If the cocoa powder arrives at the processing facility in bulk bags, the frames used to discharge the bags should ideally be equipped with additional accessories to completely empty the cocoa powder from the bag. This includes features such as spring-loaded frames that will stretch the bags as they empty and lighten, removing any residual accumulations of cocoa powder in the bags. Bag activating devices are usually effective in loosening agglomerations of cocoa powder, promoting a better flow. Some of these bag activating devices also serve as a dust tight seal between the bulk bag and the receiving hopper.

After the bulk bag has been connected to the receiving hopper and the cocoa powder begins to flow, the air inside the hopper is forced out. Unless this displaced air passes through a filter, airborne dust particles can escape into the surrounding atmosphere. A dust collector mounted on the discharger frame will contain the cocoa powder inside the conveyance system. Cocoa powder dust trapped in the filter media can be returned to the receiving hopper by a pneumatic pulse through the filter. This reduces waste and the time necessary to perform the routine cleaning and sanitation typically required in most food processing environments.

If the cocoa powder is being added into the processing stream from smaller bags, a bag-breaking station with a dust hood, filtration devices and a pneumatic pulse cleaner is the recommended solution to support the manual unloading of the material. If empty bag disposal is an issue, a dust-tight bag compacting system may be necessary.

With its poor flow characteristics, cocoa powder will tend to "rat hole" or bridge in hoppers, completely blocking the flow of the material. Because of this, feed hoppers should be designed with proper geometry and may need to incorporate devices such as mechanical agitators, vibrators or air fluidizers to promote flow. A hopper grate above the receiving vessel will help to prevent the introduction of foreign objects and protects the operators from any moving equipment inside the hoppers.

If a flexible screw is being used to convey the cocoa powder, it is important to use a screw that matches the material's characteristics and other application requirements. Generally a screw with a wider, flatter surface than the standard-sized screw is necessary for this type of material.

Should your cocoa powder application feature the loading the material into bulk bags, the bag capacity will be maximized by use of a vibratory densification deck to level the cocoa powder as it fills the bag and by the application of load cells to attain the desired weight. Seals and other dust containment devices will ensure a dust-tight operation.

 

Flexicon Applications:

Flexicon's automated bulk powder discharge system increased blending speeds by 25% for an Ohio USA chocolate processor.

Flexicon's expert design and engineering staff will weigh each parameter and recommend the best solution for you. Upon request, Flexicon's test lab will simulate your cocoa powder handling applications before the system is installed in your plant.

Flexicon's Dust Suppression and Collection Systems ensure proper containment of cocoa powder throughout the conveyance process. Flexicon's BLOCK-BUSTER^® Bulk Bag Conditioner loosens bulk solid materials that have solidified during storage and shipment, enabling bulk bag unloaders to discharge the material through bag spouts. Flexicon's bag compacting stations will allow you dispose of empty bags safely and efficiently.

Flexicon's product line of advanced flow promotion conveyors, high flow hoppers, deaeration/densification decks and a host of other components and accessories are proven performers that promote flow while reducing degradation, dusting and/or the separation of blends comprised of disparate particles.