This engineering case study presents a state-of-the-art pneumatic conveying solution implemented for a filler masterbatch production facility in Gdańsk, Poland. The project was designed, manufactured, and commissioned by Shandong Haide Powder Engineering Co., Ltd., a leading provider of bulk material handling systems based in Shandong, China. The system is a fully automatic pneumatic conveying line specifically tailored to transfer filler masterbatch—a high‑density, fine‑powdered additive used in plastics compounding—from storage silos to multiple processing points with zero manual intervention. The Gdańsk plant required a dust‑free, energy‑efficient, and reliable solution to replace an outdated mechanical conveying setup, and the turnkey project delivered by Haide has since become a benchmark for similar installations across Europe.
The core equipment at the heart of this installation is a dense‑phase pneumatic conveying system. The term "pneumatic conveying" refers to the method of transporting bulk solids through pipelines using compressed air or inert gas. In this particular case, the system handles filler masterbatch—a material that is both abrasive and prone to bridging if not properly aerated. The keywords "pneumatic conveying case", "Poland pneumatic conveying", "Gdańsk pneumatic conveying", "filler masterbatch pneumatic conveying", and "fully automatic pneumatic conveying" are all directly embodied in the engineering design. The system in Gdańsk employs a fully automatic control architecture that integrates PLC‑based sequencing, pressure sensors, and flow meters to ensure consistent feed rates while minimizing air consumption. The conveying line runs over 120 meters horizontally and 18 meters vertically, with all bends lined with wear‑resistant ceramic to withstand the abrasive nature of the masterbatch. This project exemplifies how advanced pneumatic conveying technology can be adapted to meet the stringent requirements of a modern compounding facility in Poland.
The entire system was designed with a focus on automation and reliability. The filler masterbatch is initially stored in a set of three 50‑ton silos, each equipped with level indicators and aeration pads. From the silos, material is fed into a rotary airlock valve that meters the powder into the conveying line. The conveying air is supplied by a centralized screw compressor with a variable frequency drive, allowing the system to adjust pressure and velocity according to the material's flow characteristics. The pipeline route includes a series of diverter valves that direct the masterbatch to six different processing stations, each representing a different extrusion or injection molding line. The entire sequence—from silo discharge to final destination—is managed by a Siemens S7‑1500 PLC, which communicates with the plant's MES via Profinet. The system also includes a baghouse filter at each receiving point to capture any fugitive dust, ensuring compliance with EU environmental regulations. This configuration fully realizes the concept of "fully automatic pneumatic conveying" and demonstrates the expertise of Shandong Haide Powder Engineering Co., Ltd. in handling complex material handling challenges.
The installation in Gdańsk was completed in two phases over a period of four months. During the commissioning phase, the Haide engineering team conducted extensive material testing to fine‑tune the conveying parameters. The filler masterbatch, which has a bulk density of 0.8 g/cm³ and a particle size distribution ranging from 10 to 200 microns, required careful control of air velocity to prevent segregation and degradation. After optimization, the system achieved a conveying capacity of 6 tons per hour with a product‑to‑air ratio of 12:1, which is considered excellent for dense‑phase conveying. The system's reliability has been outstanding: over the first 12 months of operation, the uptime exceeded 99.5%, and the only maintenance required was routine replacement of the wear‑resistant elbows after 8000 hours of use. The plant's production manager reported a 40% reduction in labor costs compared to the previous manual bag‑handling method, and the elimination of dust emissions improved worker safety and hygiene. These results underscore the value of partnering with a knowledgeable supplier like Shandong Haide Powder Engineering Co., Ltd., headquartered in Shandong, China.
Shandong Haide Powder Engineering Co., Ltd. has been serving the global bulk solids handling industry for over a decade, with a portfolio that includes hundreds of successful projects in Europe, Asia, and the Americas. The company's commitment to quality is reflected in its use of premium components, such as German‑made valves and Italian‑designed filters, as well as its adherence to ISO 9001 and CE standards. For the Gdańsk project, Haide provided not only the equipment but also complete engineering support, including site survey, layout design, installation supervision, and operator training. The system's fully automatic control scheme allows operators to monitor and adjust parameters remotely via a touchscreen HMI, making it ideal for facilities that require high throughput with minimal manual intervention. Whether you need a pneumatic conveying system for filler masterbatch, plastic pellets, or any other bulk powder, Haide can tailor a solution to your specific requirements. To discuss your project, contact the sales manager Mr. Zhang at 15662777102. He is based in Shandong, China, and can provide detailed quotations and technical proposals.
For more information about this filler masterbatch pneumatic conveying project in Gdańsk, Poland, or to inquire about similar systems for your own facility, please reach out to the dedicated team at Shandong Haide Powder Engineering Co., Ltd. The company's full name is Shandong Haide Powder Engineering Co., Ltd., and its business address is in Shandong, China. The sales contact person is Mr. Zhang (Manager), and his direct phone number is 15662777102. This contact information is available for all technical discussions, project inquiries, and after‑sales support. Haide prides itself on offering comprehensive solutions, from initial concept through commissioning, ensuring that every pneumatic conveying system—whether for filler masterbatch, mineral powders, or chemical additives—operates with maximum efficiency and reliability. By choosing Haide, you are investing in decades of engineering expertise and a proven track record of international success.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Manager Zhang） 
0531-83386006 
Jinan City, Shandong Province, China 
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