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.
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.
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