Vacuum Transfer Systems: Industry Solutions
The vacuum transfer system is an advanced material handling system that has found significant use in a wide range of industries. This innovative technology works by producing a vacuum within a closed pipeline, allowing for the efficient and contamination-free flow of products such as bulk solids, powders and granules.
One of the vacuum powder transfer systems major advantages is its ability to handle bulk solid, powder and granules with accuracy, minimal wastage, and care. Whether in pharmaceuticals, food processing, battery, resin or chemical industry, the system is designed to ensure product integrity while limiting dust emissions—an important requirement in industries where product purity is vital. A vacuum transfer system helps industries improve powder handling processes with a focus on quality and safety.
How does it work?
The vacuum transfer system uses suction to move dry materials, such as powders and granules, through a closed pipeline with precision and efficiency. This process utilizes vacuum pressure to remove the necessity for mechanical components and manual work. It relies on the fundamental principles of creating a pressure differential between the source point (where materials are stored) and the destination point (where materials are needed). As the vacuum is applied, materials are gently drawn into the pipeline and transported to their intended location.
Aishin Industrial Corporation, a pneumatic conveying system manufacturer, is well known for its expertise in material and powder transfer systems. We specialize in vacuum conveying systems for powder and granules and have expertise in developing and providing systems that meet various material handling needs for companies in India and across the globe.
Benefits of Aishin Vacuum Transfer System
Boxer
- Transfer rates up to 4000 Kg/hr can be achieved.
- Bulk densities as high as 2.5 g/cc and as low as 0.2g/cc can be conveyed.
- Modular design with easy opening and cleaning
- Flap type discharge valve for easy discharge
Dense Phase Transfer System
- Stable transfer is possible for powders and granular that is difficult to transfer by suction like highly adhesive and cohesive fine powder etc.
- It is possible to set high or low pressure transfer, high or low density transfer
- Air quantity required is less and filter area can be reduced
- It is a complete discharge type and there are no remains in the equipment
- Suitable for long distance transfer
A unique combination of airflow and vibration
- Wet Material Capability: Unlike traditional feeders that struggle with damp or sticky materials, the air blow feeder effectively transports these substances, minimizing downtime.
- Versatility for Difficult Materials: Dense phase conveying with a balanced air and vibration mixture allows the feeder to handle a wider range of materials, including those with varying specific gravities, that might cause issues in conventional systems.
- Preserved Material Integrity: The carefully calibrated airflow and vibration minimize segregation and crystal breakage, ensuring your materials arrive in their desired state, ready for further processing.
- Long-Distance Conveying The air blow feeder boasts an impressive conveying distance of up to 300 meters using low-pressure air. This translates to cost-effective and efficient material handling over extended distances within your facility.
Volkmann
Volkmann vacuum conveying systems from Germany are the best in class solution for vacuum conveying of various types of powders, granules, tablets & capsules. Volkmann offers a wide variety of products for Pneumatic conveying.
- Vacuum conveying with electrical as well as venturi pumps
- High containment closed loop vacuum conveying with up to OEB Level 5
- Transfer rates up to 5000 Kg/hr
- Various types of Anti corrosive, Anti Abrasive coatings available
- ATEX models available
- CIP available
The perfect Japanese engineering for solving
specific industry based problems
Confectionary Manufacturing
Confectionery manufacturing demands delicate handling. Traditional transfer systems can be rough on your precious candies, causing breakage, deformation, and product inconsistencies. Here’s where Volkmann’s innovative vacuum transfer systems come in, offering a gentle touch that safeguards the integrity of your confections.
- Gentle Handling of Confections: Imagine your candies being cradled by a bed of air during transfer. Volkmann's vacuum conveyors utilize a unique mechanism that ensures delicate items like chocolates and candies are not crushed or deformed. This gentle handling is crucial for maintaining the integrity of your products, which is essential in the competitive confectionery market.
- Specialized Accessories for Optimal Performance To further enhance the handling of confectionery products, Volkmann offers specialized accessories that eliminate air pockets within the candies. This feature prevents unwanted voids that can negatively impact texture and appearance, ensuring that your confections meet the highest quality standards.
- Solutions for Sticky and Hygroscopic Ingredients :Volkmann's systems are particularly effective for handling sticky candies and high-sugar content ingredients, which can often clog traditional transfer lines. This capability reduces downtime and maintenance issues, allowing for a smoother production process. For hygroscopic confections like gummies, moisture loss during transfer can be a significant concern. Volkmann's process engineers are equipped with the expertise to minimize this loss, preserving the texture and extending the shelf life of your candies.
Chemicals Manufacturing
When it comes to transferring sensitive materials like chemical fibers, pigments, salts, and corrosive chemicals, the chemical industry faces unique challenges. The answer? Volkmann’s VS range of vacuum conveyors.
continous charging
- High Throughput and Minimal Downtime: Volkmann systems facilitate high throughput rates, allowing for continuous operation with reduced interruptions, which is essential in maintaining production efficiency.
- Operator Convenience: The suction lance is designed for optimal operator convenience, featuring a smooth inner surface to prevent blockages and a double-walled design for height adjustability, making it user-friendly during operation.
Pharmaceutical manufacturing
Volkmann offers advanced pneumatic vacuum conveyors are designed for the pharmaceutical industry, addressing the sector’s critical needs for precision, hygiene, and efficiency. Their systems are designed to integrate seamlessly into various processes, including refilling bins, weighing, blending, and compressing, while minimizing manual intervention and error.
- Diverse Applications: Volkmann conveyors facilitate multiple processes without segregation of mixtures, making them ideal for handling capsules and tablets.
- High-Quality Standards: The VS and PPC Vacuum Conveyors feature modular designs that allow for easy cleaning and are compatible with containment systems, ensuring dust-free material transfer essential for maintaining pharmaceutical purity.
How we Solve this?
damage free transfer from production to packaging
Defects during the transfer of unpacked tablets, especially when using manual or cushion-less methods, can lead to breakage, scratches, and other damages. Such issues negatively affect product perception in the market.
Volkmann, Inc. offers pneumatic conveying systems that facilitate the transfer of tablets directly from production to packaging. These advanced systems are designed to minimize the risk of damage, ensuring that the tablets maintain their exterior finish throughout the process.
damage free transfer from production to packaging
Volkmann, Inc. revolutionizes powder transfer in manufacturing with innovative pneumatic vacuum conveying solutions tailored for the pharmaceutical industry. Our systems ensure swift, secure, and loss-free transport of powders and granules, making them essential for flawless operations. Key features include seamless feeding into tablet presses and capsule-filling machines, safe loading of reactors in pharmaceutical primary plants, and dust-free supply to mixers, all while minimizing contamination risks.
Expertise in handling critical pharmaceutical environments
Volkmann’s PPC (Pneumatic Pharma Conveyor) Vacuum Conveyors are designed for efficient cleaning in the pharmaceutical industry, offering both WIP (Washing In Place) and CIP (Cleaning In Place) options. The key difference is that WIP allows rinsing of all product-contacting surfaces without disassembling the conveyor, thanks to its smooth design and hygienic valves that effectively wet all components and surfaces after rinsing and flooding, the washing liquid is fully drained
Critical Pharmaceutical Product manufacturing
When it comes to transferring sensitive materials like chemical fibers, pigments, salts, and corrosive chemicals, the chemical industry faces unique challenges. The answer? Volkmann’s VS range of vacuum conveyors.
continous charging
- High Throughput and Minimal Downtime: Volkmann systems facilitate high throughput rates, allowing for continuous operation with reduced interruptions, which is essential in maintaining production efficiency.
- Operator Convenience: The suction lance is designed for optimal operator convenience, featuring a smooth inner surface to prevent blockages and a double-walled design for height adjustability, making it user-friendly during operation.
Softgel manufacturing
zero clamping issue
Traditional vacuum conveyors often cause soft gels to clump together, requiring manual intervention to resolve the issue. However, Volkmann’s pharmaceutical transfer systems effectively address this problem by utilizing dense phase and low velocity conveying methods. This approach ensures that soft gels are transferred gently, minimizing the risk of damage and significantly reducing clumping. By precisely controlling and optimizing conveying parameters, Volkmann enhances the efficiency and smoothness of the transfer process, making it a reliable solution for handling delicate soft gels
Reduce damage
Volkmann, Inc. offers a specialized solution for the challenges of manually loading soft gels into filling and bottling machines. Their pharmaceutical-grade vacuum conveyors are designed to operate under vacuum conditions, adhering to cGMP standards, which reduces manual handling and minimizes product damage. By employing dense phase and low velocity conveying methods, Volkmann’s systems effectively mitigate impact damage that often occurs with traditional pneumatic conveying, leading to more efficient manufacturing processes for soft gels.
Prevents Inconsistent feeding
Volkmann Systems offers a solution to these challenges with our vacuum transfer system. Engineered to handle soft gel capsules with care, our system ensures a consistent flow into all secondary machines. By integrating a gentle dense phase mechanism, we facilitate smooth and controlled transfer, enhancing efficiency and reliability in loading processes.
Food Manufacturing
- Food ingredients are organic and potentially flammable, there's a critical need to manage the risk of explosive dust. The Volkmann Vacuum Conveyors come with an ATEX certification, ensuring safe transportation of even low-ignition substances like maltodextrin or corn flour.
- Real-world applications of the Volkmann Vacuum Conveyors in Food Processing Include: Efficiently handling bagged goods, safe transportation of large quantities, and enhancing mixer productivity through precise mixer loading. Seamless product supply to critical systems, ensuring cleanliness with dust extraction and return during packing. Replenishing material to dusting systems and recovering excess material.
Our engineering services ensure minimize product loss, Perfect uniformity in your ingredients for flawless end products, improved efficiency and unmatched quality designed to perfection.
- Precision Powder Transfer: From flour to sugar, cocoa to spices, our engineered solutions ensure seamless transfer of even the most delicate food powders.
- Top -Tier Processing Equipment: Mix, grind, and handle all your dry and wet ingredients with confidence using Aishin’s high-performance machinery.
- Expert Engineering Services: Our Japanese-trained engineers bring unmatched precision and innovation to every project, ensuring optimal performance and food safety.
F.A.Q.
Have any Question?
Vacuum transfer systems work by creating a pressure differential between two points, typically using a vacuum pump. This pressure difference allows materials to be conveyed through a network of pipes or tubing to their desired destination.
Vacuum Material Transfer Systems can handle a wide range of materials, including powders, granules, pellets, and other dry powders. They are versatile and suitable for various industrial applications.
Maintenance requirements vary depending on the system’s complexity and usage. Regular inspections, cleaning, and servicing of components such as filters, pumps, and valves are typically needed to ensure optimal performance.
These systems maintain a sealed environment to prevent contaminants from entering the process. The vacuum suction ensures that powders are transferred without exposure to the surrounding atmosphere.
Vacuum transfer systems can help reduce material wastage, minimize dust emissions, and improve overall process efficiency, which can lead to environmental benefits such as reduced energy consumption and fewer emissions.