Desiccant Conveying to
Filling Machines
Automated vacuum conveying from bulk supply to six packaging lines — dust-free, continuous, and operator-free
A leading desiccant manufacturer needed to modernize their packaging operation. Operators were manually wheeling 55-gallon drums of silica gel and molecular sieve desiccant to each filling machine on the packaging floor — a labor-intensive, dusty process that couldn't keep pace with growing demand. Zephyr engineered a centralized vacuum conveying system that automatically delivers desiccant material from bulk bag unloading stations to the hoppers of six filling machines, eliminating manual handling entirely and keeping the packaging environment clean and dust-free.
Manual Handling & Machine Starvation
The facility's six filling machines were each fed by operators manually dumping desiccant from 55-gallon drums into machine hoppers. This process created airborne silica dust on the packaging floor, required dedicated labor around the clock, and frequently caused machines to sit idle waiting for material refills — directly impacting production throughput.
The facility needed to:
- Eliminate manual drum handling and the associated labor costs across three shifts.
- Provide continuous, on-demand material delivery to six filling machines simultaneously.
- Contain fine silica gel and molecular sieve dust to maintain a clean packaging environment.
- Handle both silica gel beads and molecular sieve clay with a single conveying system.
- Integrate level sensing at each machine hopper to prevent material starvation and overfilling.
Centralized Vacuum Conveying
Zephyr designed a centralized vacuum dilute phase conveying system to automate the full material path from bulk supply to machine hopper:
Bulk Bag Unloading
Two bulk bag unloading stations with integrated massaging paddles and bag spout closures introduce desiccant material into the system. Operators simply connect a new bag — no manual dumping or drum handling required.
Vacuum Conveying Network
A central vacuum producer draws material through a network of stainless steel tubing routed across the packaging floor. Diverter valves direct material flow to whichever machine hopper calls for product, with line purge sequences preventing cross-contamination when switching between silica gel and molecular sieve runs.
Vacuum Receivers at Each Machine
Each of the six filling machines is fitted with a dedicated vacuum receiver and filter assembly mounted above its existing hopper. Material is conveyed on demand, with receivers cycling automatically to maintain a consistent supply.
Level-Sensing Hopper Control
Capacitance level probes in each machine hopper continuously monitor material levels. When a hopper drops below the low-level set point, the system automatically initiates a conveying cycle to refill it — ensuring machines never run empty and never overfill.
Integrated Controls & Monitoring
A PLC-based control system manages sequencing, valve actuation, and vacuum producer operation across all six lines. A touchscreen HMI provides operators with real-time status of each hopper level, active conveying cycles, and system diagnostics — all from a single station on the packaging floor.
The system was designed with quick-disconnect fittings and CIP-compatible connections at all receiver stations, allowing the facility to perform thorough cleanouts between product changeovers with minimal downtime.
Measurable Impact
The system delivered immediate operational improvements across the packaging floor:
A single vacuum conveying system simultaneously feeds six filling machines from one bulk supply — eliminating manual drum handling.
Fully enclosed conveying from bulk bag to machine hopper eliminates airborne desiccant dust and keeps the packaging floor clean.
Automated material delivery with level-sensing hoppers ensures machines never starve for material, virtually eliminating conveying-related downtime.
Labor savings from eliminating manual drum handling and reduced material waste delivered full payback in under 14 months.
Engineered for Your Process
Every packaging line has different requirements — machine spacing, material characteristics, changeover frequency, and throughput targets all factor into system design. Zephyr works directly with your operations and engineering teams from initial concept through commissioning to deliver a conveying system that fits your process exactly. Whether you're feeding two machines or twenty, we engineer a solution sized and configured for your facility.
Before & After
The Problem — Manual drum handling on the packaging floor 
The Solution — Automated vacuum conveying system installed Let's Engineer
Your Solution
Tell us about your desiccant handling challenge and we'll design a conveying system tailored to your packaging operation.
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