MATERIAL HANDLING

SYSTEM

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• Material handling refers to the movement, protection, storage, and control of materials and
products during manufacturing, storage, distribution, consumption, and disposal.

• It involves the use of manual, semi-automated, and automated equipment.

• Conveying is a part of material handling and refers to the continuous movement of materials
from one place to another.

• Any delay in raw material movement according to the production schedule can slow down the
manufacturing process.
• In the pharmaceutical industry, conveyors are widely used in the production of:
• Tablets
• Capsules
• Liquid oral dosage forms

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OBJECTIVES OF CONVEYING
The main objectives of conveying systems are:
• To reduce overall product cost
• To reduce manufacturing cycle time
• To increase manufacturing capacity
• To reduce raw material handling cost
• To reduce processing time
• To prevent contamination and dust formation
• To achieve a high degree of uniformity and productivity at low manufacturing cost
• To provide better quality products without damage
• To increase storage capacity
• To provide better and safer working conditions

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APPLICATIONS OF CONVEYING

1. Ergonomics

• Conveyors reduce manual handling of loads, thereby minimizing operator fatigue and injury
caused by pushing or pulling heavy materials.

2. Process Flow

• Conveyors ensure a smooth and continuous flow of materials, making them an integral part of
assembly lines and manufacturing processes.

3. Safety

• Since conveyors move materials along a fixed and controlled path, they reduce accidents and
collisions associated with forklifts and manual handling.

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4. Speed Control

• The speed of conveyors can be adjusted according to process requirements, ensuring

efficient material transfer.

5. Transportation

• Conveyors facilitate the internal movement of raw materials, containers, and finished
products with minimum or no labor, improving efficiency.

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TYPES OF CONVEYORS

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BELT CONVEYORS

Principle

• Belt conveyors are used to transport solid materials and bulk objects at high speed.
They work on the principle of moving materials from the feeding point to the discharge point
using a continuous rotating belt driven by a motor through pulleys.

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Construction

• The main components of a belt conveyor are:

• Belt & Belt Tightening System

• The belt consists of a core carcass made of multiple plies of cotton duck, bonded and coated
with rubber.
• Both ends of the belt are joined to form a continuous loop.
• Special belts made of neoprene, Teflon, or cord are used for abrasive materials or superior
performance.
• Belt thickness: Should be optimal—too thin causes sagging; too thick prevents proper
troughing.
• Tighteners: Adjust for changes in belt length due to temperature and humidity to maintain
uniform stress.
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Belt Drive & Power Supply

• A bare steel pulley powered by a motor drives the belt.

• Snubber idlers below the pulley increase the contact area for better traction

Rollers (Idlers)

• Rollers support the belt along its path and are called idlers.

• Troughed idlers lift the belt edges and depress the center to hold material properly.

• Correct selection of idlers ensures optimal load capacity and efficiency based on the
environment.

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Feeding & Discharge Arrangement

• Material is fed at the start and discharged at the end of the belt.

• In pharmaceuticals, belts are used for strip and blister packing of tablets and capsules.

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Working of a Belt Conveyor

• How the belt moves

• The rotor (pulley) rotates, and the belt moves because of friction between the pulley
and the belt.

• One side of the belt moves in the forward direction, while the other side moves back on
the return side.

• Close contact between the pulley and belt is essential to prevent slipping.

• Snubber idlers are used to press the belt against the pulley, improving friction and
ensuring smooth movement.

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Loading the material

• Material is fed onto the belt using a hopper.

• It is usually loaded from one side to the center of the belt.

• The moving belt carries the material forward continuously.

Discharge of material

• At the end of the conveyor, material is collected in a discharge bin.

• Collection can be mechanical (e.g., scraper or chute) or manual.

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Selection of a belt conveyor
When choosing a belt conveyor, the following factors are considered:

• Speed of the belt – How fast material needs to move

• Width of the belt – Depends on the amount of material

• Power required – Motor size to move the belt with load

• Mechanical & tensile strength – Strength of belt and structure

• Troughability – Ability of belt to form a trough for holding material

• Material size – Size of particles or objects being conveyed

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Applications:
• During production of dosage form (such as injections, liquid orals and ointments), belt conveyors
are used to transport container for filling, capping, labeling etc.
• Stripes are conveyed through moving belt for strip and blister packing of tablet and capsule.
Advantages:
• Simple structure.
• Easy to maintain.
• Low energy consumption.
• Large load capacity. Belt conveyors run at speed of 1000 fpm and load 5000 tons per hr.
Disadvantages
• Costly equipment.

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 SCREW CONVEYOR
Principle

• Screw conveyors work on the principle of transporting material from the feeding point to
the discharge point by the rotation of a helical screw (flight) driven by a motor.
When the screw rotates, the material moves forward along the trough.

• Simply put: rotation of the screw = forward movement of material.

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Construction

1. Trough System

• Made of U-shaped steel trough.

• It houses the screw and prevents material from spilling.

• Supports and guides the movement of material.

2. Screw / Flight

• The spiral blade, called the flight, is the main conveying element.

• It is a long ribbon twisted into a spiral (helicoid shape).

• Flights are welded to a central shaft using hangers.

• When the shaft rotates, the flight also rotates.

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3. Shaft and Power Supply

• Power from the motor is transmitted through the shaft to rotate the screw.

• Bevel gears are installed at the drive end to:

• Maintain proper speed

• Ensure smooth rotation of the shaft

4. Feeding Arrangement

• Material is fed through a hopper.

• Different feed arrangements used.

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5. Discharge Arrangement

• Material exits through various discharge systems such as:

• Open-end trough

• Open bottom trough

• Curved side gate

• The drive end and discharge end together are called box ends.

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Working of Screw Conveyor

• Power supply is switched on.

• The motor rotates the shaft with the help of bevel gears.

• The shaft rotates axially, causing the flight (spiral blade) to rotate.

• Material is fed through the hopper.

• The material gets trapped between the flights and the trough.

• As the screw rotates, the material is pushed forward along the trough.

• Finally, the material is collected in the discharge bin, usually through an open-end trough.

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Applications:

• It is used to convey fine, pasty solids, abrasive and non abrasive materials.

• It can transport material with capacity of 280 m3/hr.

• Incorporated for in situ devices for mixing, heating, cooling etc.

Advantages:

• Operated at positive as well as negative pressure.

• It occupies less space.

• Material can be conveyed horizontally as well as vertically.

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Disadvantages:

• High power consumption.

• High speed cause abrasive problem.

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 PNEUMATIC CONVEYORS
Principle

• Pneumatic conveyors work on the principle of transporting materials using a high-velocity air
stream.
The air stream suspends solid particles and carries them through pipelines from the feeding point
to the discharge point.

• This mode of transport is known as a fluidized system, where solid particles behave like a fluid
due to air suspension.

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Construction

• Air Supply System

• Includes fans or cycloid blowers.

• Generates high-velocity air required for conveying.

• Pump / Blower

• Supplies air at a pressure of about 7 kPa.

• Air Slides

• Help in fluidizing the material before it enters the pipeline.

• Feed Arrangement

• Material is fed using a rotary feeder valve.

• It controls the rate of feed and prevents air leakage.

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Pipelines

• Carry the air-material mixture to the discharge point.

Discharge Arrangement
•The pipeline end is connected to a cyclone separator.
•Separates solids from air.
Collection System
•Large particles are collected in bins.
•Fine particles are trapped using bag filters.
•Clean air is released or recycled.

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Working

• The cycloid blower generates air at a pressure of about 7 kilopascals.

• Air passes through the air slide, fluidizing the material.

• The rotary feeder valve rotates, allowing material to enter the pipeline.

• Solid particles become suspended in the air stream.

• The air-solid mixture moves through the pipeline.

• The mixture enters the cyclone separator:

• Large particles settle in the collection bin.

• Fine particles are removed using bag filters.

• The air is either released or recycled back into the system.

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Applications:

• It is used for transferring powders, granules, and other dry bulk materials through enclosed

• pipelines.

• It is used to move lightweight material quickly from one place to another without vessel.

• As it is a closed system, therefore also used to handle poisonous material.

• Fine powder having bulk density 1 to 200 lb/ft3 can be handled by pneumatic conveyors.

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Advantages:

• The material travel from few meters to several hundred meters.

• It consists of simple, small diameter pipeline to transfer material.

• The system is totally enclosed and typically has few moving parts.

• Friction losses are small.

Disadvantages:

• A pneumatic conveying system requires more horsepower than other conveyor system.

• In case of large particle size and extremely sticky material there are chances of total pipeline blockage.

• Sometime attrition of solid occurs.

• Chances of erosion of internal surface

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