Screw Feeder Keeps Soda Ash Flowing for Packaging Operation

General Description

A $3.5 billion company and one of the fastest growing Consumer Packaged Goods companies in the United States was adding a new pouch filling line and in need of engineering and conveying solutions. The project required the Customer to transfer sodium carbonate (soda ash) from the discharge of an existing drag conveyor and meter and elevate it to the inlet of a 7-cubic foot bifurcated surge bin.

The unique design of the new screw feeder would have a capacity less than the drag conveyor so that the inlet of the screw feeder would always be flooded. Excess soda ash continues in a loop in the drag conveyor. The 7-cubic foot surge bin provides soda ash to refill two All-Fill pouch filling lines as needed. The bagged soda ash is sold for commercial use in the manufacture of glass, soaps, detergents, and many other products.

Design Parameters

1. Product Type: Soda Ash
2. Material Density: 67 to 68 Lbs. per Cubic Foot
3. Conveyor System Capacity: 756 Cubic Feet per Hour
4. Duty: Intermittent

KWS Advantages

The Customer contacted KWS at the early stages of the project for preliminary design and budgeting. A highly trained local KWS manufacturer’s representative met with the Customer, toured the plant, and gathered important design information. The Customer provided KWS with photos and basic layout dimensions of the desired footprint and constraints for the new equipment.

The KWS sales and engineering teams determined the ideal inclined conveying solution that would satisfy the layout requirements while maneuvering the space constraints in the plant. KWS engineers created a 3D general arrangement model of the equipment, including the existing drag conveyor and All-Fill machines, that would ensure that the stack-up and integration would be seamless during installation.

Special Features

The new KWS screw conveyor spanned the required 21-feet, 6-inches without the use of an internal intermediate bearing. Internal bearings create a restriction to the flow of the soda ash and cause downtime and maintenance issues. The one-piece screw was manufactured using large diameter pipe that spanned the required 21-feet, 6-inches length. The screw was mounted on large diameter pipe to prevent excessive screw deflection that would lead to premature failure.

Due the weight and length of the single piece screw, KWS utilized the KWS Torque Arm Trough End. With the KWS Torque Arm Trough End, the shaft mounted gear reducer is allowed freedom to move with the run out of the driveshaft, reducing radial loads on the gear reducer and increasing the overall reliability of the screw feeder. The design incorporates the use of a pillow block roller bearing that supports the screw and acts as a thrust bearing.