UNIT V: Material handling in Food plants

Expressed in simple language, materials handling is loading, moving and unloading of

materials. To do it safely and economically, different types of tackles, gadgets and
equipment are used, when the materials handling is referred to as mechanical handling
of materials.

One of the definition adopted way back by the American Materials Handling Society is:
Materials handling is the art and science involving the moving, packaging and
storing of substances in any form. Some of the other definitions are:

• Materials handling is the movement and storage of materials at the lowest possible cost
through the use of proper methods and equipment.

• Materials handling is the moving of materials or product by any means, including

storage, and all movements except processing operations and inspection.

• Materials handling is the art and science of conveying, elevating, positioning,

transporting, packaging and storing of materials.

Materials handling uses different equipment and mechanisms called Materials Handling
Equipment. Though in one of the definitions, processing operations and inspection have
been specifically excluded from scope of materials handling operations, it is worth
mentioning that in specific cases processing or inspection of materials may be
accomplished simultaneously with handling activity. One definition also covers the
important objective of materials handling which is lowest cost solution.

The essential requirements of a good materials handling system may be summarized as:
(i) Efficient and safe movement of materials to the desired place.

(ii) Timely movement of the materials when needed.

(iii) Supply of materials at the desired rate.

(iv) Storing of materials utilizing minimum space.

(v) Lowest cost solution to the materials handling activities.

Functional scope of materials handling within an industry covers the following:

(i) Bulk materials as well as unit materials handing. Bulk handling is particularly
relevant in the processing, mining and construction industries. Unit materials
handling covers handling of formed materials in the initial, intermediate and final
stages of manufacture.

(ii) Industrial packaging of in-process materials, semi finished or finished goods,

primarily from the point of view of ease and safety of handling, storage and
transportation. However, consumer packaging is not directly related to materials
handling.

(iii) Handling of materials for storage or warehousing from raw materials to finished
product stage.

IMPORTANCE OF MECHANICAL HANDLING SYSTEM

A well designed materials handling system is important because it attempts to achieve

the following:

(i) Improve efficiency of a production system by ensuring the right quantity of

materials delivered at the right place at the right time most economically.

(ii) Cut down indirect labour cost.

(iii) Reduce damage of materials during storage and movement.

(iv) Maximize space utilization by proper storage of materials and there by reduce
storage and handling cost.

(v) Minimize accident during materials handling.

(vi) Reduce overall cost by improving materials handling.

(vii) Improve customer services by supplying materials in a manner convenient for

handlings.

(viii) Increase efficiency and saleability of plant and equipment with integral
materials handling features.

BASIC EQUIPMENT TYPES

i) Industrial Vehicles/Trucks.

ii) Conveyors.

iii) Hoisting Equipment.

iv) Bulk Handling Equipment/System.

 v) Robotic handling system.

vi) Containers and Supports.

vii) Auxiliary Equipment.

Conveyors

These are gravity or powered equipment commonly used for moving bulk or unit load
continuously or intermittently, unidirectionally from one point to another over fixed path,
where the primary function is conveying of the material by the help of movement of
some parts/components of the equipment. The equipment as a whole does not move. e.g.,
belt conveyor, screw conveyor, slat conveyor & pneumatic conveyor.

Hoisting Equipment

These equipment are generally utilized to lift and lower and move unit and varying loads
intermittently, between points within an area known as the reach of the equipment, where
the primary function is transferring. A hoisting equipment may also be mounted on a
powered vehicle when the movement of the lifted load is not limited within a fixed area
of operation. e.g., bucket elevator and crane.

Elevators: The term elevator is used to signify a group of materials handling equipment
which carries materials up or down. The group includes a number of diverse type of
equipment like bucket elevators, skip hoists, freight elevators, lifts etc.

Bulk Handling Equipment/System

In the large process industries and constructional projects, a wide range of heavy
equipment are used for handling and storage of large amount of bulk solids. These are
called bulk handling equipment. e.g., ship loader and unloader and container handling
crane.

BELT CONVEYORS (belt conveyors are not in syllabus)

Definition / Description

A belt conveyor consists of an endless flat and flexible belt of sufficient strength, made of
fabric, rubber, plastic, leather or metal, which is laid over two metallic flat pulleys at two
ends, and driven in one direction by driving one of the two end pulleys. Material is placed
on this moving belt for transportation. The active half of the belt is supported by idler
rollers or slider bed. The return half of the belt may or may not be supported, as it
generally does not carry any additional load other than its own weight. The endless belt is
kept taught by a belt tensioning arrangement.

General Characteristics

(i) Belt conveyors operate in one vertical plane, horizontally or with an inclination
(up or down) depending on the frictional property of the load conveyed.

(ii) For changing direction of the materials being conveyed, in the horizontal plane,
more than one belt conveyors are needed.

(iii) Conveying capacity of a conveyor can be controlled by changing belt speed.

(iv) Belt conveyors are generally employed for continuous flow of materials.

(v) Metal/special belts can carry hot, abrasive or reactive materials.

Types

Flat Belt Conveyor: In this conveyor, the active side of belt remains flat supported by
cylindrical rollers or flat slider bed. The conveyor is generally short in length and suitable
for conveying unit loads like crates, boxes, packages, bundles etc. in manufacturing, ship-
ping, warehousing and assembly operations. Flat belts are conveniently used for
conveying parts between workstations or in an assembly line in mass production of
goods.
Troughed Belt Conveyor: In this conveyor, comparatively wide flat belt is supported on
troughed carrying rollers or shaped supporting surface so that the two edges of the active
side of the belt are elevated from the middle part to form a trough. This provides a greater
carrying capacity than a flat belt of equal width for conveying bulk materials or those
materials which would slide off flat belts. These conveyors are used in handling bulk
materials of different classes. The return side of the belt is generally kept flat supported
on cylindrical rollers.

SLAT CHAIN CONVEYORS

Definition / Description

The term chain conveyor means a group of different types of conveyors used in diverse
applications, characterized by one or multiple strands of endless chains that travel entire
conveyor path, driven by one or a set of sprockets at one end and supported by one or a
set of sprockets on the other end. Materials to be conveyed are carried directly on the
links of the chain or on specially designed elements attached to the chain. The load
carrying chain is generally supported on idle sprockets or guide ways. The endless chains
are kept taught by suitable chain tensioning device at the non-driven end.

Apron or Pan Conveyor: This is the most common type of chain conveyor. It consists of
one or more strands of endless chain, usually link plate roller type, running in steel
guides. Rollers ensure minimum pulling effort in the chain, while roller guides supported
on the superstructure of the conveyor, carry the entire load of the materials and chains.
The carrying surface of the conveyor is composed of a series of plates or shapes called
apron, which are attached to the links of the chains through cleats. The bed created by
the aprons is used for carrying bulk materials as well as unit loads. When the conveyor
aprons have vertical flanges on all sides to form a pan like shape, if is specifically called
a pan conveyor. Materials carried by the apron is discharged over the sprockets at the
driven end, and the conveyor chain with aprons comes back empty on its return Journey.
These are generally slow speed conveyors with a speed range of 20 to 35 mpm.

Flat, spaced apron: Conveyor with rectangular shaped flat steel or wooden slat aprons
with small gaps between them, providing a flat surface for carrying unit loads are
specifically called ‘‘slat conveyor’’
 (i) Flat, spaced apron: Conveyor with rectangular shaped flat steel or wooden slat aprons
with small gaps between them, providing a flat surface for carrying unit loads are specifi-
cally called ‘‘slat conveyor’’ [Fig. 6.2.2 (a)]. Some other designs of flat and spaced aprons
with cleats for carrying different shaped object are shown in Fig. 6.2.2 (b) and (c).

(a) Slat Conveyor (b) (c)

Fig. 6.2.2. Flat spaced apron conveyor

The major components of a chain conveyor are : (i) Pulling chain, (ii) Sprocket to drive
(ii) Corrugated apron: These are the most common type of apron, made of formed steel, with
and support the chain, (iii) Take-up arrangement, (iv) Drive arrangement and (v) Various
front and rear edges beaded so that one overlaps the other to form a continuous bed or
other components specific to various type of chain conveyors.
trough. The overlaps are so made that during turning of the chain over sprockets, the apron
Pullingends moveDifferent
Chains: relative totypes
eachofother without
chains creating
are used a gap
in chain for leakage
conveyors suchofasmaterials
Round- or a jam-
link chains,
ming of Combination
adjoining apronschains or
andpans.
Link-plate chains
Fig. 6.2.3 (Sometimes
shows corrugated called leafofchain).
aprons different styles.
Chain Some
selection is based on largest practical pitch (being cheaper than the
of the aprons are plain while some are provided with overlapped verticalshorter pitch end plates
chain of equal strength), allowable tension load, capital cost and degree of maintenance
to form pans. Corrugated aprons or pans may be fabricated or cast from gray or malleable
needed.
iron. The pans are designated as leakproof (for carrying fines), shallow, deep and hinged
(for carrying
Sprockets: chips, trimmings,
each of several projections scrap
on theetc.). Deep
rim of pansthat
a pulley mayengage
be used forthe
with carrying
links ofmaterials at
a chainanorinclination
with holesof in upto
film,45°.
tape, or paper. The sprockets are made of good grade cast
iron with chilled hardened teeth or from cast steel or plate steel. The teeth are machined
to suit type of chain used.

Take-up arrangements: The most common type of take-ups is adjusting screw type for
positioning the bearing blocks supporting the takeup sprocket shaft.

Drive arrangement: Drive for a convey or generally consists of an electric motor

coupled to a speed reduction gear unit which in turn is coupled to the driving sprocket.

Applications: Generally apron and pan conveyors are used to perform severe duties of
conveying large quantities of bulk load such as coal, ore, slag, rock, foundry sand etc.
These are frequently used for feeding materials to large crushers, breakers, grinders and
similar machines. Part of an apron conveyor may be run through a liquid or water bath
for washing of the materials and then allow drainage of liquid from wet materials.

SCREW CONVEYORS

Definition, Characteristics and Use

A screw conveyor consists of a continuous or interrupted helical screw fastened to a shaft

which is rotated in a U-shaped trough to push fine grained bulk material through the
trough. The bulk material slides along the trough by the same principle a nut prevented
from rotating would move in a rotating screw. The load is prevented from rotating with
screw by the weight of the material and by the friction of the material against the wall of
the trough.

A screw conveyor is suitable for any pulverized or granular non-viscous material, and
even at high temperature. The conveyor is particularly suitable for mixing or blending
more than one materials during transportation, and also for controlling feed rate of
materials in a processing plant. Abrasion and consequently certain amount of degradation
of the material is unavoidable, hence it is not suitable for brittle and high abrasive
materials. It is also not suitable for large-lumped, packing or sticking materials.

Descriptive Specifications

A typical screw conveyor is shown in the figure. The screw shaft, if short (up to 5
meters), is supported at two ends. But for longer shafts (upto 40 to 50 m), they are
supported by bearing hangers, at intermediate points. The shaft may be solid or hollow.
Hollow shafts are lighter and can be easily joined to make a long shaft. The screw shaft is
driven at one end, and the design may permit discharge of material from the bottom or
one end. Opposite handed screw at two sides will cause the center discharge. The U-
shaped fabricated trough are generally covered at the top to avoid particulate pollution.
The bottom portion of the trough is of circular cross section matching the diameter of the
screw. Generally a radial gap of 10 mm to 20 mm is kept between the screw and the
trough, depending on size of the screw.
CONVEYORS 113

6
7 2 3 A
4
5

10

A
1
CONVEYORS
9 8
Section AA

6
7 2 3 A
4
5

10

A
1
9 8
Section AA

1-shaft with screw; 2-trough; 3-Intermediate hanger bearings; 4-front bearings; 5-terminal bearing; 6-feed
hopper; 7-sight glass; 8-Intermediate discharge spout with gate; 9-terminal discharge hopper (open); 10-
drive system (motor, gear box and coupings).
Fig. 6.7.1. Arrangement of a screw conveyor
Screws of different constructional design and style are used such as (a) solid, continuous;
Screws of different constructional design and style are used, which are shown in Fig. 6.7.2.
(b) ribbon;
Continuous (c)are
screws paddle-flight; (d) cut-flight
generally made from 4 to 8 mm sheet steel circular section with a hole corre-
sponding to the size of the shaft. One radial slit is made in this section, and then formed into one pitch of
The drive
the screw. unit comprises
The section is welded of an electrical
to the motor, or
shaft and welded gear box to
riveted and couplings.
each other to form the entire length
of the screw. The screw may also be cast integral with the shaft. The paddlebearings;
1-shaft with screw; 2-trough; 3-Intermediate hanger 4-front
type flights bearings;
consist 5-terminal bearing; 6-fe
of cast
Material is fed hopper;
throughfixed
the feed7-sight glass; 8-Intermediate discharge spout with gate; 9-terminal discharge hopper (open); 1
straight or curved segments to thehopper fixed
shaft. A on the
ribbon trough
screw cover.
is fixed A number
to the shaft byof discharge
means of radial
drive system (motor, gear box and coupings).
rods. sprouts with rack gears for closing and opening as required, are provided.
Fig. 6.7.1. Arrangement of a screw conveyor
Screw conveyors are generally operated horizontally or at a small inclination (10° to
Screws of different constructional design and style are used, which are shown in Fig
20°). However, there are special
Continuous designs
screws where themade
are generally load from
is moved
4 to 8vertically
mm sheetupsteel
or atcircular
a section with a hole
small angle to vertical.
spondingThese aresize
to the called vertical
of the shaft. screw conveyors.
One radial slit is made in this section, and then formed into one
the screw.
(a ) The section is welded to the shaft and welded or riveted to each other to form the entire
of the screw. The screw may also be cast integral with the shaft. The paddle type flights consist
straight or curved segments fixed to the shaft. A ribbon screw is fixed to the shaft by means o
rods.( b )

(c )
(a )

(d )

(b )
(a) solid, continuous; (b) ribbon; (c) paddle-flight; (d) cut-flight Photographs of different types of screw
Fig. 6.7.2. Types of screw used in screw conveyor

(c )

(d )
PNEUMATIC CONVEYORS
Definition
Pneumatic conveying is the process of conveying granular / powdered materials by
floating the materials in a gas, primarily air, and then allowing it to flow to the
destination through a closed pipe. The operating principle common to all types of
pneumatic conveying is that motion is imparted to the material by a fast moving stream
of air.
Thus any pneumatic conveyor consists of an air supply equipment (blower or
compressor), pipelines, product storages, air lock feeders and dust filters.
Application
Pneumatic conveying system is used for delivery of non-sticky, dry materials via
pipelines to various storage or process points which are economically inaccessible by
conventional conveyors. It is self cleaning system, preventing accumulation of materials
in the conveying system. Because of this, the same installation may be used for
conveying different materials.
Types of Pneumatic Conveyors
Pneumatic conveyors are broadly classified into following three groups, based on
application:
A. Pipeline Conveyor. B. Air-activated Gravity Conveyor (Air slide). C. Tube Conveyor.

Pipeline Conveyor
Further classification of pipeline conveyors are made on the basis of air pressure
used. As per IS:8647-1977 ‘‘Design Criteria for Pneumatic Conveying Systems’’, the
following classifications may be made:
(a) Low pressure system, in which the operating air pressure is normally limited to
1atomsphere (760 mmHg) gauge, supplied by a positive displacement lobe type blower
(roots blower). These systems are restricted to short distances (up to 500 m) and small
flow rate. These systems are further sub-classified into:
(i) Positive pressure system.
(ii) Negative pressure (or suction) systems.
(iii) Combined negative-positive pressure (or combination) system.
(b) Medium Pressure System, with air pressure form 1 to 3 atmospheres, gauge.
(c) High Pressure System with air pressure from 4 to 7 atmospheres, gauge .
Medium and high pressure systems are essentially positive pressure type systems.

Positive pressure system: A positive low pressure pipeline system is one in which a
positive air flow, created by a positive displacement blower, effectively transport slow
flowing materials over a distance up to 500 meters.
The major characteristics of this system is that it can pick up material from one source
and discharge the same to more than one points.
 Negative pressure (or suction) system: In this type of conveyor, a positive displacement
blower creates a vacuum in the conveyor pipe line, which causes the material to be
sucked through one or multiple nozzles and conveyed to a receiving hopper. The
conveyed material is separated from the air stream and collected in the hopper. The air is
generally made to pass through a dust collector to be freed from remaining finer particles
of materials and then released to the atmosphere.
Easy flowing materials like cereals, grains, powdery materials etc. are conveyed in
ND HYDRAULIC suction conveyors. In thisPNEUMATIC
CONVEYORS
AND HYDRAULIC CONVEYORS
system, materials from
121multiple storage points may be
collected and transported to a single storage point.

Vent Lines
Vent Lines
Dust
Bin Vent Collector
Filters Receiving
Conveying
Lines Hopper
Dust
Collector

Receiving
122 INTRODUCTION TO MATERIALS HANDLING
Hopper Storage
Hopper
collector to be freed from remaining finer particles Air
of Inlet
materials and then released to the atmos- Diverting
Feeding phere. Schematic view of aDiverting
negative pressure pipeline
Nozzleconveyor is shown in Fig. 7.1.2. Easy Valves
Hopper Valves
Silo flowing materials like cereals, grains, powdery materials etc. are conveyed in suction convey-

Conveying
ors. In this system, materials from multiple storage points may be collected and transported to a

Lines
Cyclone
single storage point. Filter Receiver
Wagon Suction Intermediate
The major advantage of thisLine
Conveying system is that at leakage points, air from surroundings
Side enters the
Air Inlet Storage Feeders
Filter system, and hence air pollution through materials leakage is virtually nil. Therefore,
Motor this sys-
Blower Rotary Air
Rotary Airlock Feeder
tem is particularly useful for toxic and very fine powdered materials. However, the major limi- Lock
Feeders
tation is that, if the air is not totally separated from the conveyed materials, dust laden air passes
Blower
through the blower and tends to damage it. Moreover, the distance and volume of conveying is
also limited because the actual vacuum created inside the pipeline is often not below 0.3 atmos-
phere (230 positive
mmHg), absolute. Fig. 7.1.3. Positive-negative pressure system
Fig. 7.1.1. A typical pressure system
The three figures 7.1.1, 7.1.2 and 7.1.3 are based on figures in IS:8647-1977.
itive displacement blower (lobe type or roots blower) sucks air from the atmosphere
h a suction filter and delivers pressurized air into the conveyor Medium and high Filter Receiver
pressure systems: These systems are basically similar to a positive pres
Air pipe
Line line. Materials to be
system in its
yed are introduced into the pipelines from the feeding bin/hopper through different typesoperational principles. The difference is the range of air pressure used. Becaus
Rotary
use of increased air pressure, the medium
Airlock and high pressure systems principally differ fro
lock feeder at controlled rate. Air lock feeders are used Filter
at the outlet port of the feeding Feeder
low pressure system in two aspects. Firstly, the type of air supply equipment will vary accord
or discharge of materials into the pipeline, without being blown out from the top of such
to the pressure selected. Secondly, the feeding devices used will be different to make the sys
ecause of high air pressure. The materials so introduced are immediately air laden and Receiving
leakproof. Hopper
to one or a number of receiving bins / silos throughFilter
diverting valves, also called change
valves. A single stage rotary compressor is used for a medium pressure pneumatic conveying sys
Vacuum Pump
while a double stage rotary compressor is normally used for a high pressure system. The med
verting valves are generally designed for one inlet and two outlets, but multiple outlets
pressure system generally operate continuously while a high pressure systems may be used
o possible. The valves are operated either manually or through remote controlled actua-
continuous, intermittent or batching operations.
he air, after the material get discharged at the receiving hoppers, is made to pass through
propriate dust removal system, before it is allowed to escape back In to
medium pressure system generally screw feeder (also termed screw pump) is used
atmosphere.
feeding materials from the feeding hopper / silo to the conveyor pipe. Screw feeders are suit
rincipal advantage of this system is that the blower does not handle dusty
Conveying
for safeLine
air. However,
(no leakage of air through hopper) operations upto an air pressure of 2.5 to
ajor disadvantage of the system Air is Inlet
the possible leakage of highatmospheres,
pressure airgauge.
along Forwithhigh pressure system, feeding of material is done through blow t
Nozzle
als to the surroundings. (also called chamber feeder) type line charger.
ive pressure (or suction) system: In this type of conveyor, a positive displacement
In these medium and blower
high pressure systems, the materials flow takes place in the dense ph
s a vacuum in the conveyor pipe line, which causes the material to i.e. the mass flow ratioone
be sucked through of material particles to air is over 15. The low pressure systems ope
ltiple nozzles and conveyed to a receiving hopper. The conveyed material
at dilute phaseis separated
i.e. mass flow ratio being less than 15.
he air stream and collected in the hopper. The air is Fig. 7.1.2. Negative
generally made topressure system a dust
pass through
Combined negative-positive pressure (or combination) system: In this system the principles
of both positive pressure system and suction system are employed. This type of pneumatic
The major advantage of this system is that at leakage points, air from surroundings enters
the system, and hence air pollution through materials leakage is virtually nil. Therefore,
this system is particularly useful for toxic and very fine powdered materials.

Combined negative-positive pressure (or combination) system: In this system the

principles of both positive pressure system and suction system are employed.
This type of pneumatic conveyor is particularly employed when materials from more than
one points have to be picked up and simultaneously delivered to multiple delivery points.
For this system generally one positive delivery blower is used.

Medium and high pressure systems: These systems are basically similar to a positive
pressure system in its operational principles. The difference is the range of air pressure
used. Because of use of increased air pressure, the medium and high pressure systems
principally differ from a low pressure system in two aspects. Firstly, the type of air
supply equipment will vary according to the pressure selected. Secondly, the feeding
devices used will be different to make the system leak proof.
A single stage rotary compressor is used for a medium pressure pneumatic
conveying system while a double stage rotary compressor is normally used for a high
pressure system. The medium pressure system generally operate continuously while a
high pressure systems may be used for continuous, intermittent or batching operations.
BUCKET CONVEYORS / ELEVATORS
These conveyors convey bulk loads in bucket shaped vessels, which are attached to a
system of moving chains or belt. Bucket elevators are designed to convey product in a
primarily vertical direction. Bucket elevators come in a variety of sizes to handle
products that range from dry, dusty powders to heavy iron ore or aggregate. Bucket
elevators work best with dry materials, although some manufacturers have developed
designs that will work acceptably with wet materials. The key to conveying wet materials
is that they cannot be sticky or tend to build up or collect in the buckets.
Definition: These are powered equipment for conveying bulk materials in a vertical or
steep inclined path, consisting of an endless belt, or chain/s to which metallic buckets are
fixed. With the flexible belt/chain, the buckets move unidirectionally within a casing and
collects bulk materials at bottom end of the equipment and delivers it at the top end.
Product is fed to the bucket elevator through a hopper. Buckets or cups dig into
the product, convey it up, and dump it out at the discharge. These are generally classified
as (a) Gravity discharge bucket conveyor, (b) pivoted bucket conveyor and (c) bucket
elevator.
Pivoted Bucket Conveyor: These conveyors consist of two strands of chains between
which are pivot mounted a series of buckets to carry in-process movement of various unit
loads (forged components, boxes etc.) along complex contours comprising horizontal and
vertical paths in one vertical plane. The buckets are made of steel plates in the shape of
buckets for carrying powdered or granular bulk load. As the trays are pivot mounted from
the links of the chains, the bucket along with their loads always remain suspended
vertically irrespective of the path of the chain.
Bucket conveyors are loaded on vertical sections manually or automatically by
specially designed loading devices. These conveyors are particularly used for raising
/lowering of loads between floors, convey materials between processing equipment, carry
loads without transfer between interlinked horizontal and vertical sections. The conveyor
may be used for carrying load through processing stations like drying, pickling chambers
etc.
The bulk material is fed into the buckets on the lower horizontal section and
carried through various sections without transfers, and hence is not crushed en-route. The
pivoted buckets are discharged at the upper horizontal section automatically by tippers or
dischargers. The buckets are fitted with projecting curved cams or guide rollers, which on
coming in contact with the arms of tippers, tip the buckets. Pivoted bucket conveyors are
used in power plants in carrying coal and ashes, in cement mills, ceramic industry, stone
crushing plants etc.
 with the arms of tippers, tip the buckets. Fig.6.2.15 shows the two common schemes of bucke
through various
carrying load through processing stations like drying, pickling chambers [Link] without
Fig.6.2.14 illus-transfers, and hence is not crushed
tipping devices. Pivoted bucket conveyors are used in power plants in carrying
trates a typical layout of a pivoted bucket conveyor showing different components of the con- horizontal
buckets are discharged at the upper coal
section and ashe
automatically by
The buckets are fitted with projecting curved cams or guide rollers, whi
veyor. in cement mills, ceramic industry, stone crushing plants etc..
with the arms of tippers, tip the buckets. Fig.6.2.15 shows the two com
5 tipping devices. Pivoted bucket conveyors are used in power plants in
4
in cement mills, ceramic industry, stone crushing plants etc..

Unloading 1

2 3

(a)
(a) Loading 6 devices of pivoted bucket conveyor (b)
Fig. 6.2.15. Tipping (a) movable device with eleva
Fig. 6.2.15. Tipping devices of pivoted bucket conveyor (a) movable devicebuckets;
with (b)
elevating lever
guide rollers and cam on
on buckets.
buckets; (b) guide rollers on buckets.
6.2.4 Components of Chain Conveyor
The major
1. Pulling chain, 2. buckets, 3. vertical guides (to prevent oscillations), components
4. driving sprocket,of a chain conveyor are : (i) Pulling chain, (ii
6.2.4 Components of Chain Conveyor
5, take-up sprocket, 6. tipping divice. support the chain, (iii) Take-up arrangement, (iv) Drive arrangement and (v) Va
specific to various type of chain conveyors.
The major components
Fig. 6.2.14. Layoutof
of a chainbucket
a pivoted conveyor
conveyor are : (i) Pulling chain, (ii) Sprocket to drive an
(a) Pulling Chains: Different types of chains are used in chain conveyors,
support theofchain,
The design the trays(iii) Take-up
are adapted arrangement,
to the (iv) Drive
requirements of loads and arrangement
and method
demerits, ofbriefly and (v)
loadingdiscussed Various other componen
below:
/ unloading.
specific tomay
The trays various
Gravity type
be flatDischargeof chain
or curved. Bucket
When conveyors.
theConveyor or V-bucket
trays are made of steel Conveyor
plates
(i) Round-linkin thechains
shape(Fig.
of buckets
6.2.16) are low in cost and high flexibilit
for carrying powdered or granularcomprising
A conveyor bulk load, the of particular
one or more conveyorhave isflexibility
endless called which
of ischain
pivoted
strands particularly
bucket with desirable
spaced in trolley conveyors.
(a) Pulling Chains: Different types of chains are used
this in
chain chain
transverse buckets attached which push granular bulk material along a shaped [Link] lessconveyors,
contact area,which
highhave their
stretch merilo
under
andThedemerits,
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be loaded below:
at any point into the trough and discharge a
can also be effected
(i)at Round-link
various pointschains
through (Fig.
openings6.2.16)
in the are
trough low in cost
floor, closedand high flexibility
by sliding in all directions. Th
gates. Both upper
andhave flexibility
lower strand may which is particularly
be used (
for transportingadesirable
) materials in in
trolley
oppositeconveyors.
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These limitations o
this chain
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materials of small to moderate size to move them in both direction. These are used for
a
handling coal, ashes, sand, gravel, ore, wood chips, saw dust, chemicals, grains, cereals,
(b)
generally for loading bunkers and bins and also used under floorl for removal of metal
chips/cut pieces.
(a)
A typical V-bucket conveyor consists(c)of a two-chain flight conveyor with flights
made in the shape of fixed
d buckets, such a conveyor is called gravity discharge bucket
conveyor, also called V-bucket conveyor. These can fill up buckets in the horizontal
section, move through vertical sections carrying bulk material and then
Short or long-linked discharge the Round-link chain being
welded
material in another horizontal trough section at a higher level for filling upFig.of6.2.16.
bins etc.
Round-link chain
(b) l

( c)

Short or long-linked welded Round-link chain being driven by sprocket

Fig. 6.2.16. Round-link chain
 can fill up buckets in the horizontal section, move through vertical sections carrying bulk mate-
rial and then discharge the material in another horizontal trough section at a higher level for
filling up of bins etc. Scheme of such a V-bucket flight conveyor is shown in Fig. 6.3.2.

T.U. travel 8

7 6 5 2 Drive

9 Unloading
5
6
4
3
A A

Section BB
5 6 5

7
Loading 1
B

B l

1,2- horizontal trough; 3,4-casing of vertical sections; 5-chain; 6-buckets; 7-turning sprockets;
8-driving sprocket; 9-take-up sprocket.
Fig. 6.3.2. V-bucket flight conveyor
Grab bucket Elevator: These are specially designed bucket attachments, which scoop
(c) Tow Conveyor: This consists of a single strand endless chain which tows floor/ track mounted
loose
trucks,materials and
dollies or dump
cars them mechanically
on which the materials arethrough
[Link]
Tow conveyors of ropes
are from the used for
generally
crane. Grabofbuckets
handling are used
unit loads like for handling
boxes, large
barrels, amount
crates, of loose
cartons, in materials throughincranes.
the warehouse, assembly lines
The bucket essentially consists of two clam shell like scoops with rounded bottoms
and for intra-plant movement. Though the tow conveyors follow a fixed path, the carts can be which
are hung by
detached fourfrom
easily rods the
fromconveyor
a top cross-member.
and moved toThe inner
other ends of the scoops are also
points.
hung from another movable cross-member. All the joints are provided with pins for pivot
Tow conveyors are classified into following three groups.
action. The top and bottom cross-members are suspended through ropes from a crane.
(i) Overhead
When thetowropeconveyor : Thiscross-member
S1 for bottom type has alreadyis loose,been
thedescribed as open
grab buckets ‘‘loaduptowing
due trolley
to itsconveyor’’
own [Link]
At this‘‘trolley
positionconveyor’’
the bucketinis section
lowered6.2.3(e).
until the two scoops gets into the
(ii) Flush-floor
material. The ropetowS1 conveyor : In this when
is then tightened conveyor the materials
the lower are transported
cross-member moves up on andrail bound
closes the scoops with material inside. In this closed condition the grab bucket is the floor.
carts, moved by one strand of endless chain moving in a fixed guide flushed with
The carts
transferred, and are connected
at desired point,tothe
therope
conveyor chain
S1 is again by removable
loosened when thelink like open
buckets chainonwith hook,
removable
its own dog materials’
and scooped and rigid weight
drawbar andwhich engage
discharges thethe trolleys and push them.
materials.
(iii) Underfloor
There are tow
many conveyor
designs of: Inclamshell
this conveyor
bucketsanwhereendless chainofisropes
number installed
maybelow
be 1, 2floor level
or 4, either supported
or scoops by trolleys
are operated or sliding
by special in a channel or angle track. The floor mounted carts
mechanisms.
areAnconnected
elevator to theuses
that conveyor by retractable
such types of bucketpin of through
material alifting
narrowis slot in the
called floor, to pick
a grab
up connecting
bucket elevator. device on the chain.
 are operated by special mechanisms. Fig. 8.1.14 also shows an asymmetric gra
which are simple in design and close the scoop edges well.

HOISTING EQUIPMENT 151

S2 S2 S
Bucket elevator is a simple
S1 and reliable
S2 equipment widely used in process plants
1 for lifting of
S1
bulk materials like lime stone, foundry sand, coke, coal, grain, S2 dryS1chemicals and many more. Bucket
elevators are generally low cost equipment requiring little floor space.
However, bucket elevator is not suitable for large sized (100mm or above), hot or sticky materials
because buckets are generally loaded by scooping action in the boot section and discharge from the
buckets by centrifugal force or gravity. Chain type, with one or two chain, elevators are suitable for a
speed range of 0.6 to 1.55 mps, while belt type are recommended to be used in a speed range of 1.15 to
2.85 mps.
(a) (b) (c) (d)
(B) Types of bucket elevators: Bucket elevators are classified based on bucket spacing and mode
Stages of
of discharge of materials. Asoperation of a double-rope
per IS:7167-1974, ‘‘Code forgrab bucket
Selection and Use of Bucket Eleva- Asymmetric grab
tors,’’ they are classified into following three basic types.
(i) Centrifugal discharge elevators (designated as type I): In a centrifugal discharge eleva-
OTHER CONFIGURATIONS OF BUCKET ELEVATORS
tor, the buckets are spaced at a regular pitch to avoid interference in loading and discharg-
Centrifugal Discharge elevators (designated Fig. 8.1.14.
as type Grab
I):In bucket discharge
a centrifugal
ing. The charging of buckets is by scooping action and the discharge is by centrifugal
elevator, the These
action. buckets are spaced
elevators at a regular
are generally usedpitch to avoid
inplate
vertical interference
configuration andinused
loading and
for practically
(D)
discharging. Ladles: Ladles made from steel and having a refractory lining are u
all typesThe charging
of free flowing,ofsmall
buckets
lumpismaterials
by scooping action
like grain, andsand,
coal, the clay,
discharge
sugar,isdrybychemi-
hot centrifugal
liquid calsmetal.
action.
etc. BothSmall
These ladles
elevators
belt and or
chain mayarecrucibles
generally
be used and may
used be handled
theinspeed
vertical manually.
configuration
of these elevators and
range But large ladles
used
between
ladleforcars,
1.1 but
practically more
to 2 mpm. commonly
Buckets
all types of freeofflowing,bysmall
the type Acranes.2, A3A
1, Alump andcrane ladle
A4 aslike
materials essentially
pergrain,
IS:6833-1973
coal, sand, has
areclay, a bail. Smalle
generally
tilted
sugar, used.
(for dry Fig.
pouring)8.4.2 manually
chemicals illustrates
etc. Boththebelt
charging
and medium
and and discharging
chain maysize of buckets
be ladles
used ofspeed
this type
andbythehand of of
wheel elevator.
theseactuated mecha
elevators range between 1.1 to 2 mpm.
large ladles are tilted by special devices actuated from the crane itself.
(E) Electromagnets: Electro lifting magnets are used to handle magnetic ma
ent shapes and sizes like ingots, steel structurals (beams, rails etc.), plates, scraps, pigs,
The particular advantage of using magnets for lifting is that it does not need any ti
releasing of the load. It is also very convenient for stacking of such items to a large
labour. However, electromagnet has the risk of materials falling off in the event of a po
other disadvantage is the large weight of the magnet itself which reduces the capacity
crane.
Electromagnets are particularly popular in steel plants, fabrication yards and scrap yar
are generally
[Link] from and
8.4.2. Charging thedischarging
crane hook through
of buckets chain
of centrifugal slings.
discharge elevator
(ii) Positive
Positive discharge
discharge elevators
elevators (designated
(designated as III):
as type type These
III): These are similar
are similar to centrifugal
to centrifugal
discharge
discharge type excepting
type excepting that thethat the buckets
buckets are side-mounted
are side-mounted on twoonstrands
two strands of chains
of chains (i.e. (i.e.
buckets
buckets lie between
lie between twotwo strands
strands of of chains),and
chains), andare
are provided
provided with
witha apair of two
pair snubsnub
of two sprockets
sprockets under the head sprockets to invert the buckets for complete discharge. Theof the
under the head sprockets to invert the buckets for complete discharge. The speed
speedelevator may be may
of the elevator slowbein slow
the range
in theofrange
0.6 toof0.67
0.6 mpm. These
to 0.67 [Link] are used are
These elevators for light,
fluffy, sluggish and slightly sticky materials. The feeding is through scooping or digging
by the buckets. Fig. 8.4.3 shows the discharging of these elevators. An inclined elevator is
particularly suitable for perfect gravity discharge.
152 INTRODUCTION TO MATERIALS HANDLING

152 used for light, fluffy, sluggish and slightly stickyINTRODUCTION

materials. The TO
feeding is through
MATERIALS HANDLING
scooping or digging by the buckets. An inclined elevator is particularly suitable for
perfect gravity discharge.

Fig. 8.4.3. Discharging of positive discharge elevator

(iii) Continuous discharge Fig. [Link]

Discharging (designated as type II):
of positive discharge In these elevators, V-type buck-
elevator
ets are used
Continuous without
Discharge any gap(designated
Elevators between them. as typeThese
II): elevators are employed for handling
(iii) Continuous
largerelevators,discharge
lumps and elevators
materials (designated
that are
mayused be difficultas type
to II): Inby
handle these elevators,
centrifugal V-type buck-
discharge. The
In ets
theseare used V-type
without any buckets
gap between without
them. Theseany gap
elevatorsbetween
are them.
employed These
for handling
charging of the buckets are by direct filling. The discharge is by directed gravity i.e. when
elevators
larger are
lumpsemployed
and overfor handling
materials that larger
may lumps and materials that
bymay be difficult to
the buckets pass head wheel, the be difficult
flanged end to
of handle
the preceding centrifugal
bucket act discharge.
as a chuteTheto
handle by
charging centrifugal
of the discharge.
buckets are byThe charging
direct [Link] the
The buckets
discharge areisbyby direct
directedfilling. The
gravity i.e. when
deliver materials gently to the discharging spout. This type of charging and dischargeing is
discharge
the is by pass
buckets directed
overgravity
head i.e. when
wheel, the the buckets
flanged endpass overpreceding
of Bucket
the head wheel, the flanged
particularly effective for handling fragile materials. type B1bucket
, B2, Bact as a chute to
3 and B4 as per
enddeliver
of the preceding
materials bucket act as a chute to deliver materials gently to the discharging
IS:6833-1973 is gently
used for tothese
the discharging
elevators. Both [Link]
This
andtype of charging
chain are used as and dischargeing
pulling [Link]
spout. This
particularlytype of charging
effective and
forlow. discharging
handling is particularly effective for handling fragile
Speed is generally kept These fragile
elevators materials.
are usedBucket
verticallytypeor B 1, B2, BWhen
inclined. 3 and B 4 as per
inclined,
IS:6833-1973
materials. Both
special supports is used
belt and for thesefor
chain are
are provided elevators.
used as Both
pulling
belt/chain beltreturn
medium.
in the and chain
Speed is are wider
run, and used ascasing
generally pulling
kept low. medium.
is provided
Speed
These is generally
to allow for returnkept
elevators are run low.
used These
vertically
sag. Fig. or elevators
8.4.4 shows are
inclined. theused
When vertically
inclined,
charging or [Link]
special
and discharging supports Whenare inclined,
a continuous
special
bucket supports
provided for [Link] provided for belt/chain in the return run, and wider casing is provided
belt/chain in the return run, and wider casing is provided to allow for return
runto allow for return run sag. Fig. 8.4.4 shows the charging and discharging of a continuous
sag.
bucket elevator.

Fig. 8.4.4. Charging and discharging of a continuous bucket elevator

Fig. 8.4.5 shows photograph of head section (with part of cover removed) of a working bucket
Fig. 8.4.4. Charging and discharging of a continuous bucket elevator
elevator.
Fig. 8.4.5 shows photograph of head section (with part of cover removed) of a working bucket
elevator.
Rigid Buckets
Rigid buckets, as stated earlier, are mounted to a belt or chain or can be an integral part of
a plastic belt. The buckets can be constructed from steel, stainless steel, aluminum, or
molded plastic, typically nylon. The buckets are bolted through the flat belt using
flathead screws and are evenly spaced over the length of the belt. Likewise the buckets
can be bolted to special attachment links on a roller chain. With chain-mounted buckets,
it is critical that the chains be kept consistently in sync with each other. Otherwise the
buckets can get twisted and this prevents them from navigating the end sprockets
properly. Chain elevators typically are used for handling nonabrasive materials, whereas
belt elevators will handle more abrasive material as long as there are no slivers or sharp
objects that will damage the belt.
Suspended Buckets
Suspended buckets are typically mounted so that they hang freely between two chains.
Some manufacturers do offer their bucket suspended between two specialty belts. Either
way, the suspended bucket will retain its contents until it is tipped over. This allows the
elevator to have multiple discharge points. This is accomplished using a mechanism that
can be triggered to tip the buckets as they go by. This cannot be used as a sorter for
multiple products, but can be used to balance the product load among multiple discharge
points. The buckets are typically made from the same materials as the rigid buckets.