How Hapman Engineered a Custom Solution for a Difficult Salt Handling Application
Not every bulk bag unloading application is straightforward.
Many materials discharge easily with gravity alone. Others require simple flow aids, such as bag massagers or agitation paddles, to maintain a consistent flow. But some materials behave differently. They bridge, compact, absorb moisture, or form hard agglomerations that standard unloading equipment simply wasn’t designed to handle.
When that happens, solving the problem requires more than selecting a bulk bag unloader—it requires understanding the material itself.
That was the challenge one premium food processor faced while expanding production.
The Challenge
The processor needed to introduce granulated salt into a reactor of boiling water where it was dissolved before the pasta cooking process. The salt arrived in 2,000-pound bulk bags and, because of its hygroscopic nature, absorbed moisture during storage and transportation.
Instead of flowing freely, the material formed large, dense clumps inside the bags.
These agglomerations created several production problems:
- Inconsistent discharge from the bulk bag
- Difficulty maintaining consistent salt concentration in the process
- Product remaining in the bag after discharge
- Increased operator intervention
- Reduced process efficiency
At first glance, the solution seemed simple: improve the flow from the bulk bag.
The challenge was that conventional flow aids weren’t enough.
Why a Standard Solution Wouldn’t Work
In many applications, pneumatic bag massagers are an effective way to encourage compacted material to flow. By gently flexing the sides of the bag, they loosen material and promote consistent discharge.
However, this salt behaved differently.
The agglomerations were too large and too dense to be broken apart through bag massage alone. Simply adding more agitation wouldn’t solve the problem.
Engineering the Right Solution
Recognizing that a conventional approach would not deliver reliable performance, Hapman engineered a custom Bulk Bag Unloader specifically for the material’s behavior. Working closely with the processor, the engineering team developed a series of stainless-steel breaker bars that were mounted directly to the pneumatic agitator panels. Arranged in parallel at multiple heights, the breaker bars were driven into the bulk bag from opposing sides as the agitator panels cycled. Each stroke progressively fractured the hardened salt agglomerations, allowing free-flowing material to discharge while continuously breaking apart larger clumps throughout the unloading process.
The processor also needed to elevate the material approximately 12 feet to a mezzanine-mounted reactor while working within limited ceiling height.
To accomplish this, Hapman integrated an enclosed Helix® Flexible Screw Conveyor directly beneath the bulk bag unloader. Material discharged into an integral hopper before being conveyed to the reactor through a sealed conveying path. By combining unloading, conditioning, and conveying into a single engineered system, Hapman eliminated unnecessary transfer points while maintaining a compact footprint that fit the existing facility.
The result wasn’t simply a bulk bag unloader—it was a complete material handling solution engineered around the application’s unique challenges.
Results
By addressing the material’s behavior at the point of discharge, the processor was able to stabilize the entire process upstream.
The integrated system provided:
- Reliable, consistent material flow
- Improved process control and salinity consistency
- More complete bulk bag emptying with reduced product loss
- Less operator intervention during unloading
- Enclosed conveying that minimized housekeeping and material loss
- A compact system that fit within the facility’s existing layout
Instead of managing the symptoms downstream, the processor solved the problem where it began.
Engineering Around the Material
This application demonstrates that difficult material handling challenges aren’t always solved with standard equipment. By understanding how the material behaved and engineering a solution around the application, Hapman delivered reliable unloading, consistent conveying, and improved process performance.
Ready to Solve Your Material Handling Challenge?
Whether you’re handling salt, flour, minerals, chemicals, or another difficult-to-flow bulk material, Hapman’s engineers can design a bulk bag unloading solution tailored to your process. Contact us to discuss your application or schedule material testing to find the right solution.