for IBC stacking) and its support structure with two-way fork truck transport. In addition, natural polyethylene containers are usually lighter and give a good visual indication of the content level. Thus, they are easier to handle manually.
The standard fill station is operated by a pneumatic cylinder to lower and clamp the fill lid to the IBC or other process vessel inlet. The fill lid seals to an integrated cone valve when raised. Closing off the inside of the station and the powder transfer equipment above. This provides a straightforward and worry-free operation during the filling process in our IBCs.
It has an integral vent pipe to exhaust the displaced air in the IBC or process vessel as the powder is loaded. It provides a degree of containment with the inside of the station and the IBC or process vessel being exposed to the outer environment only during the engagement or the disengagement of the fill lid which remains tightly sealed to the inlet during the product transfer.
Thus providing a total dust containment-free process during the filling. This is crucial and facilitates applications for the chemical, pharmaceutical, and nutraceutical sectors. With the aid of floor locators and sensors, the Fill Head can only be lowered when the IBC is in position with the lid removed and the cone valve installed. For added assurance that the IBC is filled with the appropriate amount of goods, a floor scale is an optional addition.
The Discharge System is designed to discharge the products from the IBC with control of the discharge rate of the product flow. It is designed to safely and hygienically discharge materials such as powders and granules into processes such as mixing, packaging, screening, and conveying.
As the IBC is lowered, the IBC outlet engages into the Station “top liner” and the IBC Cone Valve locates onto the Station central “probe” thus creating an environmental seal between IBC and process. When the IBC is empty, it is lifted off the Station, as it lifts the IBC outlet remains sealed into the top liner until just after the valve re-seats in the IBC outlet. Thus, there is not even a momentary exposure to the product before, during, or after discharge.
Load cells can be mounted to the frame to check the weight of the product in the IBC or Loss-of-Weight Application. In addition, optional Frame Vibrators can be installed to create flow for difficult-to-flow powders and to ensure full discharge of powders.
After the IBC is removed the Station can be cleaned and dismantled in seconds for cleaning off place (COP) or, in place (CIP) by replacing the IBC with a “Station Wash Bin” having an integral spray ball. The Station incorporates a “rate & position transducer” which totally controls the valve aperture so as to maintain either any number of positions or continuous flow rate; making it an accurate batch and continuous gravimetric feeder as well as a fail-safe valve. In rate control mode, the system automatically accommodates for any change in product characteristics or even totally different products.
The IBC is most suitable where the product must be handled gently with minimum damage or degradation. Mixing directly within the IBC reduces the number of product transfers by Two (02) and an unique advantage to the cone valve is that during each revolution, it separates and re-mixes the product, so creating a better quality mix.
The Tumble Blender comprises a freestanding steel framed structure with a trunnion-mounted rotating cage to hold the IBC. The IBC is loaded into the cage by a forklift truck. As it is lowered down into the cage, the Cone Lock device at the bottom of the cage automatically locks the valve in place. The truck and operator exit the blender enclosure, lock the access gate, remove the interlock key and insert it into the control panel. The start button is pressed; the clamping system operates to clamp the IBC in the cage. The cage then rotates at a predetermined speed and duration (optimum speed and blend duration and time found on commissioning).
There are safety interlocks to stop the process if either the clamps slacken or the valve clamp releases. The door is interlocked closed to prevent entry during operation. The main drive motor is controlled by an inverter controller which starts and drops the process by gradually running up and down to full speed. This is a vital feature to minimize the torque and torsional stresses on shafts, cage, and support structures.
When the cage has slowed down at end of the cycle, it is locked in the vertical position by a dynamic brake and then a pneumatic cylinder drives a locking bolt to secure the cage. The clamping system retracts to release the IBC and then releases the door interlock to allow the operator to take the key from the panel, unlock the door and enter to remove the IBC.
Regardless of the scale of the project, ISL is always willing to sit with you and discuss the details of the project. An IBC system, may at times require support structures, frames, and other components that may not be in our scope of supply, but we can undertake full design responsibility.
At ISL Technology we have incorporated such projects which include Silos, Dust Collectors, Vacuum / Pressure Conveying systems, etc. We also provide Roller Conveyors, Chain Conveyors, or AGVs, as required by the needs of the project, to move to the IBC system for the formulation system.
This system for the food industry consists of a “carousel” of six Discharge/Dosing Stations on a support structure, each feeding through angled pipes to a Formulation IBC. This particular system has a weigh platform under the Formulation IBC which, via the controller, automatically discharges an accurate batch of products sequentially from each Product IBC on the Stations. The Product IBC then is taken for Mixing in an ISL IBC Tumble Blender and then on for final process feed to packing into sacks through an ISL Dosing/packing system. Such formulation systems can be GIW (gain in weight) like this one, or LIW (loss in weight) with load cells at each station so all operate simultaneously. Rather than a carousel, they can have the Stations in a single or two lines with the Mix IBC on a chain or other conveyor.
Simple standard controls for local operators and remote interfacing allows for continuous control of valve lift height and stroke frequency or pre-set lift heights. When integrating with a plant SCADA, interfacing with other process equipment, and managing formulations, ISL also provides complete Control System packages to suit the requirements of your project.
The biggest advantage of an IBC System installation is that the IBC can be washed and dried without, any downtime at the production level. Depending on what types of powders are stored in the IBC, we at ISL can design an appropriate Washing and Drying System (application specific). Our sales and application engineers can sit down with your team to go through requirements in detail and provide your company a solution, which meets the specification and also your budget demands.