Lowering Pneumatic Barrier System for Safe Loading of Road Tankers

Lowering Pneumatic Barrier System for Safe Loading of Road Tankers

The purpose of this article is to present the importance of safe loading systems for road tankers. This is an essential process in view of the growing popularity of road transport for bulk materials. We will focus on a unique system of lowered barriers, developed and installed by CPP “PREMA” S.A.. This application significantly minimized the risks associated with the loading process, while improving operational efficiency. We will also present our experience in integrating a pneumatic system with a central control system at one of the largest cement plants in Poland.

Advantages of automating the loading process

Road transport of bulk materials such as grain, fertilizer or cement is an important pillar of modern industry and transportation. However, the process of loading these materials into road tankers poses significant challenges, especially in terms of worker safety. Below, we delve into the risks associated with the manual loading of bulk materials, which not only poses a risk to the health and lives of workers, but can also negatively impact the operational efficiency of a company.

Requirement for manual opening and closing of loading flaps

The traditional process of loading bulk materials into road tankers requires drivers to manually open and close loading flaps before and after each load. This is a task that requires not only physical effort, but also time.

Hazards associated with working at heights

In order to access the loading flaps, drivers must climb onto the tanker, which in turn exposes them to the risk of falling to the ground. Working at heights without proper safeguards is one of the main safety risks for workers involved in the loading process.

Impact of weather conditions on driver safety

Loading takes place throughout the year in different weather conditions. During sunny days, the loading process is much less complicated. However, rain or snowfall significantly increase the risk of dangerous situations. Slippery surfaces can lead to accidents, while cold temperatures can hamper manual loading operations.

Both companies and drivers are aware of these difficulties. Which has resulted in the search for new, innovative solutions to reduce risks and improve the efficiency of the loading process. One such solution is the drop barrier system, which will be discussed in more detail later in this article. A safe and efficient loading process is not only a benefit to employees, but also contributes to the competitiveness of companies in the bulk material transportation market.

Lowering pneumatic barrier technology: an overview

So far, we have pointed out that road transport of bulk materials is an important part of today’s supply chains, but it comes with significant challenges, especially in terms of loading safety. However, thanks to technological advances, we can address these challenges by offering solutions that not only improve safety, but also significantly increase companies’ operational efficiency. In this segment, we will focus on the benefits of automating the road tanker loading process.

Reducing the risk of accidents

Automating the loading process significantly reduces the risk of accidents associated with working at heights. Systems such as lowering pneumatic barriers eliminate the need to climb onto a tanker, which in turn will minimize the risk of a worker-driver falling.

Reduce exposure to adverse weather conditions

Automation minimizes the need for manual outdoor operations in harsh weather conditions. As a result, drivers and loading personnel are less exposed to adverse weather conditions, further enhancing their well-being and job satisfaction.

Standardization of loading processes

Automation introduces standards that guarantee uniformity and precision in every loading process. This makes it easy for companies to monitor and control the quality of loading, resulting in higher quality transportation services.

Although the implementation of automatic loading systems requires an initial investment, in the long term it can significantly reduce a company’s operating costs.

Lowering pneumatic barrier technology - operation

One solution that could revolutionize this area is the technology of lowering pneumatic barriers. This innovative approach will not only minimize safety risks, but also help improve the operational efficiency of companies. In this section, we take a closer look at this technology, explaining its key elements and the benefits it can bring to the bulk material handling industry.

Construction and operation of the drop barrier system

The lowering pneumatic barrier system consists of several key components, including pneumatic actuators, a pneumatic box and an electrical box. The pneumatic actuators are electrically controlled, and their movement is controlled by a control system located in the boxes. With this solution, the process of opening and closing loading flaps becomes automated, eliminating the need for manual intervention.

Application in the context of loading road tankers

Lowered pneumatic barriers can be installed directly on loading bays, preventing water from entering tankers and eliminating the need for drivers to use safety harnesses. This technology reduces the risk of accidents. They increase the operational efficiency of the loading process, further minimizing the time required for each individual operation.

Integration with existing control systems

Lowered pneumatic barriers can be integrated with the company’s central control systems to further automate processes and remotely monitor and control loading operations.

Security and safety features

The lowered pneumatic barrier system also includes safety features such as safety interlocks and sirens that inform operators of the system’s status, ensuring that the loading process can be carried out in a safe and controlled manner.

Use cases and practical implementations

Many companies have already seen the benefits of implementing lowered pneumatic barrier technology. A concrete example is a project carried out by CPP “PREMA” S.A., which involved the supply and installation of a system of lowered barriers at one of Poland’s leading cement plants.

Case study - implementation of the system in a Polish cement plant

Having understood the theoretical aspects and benefits of automating the bulk material loading process, it is worth familiarizing ourselves with the practical application of these solutions. Nothing illustrates this better than a specific case study of the implementation of a lowered pneumatic barriers system in one of Poland’s leading cement plants. Practical experiences of implementing new technologies often provide valuable insights that can inspire other companies looking to raise safety standards and operational efficiency. We encourage you to dive into the following case study to understand how theory translates into practice in a real industrial environment.

Supply and installation of pneumatic, electrical and automation system

The project carried out by our company included the supply of a complete pneumatic system, electrics and automation necessary for the operation of the lowered barrier system. Precise planning and execution of the supply and installation was crucial to the success of the project, which shows the importance of experience and professionalism in the implementation of advanced technologies.

Integration with the central control system of the cement plant

The next step was to integrate the newly installed system with the cement plant’s central control system. This phase of the project demonstrated how flexible and compatible the lowered pneumatic barrier systems can be, allowing them to work seamlessly with the existing technological infrastructure.

Functionality and verification of the system

Once the installation and integration were completed, detailed tests of the system’s functionality were conducted to ensure that it met all safety and operational requirements. These tests confirmed that the lowered barrier system significantly increases the safety of the loading process, reducing the risks associated with working at heights and improving operational efficiency.

Operating and maintenance instructions for the lowererd barrier system

In workshops, the heart of any automated system hides in its control and control components. This is also the case with the pneumatic drop barrier system, where pneumatic and electrical boxes play a key role. Understanding the design and use of quality components, contributes to the safety of the bulk material loading process. In this section, we invite you to dive into the world of the internal components of these boxes to see how precision engineering and innovation come together to form the foundation for automated loading.

Pneumatic box insight

The pneumatic box is the heart of the lowering barrier system, containing components such as pneumatic actuators, valves, compressed air preparation elements, relays and other components necessary to control the flow of air that drives the movement of the barriers. All of these components are carefully positioned and protected to ensure the reliability and longevity of the system.

Electrical components

The electrical box, on the other hand, is the brain of the operation, containing the electrical controls that direct the operation of the pneumatic components. Here you’ll find various control modules, safety devices and communication interfaces for integration with external control systems.

Integrated control solutions

The key thing about lowering pneumatic barrier technology is how elegantly the pneumatic and electric boxes work together to form an integrated control system. This cohesive system enables precise control of the loading process while minimizing the risk of human mistakes.

Security and safety features

Both boxes contain various safety features and functions, such as pneumatic interlocks and electrical protection, which ensure that the system remains safe and functional even in harsh industrial environments.


Throughout our journey into the world of automated road tanker loading, we have gained valuable insights into the challenges and solutions of the bulk material handling industry. These solutions, associated with lowered pneumatic barriers, open the door to a new era of safety and operational efficiency. In this final section, we will summarize the key points of our discussion, while offering some thoughts on how these innovations can shape the future of the industry. We encourage you to reflect on the lessons learned and explore the opportunities these technologies can bring to your business.

The Importance of Safe Loading

Working at heights, especially when loading bulk materials, involves significant risks. Solutions such as lowering pneumatic barrier systems are a significant step forward in minimizing these risks, offering a safer working environment for operators.

Benefits of Automation

Automating the loading process not only improves safety, but also contributes to operational efficiency by reducing loading and unloading times and reducing the possibility of human mistakes.

Innovation of Lowering Pneumatic Barrier Technology

Lowered Pneumatic Barrier Technology represents innovation in the industry, combining advanced pneumatic and electric solutions to automate key operational processes.

Practical Implementations and Case Studies

Case studies, such as a system implementation at a Polish cement plant, demonstrate the practical value of these technologies and offer insights into how they can be successfully implemented in various industrial scenarios.

Way Forward

These technologies have tremendous potential to transform the way companies approach bulk material loading and transportation. As the industry evolves, adapting innovative solutions will be key to staying competitive and achieving higher safety standards.

We encourage you to reflect on the concepts discussed here and consider how technologies related to lowered pneumatic barriers can be integrated into your company’s operations. If you need assistance or would like to learn more about our system, we encourage you to contact us.