Handling with care: Optimised pipework systems for bulk ingredients

System design trends within powder, bulk and food-ingredients handling continue to move towards highly optimised processes that integrate controlled containment, intelligent routing and complete process assurance within single solutions.
It used to be that conveying was king. Bulk material handling plants were designed around long stretches of pipework linking key areas of the production facility. Whilst this achieves the basic function of moving product around the plant, it offers little opportunity for routing flexibility and can be expensive and time-consuming to adapt should the process require change.
With powder handling plant design now taking a more holistic approach, the focus for modern infrastructure has shifted to the implementation of fully-integrated pipework systems with engineered components to facilitate complete control of material flow throughout the process.

Precision pipework to keep things moving

Food grade stainless steel is by far the preferred construction material for bulk solids handling plants. Offering complete durability and reliability within food-safe environments, well-designed systems provide a number of key benefits over alternative construction materials.
In order to provide effective, long-term solutions however, a number of key design principles must be observed. Not only should all pipework be constructed from grade 316 stainless steel with welded joints throughout, care should also be taken to ensure that pipe runs maintain a smooth surface profile and incorporate as few dead ends as possible. These criteria help to minimise product retention and ensure swift transition of ingredients through the network.

Engineered components for smart flow control

The best manufacturers understand that effective control of material flow is just as important as the initial conveying design. That’s why they will offer a comprehensive portfolio of engineered components to enhance the flexibility of your chosen systems. Some of the most common parts include:

Slide gates

Ideal for providing complete isolation of materials within your pipework system, slide gate valves enable plant operators to release ingredients for loading out or diverting flows of material to alternative destinations.
Whether you’re facilitating easy maintenance and cleaning of equipment, executing quick changeovers between ingredients or simply providing a safe method of cutting material flow, should an issue occur further along the production line, slide gate valves are designed to repeatedly provide secure sealing and precise operator control.

Two-way diverters

When it comes to smart routing within pipework systems, compact two-way diverters enable controlled separation of material flow to two destination points. This is especially useful for multi-line powder handling plants which utilise a single pipe run to transport multiple ingredients around the facility. Two-way diverters can offer maximum flexibility by facilitating rapid switching between material types without the need for complex pipeline modifications.

Turn heads

For even greater distribution capabilities, a range of turn head systems allows bulk solids to be routed to multiple outlets from a single source. Again, ideal for high-volume powder handling plants with several silos or loading stations to service, turn heads are essential for simplifying complex piping architectures.

Integration at its finest

The key to success within any powder or bulk ingredients facility is integration. Rather than functioning as separate elements, all aspects of the handling process should operate collectively to form a fully cohesive unit.
Utilising stainless steel pipework as one core system not only simplifies the overall design and facilitates easier maintenance across the network, but ensures that slide gates, diverters and turn heads can be operated with maximum efficiency and minimal downtime.

Built to last and future focused

Facilities management is all about longevity, which is why it’s key that all of your chosen engineered components are built to offer unrivalled durability and resistance to wear.
Check with manufacturers that parts are designed to retain optimum performance even under the harshest of conditions and can easily withstand high-pressure applications, extreme temperatures and regular exposure to aggressive cleaning agents.
Needless to say, quality built components won’t just improve the reliability of your bulk handling plant – they’ll save you money in the long run.
Keeping an eye on the longer term, future-proof solutions are being developed with a significant trend toward automation as well as real-time intelligence. Pipework networks designed with integrated control from the start are allowing flow rates, valve positions, and routes to be monitored and adjusted in real time. Providing operators the visibility they need to optimise production on the fly, adapt quickly to process changes and minimise human error. Integrating automation with stainless steel modularity and precision flow control components improves process consistency,traceability and control. 
As demand for versatility and productivity within powder handling facilities continues to increase, facilities managers are recognising the benefits of taking a more rounded approach to plant design. By combining stainless steel pipework with intelligent components, modern bulk solids handling plants can achieve total control over material flow without compromising on performance or ease of use.