A.I.S. Bulk Bag Loaders—also known as FIBC or Super Sack filling systems—are engineered for the controlled, dust-free filling of bulk bags with powders, granules, flakes, and other dry bulk materials. AIS systems are designed to deliver accurate fill weights, protect operators, and maintain clean production environments while integrating seamlessly with upstream storage and conveying systems.
These systems are widely used in food & beverage, pharmaceutical, nutraceutical, chemical, plastics, battery materials, agriculture, and mineral processing industries.
What Is a Bulk Bag Loader?
A bulk bag loader is used to safely suspend, fill, and seal FIBCs during packaging or transfer operations. AIS bulk bag loaders ensure:
• Controlled material flow into the bag
• Accurate and repeatable fill weights
• Effective dust containment during filling
• Safe operator access and ergonomics
• Reliable bag support throughout the fill cycle
Whether filling from a silo, bin, hopper, or conveyor, AIS designs loaders as part of a complete material handling system—not a stand-alone frame hoping for cooperation.
Core System Features
AIS bulk bag loaders are built for accuracy, safety, and uptime:
• Heavy-duty structural frames for one-ton-plus loads
• Adjustable bag lifting frames for multiple bag sizes
• Integrated bag spout sealing and dust collars
• Height-adjustable fill heads
• Modular designs for future expansion
• Indoor or outdoor-rated construction
Systems are engineered based on material properties, throughput requirements, and filling accuracy targets.
Accurate Weighing & Fill Control
When bulk bags are part of inventory or shipping, accuracy matters.
AIS bulk bag loaders can be equipped with:
• Gain-in-weight load cells
• Loss-in-weight filling control
• Coarse and fine feed control
• Automated cut-off valves
• PLC-based batch control systems
These features ensure consistent fill weights while minimizing product giveaway and rework.
Dust Collection & Containment
Bulk bag filling can generate significant dust if not properly controlled. AIS addresses this directly at the fill point.
Available dust-control options include:
• Dust-tight inflatable or mechanical bag spout seals
• Integrated dust collection hoods
• Cartridge or bag-style dust collectors
• Reverse-pulse filter cleaning
• HEPA filtration for fine or hazardous powders
Dust is captured during filling and returned to the bag or safely filtered—protecting operators and maintaining compliance.
Filling From Any Upstream Source
AIS bulk bag loaders can be integrated with:
• Storage bins and silos
• Day bins or surge hoppers
• Pneumatic conveying systems
• Mechanical conveyors or bucket elevators
• Bag dump stations or bulk bag unloaders
Flow control devices such as slide gates, rotary valves, or screw feeders are selected to match the material and required fill rate.
Materials of Construction & Sanitary Designs
AIS bulk bag loaders are available in configurations to suit both industrial and regulated environments:
• Carbon steel for industrial applications
• 304 / 316 / 316L stainless steel for sanitary service
• FDA-compliant seals and gaskets
• Polished product-contact surfaces
• Washdown and CIP-ready designs where required
This makes AIS loaders suitable for everything from minerals and polymers to food ingredients and pharmaceutical powders.
ATEX & NFPA Compliance for Hazardous Areas
For combustible dusts and hazardous environments, AIS bulk bag loaders can be designed in accordance with:
• ATEX Zones 20, 21, and 22
• NFPA standards including NFPA 652, 654, 61, 68, and 69
Available safety features include:
• Explosion-proof motors and electrical components
• Grounding and bonding provisions
• Dust-tight enclosures
• Explosion venting or isolation interfaces
• Inert gas purge compatibility
These designs help facilities meet safety requirements without sacrificing productivity.
Typical Applications
AIS bulk bag loaders are commonly used for:
Food ingredients and powders
Nutraceuticals and supplements
Pharmaceutical intermediates
Chemical powders and additives
Plastics and polymer compounds
Battery and energy materials
Minerals, pigments, and fillers
Anywhere bulk material leaves your facility in a super sack, this equipment defines consistency and professionalism.
Why AIS?
AIS bulk bag loaders are not just frames with hooks—they are engineered filling systems designed around material behavior, dust control, accuracy, and safety compliance.
When bulk bags are filled cleanly and accurately, logistics improves, customers notice, and operators stop fighting the equipment.
A.I.S. Bulk Bag Unloaders (also known as FIBC or Super Sack unloaders) are engineered for the controlled, dust-free discharge of bulk bags into downstream processes. Designed for powders, granules, and difficult-flow materials, AIS systems protect operators, preserve product quality, and integrate seamlessly with conveying, sifting, milling, and storage equipment.
These systems are widely used in food & beverage, pharmaceutical, nutraceutical, chemical, plastics, battery materials, agriculture, and minerals processing.
What Is a Bulk Bag Unloader?
A bulk bag unloader safely supports, opens, and discharges Flexible Intermediate Bulk Containers (FIBCs) while controlling dust and maintaining consistent material flow. AIS designs these systems to eliminate common problems like uncontrolled dumping, dust clouds, product segregation, and operator exposure.
AIS bulk bag unloaders can operate as stand-alone units or as the front end of a fully automated bulk material handling system.
Core Design Features
AIS bulk bag unloaders are built for industrial reality—not brochure conditions:
• Heavy-duty structural frames for safe bag handling
• Adjustable bag lifting frames or hoists
• Bag spout access doors with dust-tight sealing
• Flow-assist hoppers to prevent bridging and rat-holing
• Ergonomic operator access for safe connection and disconnection
• Indoor or outdoor-rated construction
Each system is sized and configured based on bag size, material flow characteristics, and downstream process requirements.
Dust Collection & Containment Options
Bulk bags love to make dust. AIS refuses to let them.
Available dust-control features include:
• Integrated dust collection hoods
• Cartridge or bag-style dust collectors
• Reverse-pulse filter cleaning
• HEPA filtration for fine or hazardous powders
• Central dust collection system tie-ins
Dust is captured directly at the bag discharge point—keeping air clean, product contained, and compliance intact.
Flow Promotion & Difficult Material Handling
For cohesive, aeratable, or poorly flowing materials, AIS offers multiple flow-assist options:
• Massage paddles or bag activators
• Pneumatic bag conditioning systems
• Vibratory bases or bin vibrators
• Mass-flow hopper geometries
• Live-bottom screw reclaim systems
These options ensure consistent discharge without operators resorting to persuasion tactics involving rubber mallets.
Integrated Sifting, Milling & Conditioning
AIS bulk bag unloaders can be equipped with downstream conditioning equipment to protect processes and improve product quality:
• Vibratory or rotary sifters
• Lump breakers and crushers
• Inline mills (application-dependent)
• Magnetic traps and metal detectors
This ensures oversized material, agglomerates, or foreign objects never make it into mixers, extruders, or packaging lines.
Conveying & Discharge Options
AIS bulk bag unloaders are commonly integrated with:
• Pneumatic conveying systems (vacuum or pressure)
• Flexible screw conveyors
• Mechanical augers
• Bucket elevators
• Direct gravity feed into bins, silos, or mixers
Systems are engineered so material moves smoothly from bag to process—without air loss, flooding, or segregation.
Materials of Construction & Sanitary Designs
AIS offers configurations to match application and compliance needs:
• Carbon steel for industrial applications
• 304 / 316 / 316L stainless steel for sanitary service
• FDA-compliant seals and gaskets
• Polished internal surfaces for hygienic environments
• Washdown and CIP-ready designs where required
These options support use in regulated food and pharmaceutical environments as well as demanding industrial settings.
ATEX & NFPA Compliance for Hazardous Areas
For combustible dusts and hazardous materials, AIS bulk bag unloaders can be designed in accordance with:
• ATEX (Zones 20, 21, and 22)
• NFPA (NFPA 652, 654, 61, 68, and 69 as applicable)
Safety features may include:
• Explosion-proof hoists and electrical components
• Grounding and bonding systems
• Dust-tight enclosures
• Explosion venting or isolation interfaces
• Inert gas purge compatibility
These designs reduce risk while maintaining productivity and serviceability.
Industries Served
AIS bulk bag unloaders are trusted across industries where safe, clean bulk material discharge is critical:
Food & Beverage
Pharmaceutical & Life Sciences
Nutraceuticals & Supplements
Chemicals & Specialty Materials
Plastics & Polymers
Battery & Energy Materials
Minerals, Pigments & Additives
If your raw material arrives in a one-ton bag, this is where process control begins.
Why AIS?
AIS doesn’t treat bulk bag unloading as a commodity. Each system is engineered around material behavior, dust risk, safety standards, and downstream integration—because the first step in a process often determines how smooth the rest of the line runs.
When bulk bags unload cleanly, everything downstream breathes easier.