For feed, grain, and allied grain processing facility owners and managers, walking onto the production floor can feel like stepping into a Dr. Seuss book, with conveyor tubes winding through machinery in a seemingly chaotic fashion. Even experienced industry professionals can struggle to distinguish between screw, pneumatic, vacuum, aeromechanical, tubular drag chain and disc, or tubular drag cable and disc conveyors.
This lack of technical knowledge can have serious consequences when it comes to reliably and accurately conveying delicate or precise blends of feed and grain. In this assessment, we will address six common misconceptions about tubular drag cable and disc conveyors, helping facility owners and managers improve product quality, productivity, efficiency, and profitability.
These versatile conveyors gently move product through a sealed tube using a coated, flexible stainless-steel drag cable and solid circular discs, making them ideal for transporting delicate blends in various layouts and configurations without the use of air.
Misconception #1:The use of conveyor systems for transporting a blend of feed and grain products or supplements is often misunderstood. While maintaining a consistent mix ratio is crucial for optimal results, conventional conveyor systems are not designed to precisely transport blends without altering the mix ratio.
The varying weights, sizes, and shapes of product materials can shift and disperse during transport, especially in open systems like bucket conveyors that are prone to vibrations. Even vacuum and pneumatic systems can cause issues, as they may move smaller particles at different speeds than larger or heavier particles, ultimately leading to blend restructuring upon discharge.
Misconception #2: The Difference Between Screw Systems and Tubular Drag Cable Conveyors Screw systems, also known as auger conveyors, use a helical blade to move granular materials within a tube. However, this can potentially damage products and harm blends. When material integrity is essential, such as when handling food waste, tubular drag cable conveyors are a preferred option.
Unlike augers, they use a sealed cable to pull material between two discs, ensuring the protection of delicate feed and grain products and blends. The material transfer speed is determined by the rotation speed of the screw in auger conveyors, while tubular drag cable conveyors offer more control and precision.
Misconception #3: Tubular drag cable systems are capable of conveying various forms and states of feed and grain, including whole, pellet, powdered, moist, or hot material at high throughput rates of up to 80,000 pounds per hour. The conveyors can even handle materials with high moisture content if needed.
Despite being made of plastic components, these conveyors can operate at temperatures up to 180°F (82°C), with the option of a high-temperature design that can reach 230°F (110°C), making them suitable for receiving products from dryers or ovens.
Misconception #4: Tubular Conveyors Can Fit Within Any Facility’s Available Space and Accommodate Complex Layouts Many in the feed and grain industry believe that tubular conveyors cannot fit within their facility’s available space or accommodate complex layouts. However, this is a common misconception. Modular systems like tubular drag cable conveyors are excellent options for facilities with inclines, elevation changes, or other obstacles.
They can easily adapt to existing equipment and can even be installed at various angles. This makes them a great choice for facilities with limited space and flexibility. Additionally, tubular conveyors are very space efficient, with the option to conserve even more space by using gravity discharge.
Misconception #5: Contrary to popular belief, tubular conveyors can be installed both indoors and outdoors. It is not uncommon to see sections of feed and grain equipment protruding outside when moving products from one location to another, such as unloading materials from trucks or loading finished products into transport vehicles.
In situations where equipment is used outdoors and with moist products, it may be beneficial to utilize heat tape to prevent condensation or freezing in the tubes. Conveyor manufacturers are also able to provide solutions for factors like wind, dust, rain, insects, and sunlight exposure.
Misconception #6: Streamlined Cleaning Process Without Extended Downtime Between Product Changeovers, traditional conveyor systems often require disassembly, cleaning, and reassembly, which can be time and labor-intensive. However, tubular conveyors offer various options for dry, wet, and in-line cleaning, including brush boxes, air-knives, and brushes and wipers.
Sanitization can also be achieved without fully wetting the system, using a sponge soaked in sanitizer. For a thorough clean, the cable conveyor uses a multi-step process of water rinse, foaming agent, sanitizing rinse, and final water rinse.
After flushing out the system, urethane wipers attached to the discs act as a squeegee to remove any remaining water. With this knowledge, feed and grain industry professionals can maximize the benefits of tubular conveyors and optimize their production and downtime efficiency.