Archive: Dec 2024

How to Solve Material Flow in 10 Common Processing Vessels

Comments Off on How to Solve Material Flow in 10 Common Processing Vessels
Managing bulk materials comes with a common challenge: ensuring smooth flow through every stage of processing. Blockages can strike at any point, leading to costly downtime, wasted product, and frustrated teams. Here’s a look at the processing vessels most prone to material hang-ups.

Hoppers

Hoppers store and dispense bulk materials like powders and granules, feeding them into the next stage of processing.

Material hang-up: Bridging and rat-holing are the biggest culprits here. Materials can form a solid arch across the outlet or flow unevenly through a narrow channel. Sticky powders can also cling to hopper walls, disrupting flow and creating bottlenecks.

Silos

Silos store massive quantities of materials, from cement and grains to plastic pellets. They’re essential for large-scale operations.

Material hang-up: Moisture and compaction can cause materials to stick to the silo walls or create blockages. Fine powders, in particular, tend to clump and resist flow, which leads to uneven discharge and wasted product.

Bins

Bins serve as short-term storage vessels for bulk solids, often holding material right before it’s processed.

Material hang-up: Like hoppers, bins suffer from material stagnation. Solids may become compacted or form dead zones, preventing a consistent flow. Dusty materials can also accumulate on bin walls.

AirSweep on an additive surge bin processing vessel

Chutes

Chutes transfer materials using gravity, directing them from one stage of processing to another.

Material hang-up: Insufficient slope or the wrong surface finish can cause materials to stick or clump together, especially if they’re damp or adhesive. This results in blockages that stop material movement entirely.

Cyclones

Cyclones separate particles by size or density in pneumatic systems, a common process in industries handling fine powders or particulates.
Material hang-up: Accumulation of fine particles often occurs in bends or outlets, especially in systems that deal with sticky or moisture-laden materials. This can clog the system and reduce efficiency.

Mixing Vessels

Mixing vessels homogenize ingredients, blending powders, liquids, or slurries in food, chemical, or pharmaceutical production.

Material hang-up: Settling and clumping are common issues, especially with viscous materials. Unmixed components can adhere to the walls or bottom of the vessel, reducing the quality of the final blend.

Feeders

Feeders dispense materials in precise quantities, ensuring consistent input for downstream equipment.

Material hang-up: Sticky or fine-grained materials can clog feeder mechanisms, leading to uneven discharge or complete blockages.

Weigh Hoppers

Weigh hoppers measure and dispense materials by weight, a critical function for accurate batching.

Material hang-up: Material bridging or sticking to the hopper walls can result in inaccurate measurements. Over time, residual material build-up can compromise efficiency.

AirSweep flow aid on a weighing hopper processing vessel

Bag Dump Stations

Bag dump stations transfer materials from bags into processing lines, filtering dust and contaminants in the process.

Material hang-up: Residue from bags can collect on the grids, while powders may clog the transfer points, slowing down production.

Storage Tanks for Slurries or Powders

Storage tanks hold materials for later use, whether it’s liquid, slurry, or powder.

Material hang-up: Sedimentation or compaction at the bottom of the tank is a frequent issue. These blockages make discharge inconsistent and increase clean-up time.

Solve Material Blocks in Processing Vessels

Material flow issues are more than just a nuisance—they can cost your operation valuable time and money. The good news is that these problems are solvable. With the right system in place, you can keep your processing vessels running smoothly, no matter the material.

AirSweep is a pneumatic flow aid system that uses powerful bursts of compressed air to activate stagnant material and restore flow. Unlike vibrators or other mechanical aids that only address surface-level issues, AirSweep penetrates the material column, breaking up blockages at the source.

AirSweep can be installed in all types of processing vessels—whether you’re dealing with a stubborn hopper, a silo that refuses to empty evenly, or a bin plagued by dead zones. It works seamlessly with powders, grains, and even sticky materials, ensuring efficient flow every time. Find out more about how AirSweep works.

 

5 Food Industry Trends for 2025

Comments Off on 5 Food Industry Trends for 2025

The food processing industry has undergoing significant transformations, driven by factors such as changing consumer preferences, technological advancements, economic conditions, regulatory policies, and environmental concerns. Learn about food industry trends that can affect plant operations and production goals.

1. Green Food Processing

Sustainability is no longer a buzzword; it’s a mandate. Consumers and regulators alike demand eco-friendly practices that minimize environmental impact. This shift compels manufacturers to adopt renewable energy sources, reduce waste, and implement sustainable methods throughout production. Embracing green food processing not only meets regulatory requirements but also appeals to the growing segment of eco-conscious consumers.

2. Food Waste Management

With global food waste contributing significantly to environmental degradation, the industry is under pressure to enhance resource utilization. Innovations in processing techniques and supply chain management are being developed to address this issue. Efficient utilization of resources, improved storage solutions, and advanced inventory management systems are among the strategies employed to minimize waste. By tackling food waste, manufacturers can enhance profitability and contribute to food security.

Flow aids can help minimize material waste caused by inconsistent flow. A food company threw away 40 pounds of mixture a day, and even had to pay to have it hauled away, until they installed AirSweep. Watch how AirSweep can be used to promote first-in/first-out flow for all types of food materials.

 

3. Alternative Proteins

The rise of plant-based and lab-grown proteins is transforming the food landscape. These alternatives cater to health-conscious consumers and address environmental concerns associated with traditional meat production. Incorporating alternative proteins into product lines allows manufacturers to diversify offerings and meet the evolving preferences of consumers seeking sustainable and ethical food choices.

4. Enhanced Food Safety Measures

Advancements in technology are leading to improved food safety protocols. The implementation of early warning systems, real-time analytics, and AI-driven solutions helps in the proactive detection and prevention of foodborne illnesses. By prioritizing food safety, manufacturers can protect public health, comply with stringent regulations, and maintain consumer trust.

5. Personalized Nutrition

With the rise of personalized nutrition, food safety is becoming more tailored to individual dietary needs. Technologies that track dietary preferences, allergens, and nutritional requirements are driving the development of personalized food products. This trend enables manufacturers to offer customized solutions, enhancing customer satisfaction and opening new market opportunities.

Keep up with Food Industry Trends with a Smarter Flow Aid

AirSweep can help food manufacturers align with industry trends such as sustainability, waste reduction, and enhanced food safety. The system’s efficiency contributes to greener processing by minimizing material waste and reducing energy consumption associated with manual cleaning and maintenance. It also provides consistent and powerful material flow, even for challenging materials like alternative protein products. Find out more about how AirSweep is used in the food industry and why it is more effective than other flow aids.

 

 

7 Most Common Bulk Materials Prone to Bridging and Ratholing

Comments Off on 7 Most Common Bulk Materials Prone to Bridging and Ratholing

Bridging and ratholing are common problems in bulk material handling, and some materials are notorious for poor flow properties. Learn about the most challenging bulk materials and see proof of why AirSweep is the best flow aid for the job.

What are bridging and ratholing?

Bridging happens when bulk materials form a stable arch above an outlet, completely stopping the flow. This usually occurs because of particle cohesion, moisture, or poor hopper design.

Ratholing creates a narrow channel through the material, leaving stagnant product clinging to the container walls. It’s common with materials that have poor flow properties or stick easily to surfaces.

Both problems cause production stoppages, material spoilage, and costly manual intervention—headaches no plant manager wants.

What materials are prone to bridging and ratholing?

Flow problems can be caused by many factors, including vessel design or plant environment (like humidity and temperature). However, these materials have inherent properties that affect how they behave when they are stored, transported, or mixed.

1. Cement and Fly Ash

Cement and fly ash are ultra-fine powders that easily absorb moisture. This leads to clumping, compacting, and cohesion that quickly cause bridging. When stored under pressure, these materials become even tougher to handle because the pressure forces particles closer together, increasing their density and cohesion. The compacted material can form stable arches or stick tightly to hopper walls, making flow nearly impossible without external intervention.

Watch: AirSweep Cement Mix Material Flow Test

2. Food Powders

Most food or beverage processing facilities or commercial bakeries use fine powders like flour, cornstarch, cocoa, and milk powder. These powders are hygroscopic, or readily absorb moisture from the air. Flour and starch compact under their own weight, while cocoa and milk powder stick to hopper walls due to moisture or static charges. These properties make bridging and ratholing and bridging frequent problems.

Food and beverage manufacturers also have to meet strict sanitation standards. Stagnant material can become spoiled, and manually clearing out material blocks may cause contamination.

Watch: AirSweep Moist Cornstarch Material Flow Test

3. Chemicals and Fertilizers

Many chemicals and fertilizers absorb moisture, leading to cohesion and clumping. Granular fertilizers often bridge because of uneven particle sizes, while fine chemical powders compact or stick to equipment surfaces.

Aside from slowing down operations, flow interruptions in fertilizers and chemicals disrupt batching accuracy and downstream processes like mixing and packaging.

4. Plastic Pellets and Resins

Plastic pellets and resins used in plastic production and packaging pose unique challenges. Smooth, spherical pellets interlock under pressure, causing bridging. Irregularly shaped   compact and form stable arches in hoppers.

Recycled plastic and resins also pose more challenges. They have varying particle sizes and shapes, increasing the chances of bridging and compacting. As “green manufacturing” becomes a bigger priority because of sustainability goals, reliable flow systems ensure that recycling operations remain efficient, sustainable, and cost-effective.

Watch: AirSweep Plastic Regrind Material Flow Test

5. Coal and Aggregates

Coal and aggregates are typically used in energy production, mining, and construction. These materials often have irregular particle sizes and varying moisture content. Fine coal dust, in particular, sticks together due to cohesion and compaction. Material blocks can choke boiler feed lines and delay energy production—a costly problem for any plant.

6. Metal powders

Metal powders are extremely fine, dense, and prone to static charge buildup. These properties cause bridging, compaction, and ratholing, particularly in precision processes like additive manufacturing.

7. Sawdust and Wood Chips

Sawdust and wood chips are typically used in paper and pulp industries, wood processing, and biomass energy production. They are lightweight and irregularly shaped, which makes them prone to interlocking and bridging in hoppers and silos. Their fibrous nature also causes the material to compress and compact over time, creating blockages that restrict flow.

Watch: AirSweep Sawdust Material Flow Test 

Solve bridging and ratholing for good

Do you work with a tough material that is prone to bridging and ratholing? Have you tried other flow aids but still resort to manual cleaning or hammering the vessel? AirSweep provides a proven solution to keep your materials flowing, eliminate costly disruptions, and maximize productivity. To learn how AirSweep can improve your plant’s operations, contact us for a consultation.

How to Solve Bridging and Ratholing of Cement and Mined Materials

Comments Off on How to Solve Bridging and Ratholing of Cement and Mined Materials

Material flow is the backbone of any successful operation in the mining and cement industries. Yet, common issues like bridging, ratholing, and material pileups can derail even the best-laid plans. These disruptions not only impact productivity but also drive up costs with additional labor and energy consumption.

The solution? AirSweep—a proven flow aid trusted by over 10,000 installations worldwide. Designed to handle the heavy-duty challenges of materials like clinker, fly ash, and copper concentrate, AirSweep ensures consistent material flow, minimizes downtime, and keeps operations running smoothly. Read on to discover why AirSweep outperforms traditional flow aids and how it’s revolutionizing bulk material handling in the cement and mining industries.

Common material flow problems in mining and cement

Heavy materials like clinker, fly ash, and copper concentrate pose significant challenges in processing plants. They often:

  • Bridge or rathole inside vessels, reducing live capacity.
  • Plug outlets, halting production lines.
  • Segregate particles, disrupting material quality.
  • Flood or flush fine powders, causing inefficiency and waste.

Traditional flow aids like vibrators, air cannons, and fluidizers are no match for such issues. They can compact materials, waste energy, or create safety risks by dispersing particles.

common material flow problems of cement and mined materials

AirSweep flow aids solve the toughest flow problems of cement and mined materials.

 

Why AirSweep is the best flow aid for cement and mined materials

AirSweep releases high-pressure, high-volume, 360-degree pulses of compressed air that break through material blocks and clear vessel walls. It’s efficient, safe, and designed to tackle the toughest materials. It’s also more efficient, safe, and cost-effective than other flow aids.

  • Fluidizers fail to activate heavy materials.
  • Air cannons waste energy and spread material dangerously.
  • Vibrators compact materials instead of clearing them.

AirSweep, on the other hand, activates materials quickly and completely, using less energy and plant air.

AirSweep is trusted by cement and mining companies worldwide

AirSweep has consistently delivered outstanding results across the mining and cement industries, solving some of the toughest material flow challenges.

For a leading cement manufacturer, conventional air cannons failed to eliminate stubborn clogs and clinker, forcing workers to break blockages manually using bars—a time-consuming and inefficient process. By switching to AirSweep VA-51 units, the company significantly improved efficiency, completely eliminating residue buildup. The success was so remarkable that they implemented the system across multiple plants.

In the mining sector, a company handling copper concentrate faced daily disruptions, with workers spending up to two hours clearing material blockages. Air cannons posed safety hazards by dispersing materials, while vibrators were both noisy and ineffective. Installing three AirSweep VA-12 units transformed their operations, providing a quiet and effective solution that allowed workers to redirect their efforts to other critical tasks.

For a concrete company dealing with fly ash, material bridging around vessel outlets brought production to a standstill. Four AirSweep units were installed while approximately eight tons of fly ash remained in the bin. The result? Production went from zero to full capacity overnight, ultimately boosting overall output by 60%.

These real-world applications highlight AirSweep’s ability to optimize material flow, reduce labor, and enhance productivity in even the most demanding environments.

Fits Every Vessel, From Silos to Trucks

AirSweep can be installed on all types of bulk material handling equipment, from silos and hoppers to truck trailers. The wear plates and hard-facing AirSweep units can be bolted on flat walls or surfaces to protect equipment. In truck applications, AirSweep proves equally effective, activating materials during transport to guarantee smooth and efficient unloading.

AirSweep can be installed on equipment used to transport cement and mined materials.

 

Built for Durability and Performance

AirSweep systems come with the longest warranty in the business—seven years—a testament to their reliability. Whether you need to clear stubborn clogs in silos or ensure smooth transport in trailers, AirSweep delivers unmatched performance.

Ready to revolutionize your operations? Contact the AirSweep team today to find out how we can optimize your material flow and prevent costly downtime.