Automation Revolutionizing Material Handling at Track Hopper

Abstract

Bulk material handling systems play a critical role in power plants and metallurgical industries, where efficiency, safety, and quality monitoring directly influence plant performance. Track Hoppers are the primary unloading interface for bulk materials such as coal, and traditional sampling methods involve significant manual intervention, leading to safety risks, material spillage, and inconsistent sampling quality. This paper presents the implementation of an automated material handling and coal sampling system using a PLC-based Cross Belt Sampling Unit (CSU) integrated with a Bucket Elevator installed within a Track Hopper tunnel conveyor at a depth of –12 meters. The system enables fully automated, enclosed sample collection and transfer to ground level without manual handling. PLC and SCADA-based automation ensures accurate sampling, improved safety, reduced spillage, real-time monitoring, and reliable data logging. Operational results demonstrate enhanced sampling accuracy, reduced manpower dependency, and improved housekeeping. The proposed system establishes a foundation for Industry 4.0–ready material handling with scope for predictive maintenance and advanced analytics.

Introduction

Automation has modernized industrial material handling, enhancing productivity, safety, and reliability. In coal unloading at Track Hoppers, traditional manual sampling poses risks, spillage, and inconsistent results.

The proposed system automates coal sampling using a PLC-controlled Cross Belt Sampling Unit (CSU) integrated with a Bucket Elevator. The PLC manages motor sequencing, interlocks, monitoring, fault detection, and emergency shutdowns. Sensors ensure safe operation, detecting belt speed, elevator vibration, blockage, and other hazards.

During operation, the CSU extracts coal samples automatically, which are transferred vertically by the Bucket Elevator to ground level without interrupting material flow. The system eliminates manual handling, reduces safety risks, prevents spillage, improves sampling accuracy, accelerates quality analysis, and enhances housekeeping and maintenance efficiency. Digital logging supports traceability and data-driven decision-making.

This automated setup demonstrates a safer, faster, and more reliable coal sampling process for Track Hopper operations.

Conclusion

The PLC-based automated material handling and coal sampling system implemented at the Track Hopper represents a significant advancement over conventional manual sampling practices. By integrating a Cross Belt Sampling Unit with a Bucket Elevator and SCADA-based monitoring, the system enhances safety, reliability, and sampling accuracy while reducing manpower dependency and operational risks. The successful implementation confirms that automation in bulk material handling is not only feasible but essential for modern industrial facilities. The system also provides a scalable platform for future Industry 4.0 enhancements such as predictive maintenance, smart diagnostics, and performance analytics.

Copyright

Copyright © 2025 Ajit Biswal. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.