Shandong Headpowder Engineering Co., Ltd. (headpowder) successfully delivered a fully automated pneumatic conveying system for a filler masterbatch production line in Erbil, Iraq. This project demonstrates the company's expertise in handling abrasive, high-density powder materials under challenging ambient conditions. The client required a reliable, dust-free solution that could transport filler masterbatch from the mixing section to the storage silos and then to the packaging machines, all without manual intervention. headpowder's engineering team designed a system that integrates multiple conveying stages, using pressure dilute-phase pneumatic conveying for the main pipeline and vacuum conveying for the final dosing points. The system operates 24/7, handling up to 6 tons per hour of filler masterbatch with a bulk density of 0.8 g/cm³. Key components include a rotary airlock, a roots blower, a cyclone separator, and a baghouse filter. The entire process is controlled by a PLC-based automation system, allowing remote monitoring and adjustment of conveying parameters. This case study is a prime example of how headpowder applies its pneumatic conveying technology to real-world Iraqi filler masterbatch production, ensuring high efficiency, low maintenance, and compliance with local safety standards.
The project was initiated by a major filler masterbatch manufacturer in Erbil, the capital of the Kurdistan Region of Iraq. The client had been using manual bag dumping and bucket elevators, which caused frequent dust emissions, material contamination, and high labor costs. They sought a modern, automated pneumatic conveying solution that could eliminate these issues. The primary requirements included: (1) transport of filler masterbatch from the mixer discharge to three 200-ton silos located 50 m away; (2) subsequent conveying from the silos to four packaging stations; (3) minimal particle degradation; (4) fully automated start/stop and cleaning cycles; (5) ability to handle both calcium carbonate-based and talc-based filler masterbatches with different particle sizes. headpowder's team visited the site in Erbil to assess the layout, ambient temperature (up to 50 °C in summer), and existing electrical infrastructure. Based on the survey, they proposed a custom pneumatic conveying system that combines positive pressure and negative pressure technologies. The solution was designed to meet the client's strict requirement for zero dust leakage and low noise operation.
The automated pneumatic conveying system for this Iraqi filler masterbatch project consists of three main loops. The first loop uses a positive pressure dilute-phase system with a rotary airlock feeder and a roots blower (600 m³/h, 0.5 bar). The filler masterbatch is fed into the pipeline at the mixer discharge, mixed with air at a ratio of approximately 4:1, and conveyed through a 150 mm diameter carbon steel pipe to the silos. The pipeline is equipped with wear-resistant bends to reduce abrasion from the abrasive filler. The second loop employs a vacuum pneumatic conveying system for the transfer from the silos to the packaging hoppers. A vacuum pump (200 m³/h, -0.4 bar) creates suction, drawing the material through a 100 mm stainless steel pipe. The vacuum system is chosen to minimize dust escaping during the unloading process. The third loop is a gravity-fed system for the final filling of valve bags, using a load cell-based weighing system. All conveying parameters—air velocity, pressure, material level—are monitored by sensors and controlled by a Siemens S7-1200 PLC. The HMI (Human Machine Interface) is installed in the control room, providing real-time data and alarm logs. The system also includes an automatic filter cleaning mechanism using compressed air pulses, ensuring the baghouse filter remains efficient for extended periods.
This automated pneumatic conveying case study in Erbil highlights several advantages tailored to filler masterbatch processing. First, the system eliminates direct contact between operators and the material, significantly reducing health risks from fine dust. Second, the closed-loop design prevents moisture ingress, which is critical for filler masterbatch that can absorb humidity and become lumpy. Third, the conveying speed is adjustable between 8 m/s and 15 m/s, allowing the operator to balance throughput and particle degradation. The rotary airlock is specially designed with a ceramic coating to withstand the abrasive nature of calcium carbonate. Additionally, the PLC-based automation enables the system to automatically switch between different conveying modes—for example, high-speed for bulk transfer and low-speed for precise dosing. The system also includes a metal detector and a magnetic separator to protect downstream equipment from tramp metal. Maintenance is simplified through quick-release couplings and modular pipeline sections. The entire system was pre-assembled and tested at headpowder's facility in Shandong, China, before being shipped to Erbil, reducing on-site installation time to just three weeks.
After the system arrived in Erbil, headpowder’s field service team supervised the installation and commissioning. The local crew was trained on site for two weeks. The system was successfully commissioned in July 2023, achieving a conveying rate of 5.5 tons per hour for the main filler masterbatch line, with a dust emission level below 0.1 mg/m³. The automation software was fine-tuned to match the specific gravity and flow characteristics of the client's filler masterbatch formulations. Since operation, the system has run for over 8,000 hours without any major breakdown. The client reported a 40% reduction in labor costs and a 95% reduction in product waste. The system also saved energy by using variable frequency drives on the blower and vacuum pump, adjusting power consumption based on the actual conveying load. The client has since ordered a second line for a different filler masterbatch product, confirming the success of the first project. For any inquiries about this automated pneumatic conveying solution for filler masterbatch, please contact Manager Zhang at headpowder's Shandong office. The company continues to provide ongoing technical support for the Iraq Erbil facility.
Shandong Headpowder Engineering Co., Ltd. (headpowder) is located in Shandong, China, and specializes in the design and manufacture of pneumatic conveying systems for dry bulk materials. With over 15 years of experience, the company has completed more than 100 projects worldwide, including several in the Middle East. The filler masterbatch automated pneumatic conveying case in Erbil is a testament to headpowder's ability to adapt to harsh climate conditions and complex material properties. headpowder offers a full range of services: from feasibility study and system simulation to fabrication, installation, and after-sales support. The company's engineering team holds expertise in both dilute-phase and dense-phase conveying, as well as vacuum conveying, pressure conveying, and combined systems. For the Iraqi filler masterbatch industry, headpowder provides customized solutions that comply with local electrical and safety regulations. The automation system can be integrated with existing plant SCADA or operated independently. If you are looking for a reliable partner for your pneumatic conveying needs in Iraq or elsewhere, do not hesitate to reach out to the contact person: Manager Zhang. With headpowder, you get not only advanced equipment but also a commitment to long-term performance and customer satisfaction.
Contact: Manager Zhang
Shandong Headpowder Engineering Co., Ltd.
Shandong, China
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Manager Zhang） 
0531-83386006 
Jinan, Shandong Province, China 
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