Automatic Sampling in the Bulk Material Process: The RATEC Sample Carousel

Anyone filling bulk materials into big bags is familiar with retained samples as a fixed part of quality assurance. In many operations, however, it’s still done by hand: an employee has to be in the right place at the right time, hold a bottle under the outlet, label it, and assign the sample to the correct batch. That costs time, is prone to error, and for fine, dust-generating products also involves a certain dust exposure for the person taking the sample.

RATEC has developed an automated solution for exactly this problem: the sample carousel.

The starting situation

A meaningful sample must fulfill three things at once: it must be taken at the right moment in the process, have a reproducible volume, and be clearly assignable to a batch. When this runs manually, the quality of sampling depends on the operator’s attentiveness, and every handwritten label is a potential source of error in traceability. For dust-generating or hygroscopic products, there’s the added issue that every manual extraction means unwanted dust release during ongoing operation.

The solution: automatic sampling directly from the conveying line

A diverter valve sits in the pipe system upstream of the big-bag filling station. The straight outlet leads to regular filling, while the angled outlet serves to fully empty the surge hopper. As soon as the plant switches to final emptying, a vertical sample line automatically fills via the angled outlet with a defined volume of around one liter. Only once the surge hopper has actually been completely emptied is this sample transferred, in a controlled manner, to the carousel below.

The carousel holds up to twelve 1,000-milliliter sample bottles ready and automatically detects which ones are empty and which are already filled. For the new sample, the next free bottle is automatically and low-dust docked to the filling line. A labeler prints it with a barcode according to customer specifications in the same step – so the batch is clearly documented from the very start. To allow any stirred-up dust to settle, the bottle remains docked for a few more minutes before being placed back on the carousel tray. A signal light on site shows the plant’s status at all times, from normal operation to messages such as “carousel full” or “magazine empty.” The maximum sampling rate is one sample per hour or once per batch; all product-contact parts are made entirely of 1.4301 stainless steel, welded and ground flush.

Customized to customer requirements

The carousel described here, with twelve one-liter bottles, is one of many possible configurations. RATEC adapts the number and size of bottles, labeling, and settling time to the respective product and plant. A version for potentially explosive atmospheres per ATEX or with FDA-compliant, product-contact materials is equally possible – depending on what the application requires.

What changes concretely for operations

No more manual sampling needed – the process runs without operator intervention

• Complete traceability through automatic barcode labeling

• Significantly reduced dust exposure for personnel thanks to sealed docking

• Plant status visible at a glance via the on-site signal light

• Robust, hygienically finished stainless steel design for continuous operation

Interested in automated sampling?

Whether a standard configuration or custom-tailored to your product, including ATEX or FDA requirements: RATEC develops and manufactures every sample carousel to fit the respective plant. Talk to us about your application.