Bulk Material Handling
Published on : Friday 15-12-2023
Bulk material handling is an essential part of all industries, says Darshana Thakkar.
Under the Atmanirbhar Bharat campaign, many SMEs – small and medium businesses – are under operations in diverse sectors. A few examples are:
1. Agriculture
2. Food processing
3. Food & beverage industry
4. Chemical and petrochemical industry
5. Wood and paper industry
6. Plastics and rubber processing
7. Textile industry
8. Recycling and waste management
9. Mining and quarrying, and
10. Construction and building materials.
Due to the abundance of workforce availability in India, many material handling processes are done manually, especially in small enterprises where affordability, cost and awareness of the right technology is a constraint.
The above industry sectors are handling large volumes of dry materials. Transportation of these large volumes of materials as raw materials during the process, and as finished goods, requires considerable time and effort.
Bulk material handling is an essential part of all industries that process bulk ingredients, including food, beverage, confectionery, pet food, animal feed, tobacco, chemical, agricultural, polymer, plastic, rubber, ceramic, electronics, metals, minerals, paint, paper, textiles and more.
These materials are usually loose and need specialised equipment for efficient handling, transportation, and storage. Here are some common types of bulk material handling equipment:
1. Conveyors
• Belt Conveyors: These are the most common type and used for bulk materials' horizontal, inclined, or vertical transportation.
• Screw Conveyors: Utilise a rotating screw to move materials along the length of a trough. They are suitable for transporting materials at an angle.
• Bucket Elevators: Lift materials vertically using buckets attached to a belt or chain.
2. Stackers and Reclaimers
• Stackers: Used to pile bulk materials in stockyards in layers, making them easier to retrieve.
• Reclaimers: Extract material from stockpiles, ensuring a consistent flow to downstream processes.
3. Hoppers
• Receiving Hoppers: Collect material dumped from trucks or other transport vehicles.
• Storage Hoppers: Store bulk materials before further processing or transportation.
4. Chutes and Feeders
• Chutes: Direct the flow of materials from one process to another.
• Feeders: Control the rate at which materials are introduced to a processing system.
5. Crushers and Grinders
• Crushers: Reduce large rocks, ore, or other materials to smaller sizes for further processing.
• Grinders: Reduce the size of bulk materials through grinding or milling processes.
6. Silo and Storage Systems
• Silos: Tall cylindrical structures for storing bulk materials in large quantities.
• Storage Bins: Containers for bulk material storage with various shapes and sizes.
7. Bulk Bag Fillers and Dischargers
• Fillers: Load bulk materials into large bags for storage or transportation.
• Dischargers: Empty the contents of bulk bags efficiently.
8. Dust Collection Systems
• Collect and filter dust generated during material handling processes, maintaining a clean and safe working environment.
9. Weighing and Measurement Equipment
• Ensure accurate measurement and control of the quantity of bulk materials.
10. Vibrating Screens and Feeders
• Separate materials of different sizes and ensure a consistent flow.
There are diverse applications of bulk material handling across various industries. The specific systems used depend on the nature of the materials, the transportation distance, and the industrial process requirements.
Application of various bulk materials handling equipment – Industry sectors
1. Conveyor Systems
• Mining Industry: To transport coal, minerals, and other mined materials from one point to another.
• Manufacturing: To move raw materials and finished products on production lines in industries like automotive and electronics.
2. Bucket Elevators
• Agriculture: Used to lift and transport grains, seeds, and other agricultural products.
• Mining: Elevators move bulk materials like ores and minerals vertically.
3. Pneumatic Conveying Systems
• Food Processing: To transport powdered ingredients in the production of food products.
• Chemical Industry: Conveying of powders and granules in chemical processing plants.
• Construction: transporting bulk materials such as sand, gravel, and concrete on construction sites.
• Power Plants: Belt conveyors move coal from storage areas to boilers for power generation.
5. Screw Conveyors
• Waste Treatment: Used to transport and process bulk materials in municipal wastewater treatment plants.
• Cement Industry: Conveying of cement, fly ash, and other materials in cement p production.
6. Hoppers and Silos
• Grain Storage: Silos are used for the storage of grains on farms and in grain processing facilities.
• Chemical Plants: Hoppers and silos store bulk chemicals before further processing.
7. Ship Loaders and Unloaders
• Ports: Ship loaders load bulk materials such as coal, grain, and ore onto ships for transport.
• Ports: Ship unloaders to unload bulk cargo from ships.
8. Stackers and Reclaimers
• Mining: Stackers pile bulk materials like ores while reclaimers retrieve and unload them for further processing.
• Power Plants: Stackers and reclaimers handle coal and other materials for power generation.
9. Automated Guided Vehicles (AGVs)
• Warehousing: AGVs transport bulk materials within warehouses and distribution centers.
• Manufacturing: AGVs, to move raw materials and components into manufacturing facilities.
10. Railcar Dumpers
• Mining: Railcar dumpers unload bulk materials from railcars for processing.
• Coal Industry: Railcar dumpers to unload coal from railcars for storage or further transportation.
These are the diverse applications of bulk material handling across various industries. The specific systems used depend on the nature of the materials, the transportation distance, and the industrial process requirements.
Advantages of bulk material handling equipment
Various industries use large quantities of granular, powder, or liquid materials. The need for such equipment arises from the challenges associated with efficiently and safely transporting, storing, and processing bulk materials – some critical benefits of bulk material handling equipment in industrial settings.
In the era of technology and global competition, it's high time for Small and medium enterprises to adopt modern bulk material handling equipment. Despite the high initial cost of the above equipment, there are long-term benefits of the contemporary equipment apart from reducing dependency on manual labour.
1. Efficiency Improvement
• Transportation: Efficient movement of materials within a facility or between different stages of the production process. For example, conveyors, elevators, and pneumatic systems help streamline material flow.
• Storage: Silos, bins, and hoppers provide organised and space-efficient storage solutions, ensuring easy retrieval of materials when needed.
2. Cost Reduction
• Labour Savings: Automation and mechanisation of material handling processes reduce the need for manual labor, leading to cost savings and increased productivity.
• Energy Efficiency: Modern bulk material handling equipment is energy-efficient, helping industries reduce operational costs and environmental impact.
3. Safety and Environmental Compliance
• Material Containment: Manual handling can be hazardous, leading to injuries and safety issues. Bulk material handling equipment ensures the containment and controlled movement of materials, minimising the risk of accidents.
• Dust Control: Many bulk materials generate dust during handling, posing health risks and environmental concerns. Equipment such as dust collectors and enclosures help control and mitigate dust emissions.
4. Process Integration
• Automation: Bulk material handling equipment can be integrated into automated systems, enhancing overall process efficiency and consistency.
• Compatibility: Equipment is designed to handle specific types of materials, ensuring compatibility with the characteristics and requirements of the materials to be processed.
5. Customisation and Flexibility
• Adaptability: It can be customised to suit the specific needs of different industries and materials, providing flexibility in handling various bulk materials.
• Scalability: Industries can scale their operations by adding or modifying equipment to meet changing production demands.
6. Quality Control
• Gentle Handling: Some materials are sensitive and require gentle handling to prevent degradation or contamination. Specialised equipment can ensure the gentle transport and processing of such materials.
• Accurate Measurement: Equipment such as weigh feeders and belt scales enable precise measurement and control of material quantities, ensuring quality in the production process.
7. Regulatory Compliance
• Environmental Regulations: Compliance with environmental regulations often requires industries to invest in equipment that minimises emissions, controls pollution, and ensures proper waste disposal.
Leading companies in India involved in bulk material handling equipment include, but are not limited to:
1. Elecon Engineering Company Limited – Anand, Vadodara, Gujarat
2. Thyssenkrupp Industries India Pvt Ltd – A global conglomerate with a significant presence in India
3. TRF Limited – Formerly known as Tata Robins Fraser Limited, TRF is part of the Tata Group
4. Macmet India Limited, Kolkata, West Bengal
5. BevconWayors Pvt Ltd – Hyderabad, Telangana
6. Essar Constructions (India) Limited
7. Schenck Process India Pvt Ltd – A global player
8. FLSmidth Pvt Ltd – A global engineering company with presence in India
9. Demag Cranes and Components (India) Pvt Ltd, Pune, Maharashtra
10. ElectroMech, Pune, Maharashtra.
Darshana Thakkar is MSME Transformation Specialist and Founder, Transformation – The Strategy Hub. An Electrical Engineer followed by MBA – Operations with hardcore industry experience in managing business operations, Darshana is an expert in transformation of businesses that helps them achieve growth with speed and scale. She has invested 27 years in transforming Micro and Small Enterprises. Her rich experience in resolving pain areas and the MSME/SME industry's real-life problems are helping the organisation for quick results.
Darshana has helped many MSMEs to increase profitability & achieve sustainable growth. She is keen on the growth of Indian Startups, providing mentoring and hand-holding support to startups to make them succeed quickly.
She is very passionate about supporting women in pursuing their career and life goals. She is actively working for women's entrepreneurship and leadership development.
She is:
· Founder and CEO of Transformation
· Certified Women Director by IICA, Ministry of Corporate Affairs, Government of India
· Empanel and recognised Startup mentor and Trainer by CED, Government of Gujarat
· Registered and Verified Business Advisor – Tata Nexarc, Tata Business HUB, Mumbai, and
· Chairperson: MSME Support & PRO at Makarpura GIDC Association, Vadodara.
MSME Transformation and Strategic Advisor – MSME Business Forum India, Darshana has received various accolades:
· Winner of Gujarat Women's leader award 2022 by CMO Asia
· Winner of Influential Women leader in business by Insight Success 2022
· Recognised as India's most trusted consulting company by Insight Success 2022
· Felicitated by Mentor my board in the gracious presence of Honourable FM Mrs. Nirmala Sitaraman during Women Director's conclave – 2022
· Felicitated by the president of Makarpura GIDC Association during the Suvarna Jayanti Mahotsav on 17th December 2022 for her excellent contribution in supporting MSME and startup Businesses.
Apart from this, she is an author and publishes her blog, article, and case study related to the industry. Email: [email protected]
