Elimination of Product Return

Our Case

Elimination of Product Return

Increase in operational capacity from 230 t/h to 300 t/h.

Increase of

30%

PROBLEMs

A client from a grain storage facility in Mato Grosso (MT) approached Ucelo for a performance analysis of their bucket elevator. The goal was to identify the best plastic bucket solution and assess the need for structural changes to optimize the grain handling capacity.

The system faced challenges in feeding and discharging soybeans, leading to a high return of load and an increased risk of jamming. The system's capacity was 230 t/h, but with a return of approximately 35 t/h, which compromised operational efficiency.

The graph shows that the maximum capacity will be approximately 230 t/h. However, the equipment returns about 35 t/h, which will soon cause blockages.

Diagnosis and Solution

Based on advanced simulations and diagnostic analysis, the Ucelo team identified issues with the layout of the feed chute and the head of the elevator, which directly impacted the equipment's performance.

The following solutions were implemented:

Replacement of Buckets: Installation of the 14x8 Special PEAD Eagle model, ensuring higher resistance and load capacity.
Feeding Optimization: Modification of the feed chute to increase the product's arrival speed.
Redesign of the Elevator Head: Addition of a rolled plate to optimize the discharge flow.
Recommendation for Drive System Change: It was recommended to replace the drive motor to meet the new 300 t/h capacity.

Results

Capacity Increase: The unit increased from 230 t/h to 300 t/h, reaching the equipment's nominal capacity.
Elimination of Load Return: With the implemented improvements, the load return was reduced to nearly 0 t/h, preventing blockages and unscheduled shutdowns.
Operational Efficiency: The new layout ensured better feeding and efficient discharge, optimizing product flow.
Longer Component Life: The appropriate selection of buckets and materials increased durability, reducing maintenance and frequent replacement costs.

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