Bulk Bag Unloaders

A.I.S. Bulk Bag Unloaders are engineered systems designed for the safe, efficient, and dust-controlled unloading of Flexible Intermediate Bulk Containers (FIBCs), commonly known as super sacks or bulk bags. These systems form a critical interface between incoming raw materials and downstream processing equipment, ensuring controlled flow, operator safety, and consistent material quality.

AIS bulk bag unloaders are widely used across food & beverage, pharmaceutical, nutraceutical, chemical, plastics, battery materials, agriculture, and mineral processing industries.

Purpose-Built Bulk Bag Unloading

Bulk bags can weigh over a ton, generate airborne dust, and contain materials that bridge, flood, or segregate if mishandled. AIS bulk bag unloaders are designed to manage these challenges by providing:

• Secure bag support and controlled discharge
• Dust-tight connection to the bag spout
• Predictable, repeatable material flow
• Safe operator access and ergonomics
• Seamless integration with downstream systems

Whether feeding a mixer, conveyor, mill, or silo, AIS unloaders ensure material moves cleanly and consistently from bag to process.

Core System Features

AIS bulk bag unloaders are engineered to industrial standards—not light-duty compromises:

• Heavy-duty structural steel or stainless-steel frames
• Adjustable lifting frames or hoist-mounted designs
• Bag spout access chambers with dust-tight seals
• Conical or mass-flow hoppers for reliable discharge
• Indoor or outdoor-rated configurations
• Modular designs for future system expansion

Each system is customized based on bag dimensions, material characteristics, and required throughput.

Dust Collection & Containment

Dust control is central to bulk bag unloading—especially in regulated or hazardous environments.

AIS offers integrated dust management options including:

• Local dust collection hoods at bag discharge
• Cartridge or bag-style dust collectors
• Reverse-pulse filter cleaning systems
• HEPA filtration for fine or hazardous powders
• Connections to central plant dust collection systems

Dust is captured at the source, protecting personnel, preventing product loss, and maintaining clean production areas.

Flow Promotion & Difficult Materials

Not all bulk materials want to flow. AIS designs systems that persuade them without force.

Available flow-assist options include:

• Bag massagers or paddles
• Pneumatic bag conditioning systems
• Vibratory hopper bases
• Live-bottom screw reclaim systems
• Optimized hopper geometries for mass flow

These features prevent bridging, rat-holing, and erratic discharge—especially for cohesive or aerated powders.

Integrated Conditioning: Sifting, Milling & Protection

To protect downstream equipment and ensure material consistency, AIS bulk bag unloaders can include:

• Vibratory or rotary sifters
• Lump breakers or crushers
• Inline milling systems (application-specific)
• Magnetic traps or metal separation

This ensures oversize particles, agglomerates, or contaminants never reach mixers, extruders, or packaging equipment.

Discharge & Conveying Integration

AIS bulk bag unloaders can discharge via:

• Gravity feed
• Flexible screw conveyors
• Mechanical augers
• Pneumatic conveying (vacuum or pressure)
• Direct feed to bins, silos, mixers, or reactors

Systems are engineered as part of the entire material handling line, ensuring stable flow, pressure balance, and dust containment.

Materials of Construction & Sanitary Designs

AIS offers configurations to match both industrial and regulated applications:

• Carbon steel for industrial environments
• 304 / 316 / 316L stainless steel for sanitary use
• FDA-compliant seals and elastomers
• Polished internal surfaces
• Washdown and CIP-ready designs

This flexibility supports applications ranging from food ingredients to APIs and advanced battery powders.

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 standards including NFPA 652, 654, 61, 68, and 69

Available safety features 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 support compliance while maintaining safe, efficient operation.

Typical Applications

AIS bulk bag unloaders are used for:

Food ingredients & additives
Pharmaceutical and nutraceutical powders
Chemical intermediates
Plastics and polymer compounds
Battery and energy materials
Minerals, pigments, and fillers

If material arrives in a bulk bag, AIS designs the system that introduces it safely into your process.

Why AIS?

AIS bulk bag unloaders are not off-the-shelf frames with a hoist. They are engineered material handling systems designed around material behavior, dust risk, safety compliance, and downstream integration.

The first step of material handling sets the tone for the entire process. AIS makes sure it starts clean, controlled, and predictable.