Powder Transfer System – Process Flow Explanation

In pharmaceutical, chemical, food, and bulk material handling plants, the Powder Transfer System – Process Flow Explanation (PTS) plays a critical role in ensuring clean, safe, and efficient movement of powders between different process stages.

Understanding the Powder Transfer System –process flow explanation of a powder transfer system helps plant engineers, operators, and decision-makers optimize productivity and maintain high product quality.

Step 1 – Raw Material Feeding

Powder is charged into the system from:

• Bags / sacks

• Drums / big bags

• IBCs / silos

This is done through:

• Bag Emptying Station

• Feed Hopper

• Vacuum Loading Point

Dust extraction ensures clean & safe feeding.

Step 2 – Conveying Generation

A vacuum pump or roots blower creates the required conveying force.

Depending on application:

• Vacuum → pulls powder

• Pressure → pushes powder

This energy source controls the material flow velocity and conveying capacity.

Step 3 – Material Transport Through Pipeline

The powder moves through a closed stainless-steel pipeline.

Transport modes:

• Dense Phase – slow, gentle, low degradation

• Dilute Phase – fast, high throughput

The pipeline is designed with:

• Minimal bends

• Smooth interiors

• Optimized diameter

This prevents product breakage and pipeline choking.

Step 4 – Air–Material Separation

At the destination, the mixture enters a Receiving Hopper / Cyclone Separator.

Here:

• Powder drops by gravity

• Air passes through cartridge filters

• Clean air exits to atmosphere

Automatic pulse jet cleaning maintains filter efficiency.

Step 5 – Product Discharge to Process Equipment

The separated powder is discharged into:

• Reactor

• Blender

• Dryer (FBD, RVD, VTD, ANFD)

• Storage hopper

• Packing machine

Discharge devices used:

• Rotary airlock valve

• Butterfly valve

• Double flap valve

Step 6 – Control & Automation

The entire process is controlled through a PLC-based control panel:

Controls:

• Conveying sequence

• Filter cleaning

• Level sensors

• Interlocks & safety

This ensures fully automatic, repeatable and safe operation.

Resulting Benefits

✔ Dust-free production
✔ Zero contamination
✔ Higher productivity
✔ GMP-compliant operation
✔ Reduced manpower
✔ Consistent product quality