Hunan Chenzhou Dye Powder Dust-Free Anti-Pollution Conveying Complete Set
A chemical enterprise has long been engaged in the production and processing of dye powders, and during production, powdered dyes need to be transported from the raw material silo to the next step. Because dye powders have fine particles, are easily lifted, prone to moisture, and some varieties carry typically pungent odors, traditional manual handling or open conveying methods cannot meet safety, environmental protection, and quality requirements. After extensive investigation, the company ultimately chose the pneumatic conveying system designed by Head Powder, achieving sealed, dust-free, and automated transfer of dye powders, thereby improving dust pollution and material loss issues at the production site.
Customer pain points
- Dust pollution is severe: During transportation, dye powder is highly prone to generating dust, and excessive dust concentration in the workshop not only threatens operator health, but also poses explosion hazards and does not meet environmental emission standards.
- Material loss and cross-contamination: Open handling causes large amounts of powder to scatter and fly, resulting in a high raw material loss rate; At the same time, mixing dyes of different batches and colors in the air can easily cause cross-contamination and affect product quality.
- Low labor efficiency and high labor intensity: Manual handling, unpacking, and feeding are cumbersome, causing workers to tire easily after prolonged exposure to dust, and production efficiency is limited by human labor, making it difficult to meet increased output demands.
- Equipment maintenance and cleaning are difficult: Traditional conveying equipment is prone to material accumulation and blockages, requiring shutdown and disassembly during cleaning, which is time-consuming and costly, affecting continuous production.
Product advantages
To address these pain points, Head Powder has customized a positive pressure dense phase pneumatic conveying system for the customer, with main features including:
- Fully enclosed pipeline transportation: Sealed pipelines are used throughout the entire process from feed to discharge, allowing dye powder to flow in the airflow with no leakage points, eliminating dust emissions at the source, and ensuring a cleanliness environment meets dust-free standards.
- Low airflow and low crushing design: Using dense phase conveying technology, the material moves slowly in a plug or plunger shape, with conveying speed controlled within a low range, reducing impact and breakage on dye particles, and maintaining product particle size and shape integrity.
- Intelligent control and monitoring: The system is equipped with a PLC automatic controller and sensors, allowing real-time adjustment of air volume, pressure, and conveying speed to achieve more accurate batching and automatic start/stop; At the same time, monitor the material-air ratio and the risk of pipeline blockage to reduce manual intervention.
- Easy to clean, low-maintenance structure: Key components use a quick-release design, with smooth inner walls of the pipeline. Combined with the blowing function, material types can be quickly switched, significantly shortening cleaning time for color and batch changes, and improving equipment utilization.
After system upgrades, the dust concentration in the workshop dropped below 20% of the national occupational health limit, dye yield increased by about 3%, labor costs decreased by 60%, and the company successfully passed the local environmental protection department's acceptance. Head Powder has provided similar pneumatic conveying solutions to many dye and pigment companies in regions such as Hunan and Chenzhou, continuously helping the industry achieve green and efficient production.