Transformación digital
Founded in 1992, RIBUS Inc. is a functional ingredient manufacturing company that supplies natural and organic, plant-based ingredients.
Using patented processing technology, RIBUS takes rice byproducts generated during milling—specifically the rice hulls left behind when brown rice is refined into white rice—and transforms them into high-value functional ingredients. Instead of treating the hulls as waste, RIBUS grinds and refines this outer shell material into fine powders, creating protein-like, functional ingredient blends that manufacturers can use to improve performance while maintaining clean, transparent labels.
As with many grain and seed operations, their process generates fine organic dust (particularly during conveying, milling, and transfer points.) This dust includes lightweight rice hulls and fines that can remain airborne if not properly controlled, creating both operational and combustible dust safety concerns.
RIBUS initially reached out to Baghouse.com with a very specific need: they were looking for a baghouse to support their process. What started as a single piece of equipment quickly evolved as the project moved forward. As we worked with their team, they saw that we understood their process, asked the right questions, and could design solutions that others involved simply weren’t addressing.
After the first baghouse was in motion, they began asking for support beyond dust collection… first with pneumatic conveying, where we ultimately designed and supplied three separate conveying systems. From there, the scope continued to expand. RIBUS asked us to design and supply two storage silos, followed by a bag dump station that allows operators to safely and efficiently unload supersacks of material into the process. Along the way, they regularly leaned on us for engineering guidance, even questioning recommendations from other engineering firms.
In one case, they were advised to use light-duty silos better suited for wood chips, not food-grade applications. We explained why those designs were inappropriate for their product and process, proposed the correct food-grade solution, and they moved forward with our recommendation. By the end of the project, nearly half of the major process equipment in the facility—baghouses, fans, ductwork, pneumatic conveying systems, rotary airlocks, silos, and related components—had been designed and supplied by Baghouse.com.
Scope of Work
The scope of work included evaluating dust generation points across the milling and conveying process, designing a properly sized dust collection system, and integrating bulk storage silos for collected rice hulls.
Key elements of the scope included:
- • A filter receiver–style dust collector sized for 4,200 ACFM
- • Combustible dust safety considerations per NFPA guidance
- • Integration with conveying equipment and cyclonic separation
- • Design and supply of two ground-mounted rice hull storage silos
- • Coordination with an existing conveying project to streamline fabrication and shipment
During project development, design adjustments were made based on feedback from the Ribus team and initial layout mockups. These refinements allowed the project to reduce unnecessary components (such as removing one rotary airlock and downsizing a cyclone), resulting in both cost savings and a cleaner system layout.
solución
Dust Collection System
The dust collection system was built around a filter receiver designed specifically for rice milling applications. The system was engineered for 4,200 ACFM at 75°F, with a total filter area of 1,840 square feet, yielding a conservative air-to-cloth ratio of 2.28:1. This design approach supports stable pressure drop, longer filter life, and consistent performance under variable dust loading.
The collector utilized 80 bottom-load pleated filter elements, allowing for safe and efficient maintenance without overhead access. Internal velocities were carefully controlled, with a can velocity of 110 FPM y interstitial velocity of 196 FPM, reducing the risk of dust re-entrainment while maintaining effective capture of fine rice hull particles.
Dust characteristics (including low moisture content, free-flowing behavior, and moderate abrasiveness) were factored into material selection and internal geometry. Abrasion-resistant lining was evaluated and retained as an option depending on long-term wear expectations.
Rice Hull Storage Silos
To complement the dust collection system, two NFPA-compliant ground storage silos were designed and supplied for bulk storage of collected rice hulls. Each silo provides 1,500 cubic feet of usable storage volume, allowing Ribus to manage material accumulation efficiently without frequent handling interruptions.
The silos were constructed from 10-gauge welded carbon steel and designed with a 12-foot nominal diameter and 14-foot straight wall, supported by a welded structural steel frame. A 60-degree hopper angle was selected to promote reliable discharge of lightweight rice hull material.
Combustible dust safety was a primary design consideration. Each silo includes:
- • Six explosion relief panels (40” x 40”) rated at 1.0 PSIG
- • A combination pressure/vacuum relief valve
- • Proper venting geometry to maintain NFPA compliance
- • Ground-mounted access and structural spacing designed to accommodate explosion venting requirements
Additional features included top-mounted manway access, integrated convey line brackets, high- and low-level point sensors, and flanged connections to mate directly with the cyclone and downstream conveying equipment. The silos were finished with an industrial coating system suitable for outdoor service and shipped with cradles to simplify on-site placement.
Installation Challenges
As with many agricultural facilities, installation required close coordination between mechanical design and real-world site conditions. Adjustments were made in the field to accommodate structural constraints, equipment access, and routing of conveying and venting connections.
For the silo installation, considerations included foundation coordination, discharge elevation, and alignment with existing conveying infrastructure. While concrete anchors, grout, and final structural revisions were handled by others, the silo design accounted for these interfaces from the outset to minimize surprises during installation.
By aligning the silo fabrication schedule with the existing conveying project, equipment shipments were consolidated, reducing lead times and simplifying logistics for the customer.
Outcome and Conclusion
The completed system provided RIBUS with an integrated solution that addressed dust control and bulk material storage as a single, cohesive system. The dust collection equipment delivered reliable airflow, efficient filtration, and stable operating conditions, while the storage silos gave Ribus a safe and compliant way to manage rice hull byproducts without disrupting production.
From an operational perspective, the combination of conservative filtration design, gravity-assisted material handling, and bulk storage capacity reduced maintenance demands and improved housekeeping. From a safety standpoint, NFPA-compliant explosion protection was built into both the dust collection and storage portions of the system.
This project highlights an important principle in agricultural dust control: effective solutions go beyond capturing dust at the source. When dust collection, separation, conveying, and storage are designed together, facilities gain safer operations, better reliability, and systems that continue to perform as production scales.
