Background

When a global leader in corn-derived ingredients like Primient upgrades their facility, the equipment must meet rigorous industrial standards. AMG, Inc., bringing over 45 years of industrial and process plant engineering expertise, was tasked with managing the receiving pit improvements. Having successfully implemented Burnley® Baffles on several previous projects, AMG’s Senior Project Manager returned to Mideco for a solution that was proven to handle the high throughput of whole corn operations.

Problem

The Loudon site faced significant fugitive dust challenges during the unloading of whole corn (bulk density of 720 kg/m³). While the initial scope focused on a single road receiving pit, the project requirements evolved as the site’s aging infrastructure was assessed.

The final challenge involved two distinct receiving areas with different configurations:

  • Rail Hopper L-1105 (Rail Car Unload): A large 3m x 6m pit requiring a high-capacity baffle layout.
  • Road Hopper L-1107 (Truck Unload): A 3m x 3m pit requiring a more compact, specialised fit.
  • The goal was to eliminate 80% of the dust generated by air displacement during high-speed unloading while ensuring the new baffles could withstand the constant abrasion of whole corn.

Solution

Mideco’s approach is never one size fits all. We worked closely with AMG to tailor the baffle configurations of the two hoppers, utilising 1.6mm thick galvanised steel for maximum durability.

  1. For the Rail Pit: Mideco designed a heavy-duty layout consisting of three columns and supplied 18 full Model 1 Burnley Baffles (800mm x ~1200mm), creating a complete surface seal that remains responsive even under the heavy, rapid flow of rail car discharge.
  2. For the Road Pit: To fit the 9-square-metre footprint, Mideco designed a mixed-component layout. This included 9 full Burnley Baffles and 3 half-baffles (575mm x ~1200mm). The inclusion of half-baffles ensured the entire surface area was closed off, preventing any gaps that standard-sized baffles might miss.
  3. Engineering Reliability: The bolted construction and gravity-operated design allowed these systems to be installed without complex power requirements, providing an immediate 80% reduction in dust.

Result

The project was completed in June 2023, delivering a clean, compliant unloading environment for Primient. By suppressing 80% of the dust, the Burnley Baffles significantly reduced the risk of combustible dust accumulation and ensured Work Health and Safety in the facility.

The success of the Loudon project is a testament to the effectiveness of Mideco’s tailored approach. As the Senior Project Manager of AMG, Inc. noted:

“We have used your [Burnley Baffles] successfully on several projects.”

This repeat business highlights the core value of the Burnley Baffles as a simple, effective technology that solves the grain industry’s most persistent dust challenges. To date, the Loudon facility continues to operate as a critical production hub for high fructose corn syrup, crystalline fructose, fuel ethanol, maltodextrin, and allulose.

Is your facility facing evolving requirements for dust management? Contact us today to design a custom-fit Burnley Baffles system that scales with your operation.