LSPU Self-Paced Learning Module (SLM)

Course FME18 – MANUFACTURING AND INDUSTRIAL PROCESSES WITH PLANT VISIT

Sem/AY First Semester/2023-2024
Module No. 1
Lesson Title Methods In the Handling of Solids
Week
One Week
Duration
Date
This lesson will discuss the Methods, Processes, and equipment involved in handling
Description solids.
of the Lesson

Learning Outcomes
Intended At the end of week one, Students should be able to meet the following intended
Learning learning outcomes:
Outcomes  Identify the different processes in industrial and manufacturing plants.
 Enumerate and describe the equipment utilized in the different industrial and
manufacturing processes
 Identify the methods in the handling of solids
Targets/ At the end of the lesson, students should be able to:
Objectives  Discuss the different processes in industrial and manufacturing plants.
 Enumerate and describe the equipment utilized in the different industrial and
manufacturing processes
 Discuss the methods in the handling of solids

Student Learning Strategies

Face to Face A. classroomm setting

You will be directed to attend a four-hour-per-week class discussion on
MANUFACTURING AND INDUSTRIAL PROCESSES WITH PLANT
VISIT
B. Learning Guide Questions:
1. What are the different methods of handling solids?
2. Discuss each method and how it works?
Note: The insight that you will share during the discussion will receive additional scores in-class
participation.
 METHODS IN THE HANDLING OF SOLIDS
- Conveyors - Mechanical Conveyor
- Belt conveyors - Chutes
- Screw conveyors - Slides
- Bucket conveyors - Pneumatic conveyance systems
- Roller conveyors
- Automation and Robotics
Storage - Robotic arms for picking and placing
- Silos - Automated guided vehicles (AGVs)
- Bins - Conveyor belt systems with automated
- Hoppers sorting
- Piles
- Safety Measures
- Transportation - Dust control systems
- Trucks - Ventilation systems
- Railcars - Personal protective equipment (PPE)
- Ships - Lockout/tagout procedures
- Air freight
- Quality Control
- Material Handling Equipment - Inspection systems (vision, x-ray)
- Forklifts - Weighing and measuring equipment
- Cranes (overhead, gantry, jib) - Sampling techniques
- Pallet jacks
- Loaders and unloaders - Environmental Considerations
- Dust collection and filtration systems
- Packaging - Waste disposal methods
- Filling machines - Material recycling strategies
- Wrapping machines
- Sealing machines - Material Characteristics Consideration
- Palletizing systems - Particle size and shape
- Cohesiveness and flowability
- Processing - Abrasiveness and wear resistance
- Crushing
- Grinding - Training and Education
- Mixing - Operator training programs
- Sorting - Safety guidelines awareness
- Standard operating procedures (SOPs)

Remember that the choice of methods will depend on the specific characteristics of the solid
material being handled, the facility's layout, safety considerations, and efficiency goals.
BELT CONVEYOR
A belt conveyor is a mechanical system that uses a continuous belt to transport materials from
one location to another. It's commonly used in industries such as manufacturing, mining,
agriculture, and logistics for efficient and automated material handling. Here's how a basic belt
conveyor works:

1. Frame and Support Structure

- The conveyor starts with a sturdy frame that supports the entire system.
- Rollers or pulleys are mounted on the frame to support and guide the belt.

2. Belt
- The conveyor belt is typically made of a flexible material, such as rubber, fabric, or plastic,
which is looped around the rollers or pulleys.
- The belt forms a continuous loop that moves along the length of the conveyor.

3. Drive Mechanism
- The belt is driven by a motorized pulley called the drive pulley or head pulley.
- The motor provides the necessary power to move the belt and the materials on it.

4. Idler Rollers
- Idler rollers are placed between the drive pulley and the tail pulley to support the belt's
weight and maintain proper tension.
- These rollers prevent the belt from sagging and ensure it maintains proper contact with the
drive pulley.

5. Tensioning Mechanism
- A tensioning mechanism, often using a combination of weights, springs, or pulleys, is used to
maintain the appropriate tension on the belt.
- Proper tension ensures that the belt doesn't slip or sag excessively, leading to efficient and
smooth operation.

6. Loading Point
- At the loading point, materials are placed onto the conveyor belt.
- Depending on the application, there might be additional equipment, such as hoppers or
chutes, to guide the materials onto the belt.

7. Transport
- The motorized drive pulley rotates and moves the belt, which, in turn, transports the
materials along the length of the conveyor.
- The materials are carried on the upper surface of the moving belt.

8. Unloading Point
 - At the unloading point, the materials are manually or automatically removed from the
conveyor.
- Again, chutes or other mechanisms might be used to guide the materials off the belt.

9. Return Path
- After passing over the drive pulley, the belt returns to the starting point using idler rollers.
- The return path is typically located beneath the belt.

10. Belt Tracking

- Proper belt tracking is essential to prevent the belt from wandering off its intended path.
- Adjustments are made using tracking rollers or adjustments to the tensioning mechanism.

A belt conveyor provides a continuous and efficient method of moving materials over long
distances, up inclines, or down declines, making it an integral part of many industrial processes.
Different industries may use variations of belt conveyors, such as troughed belt conveyors for
bulk materials, inclined or declined conveyors, and enclosed belt conveyors for environmental
protection.

SCREW CONVEYOR
A screw conveyor is a mechanical device used to convey bulk materials in a semi-horizontal or
inclined manner using a rotating helical screw blade. It's commonly used in various industries
for transporting and handling materials such as grains, powders, pellets, and other bulk solids.
Here's how a screw conveyor works:

1. Helical Screw Blade The heart of a screw conveyor is a helical screw blade, often
referred to as an "auger." This blade is typically made of metal and has a helical shape,
resembling a long screw.
2. Housing or Trough The screw blade is enclosed within a tube-like housing or trough. The
housing serves to contain the material being transported and also guides the movement
of the screw.
3. Inlet and Outlet The conveyor has an inlet at one end where the material is fed into the
housing. The outlet is usually at the other end, where the material is discharged.
4. Rotation The helical screw blade is connected to a motor at one end of the conveyor.
When the motor rotates the screw blade, it causes the entire assembly to move,
effectively pushing the material along the length of the conveyor.
5. Material Engagement As the screw blade rotates, its helical shape engages with the
material present in the housing. The rotating screw effectively moves the material
forward or upward, depending on the orientation of the conveyor.
6. Conveying Action, the material moves in a "corkscrew" manner along the length of the
screw blade. The angle of the helix and the speed of rotation determine the rate of
material movement.
7. Discharge As the material reaches the outlet end of the conveyor, it is discharged from
the housing. Depending on the design, the material can be dropped directly from the
outlet or directed into another conveying system or process.
 8. Inclined Operation Screw conveyors can operate on inclines or declines, allowing for
versatile material handling. In inclined conveyors, gravity aids in material movement
along with the screw's rotation.
9. Variable Capacity The capacity of a screw conveyor can be adjusted by varying the
screw's pitch, diameter, and speed of rotation. A larger pitch or diameter increases
capacity, while slower speeds may be used for delicate materials.
10. Versatility Screw conveyors can be designed for various applications, including
horizontal, inclined, or vertical transport. They can be used for both short and long
distances, making them adaptable to different layouts.

Screw conveyors are efficient, cost-effective, and versatile solutions for handling a wide
range of bulk materials. They find applications in industries such as agriculture, food processing,
mining, chemicals, and construction. Proper design and engineering considerations are crucial
to ensure efficient and reliable operation while accounting for factors like material properties,
conveying distance, and the surrounding environment.

BUCKET CONVEYOR
A bucket conveyor, also known as a bucket elevator, is a mechanical system used to
vertically convey bulk materials like grains, powders, and other granular materials. It employs a
series of buckets attached to a chain or belt that move in a continuous loop, transporting
materials between different levels. Here's how a bucket conveyor works:

1. Bucket The key components of a bucket conveyor are the buckets themselves. These
buckets are typically made of materials like plastic, metal, or rubber and are attached to
a chain or belt at regular intervals.
2. Drive Mechanism The conveyor includes a motor-driven mechanism that powers the
chain or belt. This drive mechanism is located at the bottom or top of the conveyor,
depending on the design.
3. Infeed Hopper At the lower end of the conveyor, there's an infeed hopper where the
bulk material is loaded. The material flows into the buckets from this hopper.
4. Conveyor Movement As the motor-driven chain or belt moves, the buckets are lifted
upward in a vertical or inclined path. The movement is continuous, creating a loop.
5. Material Loading As each bucket reaches the lower end of the conveyor, it dips into the
material in the infeed hopper. The material fills the bucket as it moves along.
6. Elevation and Discharge As the buckets move upward, they reach the discharge point at
the top of the conveyor. Depending on the design, the buckets may tip over or be
mechanically opened to release the material.
7. Discharge Chute or Outlet At the top of the conveyor, there's a discharge chute or outlet
where the material is released from the buckets. The material is directed to the desired
location, such as another conveyor or a storage container.
8. Bucket Return After discharging the material, the empty buckets continue to move
downward on the return path, often located on the opposite side of the conveyor loop.
9. Continuous Operation The process of filling, elevating, and discharging buckets is
continuous, allowing for a steady flow of material between different levels.
 10. Adjustable Speed and Capacity- The speed of the conveyor and the capacity of material
handling can be adjusted by controlling the motor speed and the size of the buckets.

Bucket conveyors are widely used in industries like agriculture, food processing, mining,
and manufacturing for vertically transporting bulk materials. They are particularly useful for
moving materials between different levels efficiently and can be customized to handle various
types of materials and environmental conditions. Proper design, maintenance, and safety
considerations are essential for their reliable and safe operation.

ROLLER CONVEYOR
A roller conveyor is a simple and efficient mechanical system used for the transportation
of goods or materials within a facility. It consists of a series of cylindrical rollers mounted on a
frame, and these rollers allow items to move smoothly along a path. Here's how a roller
conveyor works:

1. Rollers The core component of a roller conveyor is a series of rollers arranged side by
side across the width of the conveyor. These rollers can be made from various materials
such as metal, plastic, or rubber.
2. Frame The rollers are mounted onto a rigid frame, which provides support and structure
to the conveyor system. The frame also determines the layout and path of the conveyor.
3. Gravity or Powered Roller conveyors can be either gravity-driven or powered. In a
gravity conveyor, items are manually or mechanically placed onto the rollers, and they
move along the conveyor due to the force of gravity. In a powered conveyor, a motor
provides the necessary force to move the rollers and the items on them.
4. Roller Rotation When the conveyor is in operation, the rollers rotate as they come into
contact with the items placed on them. The rotation of the rollers allows the items to
move along the length of the conveyor.
5. Smooth Movement The cylindrical shape of the rollers facilitates smooth movement of
the items, reducing friction and allowing for efficient transportation.
6. Loading and Unloading Items are loaded onto the conveyor manually or using
equipment like forklifts or automated systems. The items can be placed directly on the
rollers or on containers, such as pallets or trays, which are then placed on the rollers.
7. Transportation As the rollers rotate, they move the items forward along the length of
the conveyor. The items can move in a straight line, curve, or even incline/decline
depending on the design of the conveyor system.
8. Diverters and Merge Points In more complex systems, roller conveyors can have
diverters and merge points that allow items to be directed to different paths or
combined from different paths.
9. Powered Rollers In powered roller conveyors, a motor drives one or more rollers via a
belt, chain, or other mechanism. This provides controlled and consistent movement of
items along the conveyor.
10. Flexible Configurations Roller conveyors can be designed in various configurations,
including straight sections, curves, spirals, and even vertical lifts.
 11. Applications Roller conveyors are widely used in industries like manufacturing,
distribution, logistics, and warehouses for transporting items such as boxes, packages,
crates, and even heavy loads like pallets.

Roller conveyors are popular due to their simplicity, cost-effectiveness, and versatility in material
handling. They come in various sizes and designs to accommodate different types of materials,
loads, and layouts. Proper maintenance and safety measures are essential to ensure smooth and
safe operation of roller conveyors.

HANDLING OF SOLIDS
The handling of solids encompasses a range of processes essential to industries such as
manufacturing, mining, agriculture, and more. This complex endeavor involves efficiently
managing the movement, storage, and transformation of solid materials. The processes include
conveying, where methods like belt, screw, and bucket conveyors transport materials over
distances; storage techniques like silos, bins, and hoppers store materials until needed;
processing methods such as crushing, grinding, and mixing transform raw materials into usable
forms; and packaging systems ensure proper containment and presentation. Safety measures,
quality control through inspection and sampling, and environmental considerations round out
the framework. By mastering these processes, industries streamline production, enhance
safety, and optimize resource utilization, contributing to smoother operations and improved
products across various sectors.

In the handling of solids, various types of feeders are used to control the flow of
materials from a source to a downstream process. Feeders ensure a consistent and controlled
supply of solids, preventing overfeeding or underfeeding.

TYPES OF FEEDERS USED IN SOLID HANDLING

1. Screw Feeders Utilize a rotating screw to convey materials along a trough. Suitable for
free-flowing and non-free-flowing materials.
2. Belt Feeders Consist of a conveyor belt that transports materials at a controlled rate.
Used for uniform and continuous feeding.
3. Vibratory Feeders Employ vibrations to move materials in a controlled manner. Ideal for
delicate or abrasive materials.
4. Apron Feeders Feature heavy-duty chains and rollers to move materials. Used for
handling heavy and large-sized materials.
5. Rotary Valve Feeders Use a rotating rotor to control the flow of materials through a
valve. Commonly used in pneumatic conveying systems.
6. Weigh Belt Feeders Combine a conveyor belt with a weighing system to measure and
control material flow based on weight.
7. Gravimetric Feeders Measure the weight of the material being fed, ensuring precise
control.
 8. Loss-in-Weight Feeders Maintain a constant material weight in the feeder by
continuously monitoring and adjusting the feed rate.
9. Screw Volumetric Feeders Regulate material flow by adjusting the screw's speed or the
size of the screw's discharge opening.
10. Disk Feeders Use rotating disks to move and control material flow.
11. Ribbon Feeders Employ a ribbon-like blade to move materials along a trough.
12. Chain Feeders Use a chain conveyor to transport materials in a controlled manner.
13. Paddle Feeders Use rotating paddles to move materials along a conveyor.

These feeders are chosen based on the characteristics of the materials being handled,
the desired feed rate, the application's requirements, and the specific industry. Proper selection
and operation of feeders are crucial to maintaining process efficiency and preventing material
handling issues.

PROCESSES COMMONLY INVOLVED IN THE HANDLING OF SOLIDS

Conveying Testing
Belt conveyors Transportation
Screw conveyors Trucks
Bucket conveyors Railcars
Roller conveyors Ships
Air freight
Storage
Silos Environmental Considerations
Bins Dust control
Hoppers Waste management
Piles Recycling

Processing Safety Measures

Crushing Dust suppression
Grinding Personal protective equipment (PPE)
Mixing Hazard mitigation
Screening
Automation and Robotics
Packaging Robotic arms for handling
Filling Automated sorting systems
Sealing AGVs for transport
Labeling
Palletizing Material Characteristics Consideration
Particle size analysis
Quality Control Flow properties assessment
Inspection Compatibility studies
Sampling
 Training and Education
Operator training
Safety guidelines
Standard operating procedures (SOPs)

Energy Optimization
Efficient equipment design
Power consumption reduction
Energy recovery systems
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna

These processes collectively ensure the efficient, safe, and controlled handling of solids
across various industries.

SCREW FEEDER
A screw feeder is a mechanical device used to control the flow of bulk materials by using
a rotating screw to transport and discharge the materials. Screw feeders are commonly used in
various industries to accurately and consistently feed materials from a storage container or
hopper to a downstream process. Here's how a screw feeder works:

1. Screw Design The heart of a screw feeder is a helical screw, often referred to as an
"auger." This screw is designed with a specific pitch, diameter, and flight configuration
that determine its feeding capabilities.
2. Inlet Hopper The process starts with a storage container or hopper where the bulk
material to be fed is stored.
3. Screw Rotation The screw is powered by a motor and rotates within a tube or trough.
The motor's rotational motion drives the screw, causing the material to move along with
it.
4. Material Engagement As the screw rotates, the helical flights of the screw come into
contact with the material at the inlet end of the feeder.
5. Material Transport The rotating screw pushes the material along the length of the
screw's helical path. The inclined orientation of the screw causes the material to move
upward or forward, depending on the design.
6. Discharge Outlet At the discharge end of the screw feeder, there is an outlet where the
material is released. The rate of material discharge is controlled by the speed of the
screw's rotation.
7. Hopper Agitation (Optional) In some designs, the screw can be designed with agitating
features that help prevent material bridging or rat-holing in the hopper.
8. Variable Feed Rate The feed rate of the screw feeder can be adjusted by controlling the
speed of the motor that drives the screw. Faster rotation results in a higher feed rate,
while slower rotation reduces the feed rate.
9. Accuracy and Consistency Screw feeders are known for their accuracy and consistency in
delivering a controlled amount of material over time.
10. Applications Screw feeders are used in a wide range of industries, including food
processing, agriculture, pharmaceuticals, plastics, and more.
11. Materials Handled Screw feeders can handle materials ranging from fine powders to
larger granular materials, depending on the screw design and the application.

Screw feeders are versatile, efficient, and reliable solutions for precise material feeding.
Their ability to handle different types of materials and control feed rates makes them essential

LSPU SELF-PACED LEARNING MODULE: MANUFACTURING AND INDUSTRIAL PROCESSES WITH PLANT VISIT
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna

components in various manufacturing and processing operations. Proper maintenance and

customization based on material characteristics are important for optimal performance.

STORAGE SILOS
Storage silos are cylindrical structures used for storing bulk materials, such as grains,
powders, liquids, and granular substances. They come in various shapes, sizes, and materials to
suit different industries and storage requirements. Here's a breakdown of storage silos in terms
of their construction, capacity, and functions:

Construction
 Shape
Silos can have different shapes, including cylindrical, conical, or rectangular. The most
common shape is cylindrical.

 Materials
Silos are constructed from various materials such as steel, concrete, aluminum, or even
fabric (in some cases). Support Silos are supported by a foundation or base to ensure stability
and prevent settling.

 Capacity
Size Range Silos can range from small bins with capacities of a few cubic meters to large
structures with capacities exceeding thousands of cubic meters. Measuring Capacity Silo
capacity is typically measured in cubic meters or cubic feet. For liquids, it can also be measured
in liters or gallons.

 Functions
Storage
The primary function of a storage silo is to safely store bulk materials, protecting them
from environmental factors like moisture, pests, and contamination.

 Inventory Management
Silos aid in managing material inventory, allowing controlled withdrawal for production
or distribution.

 Bulk Material Handling

Silos facilitate the movement of materials from production to consumption, enabling a
steady supply for processes downstream.

 Blending and Mixing

Some silos are equipped with blending and mixing systems to ensure uniformity when
multiple batches of material are combined.

 Temperature Control

LSPU SELF-PACED LEARNING MODULE: MANUFACTURING AND INDUSTRIAL PROCESSES WITH PLANT VISIT
 Republic of the Philippines
Laguna State Polytechnic University
Province of Laguna

Insulated silos can be used to control the temperature of stored materials, keeping
them within desired ranges.

 Fermentation and Aging

In industries like agriculture and winemaking, silos can be used for fermentation and
aging of products.

 Distribution
Silos equipped with discharge systems help distribute materials to conveyors, trucks, or
other transportation methods.

 Industry-Specific Functions
Agriculture
Silos store grains and seeds, preserving their quality and facilitating controlled
distribution.

Food and Beverage

Silos store ingredients like flour, sugar, and liquids used in food production processes.

Chemical Industry
Silos store raw materials and finished products, promoting efficient material handling
and storage.
Construction
Silos store cement, concrete, and other construction materials for on-site use.

Energy
Silos store coal, biomass, or other fuels for energy production.

Waste Management
Silos store waste materials temporarily before disposal or recycling.

Storage silos play a crucial role in ensuring a stable supply of materials while protecting
them from degradation. Proper design, maintenance, and safety measures are essential to
ensure the integrity of the stored materials and the longevity of the silo structure.

LSPU SELF-PACED LEARNING MODULE: MANUFACTURING AND INDUSTRIAL PROCESSES WITH PLANT VISIT