Advantages of Smart Manufacturing:
The belt conveyor “pulls” material out from
Smart Manufacturing offers a number of benefits,
including improved efficiency, increased productivity and long-
term cost savings. In a smart factory, productivity is continuously
enhanced. If a machine is slowing down production, for example,
the data will highlight it, and the artificial intelligence systems will
work to resolve the issue. These extremely adaptable systems
enable greater flexibility.
Disadvantages of Smart Manufacturing:
A big downside to smart manufacturing is the upfront
cost of implementation. As such, many small to midsize
companies won't be able to afford the considerable expense of the
technology, particularly if they adopt a short-term philosophy.
FEEDER MACHINE - to move or “transport” materials or
products to a designated storage or to other processing equipment.
Feeders are often used in conjunction with other types of material
handling equipment, like conveyors, crushers, dryer, grinders,
blenders, and mixers.
Is a kind of feeding equipment which can feed bulk and
granular materials from the stock bin to the receiving devices
evenly, regularly and continuously.
The Importance of Feeder Machine
As the name of ‘Feeder Machine’ itself, a feeder machine
is a machine that is used or functioned to ‘fill’ or ‘feed’ a product
or object in order to maximize production to be more effective.
In other words, feeder machine is defined as a machine
that passed a container, packaging or products in one by one and
then channeled through the conveyor. This machine can be
combined with other machines, according to the intended use.
TYPES OF FEEDERS
A. Volumetric Feeders
dosing system that supplies the production system with a
certain volume of material in a set timeframe, based on the so-
called displacement principle.
B. Gravimetric Feeders
also know as a loss-in-weight feeder, is a self-calibrating
dosing system that doses based on weight in speed.
C. Bowl Feeders -
is a vibratory instrument for supplying predominantly
small parts and components to a production line for automation, or
for sorting bulk items for rapid use. Vibratory bowl feeders are a
robust and reliable solution for handling and sorting bulk materials
and orienting them correctly for assembly purposes.
D. Apron Feeders - a popular material handling choice
is a mechanical type of feeder used in material handing
operations to transfer (feed) material to other equipment or extract
material (ore/rock) from storage stockpiles, bins or hoppers at a
controlled rate of speed.
E. Belt Feeders
are short belt conveyors that are specifically designed for
material flow regulation, extracting material from one area and
ensuring that downstream equipment receives the appropriate
volume.
How does a belt feeder work?
A belt feeder consists of a hopper positioned directly
over a belt conveyor.
under the hopper, while an adjustable vertical strike-off plate
controls the height of material allowed to advance as the belt
moves forward, or in other words, the material profile on the belt.
F. Chain Feeders
Chain feeder use an endless chain both to transmit power
and to propel material through a trough, either pushed directly by
the chain or by attachments to the chain. - uses chains to regulate
the ore flow in a different manner is the ROSS Chain FEEDER.
This feeder uses a series of very large, heavy chain that has been
forged into loops. These loops are placed over cogged wheels that
are suspended over the ore passage. The free end of the chain
loops is hung down onto the rock. The size and the weight of the
chain links are sufficient to stop the flow of ore. To keep the ore
moving the chains are revolved, dragging the links over the ore
will cause it to flow.
This feeder is cheap, but it is as simple and fool-proof as any type
that is made; it is almost impossible to damage it, and the wear on
the tumbler and chains is negligible. For these reasons it is very
suitable for controlling the feed from the coarse ore bin. It is also
suitable for regulating the flow of such material on to a belt
conveyor, since, however large the lumps, it will give a quiet feed
with the minimum amount of damage to the surface of the belt.
G. Rotary – vane Feeders - type of industrial valve used in
material handling systems to process and transfer dry bulk
materials for production.
- used for low density powdered material.
These units feature a rotating vane (a rotating cross with four
separate quadrants).
Rotary feeders are primarily used for discharge of bulk solid
material from hoppers/bins, receivers, and cyclones into a pressure
or vacuum-driven pneumatic conveying system. Components of a
rotary feeder include a rotor shaft, housing, head plates, and
packing seals and bearings.
How does a rotary feeder work?
While enabling material to pass through, a Rotary
Airlock Feeder separates a pressure differential. The best way to
understand how it operates is to visualize a building's rotating
door; it lets material through while maintaining the pressure
differential between the building and the outside.
H. Screw Feeders
Screw feeders are used in thousands of material handling
applications and designed to meter bulk materials at a controlled
feed rate.
Screw Feeders - This are used to transport fluids and fine granular
materials. A rotating auger within a cylindrical encasing propels
material. The rate of discharge is controlled by the speed of
rotation
Numerous material handling applications include screw
feeders, which are created to meter bulk commodities at a
predetermined feed rate. The amount of material discharged from
a standard screw conveyor is directly proportional to the amount
fed into it at the inlet, and it is typically supplied by another
conveyor.
2 TYPES OF SCREW FEEDERS
Multiple Diameter Screw Feeder/Conveyor
- consist of a screw feeder with an extension conveyor.
A smaller diameter screw feeder is located under a
hopper, bin or silo and is flood loaded. The screw
 feeder meters the bulk material to the larger
diameter extension conveyor. When the bulk
material reaches the extension conveyor the trough
loading decreases and the bulk material is
conveyed to the discharge.
Live Bottom Screw Feeder
- Live bottom screw feeders are designed for use on large
silos, bins and hoppers with large discharge openings. The
live bottom screw feeder utilizes multiple feeder screws in
tandem to create a "live bottom" to prevent bridging. Bulk
materials are metered and drawn out equally from the full
width and length of the inlet opening. Live bottom screw
feeders are used on bulk materials which tend to pack or
bridge easily.
G. vibratory feeder - to feed components or materials into an
assembly process using controlled vibratory forces, gravity, and
guiding mechanisms that position and orient materials.
They have accumulation tracks of various widths, lengths, and
depths, which are carefully chosen to fit the needs of the
application, material, component, or part.
The goal of vibratory feeders is to move, feed, and convey bulk
materials while using various forms of vibrations so that the
materials are properly oriented for addition to a production line.
They are a highly efficient method for increasing the speed of
assembly operations and gently separating bulk materials. The
guided movement produced by a vibratory feeder is dependent on
horizontal and vertical accelerations that produce the exact amount
of force needed to put materials in position.
ACTIVITY
NUAIITDLSR ROEPSESCS INDUSTRIAL
PROCESSES
Procedures involving chemical, physical, electrical or
mechanical steps to aid in the manufacturing of an item or items
usually carried out on a very large scale. Industrial processes are
the key components of heavy industry.
NFNMRTAIUACUG MANUFACTURING
Can either mean transforming raw materials into finished
goods on a large scale, or the creation of more complex items by
selling basic goods to manufacturers for the production of items
such as automobiles, aircraft, or household appliances.
RYTOIAVBR REESDFE VIBRATORY FEEDERS
Is a conveying system designed to feed components or
materials into an assembly process using controlled vibratory
forces, gravity, and guiding mechanisms that position and orient
materials.
EIRGMIRTAVC FESEDRE GRAVIMETRIC
FEEDERS
Also known as a loss-in-weight feeder, is a self-
calibrating dosing system that doses based on weight in speed.
ICNHA EFDSERE CHAIN FEEDERS
Uses an endless chain both to transmit power and to
propel material through a trough, either pushed directly by the
chain or by attachments to the chain.
Manufacturing and Industrial Processes
Manufacturing
Manufacturing can either mean transforming raw
materials into finished goods on a large scale, or the creation of
more complex items by selling basic goods to manufacturers for
the production of items such as automobiles, aircraft, or household
appliances.
Types of Manufacturing
1. Casting and Molding is a manufacturing process in
which a liquid material (plastic or metal) is usually
poured into a mould, which contains a hollow cavity of
the desired shape, and then allowed to solidify.
Types of molding
a. Injection Molding - which melts plastic to create 3-D materials
such as phone cases and laptop covers.
b. Blow Molding - process for forming hollow plastic parts.
c. Compression Molding - A process involving pressing or
squeezing a deformable material between two halves of a heated
mold and its subsequent transformation into a molded part after
cooling or curing.
d. Rotational Molding - Is one method for dry powder resin
molding where powder thermoplastic resin is put into a metal mold
and placed in a heating furnace and rotated 360°.
2. Machining - is a technical and detail-oriented process in which
material is cut into a final shape and size to create parts, tools, and
instruments.
3. Joining - is the manufacturing process of welding and/or the
process of binding two materials together, either through,
soldering, brazing, and adhesive bonding. The many advantages to
this manufacturing process are that joining enables the piecing of
two parts together, which cannot be separated easily after.
4. Shearing and forming - Shearing is the manufacturing
process of cutting a piece of material into two separate pieces.
Forming is the manufacturing process whereby, a piece of material
is bent into a specific shape.
Industrial Processes - Procedures involving chemical, physical,
electrical or mechanical steps to aid in the manufacturing of an
item or items usually carried out on a very large scale. Industrial
processes are the key components of heavy industry.
A. General Processes
● Liquefaction of Gases - is physical conversion
of a gas into a liquid state (condensation).
● Supercritical - to remove liquid in a precise
and controlled way.
● Freeze Drying - works by freezing the
material and then reducing the surrounding
pressure to allow the frozen water in the
material to sublime directly from the solid
phase to the gas phase.
● Scrubbing - It is used to treat exhaust gases
from industrial plants or from exhaled air in
life support systems such as re-breathers or in
spacecraft, submersible craft or airtight
chambers.
B. Chemical Processes
 Haber process - also called the Haber–Bosch
process, is an artificial nitrogen fixation
process and is the main industrial procedure for
the production of ammonia today.
  Smelting - its main use is to produce a base All types of materials are transported by the conveyors.
metal from its ore. This includes production of Some of the items used by the conveyor are:
silver, iron, copper and other base metals from
their ores. • Beans
• Nuts
● Pyroprocessing - is a process in which • canned foods and vegetables
materials are subjected to high temperatures in • Bottles
order to bring about a chemical or physical • drink cans
change. • automotive (engines, car frames, and tires)
● Disinfectants - are antimicrobial agents that • medicine or supplements
are applied to the surface of non-living objects • large powders
to destroy microorganisms that are living on • Furniture
the objects.

Principle of Material Handling Choosing the Right Conveyor System

Material handling is "providing the right amount of the • Operationally safe

right material, in the right condition, at the right place, at the right
time, in the right position, in the right sequence, and for the right
cost, by using the right method.
Conveyors and Conveying System
Conveyors- provide ease of use in applications such as the
transportation of heavy or bulky materials.
Parts of A Conveyor
Following are the three parts of a conveyor:
1. Belt support is a component of a conveyor system that
allows the belt to move smoothly without any
restrictions. If the support unit is not stable, the belt fails
if there is a heavy object on top of it, and this causes the
belt to not move as smoothly or as fast as it should. The
belt remains tight and moves efficiently by the use of
support units.
2. Pulley System - It is the external component that is used
to control the speed of the belt. Each unit has two
pulleys, one is operated by electricity, and another one is
idle. And modern conveyor systems may have extra
rotors on the entire frame.
3. Drive Unit - allows the conveyor system to move or
operate. It has a counter bearing which effectively keeps
the moving components. It also provides for moving the
belt in the opposite direction and managing the repeated
adjustments in the direction for some systems.
• Energy efficient
• Reliable
• Adaptable to changing needs
• Cost-effective
Product requirements
• What type of product is being conveyed?
• What is the average weight per foot of product?
• What is the maximum weight of the products?
• What are the minimum, maximum and average
dimensions of the product (i.e., length, width and
height)?
• How are the products being conveyed and in what
orientation?
Advantages of Conveyor System
• A conveyor system is one of the cheapest process to
move material over long distances.
• The height of the conveyor may change and the material
can be seen on the surface of the conveyor while
conveying.
• The system allows for movement of objects that are too
heavy or too bulky for humans to carry by hand.
• Conveyor systems save time when transporting items
from one location to another.
• In conveyors, weigh belt sections can also be added for
continuous product weighing

Conveying System Disadvantages of Conveyor System

A conveyor system is a type of mechanical handling equipment
that is used to transfer material from one place to another
Permit fast and efficient transportation of a broad variety of
materials.
Application of Conveyor System
• Installing a conveyor system is costly
• The general design of the belt conveyor is opened. So
there is a possibility of product fall
• Sticky material can become trapped on the belt and
transfer to the return side, roll, idler, and pulley.
• Conveyor discharge always carries material and this
becomes a housekeeping problem.
• Odder control is nearly impossible.

Conveyors are used for different purposes in a variety of Types of Conveyor System
industries. They are generally used in industries such as
Ball transfer conveyor Screw or Auger conveyor
• Mining Baggage conveyor Slat or apron conveyor
• Manufacturing Belt conveyor Vertical conveyor
• Automotive Bucket conveyor Vibrating conveyor
• food processing Chain conveyor Walking beam conveyor
• Packaging Coal mine conveyor Wheel conveyor
• Pharmaceutical Chute conveyor Roller conveyor
• Bottling Magnetic conveyor
Overhead conveyor
Application of Conveyor System Pneumatic or vacuum conveyor
Powered roller conveyor

Ball Transfer Conveyor - consist of a series of ball casters to
allow for multi-directional transport of the product. They are used
at packaging and assembly lines where the product needs to be
transported in more than one direction. When multiple conveyor
lines are combined, they are used to move products from one place
to another. Multiple sizes and load carrying capacities are possible
using this conveyor. Ball transfer conveyors are not self-driven and
require external forces to move the product.
Bucket Conveyor - is also known for a grain leg. It is a
mechanism for carrying flowable bulk material vertically in an
assembly line. It uses multi-sided containers connected by cables,
belts, or chains to move products or materials. These conveyors are
made up of an interconnected loop of buckets that remain flat as
they move from horizontal to vertical so that their objects do not
fall. These conveyors can provide easy transport, huge capacity,
and require little maintenance. Used in the food, agriculture,
pharmaceutical, chemical, and glass industries.
Chain Conveyor- is a material handling device attached to moving
members (chain or cable) typically used to move materials through
production lines. A chain conveyor consists of a series of
gears connected in a continuous system by a chain. Typically,
each gear has teeth that form a free rotation along the chain. Using
chain conveyors can provide you a high load capacity, and have the
possibility of transporting very wide or long materials. Chain
conveyors are mainly used to move or transport heavy unit loads.
Coal Mine Conveyor - These conveyors are an excellent way to
transport large quantities of coal over very long distances. Coal
conveyor equipment can cut down on the cost of operation due to
low power consumption. The coal conveyors can traverse difficult
terrain more efficiently than truck or rail systems, and have the
benefit of continuous transportation. It is suitable to be installed for
handling coal at an inclination of up to 20° from horizontal.
Chute Conveyor - one of the few expensive means of conveying
materials. They use gravity to move the product from one level to
another along smooth surfaces. Chute conveyors are used for
providing increased shipping areas. A spiral chute can be used to
move objects between floors with the minimum space required.
These are designed to have a low coefficient of dynamic friction,
allowing the product or material to slide smoothly. Useful in scrap
handling, packaging, or mail handling, etc.
Magnetic Conveyor - These are types of conveyor systems that
have either a magnetic slider bed or a magnetic pulley that is used
to move ferrous material in a vertical or reverse direction. This
conveyor has magnets on its bed that hold the ferrous, or iron-
containing parts, and should run on any industrial conveyor. The
magnets are placed correctly, providing accurate magnetic holding
power for these parts. Magnetic conveyors are used to removing
ferrous chips from machining centers.
Overhead Conveyor - uses a single rail, which can be manual or
driven. These are used to perform conveying and loading tasks in
work areas. They are attached to the ceiling using a trolley or
carrier moved by chains, or cables. These types of conveyors are
designed to follow a continuous path, it can change directions from
horizontal to vertical or vice versa. This can provide you with
better use of floor space, carry items in bulk and deliver cartons or
packaging. The conveyor is primarily used in assembly line
inspection and/or processes.
pneumatic vacuum conveyor is a unique dry material transfer
system that is dust-free and without human touch. A pneumatic
Baggage Conveyor- used for transportation in bagging handling
systems. If you have traveled to the airports, then you must have
known that there are baggage claims on which you can check your
luggage. On one side of the baggage conveyor, you drop your
items, from the far side they come after checking. This rotates the
bags in a circle. You are most likely to see a conveyor belt in a
store or at the airport.
Belt Conveyor - carrying medium that uses a continuous belt to
transport products in a straight line or through changes in height or
direction. A conveyor belt uses two end-pulleys that loop over a
conveyor works on the basis that bulk cargo can be moved via air
through pipelines.
Powered or Live Roller Conveyor - use motorized rollers to
move the products or materials. Conveyor rollers are driven by
belts, chains, or O-rings depending on the load. They are effective
in horizontal transport over long distances. have parallel rollers
fixed to the frame to convey the product by gravity or manually.
These rollers are not self-powered and use gravity to transfer the
object, or manually when mounted horizontally.
These types of conveyors can be installed straight or curved
depending on the purpose of use and available floor space. It is a
very fast and safe load transport system because they are built with
a variety of sensors and equipment. The application in which it is
used is at a loading dock, baggage handling, or on the assembly
line.
screw conveyor - uses a rotating helical screw blade with a
uniform tube to move or transfer fluid or granular material easily.
It consists of a helical screw or steel auger that rotates within a
shaft, driving the work depending on the screw design and
rotational direction.
In this, the rate of volume transfer is equal to the spinning rate of
the shaft. These types of conveyors are capable of handling large
quantities of material with slow to fast flow. They are used to
transfer goods such as food waste, wood chips, cereal grains,
animal feed, boiler ash, meat, and bone meal.
slat conveyor - employs a chain-driven loop of slats to move the
objects from one end to the other. A slat conveyor consists of a slat
and chain system for moving components on an assembly line.
The steel panels are connected in series with special chain
attachments, and the chain is powered by an electric
motor and gearbox. This allows for a wide variety of heavy-load
conveyor applications. A slat conveyor can convey hot, oily parts
or items through a heat drying process.
vertical conveyor - uses rotary or linear vibration to move
products automatically from one level to another. These types of
conveyors can move goods from one height to another, raising or
lowering the load in the supply line in various stages.
Vertical conveyors are located between two horizontal conveyors
and can hold the movement stable by vertical offset. It can provide
different sizes and load capacities depending on the application.
Vertical conveyors are used to decreasing the floor space, bundling
multiple floors together, vertical accumulation systems, and many
more applications.
vibrating conveyor - solid conveying surface that is rotated
sideways to form a trough. They are capable of transmitting both
static and dynamic forces to their supporting structures.
These conveying machines can move materials downward,
horizontally, or up to a 10-degree slope. Vibrating conveyors are
more comfortable to clean surfaces and require less maintenance
than other types. They are used to transfer dry, bulk materials such
as aggregate, gravel, coal, etc.
Walking Beam Conveyor - use a combination of stationary
support and moving support to guide workpieces through
construction cells. If the object supported in a stationary position is
lifted by the conveyor and sent to its next position, where another
construction step is performed.
This action is repeated throughout the length of the conveyor. A
walking beam conveyor can provide easy handling of materials
without a human interface. These are used on automation and
assembly lines, where objects need to be located at specific places
in an orderly manner.
Wheel Conveyor -consists of a series of wheels supported in a
frame, on which objects are moved manually or flown by gravity.
This conveyor is made with a set of wheels and wheel spacing
based on load requirements and application.
Wheel conveyors are used for object or package handling
applications. They are generally employed for loading and
unloading trucks and for carrying packages, pallets, etc.
STORAGE SILOS - pit structure used to store bulk materials like
grain, coal, cement, carbon black, woodchips, food products, etc. in
large industries.
FEATURES OF STORAGE SILOS
The silos can be used in the agriculture field to store food
products, chemical industries use to store plastic resins, cement
factories use to store cement, calcium oxides, and many other
materials like activated carbons, etc. The most common geometry
of silos is a cylinder that has a metal support. Other than cylinder-
shape, the silos can take the shape of a rectangular or a square. The
silos are constructed using wood, reinforced plastic, reinforced
concrete, or stainless steel. The construction and design of silos
are dependent on the quantity of product to be stored, the
environmental conditions, and site conditions. Silos have an
opening and closing provisions for loading and unloading the
materials. The interior surface of the silos is made smooth and
lined with special coatings to avoid any reaction with the content
stored.
Advantages of Storage Silos
1. Storage silos consume less storage space compared to
horizontal storage warehouses.
2. The materials or products are stored under optimal
conditions.
3. Storage silos cost less compared to other storage options.
Disadvantages of Storage Silos
Storage silos face few issues when it comes to their handling. Some
of the problems of storage silos are:
1. Storage of fumigants and pesticides in the silos results in
intoxication.
2. Silos result in the accumulation of carbon-di-oxide,
which causes suffocation while opening it.
3. The decomposition of grains stored in silos results in
inflammable vapors. These vapors bring suffocation and
may result in poisoning if inhaled.
TYPES OF STORAGE SILOS
TOWER SILOS - have a diameter of 4 to 48 meters with a height
of 3 to 40m. Tower silos are constructed using wood, steel, or
concrete. The most commonly used silos are tower silos. Air slides
or augers facilitate the unloading of cement or woodchips or grain
from the silos. It can be unloaded into trucks or conveyor belts or
rail cars.
Advantages;
 Tends to pack well due to its own weight
 Lower Storage Losses
 Requires less area for construction
 Allows greater mechanization during filling and feedout
 Convenient to unload in winter
Disadvantages;
• Higher initial cost
• Unloads more slowly
• Silage moisture cannot be as high as compared to other
silo types
BUNKER SILOS - are trenches, which are filled and packed with
the help of tractors and loaders. Bunker silos are made from
concrete walls. Plastic tarp covers the fully packed bunker silos to
make it air tight. Loader or tractor can unload the materials from
the bunker silos. Agriculture and large manufacture industries
demand bunker silos to store a high quantity of materials. A critical
application of bunker silos is in the military. The military adopts
bunker silos to deposit and handle missiles.
Advantages;
• Holds large capacity
• Can be filled with conventional farm equipment
• Offers faster unloading rates
• Forage quality changes occur gradually if filled using the
progressive wedge
• Inexpensive
• Well suited to very large operations.
Disadvantages;
• Higher initial cost
• Requires greater care in filling and packing
• Will not work for smaller herds
• Need usually unloading with a tractor and loader.
BAG SILOS - used to store grains and fodder. It is made from
plastic or hermetic bags or tubes. Bag silos have a diameter of 2 to
21m. The height of the silo depends on the quantity of material
intended to store. Bag silos are one of the most economical silos.
Advantages;
• Lower capital investment
• Flexible storage system
• Feed is easily inventoried
• Can be used for small and large herds
• Fewer safety and health hazards
• Lower Storage Losses
Disadvantages;
• Specialized equipment may be needed
 • Plastic disposal creates extra labor and environmental
concerns

• Bags must remain intact, compromised bag can result in

a complete loss

SILO SYSTEM SOLUTIONS FOR YOUR INDUSTRY

Transit Center

At transit centers of train station, seaport or river depot,

materials mainly comes from ship, truck, train or in bags. Then
reach the purpose of transit to bulk truck or bag packing system.

Power Station

For Storage of fly ash, with fly ash grading system,

pneumatic conveyor system, silos with PLC controlled aeration
system, bulk truck loading and bag packing system.

Cement Plant Industry

Storage silo solution for Cement Plant Industry--cement

from cement milling plant, silos with PLC controlled aeration
system, bulk cement truck loading and bag packing system.

Clinker Mill Plant

For storage of low temperature clinker, additive and

finished cement, silos with PLC controlled aeration system, bulk
truck loading and bag packing system.

Mineral Production industry

For storage of various types of mineral powder materials

like sand, lime, quick lime powder, coal, rare earth metals etc.
Particle discharging by air CANNONS and powder by air aeration.

Concrete Batching Plant

Concrete batching plant uses bolted silos for storage of

cement, fly ash, slag powder and other additives. Low cost, easy
installation and movable.

Steel Silo for Plastics Plant

Silos For Plastic Granules, storing granules of PP, PE,

PVC, PC, ABS and PET.