A chemical company located in Zhuzhou, Hunan, mainly produces and processes silica. As a high value-added powder material, white carbon is widely used in industries such as rubber, plastics, and coatings. However, their fine particle size, easy lifting, and moisture absorption make traditional open-type conveying processes face issues such as dust pollution, material waste, and poor environmental compliance. The company's original conveying method was manual combined with simple pneumatic conveying, resulting in severe dust on site, prominent occupational health risks for workers, and a material loss rate exceeding 5%. To improve the production environment and operational efficiency, the company decided to introduce a dust-free, sealed automated conveying system.

Customer pain points

During the pre-project research, the Head Powder technical team identified the client's core pain points:

• Dust leakage and environmental pressure: Ultra-fine white carbon dioxide dust disperses into the workshop and surrounding areas, causing air quality to fall short and posing penalties from environmental protection authorities.
• High material loss: Material splashing during open feeding and transfer, with statistics showing annual losses equivalent to costs exceeding one million yuan.
• Potential health risks for workersLong-term exposure to white carbon dioxide dust can easily cause respiratory symptoms, increase employee turnover, and make recruitment difficult.
• High dependence on manual labor: The conveying process requires dedicated personnel on duty, resulting in high labor intensity and inability to automatically connect with upstream and downstream processes, limiting production capacity.

Product Advantage—Head Powder Solutions

To address these pain points, Head Powder provides a complete set of dust-free sealed and complete equipment for silica conveying, enabling sealed and automated operations throughout the entire process from raw material silos to batching, mixing, and packaging. The main features are as follows:

• Fully sealed pipeline transportation: Uses stainless steel pipes and highly airtight rotary valves and butterfly valves, maintaining a slight negative pressure inside the system to prevent dust leakage, with on-site dust concentration below 1mg/m³.
• Low consumption and energy-saving design: By optimizing air sources and delivery paths, energy consumption per unit material is reduced by more than 20% compared to traditional systems; Paired with a more accurate weighing module, material loss rate is reduced to within 0.5%.
• Intelligent control and monitoring:P LC+HMI control system monitors material level, pressure, and flow in real time, supports remote start-stop and fault alarms, reduces manual intervention, and enables linkage with upstream and downstream processes.
• Hygiene and easy maintenance: The inner wall of the pipeline is polished to a mirror finish to prevent material residue; The quick-release structure facilitates cleaning and maintenance, significantly shortening downtime and maintenance.

After the system was put into operation, the customer's workshop environment improved significantly and passed the local environmental inspection; Reduced material loss directly saves about 800,000 yuan in costs per year; Increased automation doubles production line capacity while reducing the number of operators by 3. With solid process design and mature engineering experience, Head Powder provides replicable dust-free conveying models for the silica industry.