Dust containment is one of the most critical issues when handling bulk raw materials. Dust emissions are not only an annoyance; in some cases, they can pose serious health risks, particularly when dealing with respirable crystalline silica (RCS).
Often found in stone, rocks, sands and clays, exposure to RCS over long periods can cause lung cancer and other serious respiratory diseases. [1] Effective dust control is, therefore, essential for ensuring a safe work environment.
When a UK-based monolithic refractory manufacturer and installer sought to enhance the safety and cleanliness of their operations, they looked to the world-leading flexible connector system, BFM® fitting, for a solution.
Producing over 300 different products, this company was particularly concerned with the dust generated during their bulk bag loading process. With raw materials such as sand, lime, and dolomite being dosed into bulk bags, the displacement of air inevitably led to dust emissions, which became a challenge for the site’s health and safety protocols.
The Dust Control Challenge
The company fills around 60 bulk bags daily, transferring materials from silos into bags that are then transported for mixing. The existing clamp system used to secure the bags during filling was proving inadequate, allowing dust to escape during the process. As the materials handled pose an RCS risk, effective dust containment was not only a priority—it was essential.
Despite having local exhaust ventilation (LEV) systems and both static and personal dust monitors in place, the site struggled to control dust leakage at the point where the bulk bags connected to the filling head.
The engineering team trialled a range of different solutions, including inflatable seals, but these options fell short, either due to insufficient dust reduction or premature wear and tear. They clearly needed a more durable, effective solution—so they contacted their local BFM® Distributor, ProSpare Ltd.
The BFM® Bulk Bag Loader: A Game-Changer
The BFM® Bulk Bag Loader was the perfect answer to their problem. This innovative product features a three-layered, inflatable filling head that includes a stainless-steel central core, all encased in durable and flexible Seeflex urethane. The BFM® Bulk Bag Loader snaps seamlessly into place on a BFM® spigot, which is welded to the filling outlet, providing a completely dust-tight seal.
During operation, the BFM® Bulk Bag Loader inflates to hold the bulk bag securely in place, creating a strong, dust-tight seal without the need for any external clamps or braces. The outer layer keeps the bag neck open and upright, ensuring a smooth, efficient filling process. Once the bag is full, the BFM® Bulk Bag Loader can be deflated quickly, allowing for easy removal of the filled bag—no mess, no hassle.
Proven Results and Lasting Impact
The company initially installed two BFM® Bulk Bag Loaders and is now preparing to install a third due to the overwhelmingly positive results.
Dust emissions during the filling process have dropped dramatically, limiting the risk of exposure to RCS. Rigorous on-site testing by the engineering team, along with external audits, confirmed that dust levels in areas where the BFM® Bulk Bag Loader is in use are now considered ‘negligible.’
The plant’s Director of Engineering said “The BFM® Bulk Bag Loader is a godsend and the only option on the market that works for us when filling.”
In addition to the impressive dust control, the team at the site has praised the durability of the BFM® Bulk Bag Loader. After more than two and a half years of daily use, the loaders show no signs of wear. This resilience, particularly in the stainless-steel core and urethane material, ensures long-lasting performance, even under continuous operation.
Additional Benefits: Easy Maintenance and Flexibility
One of the key benefits of the BFM® system is its ease of maintenance and flexibility. The bulk bag loader can be quickly snapped in and out, making cleaning between material changes simple and efficient, reducing the risk of cross-contamination.
The BFM® system’s adaptability also means that if the company needs to switch from bulk bag loading to filling a fixed bin, they can easily change to a BFM® flexible connector while still maintaining complete dust containment.
The BFM® Bulk Bag Loader has proven to be a reliable, effective solution for reducing dust emissions, providing lasting durability, and offering the flexibility to adapt to future needs.
For companies dealing with hazardous materials like RCS, BFM® fitting products can make a real difference in ensuring a safer, cleaner, and more efficient production environment.
Find out more about the BFM® fitting Bulk Bag Loader.
[1] https://www.hse.gov.uk/lung-disease/silicosis.htm Data correct as of June 2024 v270624
