Big Bag Systems · Emptying

BSB big bag emptying stations

Dust-free, fast and safe emptying of bulk bags of powders and granular materials. Every station is engineered individually: from the frame dimensions and the flow promotion system to the bag loading method and the process interface matched to your line.

Explore the BSB station Hoist or forklift truck?

up to 2000 kg bag load capacity up to 2500 mm bag height FDA · ATEX · GMP compliant builds

What dust-free big bag emptying means

Emptying with no dust, no losses and no risk to the operator

Emptying big bags by hand means dust across the shop floor, losses of expensive raw material, a health risk to operators and no control over how much material has been dispensed. BSB emptying stations (also known as big bag discharge stations or FIBC unloaders) enclose the whole operation in a closed, dust-tight system: from lifting the bag to discharging the material into the process.

Unlike catalogue equipment, every station is engineered from the ground up: an integrated electric hoist on a trolley beam does away with the forklift truck, pneumatic massage pads promote the flow of poorly flowing materials without damaging their structure, and a dust-tight docking module gives a sealed connection between bag and station. The modular design allows the station to be extended later as process requirements change.

2000 kg

maximum load capacity, lifting frame with 4-loop bag attachment

2500 mm

maximum height of big bag handled

1500 × 1500 mm

typical frame footprint; height adapted to the application

The BSB station at a glance

+Dust-free emptying of big bags weighing up to 2000 kg and up to 2500 mm high
+Loading by integrated electric hoist on a trolley beam or by forklift truck
+Flow promotion: pneumatic massage pads, vibrating rest plate, spout stretching
+Dust-tight dual-ring docking module with adjustable cover pressure
+ATEX, FDA, GMP and HACCP builds; powder-coated carbon steel or AISI 304 / 316L
+Integration with feeders, pneumatic conveying and the plant control system

The BSB emptying station

A design tailored to the application

BSB big bag emptying station with integrated electric hoist on a trolley beam

BSB stations in service (click to enlarge)

Twin big bag emptying station for granola with gentle feeding and tubular disc conveyor — Granola emptying

Four big bag emptying stations with electric hoists above feeders at a food production plant — Food production plant

Two big bag emptying stations with screw feeders and docking modules at a sugar factory — Sugar factory

Multi-station big bag emptying system with ingredient batching and pneumatic conveying — Multi-ingredient batching line

A BSB station comprises a support frame, a bag loading system, a flow promotion system and a dust-tight docking module. Frame dimensions, load capacity and equipment are matched to the bag size, the material properties and the space available. We do not offer a single standard model.

The frame is made of powder-coated carbon steel or, in the hygienic build, of AISI 304 / AISI 316L stainless steel. All product-contact parts are always stainless steel.

Key BSB station specifications

Load capacity: up to 2000 kg (lifting frame with 4-loop bag attachment)
Bag height: up to 2500 mm
Frame: approx. 1500 × 1500 mm; height adapted to the application
Hoist beam: 2800 mm long, rated 1000 or 2000 kg
Materials: powder-coated carbon steel; AISI 304 / AISI 316L optional
Product-contact parts: always AISI 304 or AISI 316L stainless steel
Docking module: dual-ring, dust-tight, with adjustable cover pressure
Options: load-cell weighing, dust filter, pneumatic spout closure, automatic bag tensioner, liner tensioner, roller conveyor, empty bag disposal
Builds: ATEX (dust or gas zone), hygienic FDA / GMP / HACCP

Downloads

BSB station data sheet (PDF) BSB station questionnaire (DOCX)

Bag loading method

Integrated hoist or forklift truck?

The BSB station comes in two loading versions: with an integrated electric chain hoist on a trolley beam (an integral part of the station), or in a version loaded by forklift truck. Both use the same frame, lifting frame and docking module.

Criterion	Integrated hoist on a trolley beam	Loading by forklift truck
Bag handling	The operator lifts the bag at the push of a button; the trolley runs it along the beam to sit exactly over the docking point	The bag is lowered in from above on forks with a lifting frame
Operator safety	✓ Lifting from the side or rear of the station, no crushing risk	Manoeuvring a heavy truck inside the working area
Space required	✓ Less, no truck manoeuvring area needed	An extra manoeuvring area beside the station
Risk of damage	✓ No contact between forks and structure	The forks may damage the frame
Capital cost	Higher (hoist and trolley beam included in the station)	Lower, uses the plant’s existing equipment
When to choose it?	Frequent bag changes, restricted space, demanding health and safety requirements	Occasional emptying, a truck and manoeuvring space already available

Enhanced safety option

Guarded loading zone with interlocked doors

Lifting the bag and moving it over the station is the most dangerous moment of the whole operation. A load of up to two tonnes travels at height, and badly hung loops or damaged fabric can bring the bag down. It therefore makes sense to enclose the bag’s entire path in guarding that nobody can enter while it is moving.

The optional loading-zone guarding is a full-height mesh panel enclosure with electromechanically interlocked doors tied into the hoist controls. The interlock works both ways: the hoist cannot be started with the doors open, and the doors stay locked until the bag has been safely set down in the docking position. The control pendant is mounted outside the enclosure, so the operator guides the bag from beyond the danger zone. More and more customers are asking for this option, including as part of their risk assessment and machinery conformity documentation.

01Doors locked while the bag is lifted and travels, no access beneath a suspended load
02Hoist disabled while the doors are open, the two functions being mutually interlocked
03Controls and emergency stop outside the enclosure, within the operator’s reach
04Full-height panels, the enclosure shaped to the station footprint and to access to the docking module
05Drives beneath the discharge point (feeder, conveyor) cut out when the doors open

Big bag emptying station with optional loading-zone guarding: mesh panels with interlocked doors and controls mounted outside

Flow promotion

Massage pads, vibrator or spout stretching?

Bulk materials cake inside the bag during transport and storage, forming bridges and rat-holes that stop the material flowing. We match the flow promotion system to the material properties, not the other way round.

Pneumatic massage pads

Poorly flowing materials

+gently work the material, breaking up bridges and rat-holes
+leave the structure of delicate products intact (granulates, flakes, crystals)
+transmit no vibration into the structure, which means less noise and lower fatigue loading
+low energy consumption, minimal maintenance

Vibrating rest plate

Moderately flowing materials

+the bag rests on a vibrating plate that loosens the material
+a simple, proven, low-cost solution
+sufficient for materials without strong cohesion
+selected individually to suit the product

Spout stretching device

Stretching the bag spout

+tensions the bag spout, keeping the full discharge cross-section open
+improves flow and complete emptying of the bag
+improves hygiene, because the spout does not hang into the material stream
+an automatic tensioner keeps the bag taut throughout emptying
+combined with massage pads or a vibrator in a single station

Flow promotion selection table

Material characteristics	Recommended flow promotion
Free-flowing: granulate, granulated sugar, pellets	None, or a vibrating rest plate
Moderately flowing, slightly caking: sugar, salt, groats	Vibrating rest plate, optionally with a bag tensioner
Cohesive and dusty: flour, milk powder, pigments, lime	Pneumatic massage pads with a spout stretching device
Delicate, easily damaged: flakes, granola, blends	Pneumatic massage pads at reduced force, no vibration
Heavily caked after prolonged storage	Massage pads and spout stretching, with a lump breaker beneath the discharge if needed

The table is an indicative guide. The final selection is confirmed by a trial on the actual material.

Not sure which flow aid to choose? We confirm the selection from the properties of the customer’s actual material (particle size, cohesion and tendency to cake), not from catalogue data alone.

Ask us to advise

Dust containment

Dust-tight docking module

The heart of the BSB station is a dual-ring docking station. The operator opens the cover, pulls the bag spout through the inner ring and closes the cover, creating a dust-tight connection. Only then is the bag spout opened, and the material flows out inside a closed system.

The docking cover pressure is adjustable, so the seal can be matched to different spout types and sizes. As an option, the station can be fitted with rear-side dust extraction and a connection to the plant’s central dust extraction system.

Bag connection: dual-ring, dust-tight, with adjustable cover pressure
Spout closure: pneumatic closure system allowing partial emptying and setting part-used bags aside
Dust extraction: optional rear-side extraction or a filter integrated into the station; draws dust-laden air out of the bag before it is removed
Material consumption monitoring: optional weighing of the bag on load cells

BSB big bag emptying station: view of the dust-tight docking module with dual-ring docking station

Process integration

Part of a larger system, not a standalone machine

The lower frame is adapted to the requirements of the installation, so the emptying station becomes an integral link in the process line: from raw material intake, through feeding and conveying, to delivering material into the process. We offer full design support in selecting the interface and the ancillary equipment.

Discharge into a buffer hopper or reactor

Direct gravity discharge of material into the process.

Intermediate hopper with a feeder

Controlled delivery by a screw, vibratory or belt feeder.

Dilute-phase pneumatic conveying

Connection through a rotary valve.

Dense-phase pneumatic conveying

Discharge into the pressure vessel of a pressure conveying system.

Vacuum conveying

A direct connection to vacuum conveying.

Operation on demand from the process

Emptying triggered by a level sensor in the receiving hopper or by a signal from the higher-level control system.

Inclined screw conveyor

Mechanical delivery of material to equipment at a higher level.

Screener or lump breaker

Protecting the process from lumps and foreign bodies immediately after discharge: a lump breaker or a check screener.

Industries and typical materials

Applications in key industries

Big bag emptying station at a food processing plant

Food and feed

Flour, sugar, starch, milk powder, premixes, animal feed. Hygienic builds (FDA, HACCP, GMP), easy cleaning and profiled frames that leave nowhere for product to settle.

Chemical

Pigments, resins, plastic granulates, salts and fillers. ATEX builds for dust and gas zones, and a dust-tight docking module.

Pharmaceutical

Active pharmaceutical ingredients (APIs) and excipients. GMP build in AISI 316L, surfaces easy to clean and validate, raw material consumption tracked by weighing.

Building materials and minerals

Cement, lime, gypsum, quartz sand, fly ash. A structure built for heavy, abrasive materials. Optional connection to pressure pneumatic conveying.

FAQ

Frequently asked questions

What are the advantages of an integrated hoist over a forklift truck?+

An integrated electric chain hoist on a trolley beam does away with manoeuvring a heavy truck in a confined space. The operator lifts the bag at the push of a button, and the trolley runs it along the beam to sit exactly over the docking point. The bag is lifted from the side or rear of the station, which markedly improves safety (no crushing risk). The station also needs less working space, because no truck manoeuvring area is required, and the hoist removes any risk of the forks damaging the structure.

Why are massage pads better than a vibrator in a big bag station?+

Pneumatic massage pads gently work the material inside the bag, breaking up the bridges and rat-holes that form through caking or powder cohesion. Unlike a vibrator, they transmit no vibration into the structure as a whole (less noise and less fatigue loading) and leave the structure of delicate products intact: granulates, flakes or crystals. They also use less energy and need minimal maintenance. For moderately flowing materials a vibrating rest plate is enough; we select the solution individually.

What does “a design tailored to the application” mean, and what does it give you?+

Every BSB station is designed from the ground up for a specific application: we match the frame dimensions to the space available and the bag size, select the flow promotion system to suit the material properties, design the process interface (feeder, buffer hopper, pneumatic conveying) and take account of industry requirements (ATEX, FDA, GMP). The station fits into the existing line without rebuilding its surroundings, and the modular design allows it to be extended later, for example with weighing, a dust filter or a roller conveyor.

Can the BSB station empty a bag only partly?+

Yes. The optional pneumatic spout closure allows the bag spout to be closed dust-free at any point during emptying. Only part of the material can be discharged, the bag closed and stored for later use, which is useful for precise portions and for emptying different recipe ingredients in sequence. Combined with optional load-cell weighing, the operator has full control over how much material has been dispensed.

How is dust-free operation ensured during emptying?+

Dust containment comes from the dual-ring docking station. The bag is lifted into the station by hoist, the operator opens the docking cover, pulls the spout through the inner ring and closes the cover, creating a dust-tight connection. Only then is the bag spout opened and the material flows out inside a closed system. The cover pressure is adjustable, and the station can optionally have rear-side dust extraction and a connection to the plant’s central dust extraction system.

Why InterProcess

Why choose our solutions?

A design tailored to the application

Every station designed from the ground up for the customer’s application.

Dust-free operation

Dust-tight docking module with adjustable cover pressure.

Process integration

Feeders, pneumatic conveying, weighing, control systems.

Experience across many industries

Food, chemical, pharmaceutical and construction.

Safety and hygiene

ATEX, FDA, HACCP and GMP builds, and guarding with interlocked doors.

Technical support and service

With a fast response, including 24/7 cover.

Looking for a big bag emptying station?

Get in touch: we will design a station to suit your material, your process conditions and the space available, integrated with feeders, conveying and the plant control system.

Get in touch