InterProcess Sp. z o.o. | Rozwiązania dla przemysłu
Solutions
Process lines for bulk solids
Complete process lines: from raw material intake and storage, through conveying, screening, feeding and weighing, to packing and control. We design, build and commission them as a single supplier, matching the line to your material and your process rather than to a catalogue.
Turnkeyfrom design through to commissioning and service
7 process stagesfrom raw material to finished product
10 industriesfrom cement to pharmaceuticals
ATEX · HACCP · GMPcompliant builds
Where to start
A new line or an extension to an existing one?
This is the first question on every project. Are you building a new process train and looking for a partner responsible for the whole of it, or do you want to automate or improve a section of an installation that is already running? We deliver both: the scope differs, the approach does not.
New investment
A complete turnkey line
We take responsibility for the entire process train: the material balance, the selection and manufacture of the equipment, the supporting structures, the automation, the installation and the commissioning. One project, one schedule and one supplier answerable for the throughput of the whole line, not of individual machines.
ScopeFrom concept to commissioning
ResponsibilityOne contract, one guarantee
Choose this if
+you are building a new plant or a new production line
+you want one partner answerable for the end result
+the whole line is to run under a single control system
+a predictable schedule and budget matter
Existing installation
Extension and upgrading
New equipment is designed around what is already running in the building: dimensions, connections and communications are matched to the existing installation and its controls. We automate sections still worked by hand and remove bottlenecks, with the installation planned so that production downtime is kept as short as possible.
ScopeA single stage or section of the line
IntegrationWith PLC / SCADA control
Choose this if
+one process stage is limiting the output of the whole line
+you want to automate manual intake, weighing out or packing
+the installation is to grow in stages alongside production
+new equipment has to work with the existing control system
Where the difficulty lies
A line is designed around the material, not around the equipment
Every bulk material has its own properties, and the same raw material from different suppliers, in a different climate and at different stages of the process can behave in a completely different way. A machine picked from a catalogue for a different characteristic becomes the bottleneck of the entire line.
So we begin the design with an analysis of the material and a balance of the whole process, and only then select the technology for each stage. We have worked with many kinds of raw material over the years, analysing them and recording their characteristics, and before you decide we offer trials of your material on our own equipment.
What we analyse before designing a line
Bulk density and flowability
Particle size and shape
Dustiness and explosibility (ATEX)
Tendency to cake
Hygroscopicity and moisture content
Abrasiveness and friability
Our range
Seven stages. One line.
Each stage can be supplied on its own, as a machine or a station, or combined into a complete line under a single control system. We design and build the equipment at our own works, so the interfaces between stages are engineered rather than negotiated between suppliers.
01
Intake and raw material reception
big bag emptying stations · sack tipping
Dust-free intake of raw material from big bags and smaller sacks, with docking units, massaging systems for caked materials and extraction at the workstation.
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02
Storage
vessels and silos with stock monitoring
Process vessels and silos with load-cell weighing systems: continuous stock monitoring, balancing of raw material received and issued, and minimum-level alarms.
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03
Conveying
pneumatic vacuum and pressure
Contained pneumatic conveying, both vacuum and pressure, together with mechanical conveyors, selected to suit the distance, the throughput and how easily the material is damaged.
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04
Size reduction and screening
delumping · particle size control
Breaking up material that has caked in storage, controlling particle size and separating out contaminants before the raw material reaches feeding and further processing.
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05
Feeding and weighing
screw, vibratory and belt feeders · scales
Volumetric and gravimetric feeding, recipe-based weighing out, and belt, hopper and platform scales. This is the heart of the line and it determines how repeatable the product is.
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06
Packing and despatch
big bag filling · packaging filling lines
Dust-free big bag filling with weighing and compaction, plus lines for filling smaller packaging, each pack leaving with a repeatable, weighed mass.
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07
Control and visualisation
PLC · SCADA · recipes · reports
A single control system for the whole line: running recipes, safety interlocks, logging of raw material consumption and communication with the plant’s higher-level systems (ERP, MES).
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Comparison
One line, or equipment from several suppliers?
A line can also be assembled from machines bought separately from different manufacturers. It is worth knowing what each option means in practice, though — from the choice of equipment through to service several years after commissioning.
| Criterion | A complete line from InterProcess | Equipment from several suppliers |
|---|---|---|
| Equipment selection | A single material balance for the whole line | Each machine specified separately; interfaces to be agreed |
| Responsibility for throughput | One guarantee covering the output of the process | Spread across the makers of the individual machines |
| Control | One system: recipes, interlocks, reports | Several control systems that have to be integrated |
| Implementation schedule | One project, one installation and start-up | Coordinating several deliveries and installation teams |
| Service | One point of contact, a service team that knows the whole line | Separate contracts and response times for each machine |
| Future expansion | Planned in at the line design stage | Dependent on the compatibility of different makers’ equipment |
Delivery
From material analysis to a working line
We draw on our experience and your knowledge of the process: the design takes shape in close cooperation, stage by stage.
01
Material and process analysis
We establish the properties of the raw materials, the throughputs and accuracies required and the layout of the building. Where necessary we run trials of your material on our own equipment.
02
Concept and line balance
We draw up the process flow diagram: the process stages, the material balance, the technology chosen for each stage and the interfaces with the existing installation.
03
Detailed design
Our design office prepares the design of the equipment, the supporting structures and the automation, together with the documentation, taking ATEX, HACCP and GMP requirements into account.
04
Equipment manufacture
The equipment is built at our own works, from the steel structures to the measuring electronics. We complete it with components from proven suppliers worldwide.
05
Installation and commissioning
We install the plant, calibrate the weighing and feeding systems, start up the controls and train the operators. The line is handed over after trials on your own material.
06
Service and line development
We provide service with a fast response, including 24/7 cover, along with inspections and spare parts. As production grows, we extend the line to the plan agreed at the design stage.
Industries
Where our lines work
The versatility of the equipment we build lets us handle a wide range of materials across many processes: from the food and pharmaceutical industries, through chemicals, plastics and power generation, to building materials.
Food
Flour, sugar, starch and additives: hygienic builds compliant with HACCP and easy to wash down.
Pharmaceutical
Active ingredients and excipients: GMP builds, sampling and batch traceability.
Chemical
Pigments, salts and dusty chemicals: ATEX builds for potentially explosive atmospheres.
Plastics
Granulates, regranulates and regrind: continuous feeding of extruders and injection moulding machines.
Cosmetics
Powders, talcs and dusty raw materials: feeding with high accuracy and a clean process.
Animal feed
Grains, meals and premixes: recipe-based weighing out and logging of component consumption.
Power generation
Coal, biomass and sorbents: high throughputs and continuous duty in demanding conditions.
Construction
Cement, lime, gypsum and aggregates: heavy, abrasive materials at high throughputs.
FAQ
Frequently asked questions
How is a complete bulk solids handling line delivered?+
In six stages: analysis of the material and the process, a concept with a material balance, detailed design, manufacture of the equipment at our own works, installation with commissioning and operator training, and service once the line has been handed over. Throughout the project you deal with one partner responsible for the end result.
Can I order just one stage of the line rather than the whole thing?+
Yes. Every stage — intake, conveying, screening, feeding, weighing, packing or control — is also supplied as a standalone machine or station. We design them so that they can later be combined into a larger line without replacing what you have already bought.
Can a new line work with the equipment I already have?+
Yes. New equipment is matched in dimensions and connections to the existing installation, and the controls communicate with the plant systems over the industrial protocols Modbus RTU/TCP, Profibus, Profinet and EtherNet/IP. We plan the upgrade so that production downtime is kept as short as possible.
Do you take on upgrades and retrofits of existing production lines?+
Yes, and it makes up a large share of our projects. We replace or upgrade individual sections of a line — manual weighing out becomes automatic feeding, open intake becomes a dust-free station — and we retrofit older installations with new weighing systems, drives and PLC control while keeping the existing structures. The work is planned in stages so that production downtime is kept as short as possible.
What determines the choice of equipment in a line?+
Above all on the properties of the material: bulk density, flowability, particle size, tendency to cake, dustiness and hygroscopicity. To that you add the throughput required, the feeding accuracy and the layout of the building. Before you decide, we offer trials of your material on our own equipment.
Can the lines work in potentially explosive atmospheres (ATEX)?+
Yes. We design both complete lines and individual machines for dust and gas explosion hazard zones. The scope of the ATEX build — the choice of drives, earthing, electrical components and the tightness of the joints — is agreed on the basis of the plant’s zone classification and the properties of the material.
What does service look like once the line is running?+
We provide technical support and service with a fast response, including 24/7 cover, together with periodic inspections and spare parts supply. Because the line comes from a single supplier, the service team knows the whole installation, from the mechanics to the controls, and there is no passing you between manufacturers.
Planning a bulk solids handling line?
Describe the material, the throughput and the process stages you want to automate, and our engineers will prepare a line concept and a quotation. We offer trials of your material on our own equipment.
One supplier: the whole process chain, from raw material to finished product
In-house manufacturing: we design and build the equipment at our own works
Material trials: tests on the real material before you decide
A single control system: recipes, reports and integration with the plant systems
Safety and hygiene: compliance with ATEX, HACCP and GMP
Technical support and service: fast response, including 24/7 cover