Before a chemical plant in South Carolina installed equipment from the DEC Group, it took them up to 8 hours to completely charge their reactor with powder (12 x 300 lb big bags). The DEC system was able to complete this process in approximately 1.5 hours (3-5 minutes to evacuate the bag, and 2-3 minutes to connect/disconnect the bag). The new equipment replaced a hopper/screw feeder system that did not work very well. Operators would lift 12 bags, 3 stories to the top of the reactor. From the elevator, they would take portable fork lifts and move powder to the screw feeder, located 6-8 feet from the reactor. A hoist was then used to lift the bag above the hopper. The string on the bag was pulled and created a huge dust cloud as the powder flowed into the hopper. They would then start the screw feeder and dump into the vessel containing solvent (xylene). The screw feeder would reliably malfunction every batch and powder would always get stuck in the screw. The screw fed to a rotary valve that would dispense powder in a reactor. They experienced problems with rotary valves when the powder was dispensed, as if the reactor was under pressure and solvent is present, solvent would enter the rotary valve. This almost always caused build up on the rotary valve and eventually powder was unable to flow. The DEC big bag station and Powder Transfer System (PTS) was superior from the start. Before discharge, the PTS is pressurized to a higher pressure than the reactor, guaranteeing that no solvent can enter the PTS chamber during discharge. During this entire process, operators were used to wearing full PPE (full body suits and respirators). The DEC solution eliminated the need to transport bags to the 3rd floor. This allowed all raw materials to be delivered, handled, and disposed of in one location. The DEC solution decreased the reactor loading time by over 530%. As you can see from the pictures, the new equipment made it possible for the operators to eliminate the need for full PPE. After the first 12 bags were emptied, operators were smiling and high-fiving one another. The operators and engineers were very pleased with the outcome of this project.