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Dust Drastically Reduced at Bulk Bag Loading Stations for High-Risk Product

BFM Bulk Bag Loader above closed bag with BBL in foreground

BFM® Bulk Bag Loaders Limit the Risk of Exposure to RCS (Respirable crystalline silica)

A UK-based monolithic refractory manufacturer that produces over 300 products was particularly concerned with the dust generated during their bulk bag loading process.

The products being handled included raw materials such as sand, lime and dolomite, all of which potentially contain respirable crystalline silica (RCS), which can cause serious respiratory diseases with long-term exposure.

After trialling a range of different solutions, they found none were durable or effective enough - until they found the BFM® fitting Bulk Bag Loader!

The Challenge

The company fills around 60 bulk bags daily, transferring materials from silos into bags that are then transported for mixing. The existing clamp system used to secure the bags during filling was proving inadequate, allowing dust to escape during the process. As the materials handled pose an RCS risk,, effective dust containment was not only a priority—it was essential.

Despite having local exhaust ventilation (LEV) systems and both static and personal dust monitors in place, the site struggled to control dust leakage at the point where the bulk bags connected to the filling head.

The engineering team trialled a range of different solutions, including inflatable seals, but these options fell short, either due to insufficient dust reduction or premature wear and tear. It was clear they needed a more durable, effective solution.

Bulk Bag Loader Before Image

The BFM® Solution

Local BFM® fitting Authorized Distributor, ProSpare Ltd, recommended installing two BFM® Bulk Bag Loaders to control the dust and improve the overall efficiency of the bag loading stations.

Dust emissions during the filling process have dropped dramatically, limiting the risk of exposure to RCS. Rigorous on-site testing by the engineering team, along with external audits, confirmed that dust levels in areas where the BFM® Bulk Bag Loader is in use are now considered ‘negligible.’

In addition to the impressive dust control, the team at the site has praised the durability of the BFM® Bulk Bag Loader. After more than two and a half years of daily use, the loaders show no signs of wear. This resilience, particularly in the stainless-steel core and urethane material, ensures long-lasting performance, even under continuous operation.

Bulk Bag Loader After Image - cropped

Benefits Achieved

BFM® Health & Safety Icon in BlueHealth & Safety

Dust in the air is now 'negligible' in the bag loading area making it much safer for staff.

BFM® Reduced Downtime Icon in BlueLess Downtime

The easy snap-fit of the BFM® Bulk Bag Loaders has made cleaning between material changes so much faster.

BFM® Durable Icon in BlueMore Durability

The BFM® Bulk Bag Loaders have been in place over two and a half years with no obvious signs of wear despite the abrasive products.

BFM® No Product Loss Icon in BlueNo Product Loss

The superior seal of the BFM® Seeflex bladder means no product leaks during bag loading, keeping the plant much cleaner.

Here's what the client said about BFM®:

“The BFM® Bulk Bag Loader is a Godsend and the only option on the market that works for us when filling.”

- Director of Engineering

 

Case Study provided courtesy of BFM® Distributor ProSpare Limited  (United Kingdom)

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