Discontinuous Dense Phase System for Calcined Lime – Power Plant, Philippines

Discontinuous Dense Phase System For Coffee & Chicory

Overview of the Client

The following case study highlights Macawber India, the leading pneumatic conveying system manufacturer in India, which delivered a specialised dense phase pneumatic conveying system solution tailored as a pneumatic conveyor for food industry by utilising Denseveyor for handling coffee & chicory mixture. This challenging lumpy blend consists of 5-8 mm coffee beans, both raw and roasted, and larger 10-15 mm chicory cubes, known for their sticky, sluggish nature. In the food industry, where product quality and hygiene are paramount, the material demands exceptionally careful handling to prevent choking, bridging, or degradation during transfer from a single feed point to 14 extractors across complex routing.

Why Macawber India was Called Upon

Macawber India was selected to create a unique Dense Phase Pneumatic Conveying System. It makes use of advanced diverter valves to control the pneumatic conveyor in a food-related process. The objective is to convey the material in a gentle velocity, dust-free and efficient manner from one central feed point to 14 different extract points arranged in two parallel rows. The idea behind it is to outperform other conventional processes, such as bucket elevators or line injectors, because they are associated with problems related to maintenance and spills.

The Problem We Had to Solve

The Coffee beans & Chicory cubes mixture's average flowability, stickiness, and lumpiness (5-8 mm beans, 10-15 mm cubes) risked choking at the Dome valve inlet, requiring a tailored feeding design.
Automatic/manual diversion via switch valve and diverter valve combos to two paths of 7 extractors each.
Navigation over 60 m distance with 12 bends, ensuring minimal downtime, no spillage, integrated pollution control, and low wear.
Handling 9 10 TPH reliably in a hygienic food setup prone to dust hazards and quality loss.

Solutions We Provided

Deployed a single, robust Denseveyor vessel for discontinuous dense-phase conveying from one feed point to 14 extractors.
Divided into two parallel paths of 7 each, with seamless diversion via switch valve and diverter valve setups.
Optimised feeding at the dome valve inlet to eliminate choking risks and promote smooth, low-velocity transfer.
Incorporated SCADA automation, pollution control for dust-free operation, and durable components exceeding 9 10 TPH over 60 m with 12 bends.

System Advantages

A superior alternative to bucket elevators or line injectors, offering greater reliability and hygiene.
Minimal downtime, enhancing continuous production uptime.
Complete automation & SCADA control for precise, hands-free operation.
Eliminates spillage with a built-in pollution control unit.
Very low wear and tear on pipelines, valves, and material.
System capacity exceeded the specified 9 10 TPH when fully loaded.

Result

Macawber India’s dense phase pneumatic conveying systems performed outstandingly well: high-capacity transfer at a rate of over 9 10 TPH with high reliability, minimal downtime, and dust-free transfer for coffee and chicory processing. The system dealt with the material’s tendency to stick, ensured better plant efficiency, minimised downtime, and ensured food-grade purity, thereby demonstrating Macawber India’s expertise in complex pneumatic conveyors for food applications.

Project Summary Table

MATERIAL CHARACTERISTICS

Property	Specification
Material	Raw Coffee Beans / Roasted Coffee Beans / Chicory Cubes
Bulk Density	300 – 350 kg/m³
Particle Size	Granular 3 to 5 mm5-8 mm (Coffee Beans); 10-15 mm (Chicory)
Characteristics	Average flowability, sticky & sluggish