Two sludge dewatering presses were producing a continuous stream of protein and secondary sludge byproduct. The challenge wasn’t creating the material—it was containing, conveying, and distributing it efficiently into large mobile storage containers without interrupting production.
As production demands increased, the processor needed a system capable of handling higher throughput while maximizing storage capacity and maintaining reliable material flow. The solution also needed to integrate seamlessly into the facility’s existing process while giving operators greater visibility and control over the entire loadout operation.
Working alongside KWS Manufacturing, IBT Industrial Solutions designed and integrated a complete automated material handling system featuring multiple screw conveyors, a PLC-based control panel, and an HMI touchscreen interface. The result was a turnkey solution that increased material processing capacity by approximately 50% while improving overall operational efficiency.
Project Snapshot
- Industry: Food Processing
- Application: Protein and secondary sludge byproduct handling following dewatering
- Material: Dewatered protein and secondary sludge byproduct
- Bulk Density: 45-50 lbs./ft³
- System Capacity: 83 ft³/hr
- Duty Cycle: 16 hours per day, 5 days per week
- Equipment: Four 9-inch diameter x 30-foot-long 304 stainless steel screw conveyors
- Storage: Two 3,000-cubic-foot mobile roll-off containers
- Controls: IBT-designed PLC control panel with HMI touchscreen interface
Primary Benefits:
- Approximately 50% increase in material processing capacity
- Complete turnkey material handling system designed and integrated by IBT
- Improved utilization of dual mobile storage containers
- Automated material routing through PLC controls
- Improved housekeeping through enclosed conveying
- Greater operational visibility through an HMI touchscreen interface
How the Automated Loadout System Works
The final solution combined four custom-engineered screw conveyors with an integrated electrical control system to create a fully automated loadout process.
Material discharged from two sludge dewatering presses enters an inclined screw conveyor. A reversible transfer conveyor then directs the material to either side of the system, where additional screw conveyors distribute it evenly into one of two 3,000-cubic-foot mobile roll-off containers.
Rather than relying on multiple independent pieces of equipment, the entire system operates as a single coordinated material-handling solution designed to maximize storage utilization before material is transported off-site for further processing.
Designing Around Material Characteristics and Production Requirements
Every successful bulk material handling system begins with understanding the material being conveyed.
For this project, the processor needed to move dewatered protein and secondary sludge byproduct with a bulk density of approximately 45-50 lbs./ft³. Although relatively free-flowing after the dewatering process, the material still required reliable, enclosed conveying to support continuous production while minimizing housekeeping requirements.
The system was engineered to convey approximately 83 cubic feet of material per hour while operating up to 16 hours per day, five days per week. Those operating conditions required equipment capable of delivering dependable performance over extended operating cycles.
Rather than selecting equipment solely based on throughput, the project team considered material properties, operating schedule, storage layout, and future production goals to develop a comprehensive conveying solution.
“The challenge wasn’t simply moving material. The challenge was containing and distributing it efficiently while maintaining continuous production.”
Why Screw Conveyors Were the Right Choice for This Application
Selecting the proper conveyor technology was critical to the project’s success.
For handling dried cake byproducts, screw conveyors offer several advantages that make them particularly well-suited for food processing applications.
- Controlled Material Flow: Unlike some conveying technologies, screw conveyors provide predictable and controlled movement of bulk materials. This helps operators maintain consistent feed rates throughout the loadout process.
- Enclosed Material Handling: The enclosed design helps contain material, minimize spillage, and improve housekeeping throughout the facility.
- Flexible System Design: Screw conveyors can accommodate multiple inlets, discharge points, and transfer locations, making them ideal for applications involving multiple storage bins.
- Compact Footprint: Many food processing facilities have limited floor space for material-handling equipment. Screw conveyors provide a relatively compact solution while maintaining high throughput capabilities.
For facilities evaluating new equipment, understanding the fundamentals of screw conveyor design and bulk material handling can help identify the best solution for specific operating conditions.
Integrated Controls Improved Operational Efficiency
The conveyors were only part of the solution.
IBT Industrial Solutions also designed and supplied the complete electrical control package, transforming the project into a fully integrated, automated material-handling system.
The control package included a programmable logic controller (PLC) and a human-machine interface (HMI) touchscreen, allowing operators to monitor system status and control material routing from a centralized interface.
By integrating conveying equipment with intelligent controls, the processor gained better visibility into system operation while simplifying day-to-day material handling.
For facilities considering automation projects, integrating mechanical equipment with modern control systems often delivers operational improvements beyond what equipment upgrades alone can achieve.
Results and Lessons for Food Processors
The completed system delivered measurable operational improvements while creating a more efficient process for handling dewatered byproduct.
Approximately 50% Higher Processing Capacity
By integrating multiple conveyors with automated controls, the processor increased material processing capacity by approximately 50%, allowing the facility to keep pace with growing production demands.
Improved Storage Utilization
The reversible transfer conveyor distributed material evenly between two large mobile roll-off containers, helping maximize available storage capacity before off-site transport.
Better Housekeeping
Enclosed screw conveyors minimized material spillage and reduced the need for washdown in surrounding production areas.
Improved Operational Visibility
The PLC and HMI control system gave operators centralized control of the conveying process while simplifying system operation.
Scalable System Design
The integrated conveyor and controls package laid the foundation to support future production growth without fundamentally changing the material-handling process.
What Other Food Processors Can Learn
This project highlights a challenge we frequently see in manufacturing operations: the biggest opportunities for efficiency improvements often exist outside the primary production process.
Three lessons stand out:
- Distribution matters as much as conveying. Moving material efficiently is only part of the equation. Effective storage utilization often determines how well a system performs over time.
- Manual processes create hidden costs. Tasks that seem minor on a daily basis can consume substantial labor resources over the course of a year.
- System design drives long-term performance. Successful material handling projects focus on the entire process rather than individual pieces of equipment.
When facilities evaluate material-handling challenges from an operational perspective rather than simply replacing equipment, they often uncover opportunities for significant improvements in productivity, storage utilization, and long-term reliability.
Common Signs a Food Processing Facility Has Outgrown Manual Loadout
Many facilities continue to rely on manual material-handling processes long after production volumes have exceeded what those processes were originally designed to support.
Over time, these inefficiencies become more noticeable as operators spend more time managing material movement rather than focusing on production.
Common warning signs include:
- Operators regularly monitor and manage production machines and storage bin levels
- Frequent overflow conditions or uneven bin utilization
- Excessive housekeeping and cleanup requirements
- Material handling tasks consume valuable labor resources
- Production interruptions caused by storage constraints
- Difficulty scaling operations as throughput increases
When these symptoms become common, automation often delivers benefits that extend well beyond labor savings. Improved material flow, increased storage utilization, and greater operational consistency can create measurable improvements across the entire facility.
Featured Brand: KWS Manufacturing
KWS Manufacturing has earned a strong reputation for designing and manufacturing custom screw conveyors and bulk material handling equipment for demanding industrial applications.
For food processors, KWS solutions offer several advantages:
- Custom-engineered conveyor systems tailored to the application
- Stainless steel construction options for food processing environments
- Multiple inlet and discharge configurations
- Integrated material handling system design
- Proven reliability in continuous-duty operations
- Engineering expertise for complex conveying challenges
Whether the goal is to automate byproduct handling, improve storage utilization, or increase production efficiency, KWS Manufacturing provides conveyor solutions designed to solve real-world operational challenges.
Have an engineering challenge? Trust IBT & KWS to get the job done right.
