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How to Operate a Screw Conveyor (Bazooka)?

Screw Conveyors, Commonly Known as “Bazookas” in the Mexican Agricultural Sector

Screw conveyors—colloquially referred to as “bazookas” in the Mexican agricultural industry—are essential equipment for moving bulk materials continuously and efficiently. These systems (also called augers, screw feeders, or worm conveyors) consist of a rotating helical blade housed inside a tube or trough, which pushes materials along the conveyor’s length. Their enclosed helical design enables the uniform transport of grains, powders, pastes, and even liquids, while minimizing clogs or blockages during operation.

Los mejores transportadores helicoidales
Stainless steel screw bazooka conveyor. ©Maquinas y Herramientas Gamex SA de CV

In this article, we’ll explore what a screw conveyor (bazooka type) is, how it works, its typical applications in agriculture, food processing, and industry, as well as safe operating practices, basic maintenance guidelines, common mistakes to avoid, and key factors for selecting the right model. This knowledge will help you safely and efficiently operate a screw conveyor for transporting materials such as corn, wheat, or other grains, optimizing performance within the Mexican market.

What Is a Screw Conveyor or “Bazooka”?

A screw conveyor is a bulk material handling mechanism that uses a rotating helical blade (helix or screw) inside a tube or U-shaped trough. As the screw rotates, it moves the material in the direction of the spiral’s advance, allowing for a continuous flow along a defined path.

In other words, it operates much like a modern Archimedes’ screw, conveying granular solids, powders, and even liquids from one point to another through the constant rotation of the spiral. This simple yet effective design has made the screw conveyor a key component in numerous industries, as it ensures uniform and reliable transport while significantly reducing the risk of blockages.

tornillo sin fin
Screw Conveyor (Auger). ©Maquinas y Herramientas Gamex SA de CV

In the Mexican agricultural context, mobile tubular screw conveyors mounted on a wheeled chassis are commonly known as “bazookas.” These helical bazookas are essentially high-capacity portable screw conveyors, designed to move grains or other products from ground level into elevated containers such as hoppers or silos.

Their structure is typically tubular and enclosed, which provides excellent strength and durability, allowing them to operate outdoors without affecting the material being transported. Thanks to this rugged design, bazookas can handle heavy materials and harsh environmental conditions with ease.

Moreover, they are capable of conveying a wide range of materials—from fine powders to large granular products—making them highly adaptable to diverse industrial and agricultural needs.

In summary, a bazooka-type screw conveyor is a versatile, efficient, and robust piece of equipment for bulk material handling, and an indispensable tool in many agricultural, food processing, and industrial operations.


How Does a Screw Conveyor Work?

The operation of a screw conveyor is based on the rotation of its internal helix to propel the material forward. When the motor drives the central shaft, the spiral screw blade begins to rotate; due to its helical shape, this rotation pushes the material resting on the flights toward the discharge end of the tube. The material’s conveying speed is directly proportional to the revolutions per minute (RPM) of the screw—the faster the rotation, the more quickly the material moves through the conveyor.

The enclosed design of a bazooka-type conveyor ensures that the material does not spill and that the surrounding area remains clean, while also protecting both the screw and the operators from accidental contact. Many screw conveyors can operate horizontally or at an incline, allowing them to elevate materials; however, as the angle increases, transport efficiency slightly decreases.

In typical applications, the feed rate of the conveyor is controlled by external devices such as dosing hoppers, rotary valves, or volumetric feeders, which regulate the amount of material entering the system—ensuring a steady flow and preventing overloading.

In summary, the mechanical simplicity of these systems—comprising just a motor, a shaft, and a helical screw—results in constant and uniform material movement, delivering efficient, controllable, and uninterrupted transport performance.


Typical Applications of Screw Conveyors (Bazookas)


A mobile screw conveyor, or “bazooka,” mounted on a wheeled chassis, used for loading grains into silos or hoppers.

Bazooka-Type Screw Conveyors have a wide range of applications in agriculture, food processing, and other industrial sectors. Below are the most common uses, particularly relevant in the Mexican market:

  • Grain Loading and Unloading in Silos and Hoppers (Agricultural Sector):


    In agriculture, helical grain bazookas are essential for moving harvested crops—such as corn, wheat, and beans—from the storage floor to silos or transport trucks. They greatly facilitate grain silo loading, acting as portable elevators that transfer products quickly and continuously to elevated containers.


    For example, a bazooka screw conveyor can take corn from a pile on the ground and carry it directly to the top opening of a silo, eliminating the need for strenuous manual labor. These machines are typically mounted on wheeled chassis with adjustable height systems, allowing operators to position them beneath grain piles and then raise the discharge end to match the height of the silo or hopper inlet. They are widely used in collection centers, farms, and agricultural storage facilities, streamlining logistics for handling grains such as corn and wheat—hence their common nickname in Mexico, “bazooka for corn and wheat.”


  • Handling Seeds, Cereals, and Food in Processing Plants (Food Industry):


    In food and beverage facilities, screw conveyors—often made of food-grade stainless steel—are used to move raw materials such as flour, sugar, ground coffee, salt, or powdered milk from one process to another. An industrial screw conveyor in a food plant, for instance, can transfer flour from a mill to a mixing hopper or dose sugar into a production line. The use of stainless steel and sanitary seals ensures that the product remains uncontaminated and meets the strict hygiene standards required in the food industry.

    Bazuca para maíz
    ©Maquinas y Herramientas Gamex SA de CV

    These food-grade versions maintain the same advantages: continuous, sealed transport (preventing dust dispersion in the environment) and low maintenance requirements. Likewise, in feed and livestock food plants, bazooka conveyors are used to transfer granular or powdered ingredients (such as ground corn, soybean meal, etc.) to mixers or packaging machines.

  • Material handling in industrial processes (general industrial sector):Outside the food industry, screw conveyors are used across multiple industries to move bulk materials. For example, in construction, screw conveyors (commonly known as bazookas) are used for cement in concrete plants (to elevate powdered cement to dosing silos) and for other powders such as fine sand or gypsum. In the chemical or mining industries, they can transport granulated fertilizers, calcium carbonate, plastic pellets, boiler ash, among others. These systems are valued for their compact and lightweight design, which saves space, and for having lower maintenance costs compared to other conveying systems (such as belt conveyors or pneumatic transport). In addition, their ability to be completely enclosed makes them ideal for dusty, corrosive, or even hazardous materials, safely containing the material during transport. Many companies in Mexico use them to move raw materials within their plants, as they can be custom-built in various diameters, lengths, and operating angles according to specific requirements.

    It is worth noting that the capacities of these conveyors vary depending on the model and diameter: a typical screw conveyor for grains handles around 20–30 tons per hour of corn, while designs with larger diameters or higher speeds can exceed that figure. In fact, there are high-efficiency screw conveyors capable of transporting up to 120 tons per hour of corn for large-scale operations. Thanks to this versatility in capacity and configurations, screw conveyors have become a standard tool in bulk material logistics in Mexico, from small farms and mills to large industrial complexes.

Recommendations for Safe and Efficient Operation

Operating a Bazooka-Type Screw Conveyor Safely and Efficiently

Operating a bazooka-type screw conveyor requires following safety measures and good operating practices to ensure the protection of both personnel and equipment, as well as the integrity of the material being handled. Below are key recommendations for safe and efficient operation:

  • Always Keep Guards and Covers in Place:Never operate the conveyor without its protective cover fully closed over the screw or other moving parts, or without safety guards over drives, belts, gears, or couplings. These covers prevent accidental contact with the rotating screw and contain the material being transported. Check that all safety shields and warning labels are installed and legible before starting the equipment. Skipping safety guards is a serious mistake—any exposed moving part poses a risk of entanglement.

  • Do Not Overload or Use for Unsuitable Materials:Follow the load capacity and feed rate recommended by the manufacturer. Overloading the screw with more material than it can handle may cause jamming, mechanical failure, or motor overheating. Likewise, never use the equipment for materials it was not designed for (e.g., overly heavy, wet, or explosive materials). Each product has unique properties—granulometry, moisture, and abrasiveness—that must be considered. Ignoring them can cause buildup, corrosion, or excessive wear. If you need to convey an unusual material, consult the supplier to confirm compatibility or necessary adjustments.

  • Verify Proper Installation and Positioning:Before starting, make sure the bazooka is properly placed, leveled, and stabilized. Incorrect positioning—such as excessive inclination, poor support, or misalignment with the discharge hopper—can cause poor performance, vibration, or even tipping hazards. Ensure the discharge end aligns correctly with the receiving container and the feed inlet is properly positioned relative to the material source. Secure the wheels or chassis supports to prevent movement during operation. These checks help prevent downtime and unnecessary wear.

  • Start and Feed Properly:Start the screw conveyor empty whenever possible, then feed material gradually. This avoids sudden motor overload during startup. Use gates, valves, or feeders to regulate the input flow so that the screw operates at a consistent load—typically between 15% and 45% of the tube’s capacity, depending on the material. Watch for abnormal sounds, vibrations, or signs of blockage; if any occur, stop immediately and inspect after disconnecting power. Never insert tools, hands, or objects into the inlet or discharge while the conveyor is running. If residual material needs to be cleared, shut off the power and follow lockout/tagout procedures before intervening.

  • Implement Additional Safety Systems in Automated Operations:When the screw conveyor is part of an automated line (e.g., feeding a bucket elevator or receiving from a hopper), install interlock safety systems. Devices such as zero-speed sensors, emergency stops, and interconnected electrical systems ensure that if one piece of equipment fails or stops, upstream or downstream units shut down automatically to prevent overloading or jams. For personnel safety, consider installing emergency stop buttons accessible along the conveyor’s length.

  • Training and Standard Operating Procedures:Ensure that all operators and maintenance staff are properly trained in conveyor operation and aware of associated hazards and safety protocols. Establish written procedures or checklists for startup, shutdown, cleaning, and routine maintenance. Good training includes recognizing warning signs of malfunction—such as unusual noises, vibrations, or bearing overheating—and responding appropriately. A well-trained team can prevent most common issues and accidents, extending equipment life and maintaining a safe work environment.

  • Always Disconnect and Lock Out Power Before Maintenance:This is critical: never perform maintenance, cleaning, or unclogging while the conveyor is connected to power. Lock and tag out the electrical switch to prevent accidental startup. Wait until the screw has come to a complete stop before opening any covers. Wear proper personal protective equipment (PPE)—gloves, safety glasses, helmet—when inspecting or servicing the conveyor. Following this simple rule prevents most maintenance-related accidents.

Additionally, keep the area around the conveyor clean and free of obstacles to prevent tripping hazards or interference with moving parts. By following these operational practices, a bazooka-type screw conveyor will deliver safe, continuous, and efficient performance, maximizing productivity and minimizing unplanned downtime.

Basic Maintenance of a Screw Conveyor

One of the advantages of bazooka-type screw conveyors is that they require relatively simple maintenance, thanks to their robust construction and limited number of moving parts. However, to ensure optimal performance and extend their service life, it is essential to carry out regular preventive maintenance. The basic maintenance tasks that should be performed are outlined below:

Periodic inspections (daily or weekly):

Carry out frequent visual inspections of the equipment. Check the condition of the screw along its entire length: look for cracks in the flighting, deformations, or excessive wear on the edges of the blades. Any noticeable reduction in the diameter of the flight or bent blades indicates wear and the need for repair or replacement. Inspect the inside of the tube or trough to ensure there is no buildup of hardened material that could obstruct flow. Also inspect the bearings (pillow blocks) at the ends and intermediate supports, checking for lubricant leaks, overheating, or excessive play. Finally, observe the motor and gearbox: unusual noises, abnormal vibration, or excessive temperatures may indicate misalignment, lack of lubrication, or worn components.

Cleaning and removal of residues:

Keep the conveyor clean after operation, especially if it handles materials that leave adhered residues. At the end of each workday (or between different material batches), stop the equipment and remove any accumulated material at the inlet, inside the casing, or at the discharge. Material buildup (for example, caking powders or jammed grains) can reduce conveying capacity and eventually cause blockages. Use appropriate tools (brushes, plastic scrapers) to clean the internal walls and the screw, avoiding damage to the finish. If the conveyed material tends to solidify, consider running the conveyor empty periodically to dislodge residues before they harden. Consistent cleaning also prevents cross-contamination (critical in the food industry) and reduces abrasive wear.

Lubrication of moving components:

Ensure that all required lubrication points are serviced according to the manufacturer’s instructions. Generally, shaft bearings or pillow blocks require periodic greasing (after a certain number of operating hours). Follow the recommended interval (for example, every 500 or 1,000 hours, depending on bearing type) and use the appropriate lubricant (grease or oil of the specified viscosity). Proper lubrication reduces friction and prevents premature failures due to overheating or seizure. Also check the drive system: if the equipment uses chains and sprockets, apply consistent grease and periodically adjust chain tension (weekly or every ~100 hours of use) to prevent slipping. On conveyors with belts and pulleys, check belt tension and alignment, replacing the belt if wear or cracks are observed. Do not forget to lubricate (or replace) the seals (stuffing box packings) at the screw ends, as they prevent material leakage and dust ingress into the bearings; these seals typically require adjustment and greasing every few months.

Adjustments and spare parts:

During inspections, tighten any loose fasteners you find (supports, section flanges, motor bases, etc.), as vibration can loosen components over time. Check alignment between the screw shaft and the motor-gearbox; if misalignment is detected, make the necessary corrections to avoid wear on bearings and couplings. Monitor motor amperage: an abnormal increase in current during startup or operation may indicate mechanical overload (incipient blockage, excessive friction). In such cases, inspect the system before a major failure occurs. Keep critical spare parts in stock: it is advisable to have at least one set of spare bearings, seals, and possibly an extra screw flight section, as these are wear components. This minimizes downtime in the event of a failure.

Preventive maintenance program:

Establish a formal maintenance schedule that includes daily, weekly, monthly, and annual tasks. For example: daily quick visual inspection; weekly lubrication and fastener checks; monthly more thorough wear inspection; annually, partial disassembly for detailed internal inspection of the screw, shafts, and structure. Following such a plan allows early detection of problem symptoms (such as developing cracks or noisy bearings) before they evolve into serious failures. Document all activities performed and any anomalies detected, maintaining a service history for the equipment.

In summary, a well-maintained screw conveyor will minimize unexpected downtime and extend its service life for many years. Most common failures (blockages, accelerated wear, abnormal noises, material leakage) can be prevented through regular cleaning, lubrication, and inspections. And remember: whenever maintenance is performed, safety comes first—equipment shut down, locked out, and serviced by trained personnel. With these basic precautions, your screw conveyor bazooka will continue operating with the efficiency and reliability for which it was designed.

Common mistakes when using a screw conveyor bazooka (and how to avoid them)

Even with good practices, it is possible to make common mistakes when operating a screw conveyor that can compromise safety or efficiency. Below are some of the most frequent errors and how to prevent them:

Operating the conveyor without proper safety guards:

As mentioned, never operate the bazooka with covers removed or guards missing. A common mistake is assuming “nothing will happen” if the cover is removed to observe material flow or if someone works near an exposed screw; this is extremely dangerous. Any moving part can cause serious injury. Avoid this error by always ensuring that all guards are in place and functioning correctly before starting the equipment. Also, do not modify or bypass safety switches or sensors—they are there to protect lives and the equipment.

Failing to consider differences in conveyed material characteristics:

It is sometimes assumed that the same screw conveyor can handle any material interchangeably, which is not the case. Ignoring material variability can lead to blockages, accelerated corrosion, or premature wear. For example, a screw designed for dry grain may fail quickly if used with wet sand or corrosive chemicals without adaptation. Each material (bulk density, abrasiveness, moisture, tendency to compact, etc.) requires evaluation to determine whether the conveyor design is suitable. Avoid this error by selecting the appropriate equipment for each material and, if necessary, using coatings, special flights, or different construction materials (stainless steel, wear-resistant steels) for demanding materials. Consult technical data sheets or the manufacturer if you plan to use the conveyor with a product different from the original one.

Incorrect installation or positioning of the equipment:

One of the most common mistakes is failing to verify proper placement of the conveyor before use. This includes leveling the equipment (a misaligned conveyor can generate uneven stresses and one-sided wear), correctly aligning the discharge point (if it does not fall into the receiving vessel, material is wasted), ensuring the proper inclination angle (an angle steeper than designed can drastically reduce capacity), and securing the frame or supports to prevent excessive vibration. Failure to do so can result in poor performance, increased wear, and even safety hazards. The solution is straightforward: dedicate sufficient time to proper installation, follow the manufacturer’s mounting recommendations, and reposition or adjust the conveyor whenever it is relocated, ensuring stability and alignment each time.

Neglecting inspections and regular maintenance:

Another common mistake is operating the bazooka indefinitely without inspections, waiting for it to “fail” before performing maintenance. Not inspecting the conveyor regularly can have serious consequences. For example, if a bearing begins to fail and is not detected in time, it could seize and cause major damage to the shaft or motor. Or an uncleaned material buildup could lead to a complete blockage. Unexpected failures result in costly repairs, operational downtime, and potential accidents. Avoid this error by implementing a preventive maintenance plan (as detailed in the previous section). Periodically check the condition of the equipment, listen for unusual noises, measure vibration if possible, and address any anomaly immediately before it worsens. A well-maintained conveyor rarely produces unpleasant surprises.

Selecting an unsuitable conveyor for the required task:

Sometimes, in an effort to reduce initial costs, a generic, lower-capacity or lower-quality bazooka is chosen for a demanding application, resulting in an overworked machine or recurring problems. For example, using a light-duty conveyor in a 24-hour continuous process or for highly abrasive material is a selection error. Industrial experience shows that a custom-built screw conveyor tailored to the material characteristics and specific use will always be the best long-term option. Avoid this error by carefully evaluating requirements before purchasing the equipment (capacity, material type, operating hours, etc.). The next section explores selection criteria for the correct model in more detail. Remember: the right equipment is not simply the cheapest one, but the one that technically meets your application—otherwise, initial “savings” will be paid back through failures, repairs, and poor performance.

In summary, the key to avoiding these errors is maintaining a proactive approach: always respect safety measures, understand equipment limitations and operating conditions, inspect and maintain regularly, and ensure that the selected conveyor is suitable for the job. By doing so, you will maximize efficiency and extend the service life of your screw conveyor bazooka, avoiding downtime and ensuring smooth operations.

How to choose the correct screw conveyor model

There are multiple models and configurations of screw conveyors (bazookas) on the market—from standardized, off-the-shelf units to fully custom designs. Choosing the right model is critical to ensure the conveyor meets your application needs without issues. Below are the main factors and criteria to consider when selecting a screw conveyor:

Type of material to be conveyed:

Clearly identify the material or product the conveyor will handle. The physical and chemical properties of the material largely determine the required design. For example, is it dry grain such as corn or wheat, a fine powder like flour or cement, a wet/pasty material, or an abrasive product like sand or a corrosive one like chemical fertilizer? Knowing the material’s density (kg/m³), particle size, moisture content, tendency to compact, or potential to generate explosive dust will help define screw diameter, flight pitch, required power, and whether special features are needed (such as shaftless screws for very sticky materials or stainless steel construction for corrosive or food-grade applications). Not all materials “flow” the same way: a good supplier will even ask whether the material is abrasive, corrosive, or explosive to select appropriate construction materials and safety measures.

Required conveying capacity:

Determine how much material needs to be moved per unit of time (for example, tons per hour). Desired hourly capacity is essential for sizing the conveyor. For instance, do you need to move 20 t/h of grain to a silo, or 5 t/h of powder to a dosing hopper? Based on this, the conveyor diameter, flight type (standard pitch, double pitch, etc.), and rotational speed are selected. Larger diameters and higher RPM allow higher throughput but also require more powerful motors and a more robust structure. It is preferable for the conveyor capacity to slightly exceed the required capacity so it does not operate at its limit. Also consider conveying distance or length, as longer conveyors may require modular sections with intermediate supports (hanger bearings) to prevent deflection, or even multiple conveyors in series. Length and layout also affect power requirements: conveying material 10 meters horizontally is not the same as lifting it 10 meters vertically.

Spatial configuration and operating angle:

Evaluate how the conveyor will be installed: horizontal, inclined, or vertical, as well as the available plant space. If the conveyor is inclined, conveying efficiency decreases as the angle increases (above ~45° it is considered a vertical screw and usually requires special design with lower RPM and specific feeders). For moderate angles, a slightly more powerful motor or a screw design that mitigates material rollback may be required. Measure the physical space where the conveyor will be installed—both length and available height—and ensure the selected model fits comfortably and allows maintenance access. Some conveyors are modular and can adapt to different configurations (e.g., adding elbows or inclined sections), but this must be confirmed. If the conveyor will be integrated into existing machinery or pass through walls/floors, consider mounting arrangements, supports, and service access.

Mobility vs. fixed installation:

Decide whether you need a mobile (portable) conveyor or a fixed, stationary one. Mobile bazookas typically include wheeled chassis, height-adjustable structures, and are ideal for moving between locations. They are commonly used in farms, warehouses, and operations where flexibility is key (for example, loading different silos or trucks in various locations). Fixed conveyors, by contrast, are integrated into industrial installations (for example, under a fixed hopper feeding a reactor) and are custom-designed for the space. If mobility is required, ensure the model has suitable wheels (including pneumatic tires for uneven outdoor terrain), a braking system, and possibly a manual or hydraulic lifting mechanism to adjust inclination. If fixed, review support or hanger options for secure anchoring. The equipment must match your mode of use: not all standard conveyors are easily movable, and vice versa.

Power source and motor type:

Consider how the conveyor will be powered. Is three-phase electricity available at the operating location? Do you need a self-contained gasoline or diesel engine? Some bazookas have the motor mounted at the top and only accept electric motors (more economical but less versatile), while others have the motor at the bottom and allow options such as electric, combustion engines, or even tractor PTO drives. For example, in a field without electricity, a tractor-driven or gasoline-powered model may be appropriate. In industrial plants, an electric motor with gearbox is typically used. Also verify the required power (HP or kW): an undersized motor will be overworked and fail, while an oversized one increases unnecessary costs. The supplier should calculate power requirements based on material, capacity, and length—be sure to provide all relevant data for proper sizing. Also consider electrical controls: do you need a soft starter, variable frequency drive, or level sensors? Integrating these from the outset improves operation.

Construction materials and build quality:

Depending on the environment and product, choose the appropriate construction. For grains and general use, carbon steel (A36) is standard; for food processing or corrosive chemicals, choose food-grade stainless steel. Review surface finish: polished interiors are important when materials are delicate or tend to stick. Ask about options such as wear-resistant coatings (e.g., hardened flights or thicker flight material) if handling highly abrasive materials—this can significantly extend service life. A reliable manufacturer will advise whether reinforced or double-pitch flights are needed. Also consider seals and bearings: for fine powders or dusty environments, high-quality seals are critical to prevent material leakage and dust ingress into bearings.

Duty cycle (intensity of use):

Be realistic about how often and how long the equipment will operate. Will it run 8 hours a day, 24/7, or only occasionally? A standard bazooka-type conveyor is suitable for moderate duty cycles, but very intensive use may require a heavy-duty industrial design with reinforced components. Manufacturers often differentiate between continuous heavy-duty equipment and light or intermittent-duty units. For example, continuous-duty motors and gearboxes, thicker flights, larger shaft diameters, and higher-grade alloys may be needed for nonstop operation. Investing in a higher-specification model is justified when the application demands it, preventing costly downtime from premature wear. Conversely, if the conveyor will only operate a few hours per week, a more economical model may suffice.

Technical support and spare parts:

Finally, when choosing a supplier and model, consider after-sales support, warranty, and spare parts availability. It is preferable to work with a manufacturer that has local presence in Mexico, offers technical assistance, manuals in Spanish, training, and a clear warranty. Verify that replacement parts such as motors, bearings, seals, and even screw sections can be easily obtained. A good supplier will provide an operation and maintenance manual specific to your equipment, along with a list of wear parts so you know which items to keep in stock. These factors make a significant difference in the long-term success of your investment.

In conclusion, selecting the right screw conveyor involves carefully analyzing your process and operating conditions. Do not hesitate to consult experts or trusted manufacturers, providing them with as much information as possible about your application—material type, capacity, space, etc.—so they can recommend the most suitable solution. By choosing the optimal screw conveyor bazooka for your needs, you ensure a reliable, safe, and efficient piece of equipment that improves bulk material handling operations in agricultural or industrial settings. By following proper operating and maintenance practices and avoiding common mistakes, you will fully benefit from the advantages of your screw conveyor bazooka for many years. Happy conveying!

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Matrix

Carretera Atotonilco - La Barca #151, Milpillas, Atotonilco el Alto, Jalisco. 47775. México.
+52 391 917 1277

Matrix

Carretera Atotonilco - La Barca #151, Milpillas, Atotonilco el Alto, Jalisco. 47775. México.
+52 391 917 1277

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