Maintaining a safe and efficient workspace is essential in manufacturing, and in environments where bulk dry material is being handled, dust control is especially critical. With rising concerns about worker health and increasing regulations surrounding inhalable particulate matter, the need for effective dust control measures has never been greater.
The Problem with Manual Handling
Manual handling, which involves lifting and dumping 50lb bags, small drums, and boxes, is common in many manufacturing settings. However, this method presents significant dust control challenges. Even with vacuums and air vents in place, some dust still escapes into the environment, posing health risks to workers and leading to regulatory compliance issues. The repetitive nature of manual handling also increases the likelihood of ergonomic injuries, furthering the need for a more effective solution.
The Benefits of Bulk Bags and Super Sacks
Bulk bags, also called super sacks, are a superior alternative to manual handling, especially when it comes to controlling dust. These containers are specifically designed to prevent dust from escaping during filling and emptying. The airtight spout seals ensure that dust remains contained within the bag, preventing it from becoming airborne.
In addition to airtight seals, bulk bags and super sacks are resistant to water and moisture, making them ideal for handling a wide range of materials in various environments. Whether dealing with powders, granules, or other fine materials, these bags can be customized to suit specific needs, further enhancing their effectiveness in controlling dust.
Bulk bags and super sacks can easily be incorporated into automated bulk handling systems. For example, bulk bag filling stations can automatically fill bags to the appropriate volume. Similarly, bulk bag unloaders are a safe, dust-free way to efficiently unload and dispense bulk bags.
By reducing the need for manual handling, bulk bags and super sacks also contribute to a safer and more efficient work environment. For example, bulk bag filling stations can automatically fill bags to the appropriate volume Workers are less exposed to dust and are less likely to suffer from ergonomic injuries. This combination of dust control and safety makes bulk handling systems an ideal option for many manufacturers.
Direct Comparison: Manual Handling vs. Bulk Bags
| Manual Handling | Bulk Bags/Super Sacks | |
| Dust Control | Limited, some dust escapes | Airtight seals, little to no dust |
| Worker Safety | Higher risk of injury | Reduced manual labor |
| Regulatory Compliance | Challenging | Easier to meet standards |
| Efficiency | Time-consuming, labor-intensive | Streamlined, automated processes |
Featured Case Study 1: Energy
We worked with a team specialized in converting municipal waste to biodiesel fuel. As part of their process, lime and zeolite were included as dry materials. These materials pose serious inhalation hazards; lime can cause chemical burns to the airways, and zeolite inhalation can result in various long-term chronic illnesses.
Rather than rely on manual handling, our team devised a solution that would unload the lime and zeolite from bulk bags. As the processed municipal waste moves under the bulk bag unloaders, the materials are introduced via loss-in-weight batching controls. Not only did the material handling system optimize their process, but the solution also minimized potential risks to workers on the team by containing and dispensing the lime and zeolite with bulk bags.
Figure 1. Lime and zeolite unloaders
Featured Case Study 2: Nickel Powder
Dust control is especially critical when working with carcinogenic material. Nickel powder is a prime example. Nickel powder is used in creating plastic pellets primarily in the context of specialized applications where enhanced properties are required, such as heavy service automotive, aerospace, or industrial applications. Adding nickel during the pelletizing process makes polymers electrically conductive and resistant to high temperatures.
Our engineering team partnered with a customer who handles nickel powder in their facility and designed a zero-emission bulk handling system with indexed entry doors for loading bulk bags and IBC’s, integrated dust collector, a positive seal between bag outlet and IBC, and a vacuum system for bag cleanout after transfer. The system we designed, shown in Figure 2, integrated seamlessly with existing production processes to create a fully contained and automated system that improved productivity and environmental safety for the facility workers.
Figure 2. Zero-emission bulk handling system for nickel powder
Improve Your Operation and Minimize Dust Exposure with Bulk Bags
When it comes to managing dust exposure, systems that incorporate bulk bags and super sacks offer a safer, more efficient alternative to manual handling. In addition to protecting worker’s health, bulk bags can also help ensure regulatory compliance.
At FormPak, we can help your team with whatever your process requires. Our extensive knowledge of hundreds of materials means we can provide you with the right bulk bags for the material you work with. Our bulk handling equipment expertise means we can design a customized system that optimizes your unique operation and fits in your unique space.
Interested in implementing bulk bags in your operation? Request a quote and we’ll connect you with a bulk bag expert.
