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Case Studies

Engineering Solutions, Proven Results

Dust-Free Powder Transfer System for a Leading Pharma Company


When one of India’s leading pharmaceutical manufacturers approached Orchid, they had a simple but critical concern:

“How do we transfer highly sensitive powders without risking operator safety or product contamination?”

Manual handling methods were creating dust clouds, exposing workers to fine APIs, and causing material loss. For a company committed to GMP compliance, this was not just inconvenient — it was unacceptable.

The Challenge

  • Frequent dust leakage during powder transfer
  • High risk of operator exposure to potent APIs
  • Batch inconsistencies due to spillage and manual handling
  • Need for a solution that complied with GMP and FDA standards

Orchid’s Solution

  • Vacuum-based enclosed transfer of powders from drums to reactors
  • Integrated filtration unit to ensure dust-free operation
  • CIP (Clean-In-Place) & SIP (Sterilize-In-Place) for hygiene compliance
  • Ergonomic bag dump stations for operator comfort and safety
  • Seamless automation integration with existing DCS controls

The Impact

  • 99% reduction in airborne dust inside the production area
  • 30% faster batch transfer compared to manual handling
  • Zero operator exposure incidents post-installation
  • Regulatory compliance strengthened for audits and inspections

Key Takeaway

This project highlights Orchid’s expertise in building safe, efficient, and GMP-compliant systems for pharmaceutical clients. By addressing both safety and productivity, Orchid delivered a solution that not only solved a pressing challenge but also set a new benchmark for powder handling in pharma.

👉 Orchid Powder Transfer Systems — keeping pharma operations dust-free, safe, and compliant.

Hygienic Jumbo Bag Handling & Pneumatic Conveying for a Leading Food Ingredients Manufacturer


A global food ingredients company approached Orchid with a challenge: handling flour, starch, and sugar powders in bulk while meeting strict hygiene standards. Their existing mechanical system was:

  • Generating dust clouds, contaminating the production area
  • Causing cross-contamination between different food batches
  • Increasing downtime due to manual unloading and frequent cleaning

The client wanted a solution that was dust-free, hygienic, and energy-efficient.

Orchid’s Solution

  • Jumbo Bag Unloading Station with bag massager and dust-tight spout sealing for complete discharge
  • Enclosed pneumatic transfer lines ensuring dust-free operation from unloading to storage
  • Food-grade stainless steel (SS304) construction for cGMP compliance
  • Automated unloading mechanism replacing manual bag slitting and lifting, minimizing operator involvement
  • Energy-optimized blower system designed for continuous, efficient conveying

The Results — Measurable Impact

  • Dust Reduction: 95% drop in airborne particles compared to old system
  • Productivity Boost: Transfer speed increased from 3 TPH → 5 TPH (≈ 65% improvement)
  • Manual to Automated: Shift reduced labor requirement by 50%
  • Operator Safety: Zero dust exposure incidents post-installation
  • Compliance: Fully compliant with global food safety norms (HACCP, GMP)

Key Metrics Snapshot

Parameter Before Orchid After Orchid Improvement
Dust Levels (mg/m³) 3.2 0.15 -95%
Transfer Capacity (TPH) 3.0 5.0 +65%
Unloading Method Manual bag cutting Automated jumbo bag system Safer & faster
Safety Incidents (per yr) 6 0 100% safer

Conclusion

By replacing manual unloading with an automated Jumbo Bag Handling System, Orchid ensured a solution that was cleaner, safer, and faster. The plant not only improved productivity but also achieved full compliance with global food safety standards.

👉 Orchid’s hygienic bulk handling systems — delivering efficiency and quality from bag to process.

Positive Pressure Pneumatic Conveying for Fly Ash Handling


A client in the power & chemical sector faced challenges in handling large volumes of fly ash generated during their process. Their old mechanical handling method created:

  • Frequent spillage & dust leakage, making the work environment unsafe
  • High manual intervention, slowing operations and risking operator health
  • Unreliable material flow, causing bottlenecks in storage and disposal
  • Non-compliance with pollution control requirements

The client needed a dust-free, efficient, and continuous conveying solution to move ash over long distances.

Orchid’s Engineering Approach

Orchid designed a Positive Pressure Dilute Phase Pneumatic Conveying System for fly ash transfer, focusing on reliability and dust control.

Key design considerations included:

  • Material property: Fine, abrasive fly ash with bulk density ~0.8 t/m³
  • Capacity requirement: 15 TPH continuous conveying
  • Conveying distance: 120 meters including bends and vertical lifts
  • Objective: Continuous operation with reduced manual handling and improved plant cleanliness

System Highlights

  • Positive Pressure Conveying: High-velocity air stream used to transport fly ash directly to storage silos
  • Enclosed Feeding & Airlocks: Rotary airlocks and dust-tight feeding points ensured zero leakage
  • Robust Piping Network: MS pipelines with wear-resistant bends designed to handle abrasive ash
  • Storage Silos with Vent Filters: Ensured dust-free operation and environmental compliance
  • Automation & Control: PLC-based automation managed airflow, pressure, and safety interlocks

The Results — Measurable Gains

  • Dust-Free Transfer: Complete elimination of visible dust leakage
  • Higher Throughput: Transfer capacity improved from 3–4 TPH → 15 TPH
  • Reduced Downtime: 60% lower maintenance needs vs mechanical handling
  • Operator Safety: Minimal manual handling ensured safer working conditions
  • Compliance: Achieved pollution control standards (<2 mg/m³ emissions)

Performance Snapshot

Parameter Before Orchid (Mechanical) After Orchid (Positive Conveying) Improvement
Transfer Capacity (TPH) 3–4 15 4X higher
Downtime (hrs/month) 20+ <8 -60%
Dust Emissions (mg/m³) 6.5 <2 Compliance achieved
Manual Labor Requirement High Minimal Safer ops

Conclusion

By implementing a Positive Pressure Pneumatic Conveying System, Orchid enabled the client to achieve 4X higher throughput (15 TPH) while ensuring a dust-free, reliable, and compliant ash handling process.

👉 Orchid’s ash handling systems — delivering safe, high-capacity, and efficient conveying solutions.

Reliable Conveying & Mixing Solutions for Polymer Compounding


A leading polymer compounding manufacturer needed a system to handle polymer pellets and CaCO₃ powder used in filler masterbatch production. Their requirements included:

  • Efficient handling of both pellets & fine powders
  • Dust-free operations for environmental safety
  • Continuous feeding into extrusion lines with high accuracy

The Challenge

  • Material Segregation: Different bulk densities of pellets & CaCO₃ created inconsistent dosing
  • Dust & Spillage: Manual handling of powders led to contamination & unsafe conditions
  • Downtime: Frequent interruptions during feeding & silo changeovers
  • Accuracy Issues: Manual dosing impacted product quality & consistency

Orchid’s Solution

  • Jumbo Bag Unloading Stations with hoist, massager & dust-tight spout sealing for complete bag discharge
  • Positive Pressure Pneumatic Conveying Lines — 2 for pellets & 4 for CaCO₃ powders
  • Vertical Ribbon Blender for uniform mixing before extrusion
  • Storage Silos with Vent Filters for clean & safe storage
  • Gravimetric Loss-in-Weight Feeders for precise, continuous dosing into extruders

Impact Delivered

  • Dust-Free Operations: Enclosed systems ensured <1 mg/m³ dust emissions
  • High Throughput: Smooth transfer of up to 12 TPH across multiple lines
  • Improved Accuracy: ±0.5% dosing accuracy maintained for consistent quality
  • Reduced Downtime: Automated systems cut manual intervention by 60%
  • Operator Safety: Ergonomic unloading & enclosed conveying ensured safer work conditions

Snapshot at a Glance

Key Factor Before Orchid After Orchid
Throughput 6–7 TPH 12 TPH
Dosing Accuracy ±2% ±0.5%
Dust Emissions 4–5 mg/m³ <1 mg/m³
Manual Handling High Minimal

Conclusion

By integrating automated conveying, precise dosing, and efficient mixing, Orchid delivered a turnkey solution for polymer compounding that ensured higher throughput, consistent product quality, and safe operations.

👉 Orchid — powering the future of polymer processing with reliable bulk handling solutions.