Automatic Big Bag Discharge System

The Automatic Big Bag Discharge System (standard configuration: chemical/food grade; customization options available: explosion-proof/dust-free/high-temperature resistant) is a fully automatic/semi-automatic closed-loop dust-free processing equipment designed specifically for unpacking and unloading 1000~2000kg ton-sized powder, granular, and lumpy materials. Leveraging the company's years of experience in bulk material conveying and dust-free processing system integration, it centers on "fully automatic ton bag hoisting + bag cutting and breaking + closed dust-free unloading + arch breaking and anti-blocking + intelligent safety interlocks." Utilizing a flange quick-installation/floor-mounted/bracket integrated structure, it boasts advantages such as high unpacking efficiency, dust-free and leak-free operation, suitability for bulk materials, low energy consumption, convenient operation and maintenance, and ample safety redundancy. It strictly complies with GB 12476, GB/T 19815, and ISO standards. Manufactured to 14644 and 3A hygiene standards, this product is suitable for various operating conditions, including unpacking volumes of 500~5000kg/h and bag types of 1000~2000kg flexible intermediate bulk bags/ton bags. It is widely used in the unpacking of ton-sized raw materials in industries such as fine chemicals, lithium battery materials, food processing, biopharmaceuticals, mining and building materials, and feed plastics. It completely solves the industry pain points of traditional manual/mechanical unpacking, such as high dust levels, low efficiency, high labor intensity, cross-contamination, excessive material residue, and inability to adapt to clean/explosion-proof/bulk material operating conditions. It achieves **zero dust leakage, fully automatic/semi-automatic unpacking, and fully controllable dust-free operation**, helping companies pass various stringent certifications and environmental inspections such as GMP, explosion-proof certificates, and food hygiene and safety certifications, significantly improving the automation, dust-free level, and production efficiency of bulk material unpacking processes.

As a core piece of equipment for unpacking bulk materials in clean, explosion-proof, and dust-free production environments, this product is based on the dual functions of "sealed dust-free unpacking of ton bags + full-process safety protection + efficient unloading." These three functions work together to connect upstream and downstream equipment such as ton-sized raw materials, silos, tubular chain conveyors, dust-free feeding stations, and mixing equipment, achieving four-fold protection of materials being dust-free, residue-free, cross-contamination-free, and damage-free. It balances unpacking efficiency with operational stability and is suitable for demanding conditions such as aseptic production, explosion-proof workshops, and fine powder/bulk material processing. It meets the stringent control requirements of cleanrooms for air quality and material cleanliness.

Fully automatic/semi-automatic enclosed dust-free unpacking and unloading : Supports fully automated/semi-automatic design of the entire process from "electric hoist/overhead crane lifting of ton bags - automatic hook/clamp fixing - bag cutting and breaking - enclosed unloading - waste bag collection/bundling". No direct manual contact with materials and packaging bags is required, significantly reducing labor intensity and occupational health risks. The equipment features a built-in fully sealed stainless steel unpacking chamber equipped with a negative pressure dust suction interface and a high-efficiency pulse dust removal system to capture dust generated during bag cutting, breaking, and unloading in real time, achieving a dust removal efficiency of over 99.99%. The dust can be recycled and reused after being filtered by the filter cartridge, with a powder leakage rate of <0.01%, completely eliminating dust and material splashing in the workshop. The unpacking chamber is equipped with a liftable sealing cover, double silicone rubber sealing rings, and explosion-proof sight glasses, ensuring a completely enclosed unpacking process. This avoids waste of large quantities of materials and guarantees workshop air quality and product quality, making it suitable for the high purity and cleanliness requirements of industries such as food, pharmaceuticals, and lithium batteries. Supports multi-ton bag type adaptation, compatible with 1000~2000kg polypropylene/PE/film-coated FIBCs. The bag cutting mechanism adopts a combination of wear-resistant alloy rotary cutter/splitter, which is suitable for different bag types and materials, avoiding problems such as cutter jamming, bag breakage, and material leakage. The discharge port is equipped with a retractable sealing receiving cylinder and wall scraping device to clean the residual material in the FIBC, with a residual rate of ≤0.3%, which greatly reduces material loss.

Anti-bridging and anti-blocking + intelligent dust removal + low consumption and long-term operation and maintenance : The standard configuration includes a PLC + touch screen intelligent control system with five preset threshold levels for differential pressure, overload, material blockage, over-temperature, and hoisting positioning. Abnormalities trigger automatic alarms and emergency shutdowns, ensuring safe and stable equipment operation. The bottom of the unloading hopper adopts a conical structure + pneumatic anti-bridging device/vibration anti-bridging + fluidized anti-bridging (optional) triple anti-blocking design, effectively preventing powder materials from bridging, blocking, and ensuring smooth unloading of bulk materials. It is suitable for high-viscosity and high-specific-gravity powders/granular materials. The built-in high-efficiency filter cartridge (customizable HEPA high-efficiency filter media/sintered plate filter media) adopts pulse back-flushing dust removal technology, eliminating the need for manual disassembly and cleaning, ensuring thorough dust removal, and extending the filter cartridge life to 2-3 years. The entire equipment adopts a quick-release buckle structure, allowing a single person to disassemble, clean, replace filter media, and remove waste bags without tools, significantly reducing operation and maintenance costs and downtime losses, and meeting the daily maintenance needs of clean production.

Explosion-proof and sterile dual safety protection + compliant material design : Utilizing a tenon-and-mortise seal + double silicone rubber sealing ring structure, the enclosure is integrally welded, ensuring excellent sealing performance. The explosion-proof model is equipped with an explosion-proof motor, anti-static enclosure, spark detection and extinguishing system, and explosion-proof dust removal system, complying with GB3836 standards and suitable for flammable and explosive dust/gas environments, eliminating the risk of dust explosions and material leaks at the source. The sterile and hygienic model is made of 316L stainless steel with a seamless polished finish, capable of withstanding CIP/SIP online cleaning and sterilization, meeting GMP and FDA hygiene requirements. All material-contacting parts meet food-grade/pharmaceutical-grade standards, possessing excellent antibacterial and antifungal properties, with an antibacterial rate ≥99.99% and an antifungal level of 0. Additional features include overload protection, emergency stop button, anti-detachment device, lifting limit, and waste bag full alarm to prevent abnormal equipment damage and personnel safety hazards, ensuring long-term safe and stable operation of the equipment.

1. Fully automated and efficient, suitable for bulk materials, with outstanding production capacity.

This equipment integrates automatic hoisting, automatic bag cutting, automatic unloading, and automatic waste bag collection/bundling functions, achieving a bag unpacking efficiency of 500~5000 kg/h, which is 10~15 times that of manual bag unpacking. It is suitable for the rapid unpacking needs of large-volume, ton-sized raw materials. The equipment operates stably with a low failure rate and supports 24-hour continuous operation, significantly improving the overall capacity of bulk material production lines while reducing manual input, lowering labor costs and labor intensity. It is suitable for the large-scale, intensive production needs of industries such as fine chemicals, lithium batteries, and mining.

2. Compact footprint, highly adaptable, and flexible installation.

With its compact, integrated design, it occupies only 35% of the space required for a traditional combination of ton bag unpacking equipment and independent dust removal equipment. It is particularly suitable for cleanrooms, small workshops, areas with dense equipment, and space-constrained scenarios near bulk material storage facilities. It can flexibly adapt to various ton bags/FIBCs weighing 1000~2000kg and supports seamless connection with silos, tubular chain conveyors, dust-free feeding stations, and mixing equipment. The flange interface complies with GB/T 9113 standards. No large-scale modification of the factory layout is required. It can be used with electric hoists or existing overhead cranes in the workshop to meet the process requirements of various workshops and realize integrated dust-free operation of ton bag unpacking, unloading, and conveying.

3. Modular customization, covering all material types and adaptable to various working conditions.

We can flexibly customize the unpacking volume, hoisting method, arch-breaking structure, dust removal level, material, and waste bag disposal method according to the characteristics of customer materials and working conditions. Materials include 304 stainless steel, 316L stainless steel, and carbon steel with anti-corrosion coating. Among them, 316L stainless steel can meet the harsh aseptic/corrosion-resistant working conditions. For viscous powders, we can choose anti-stick coating silos and fluidized arch-breaking devices. For abrasives, we can choose wear-resistant linings. For ultrafine powders, we can upgrade to a HEPA high-efficiency dust removal system. For lumpy materials, we can optimize the bag cutting mechanism and unloading channel. From ultrafine powders (such as lithium battery cathode materials and pharmaceutical powders) to lumpy materials (such as plastic blocks and ore particles), from room temperature to high temperature, from ordinary working conditions to explosion-proof/aseptic conditions, we provide full coverage and adaptability to meet the personalized ton bag unpacking needs of different industries.

4. Low energy consumption and low noise, resulting in outstanding economic efficiency in operation.

The optimized pulse dust removal system and energy-saving motor design result in energy consumption that is more than 30% lower than traditional ton bag unpacking and dust removal combination equipment. The pulse back-blowing cleaning technology requires no additional power and is driven purely by airflow, further reducing energy consumption. The sealed box structure effectively isolates operating noise, with an operating noise level of ≤65dB(A) (floor-mounted model), far below the workshop noise standard, creating a quiet production environment. The lifespan of vulnerable parts such as filter cartridges, sealing rings, and bag cutters is clearly defined, and the replacement cycle can be precisely controlled through online monitoring, reducing downtime and consumable procurement costs. At the same time, the low material residue rate reduces the waste of large quantities of materials, improves resource utilization, and has outstanding long-term economic benefits.

5. Materials are compliant, testing is complete, and certification is worry-free.

Components in contact with materials can be made of 316L food-grade/pharmaceutical-grade stainless steel, meeting 3A hygiene standards and relevant requirements for food and pharmaceutical production; explosion-proof components have all passed GB3836 third-party testing and certification, and the dust removal system meets environmental emission standards; each unit undergoes no-load/load test operation, sealing leakage test, unpacking efficiency test, dust removal efficiency test, and safety interlock function test before leaving the factory, and relevant test reports on material resistance to chemical reagents, antibacterial properties, and antifungal properties can be provided; third-party test reports, material certificates (MTC), explosion-proof certificates, and hygiene certification reports can be provided, fully complying with various stringent certification requirements and helping companies successfully pass environmental and hygiene inspections.

Shanghai Hanye Engineering Technology Co., Ltd. specializes in material handling and fluid safety, focusing on the pain points of unpacking bulk ton bags in clean, explosion-proof, and dust-free environments. With "fully automated and efficient, leak-proof, safe and reliable, and low-cost operation and maintenance" as its core principles, and combined with stringent industry standards, it provides customers with highly adaptable Automatic Big Bag Discharge Systems and related solutions. For detailed parameters, operating condition adaptation selection, unpacking volume calculation, or on-site case studies, please feel free to contact us!