By Greg Washburn and Joshua Belisle · Edited by Dana Gardner
Published August 5, 2024 · Reviewed by Greg Washburn · July 30, 2026
Summary
What are the drawbacks of self-contained loaders?
As processors grow, multiple self-contained loaders pulling from multiple Gaylords to multiple drying hoppers start to clog the production area. They need material handlers and room for forklifts, spilled material is still wasteful and dangerous, and the combined power of many small loader motors adds up against one or two vacuum pumps. Brush motor loaders also take labor for brush changes.
Self-Contained Loader Drawbacks
As processors grow, they usually find that having multiple loaders drawing material from multiple Gaylords to multiple drying hoppers starts to clog the production area. It also requires material handlers and space to run forklifts. Production space should be used for production – not as a raceway for forklifts. Material waste may be less than with the bucket brigade but it is still a big issue – and dangerous when spilled on the floor. Then there is the energy issue. Add up the Kw used by all those small loader motors and compare that to the power used by one or two vacuum pumps. The energy savings is considerable. Add to that the initial cost, space and energy used by Gaylord tilt tables. Think about how much labor is expended changing brushes in the loaders. Yes, there are brushless motor loaders but they are more expensive and have a limited life.
Ultimately, a central resin handling system – possibly with one or more central dryers is usually the most economical, energy-saving way to make your processing plant more productive and more competitive.
Frequently Asked Questions
Do multiple loaders use more energy than a central vacuum pump?
The article says yes. Add up the kilowatts used by all the small loader motors in a growing plant and compare that with the power used by one or two central vacuum pumps, and the energy savings of the central approach is considerable. Gaylord tilt tables used alongside loaders add their own cost, space and energy.
Do brushless motor loaders solve loader maintenance problems?
Loaders with brush motors take labor to change brushes, which adds up across many loaders. Brushless motor loaders avoid brush changes, but the article notes they are more expensive and have a limited life, so they shift the cost rather than removing it when a plant is running many loaders.
When should a processor move from loaders to a central system?
The pressure usually comes with growth. When multiple loaders drawing from multiple Gaylords to multiple drying hoppers start to clog the production area, need dedicated material handlers and forklift lanes, and add spillage and energy use, a central resin handling system, possibly with one or more central dryers, is usually the more economical option.
About the Authors
Vice President of Operations, Novatec
Greg Washburn is Vice President of Operations at Novatec and has been with the company for more than three decades. He is involved in all phases of engineering design and product manufacturing, giving him a broad perspective on how resin drying and conveying equipment moves from engineering concept through production and into real-world processing environments. Greg holds a B.S. in Mechanical Engineering from the University of Maryland, Baltimore County (UMBC) and an MBA from Loyola University Maryland. His experience spans engineering, manufacturing and operations across Novatec’s material-handling technologies.
Technology Manager, Novatec
Joshua Belisle is Technology Manager at Novatec, where his work focuses on simulation and technology development for resin drying. He earned a B.S. in Mechanical Engineering with a minor in Engineering Business from the University of Virginia in 2023 and joined Novatec that same year. Joshua uses simulation tools to investigate previously difficult-to-measure aspects of the drying process, helping Novatec better understand airflow, heat transfer and other variables that influence resin-drying performance.
Related Articles
Review how a self-contained loader moves resin from a Gaylord to a hopper and the equipment used to set it up.
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See how central conveying reduces manual handling, floor congestion, energy use, and material waste as a plant grows.
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