Within our case studies section, you will find a range of case studies that feature our product range and illustrate the various methods we use to successfully handle and move a vast array of ingredients. You can search case studies either by product, by industry or by material.
Thomas Tunnock needed a way to load 3 different ingredients from 3 separate points into their chocolate conche. Spiroflow supplied a flexible screw conveyor tailored to meet Tunnock’s specific requirements. It included a ‘proscrew’ spiral designed to handle materials, such as chocolate, which have a tendency to smear.
A dairy company producing an anhydrous milk fat blend with sugar for ice cream, chocolate & other confectionery wanted to unload sugar from bulk bags and transfer it to two blenders. Spiroflow supplied a bulk bag unloader with two flexible screw conveyors leading from the outlet to each of two blenders.
Our customer encases radioactive waste in cement filled drums sealed with a cement grout. A Spiroflow flexible screw conveyor is used to accurately meter precise amounts of cement & pulverized fuel ash to the mixer where the grout is produced.
Spiroflow supplied two (2) bag dump stations with bag compactors, two flexible screw conveyors to deliver constituents to weigh hoppers, two metering screws to discharge weighed materials at a metered rate into a sifter & a third flexible screw conveyor to transfer the sifted premix for final mixing/conditioning.
Solutech needed to load batches of sugar from bulk bags into a series of liquor tanks. Spiroflow mounted a bulk bag unloader on a wheeled frame complete with an integral flexible screw conveyor. The conveyor outlet is fitted with a fan to prevent the ingress of moisture.
Carroll & Meynell make transformers for the construction industry. Each one is filled with sand which is then sealed in place. The handling of the sand was a production bottle neck solved by a Spiroflow bulk bag unloader, flexible screw conveyor & distribution system.
At Joseph Dobson, sugar was manually weighed in to buckets, lifted shoulder high and tipped into the steam pan. This operation needed to be eliminated for issues of hygiene, safety & labor savings. A Spiroflow flexible screw conveyor now delivers batches of sugar efficiently, hygienically, safely & very accurately.
A change in potato powder production & handling at Premier Foods called for bulk bag unloaders & conveying systems. We supplied two bulk bag unloaders & four flexible screw conveyors to deliver ingredients to the packing lines. A fifth conveyor returns perfectly good product, recovered from any ‘out of spec’ packaging, for repackaging.
Choosing key ingredients delivered in bulk bags, Gem Pack Foods had to discharge several products and deliver each to the appropriate feed points of their packing machine. Spiroflow’s solution was a bulk bag unloader with a flexible screw conveyor and a vacuum conveyor. Each conveying system is mobile making change-over quick and easy.
Building Adhesives needed a new production line to meet output targets through single shift working & replace three aging lines each requiring double shifts to keep up with demand. Two (2) flexible screw conveyors were installed to transfer minor additives from bag dump stations to weigh hoppers above the mixer.
Innospec replicated their application at another plant making chemicals for personal care products. The main ingredient is delivered in bulk bags. Spiroflow supplied a bulk bag unloader with an integral flexible screw conveyor to supply the reactor. 55 lb/25 kg bags of catalyst are added through the unloader’s access doors.
Increased demand caused Dekura to expand capacity at their factory, where they had a pneumatic conveying system in place. Their pneumatic conveying was expensive to run, fairly noisy & required a filtration system. For the expansion, Spiroflow supplied ten (10) flexible screw conveyors, two (2) bulk bag unloaders, two (2) rigid bin unloaders, three (3) bulk bag fillers and a fountain blender.
United Utilities add powdered activated carbon (PAC) to water drawn from reservoirs to neutralize a naturally occurring organic compound which gives untreated water a harmless yet undesirable earthy taste & smell. As an approved supplier to United Utilities, Spiroflow supplied the PAC dosing systems required.
‘Adblue’, urea prills dissolved in hot, high purity water, is used in trucks to reduce air pollution from exhaust gases. A bulk bag unloader, with integral bag hoist, empties prills from bulk bags where they are then conveyed to the top of the mixing tank with a 56 ft (17m) long flexible screw conveyor.
A chemical, used in paint manufacturing was delivered in 220 lb (100 kg) bags causing back problems to operators. Switching to one ton bulk bags required a bulk bag unloader. Spiroflow supplied a special unloader ‘shoe-horned’ into limited space complete with roof mounted bag hoist - given the mezzanine floor could not support forklift trucks.
A manufacturer of cement products needed to discharge 5 components from 3,000 bulk bags for delivery to either of two mixers. Spiroflow supplied five (5) loss-in-weight bulk bag unloaders with metering feeders to transfer constituents into a horizontal aero mechanical conveyor. This feeds a second vertical aero mechanical conveyor which lifts materials to the ‘wet’ or ‘dry’ mixer.
Snack food manufacturers require a reliable, easy-to-clean method of transferring seasonings & flavorings to coating machines. Many require equipment that is mobile so that one unit can feed numerous machines and, also, so that it can be removed to a remote area for cleaning. Our solution includes a mobile bag dump station with an integral flexible screw conveyor.
Jacob’s Bakeries have used a bulk bag unloader & flexible screw conveyor to load oat flour into a mixer, via a storage silo, for 14 years - trouble-free! To produce other products in the same mixer, they are required to load alternative flours directly into the mixer. An additional flexible screw conveyor has been installed to achieve this.
Just Trays’ new casting machine doubles output of shower trays. With their previous machine, any difficulty in discharging materials was solved by bumping bags up & down on the hoist that supported them during discharge. Spiroflow supplied two (2) low headroom bulk bag unloaders. One, for calcium carbonate beads, was furnished with bag massagers to promote flow from compacted bags.
Initially, when responding to the demand for a dark chocolate alternative, the customer met this by manually adding cocoa powder into the mixer. However, this meant carrying batches of 50 lb/25 kg bags up 2 flights of stairs, from the storage area to the mixer, up to 30 times a day. The need to eliminate this chore was immediately apparent. Spiroflow supplied a flexible screw conveyor furnished with their special profile ‘proscrew’ spiral. ‘Proscrew’ spirals give maximum ‘push’ to the product with minimal contact between the spiral & the conveying tube in which it rotates.
As the bags are unloaded from ships, our customer wanted to transfer the chemical contents of bulk bags directly into road transportable ISO Tanks. We built a bulk bag unloader, with a high capacity rigid screw conveyor, into a mobile frame. A partial enclosure offers some protection from rain & sea-spray.
Faced with growing demand, Everbuild, manufacturer of building sealants, adhesives & fillers, installed a new mixer alongside an existing machine. They then needed to load bulk materials & minor additives into both mixers. Spiroflow supplied a loss-in-weight bulk bag unloader to dispense accurate quantities. Minor additives, are loaded through an adjacent bag dump station.
At another factory, our customer used a Spiroflow bulk bag unloader & flexible screw conveyor to transfer bread crumbs from bulk bags in the warehouse, through a wall, to the high-hygiene production area. The system worked so well that they duplicated the same application at their expanded North West site.
Robert McBride Ltd. manufactures private label household & personal care products. To improve efficiency & eliminate dust in their plant, they needed to eliminate manually loading 50 lb (25 kg) bags of chemicals used to manufacture their descaling gel. Spiroflow provided a bag dump station with a dust hood, a short flexible screw conveyor & an aero mechanical conveyor to do the job. The equipment meets all their needs including their required 6,600 lb/hr (2,994 kg/hr) material conveying rates.
Thomas Dudley Ltd, a manufacturer of commercial bathroom fixtures, wanted to make production efficiency as well as health & safety improvements in their plant. They specifically wanted to eliminate hand weighing & manually loading resins. Spiroflow provided a low headroom bulk bag unloader & a flexible screw conveyor to feed resin to a continuous casting machine.
This Idaho USA based producer of agricultural powders needed to eliminate significant dust & maintenance problems associated with their existing screw conveyors and bucket elevators. Spiroflow provided new flexible screw conveyors to convey flour from outdoor silos into their process inside.
Ejector specialist Transvac Systems Ltd worked with Spiroflow to develop a containerized dosing system inside of a 20 ft (6m) ISO container. The entire solids additive handling system, the dosing ejector, associated controls, safety & alarm systems operate within the mobile space.
Unifi, developer and producer of REPREVE® recycled fiber, creates plastic flake from the millions of plastic water bottles used every day. Spiroflow helped them develop a line to fill & recirculate plastic flake into large mixing silos & also convey flake onto the next step in their manufacturing process. This system included a box dumper, two (2) bulk bag unloaders, five (5) flexible screw conveyors, four (4) aero mechanical conveyors, a hopper & a comprehensive custom control panel.
Spiroflow offers a complete system for accurately discharging and metering dry water treatment chemicals. Many of the products used for pH control, such as hydrated lime, activated carbon and soda ash are now delivered in one ton bulk bags. Spiroflow is recognized worldwide as a leading manufacturer of bulk bag unloaders, as well as flexible screw conveyors, which have been used in the water treatment industry for many years for metering and conveying from silos.
Spiroflow’s bulk bag unloader/flexible screw conveyor systems have been designed to handle sensitive products in controlled environments. They are particularly suitable for those products where the highest levels of sanitation and the lowest degrees of cross contamination must be maintained during handling such as: meat, poultry, dairy, food, pharmaceutical, fine chemical, pigments/dyes and catalysts.
Spiroflow has provided a mobile bulk bag unloader with an integral flexible screw conveyor to handle aluminum oxide for Metaref, a division of Walther Trowal. The company approached Spiroflow to review the material handling aspects of their ceramic chip manufacturing process. These chips are available in various shapes & sizes & are used in the deburring, fettling & polishing of metal & ceramic castings.
Spiroflow worked with Access Security Products Ltd. to resolve a powder handling problem with a proprietary cement mixture used in their manufacturing process. The material is a fine powder, which arrives by container quite compacted, has very poor flow characteristics bridges easily, is very abrasive & readily absorbs moisture. Spiroflow installed a bulk bag unloader fitted with dual flexible screw conveyors. The flex screws deliver the cement powder to two (2) aero mechanical conveyors that fill an outdoor silo about 40 ft (12m) outside of the building.
North Carolina based Colony Gums provides the finest quality gums & stabilizers to the food, pharmaceutical & chemical industries. They turned to Spiroflow to increase their conveying capabilities. They now have two side by side powder handling systems that deliver a conveying rate of 20,000 lb/hr (9 tph), with improved productivity, additional safety features, a cleaner environment & reduced product waste.
Spiroflow loss-in-weight bulk bag unloaders are ideal for the dosing of powders used in the manufacture of white goods. High levels of dust containment maintain a hygienic atmosphere while accurate dosing ensures a consistent mix of product is maintained for every batch.
Thorough mixing is achieved over a short length of material flow with the Spiroflow in-line twin screw continuous proportional blender. It is steplessly adjustable for any blend ratio & is designed for use with any free flowing powders, granular, flake or pelleted materials.
Multi-Way flexible screw conveyors allow up to three conveyors to be fed from a single feed point. The system features swiveling inlet assemblies that allow the conveyors to be quickly installed & positioned as required, giving users valuable operational flexibility. Dry, free flowing products (sugar, salt, rusk, plastic granules & many other materials) are fed smoothly & consistently - without the pulsing that occurs with pneumatic systems - allowing ingredients & additives to be metered to processing & packaging machines.
To reduce manual handling & associated costs, pharmaceutical manufacturers have increasingly adopted large containers such as rigid IBCs for the delivery of mixed materials to tableting lines. Spiroflow has developed dedicated equipment to enable material to be conveyed automatically from a rigid IBC to pharmaceutical tableting lines or other process machinery.
Many processors need to convey raw materials or premixes to several points, but either lack of space or intermittent usage means that separate feed systems cannot be justified. Mobile feeders can provide the answer. Easy to maneuver & adjustable in delivery height, they can be fitted with customized options to enhance their versatility. Many of our mobile conveyors have been custom built to satisfy space restrictions, e.g. fitting under mixers & grinders. Even bulk bags (FIBCs) and rigid IBC unloaders can be supplied on mobile frames with integral flexible screw feeders.