Reduction of Environmental Dust and Workplace Hardship

Corporate Social & Environmental Responsibility | Khalaafarin Pars

Introduction

Granular and powder materials generally either exist naturally in the world, such as lime, gypsum, or bentonite, or are converted into granular or powder forms through industrial processes, such as cement, flour, and milk powder.

In this discussion, we do not address the various and complex production methods of powders in different industrial processes; rather, we address the common factor present across all powders and solid materials: the transfer and handling of these materials across all industrial production stages, which is a shared operational requirement across all manufacturing plants.

Packaging Methods for Granular and Powder Materials:

• Bulk delivery in dumper/compressor trucks and storage in open/covered bays
• Delivery in pressurized capsule bulk tankers (known in industry as bulk bonkers)
• Delivery in large polymer bulk bags of varying tonnage (Jumbo Bags)
• Delivery in portable sacks and bags ranging from 10 to 25 kg

In all these packaging and loading methods, once the raw materials are unloaded at factories and warehouses, they must be transferred to production lines and fed into industrial processing equipment. When this feeding and charging operation is performed traditionally or manually, the dust generated from unloading and charging spreads across workplaces, creating severe environmental and occupational hazards.

Stages of Raw Material Usage Causing Environmental Dust:

1. Unloading and feeding raw materials at the beginning of production lines
2. Transferring materials across intermediate production processes
3. Transferring processed materials to filling and packaging machines
4. Storage of processed materials in holding silos and surge hoppers

Safe & Dust-Free Enclosed Solutions:

To prevent dust dispersion during bag unloading, enclosed dumping hoppers equipped with reverse-pulse dust collectors can be deployed for small bags and jumbo bags. To prevent human inhalation of toxic powders, automatic and semi-automatic bag slitting stations are utilized where the operator only places the bag, and cutting/emptying occurs contact-free inside a sealed negative-pressure housing.

When materials are stored in bulk bonkers and silos, fully enclosed pneumatic conveying systems transport materials directly to production lines without human contact, eliminating dust escape entirely.

Disadvantages of Traditional Manual Handling:

• Inhalation of airborne micronized and light powders suspended in the work environment upon opening packages
• Physical strain and spinal injuries on operators due to manual lifting of heavy bags
• Risk of personnel falling from height while carrying bags to elevated machine hoppers
• Contamination of human food, animal feed, and pharmaceutical materials due to direct human contact

Comparison: Mechanical vs. Pneumatic Conveying:

Mechanical Elevators & Open Conveyors (Bucket elevators, Screw conveyors, Z-conveyors, Belt conveyors):
Because these are open mechanisms, material and dust continuously spill from bucket edges, pallets, and belt margins, causing environmental contamination and material waste. They are entirely unsuited for food and pharma standards.

Pneumatic Vacuum & Pressure Conveying Systems:
Materials travel through completely sealed pipelines and hoses. Dust escape during movement is impossible, labor requirements are minimized, and direct contact between personnel and process chemicals is eliminated.

۲۷ Core Industries Utilizing Granular & Powder Handling Systems: