Category Archive: Airsweep

How to Prevent Bridging in Material Hoppers (aka The Ketchup Effect)

Have you ever struggled to get ketchup or any thick sauce out of a bottle? That’s the same issue that production facilities face when they try to move solids or powders through material hoppers. The material gets stuck, and production stops.

Unlike liquids, bulk solids and powders will not flow readily without intervention. Even some thick liquids like ketchup are notoriously difficult to handle. The material clings to the vessel walls, or becomes more compact – also known as bridging.

What is bridging?

Bridging in material hoppers refers to the phenomenon where bulk materials, such as powders, granules, or pellets form an arch-like structure over the outlet. It stops material from flowing freely, which leads to several production problems:

• Need for manual intervention to loosen the material
• Lower productivity and machine downtime
• Inconsistent product formulas
• Stagnant material that can spoil or contaminate the next batch
• Material waste from throwing away spoiled material or out-of-spec batches

What causes bridging in material hoppers?

• Know your material’s flow properties. Choose non-cohesive materials whenever possible. If cohesive materials are necessary, consider additives or treatments to reduce their cohesive properties.
• Control moisture. Implement proper moisture control measures to ensure the material remains within the acceptable range for smooth flow. This might include using desiccants, heaters, or dehumidifiers.
• Select the right design of material hoppers. Select an appropriate hopper design based on the material’s characteristics. Conical material hoppers with an angle between 50 to 60 degrees, and the right outlet size, can help promote steady flow.
• Consider hopper liners. Using hopper liners made of low-friction materials like Teflon can help reduce material adhesion and bridging.
• Use the right flow aid. Many manufacturers use industrial flow aids to break up material blocks and encourage regular, reliable flow. Aside from speeding up production, it prevents stagnant or spoiled material and the safety risks from manual intervention and cleaning.

Solve bridging in material hoppers with AirSweep

Preventing bridging in material hoppers is essential to ensure the continuous and efficient flow in industrial processes.

Both global brands and SMEs use AirSweep to get smooth, on-demand flow. AirSweep is a pneumatic flow aid that releases powerful, high-pressure air pulses that break up bridging and sweep the vessel walls clean. It is energy-efficient, requires very little maintenance, and has proven effective for even the toughest flow problems.

AirSweep can be installed on material hoppers as well as other process equipment like silos, chutes, conveyor belts, or any place where material tends to hang up.

Since AirSweep uses aeration rather than vibration, it does not cause metal fatigue and damage small or thin material hoppers. AirSweep is also certified safe to use in hazardous and flammable environments, and there are models that are specifically designed for sanitary applications.

Contact us to find out more about AirSweep and how it can reduce bridging in your material hoppers.

5 Questions to Ask Before You Buy a Flow Aid

Poor material flow slows down production, compromises product quality and consistency, and can even create workplace safety hazards. That’s why many industries turn to flow aids to move material consistently and reliably.

Flow aids are bulk solid handling equipment that stimulate or improve the movement of material. They prevent bridging, ratholing, clogging, or material residue on vessel or pipe walls. Some flow aids like AirSweep can even be used to flush vessels clean between batch runs.

How do I choose the right flow aid for my process?

Before choosing a flow aid (or any bulk solids handling equipment for that matter) understand the characteristics of your bulk material – such as particle size, shape, density, moisture content, and flowability.

For example, fluidizers work for very light powders like flour but lack the volume and pressure to activate moist and heavy materials. Vibrators can also make some materials more compact.

A commercial bakery tried both types of flow aids to resolve the issue of flax bridging on the discharge and caking on vessel walls.

“The vibrators that came installed on the bottom of the hopper above the mixture practically turned the flax into concrete,” said the maintenance manager. “Then we installed fluidizers, which were terrible. We still had to use hammers and sticks, and spent an hour a day to clean and keep things flowing.”

Flax is a very moist, sticky material. Since vibration or agitation can make it settle, it needs a powerful pneumatic flow aid that releases enough pressure to move it through the vessel and even sweep the walls clean.

AirSweep was the only flow aid that fits the bill. It solved 90% of their material retention problems, reduced material waste, and saved time and manpower costs.

How much energy and plant air will it consume?

A flow aid may seem “cheaper” but actually cost more to run. For example, fluidizers run continuously, but AirSweep releases short pulses in sequence – which means it uses plant air and electricity more cost-efficiently.

Can it reduce worker intervention?

Your flow aid should be so effective that once you install it you can walk away and focus on other parts of the plant. If you still need to hammer vessels or do any other kind of manual cleaning, it’s time to look for a better alternative.

An asphalt plant in Mexico spent every Monday hammering silos, even if they had electric vibrators installed.

“Over the weekend, when the plant was unstaffed, the asphalt materials would settle completely. When workers returned on Monday, they had to climb seven meters down into the dark silo, and clear thick layers of compacted material,” said the sales manager.

But when they traded the vibrators for AirSweep, workers put away the hammers for good. “After four years, we finally have the right solution! We are very happy with the system.”

Is it easy to clean and maintain?

All bulk solids handling equipment must be periodically cleaned and checked for sanitation and safety purposes.

AirSweep is designed for fast and easy maintenance. It can be removed from the vessel with simple tools. And since the nozzle shuts tightly closed after each pulse, there is no material feedback that can contaminate the rest of the system.

Will AirSweep work with my material and process?

AirSweep can activate almost any bulk powder or solid—dry, wet, sticky, moist, and more. Tell us about your material and the kind of problems you encounter, and our engineers can recommend the best model and set-up for your needs.

Bridging, Ratholing, and Other Problems In Material Handling

All manufacturing processes need efficient material flow for smooth operations and cost-efficiency. Sluggish and inconsistent flow can cause production delays and compromise product quality and safety.

For example, in the food and pharmaceutical industry, stagnant material can cause cross-contamination between different materials or batches. This can lead to the presence of foreign substances, allergens, or contaminants in the final products, posing significant health risks to consumers.

Other industries that use precise or patented formulas – such as chemicals, cement, pharmaceuticals, electronics, and manufacturing – may also lose product integrity and performance if materials aren’t mixed in the correct proportions.

The two most common problems in material handling are “bridging” and “ratholing.” Let’s look at their definitions, causes, and what you can do to prevent these flow problems.

What is bridging?

Bridging, also known as arching, occurs when bulk materials form a stable, compacted bridge across a hopper or silo outlet. This restricts – and eventually stops – material flow.

Bridging is common in fine powders, fibrous substances, or materials with high moisture content. These have a tendency to bind together and become even more compact as more material is poured into the vessel.

Bridging can become even more challenging when materials stick to the hopper walls. This often happens with moist, sticky solids like cement mixes or food ingredients like whey protein.

What causes bridging?

Bridging and other problems in material handling are caused by two major factors: the material properties and the shape of the vessel.

Material properties include particle size and shape, tendency to attract moisture, and natural cohesion and adhesion. Cohesion is the tendency of particles to stick together, and adhesion is the tendency to stick to vessel walls and other surfaces.

The geometry of the hopper or silo outlet also impacts the potential for bridging. A funnel-shaped outlet with a steep angle and narrow opening can be more prone to blocks. External factors such as vibrations or uneven flow rates can also disturb the material flow.

What are some materials that are prone to bridging?

These materials are more likely to cause material handling problems.

• Fine powders like cement, fly ash, powdered sugar, cocoa powder, detergents and cleaning agents, or some additives and preservatives
• Fibrous materials like wood chips, tobacco, straw, and certain types of grain
• Hygroscopic materials like sugar, salt, fertilizers, and other powders that absorb moisture from the air
• Thin flakes or fluffy materials like certain cereals, animal feed, and plastic flakes
• Sticky or viscous materials like adhesives, resins, or certain chemicals
• High-fat or oily materials like nuts, seeds, and certain grains
• Resins and polymers with high cohesive properties
• Chemicals and salts with electrostatic properties

What is Ratholing?

Ratholing is also one of the most common problems in material handling. It occurs when material cakes on the vessel walls.

Ratholing causes two problems: it narrows the space for the material to flow out (also called funnel flow) and leaves stagnant material that can spoil or contaminate the formula.

Ratholing can also limit the bin’s total capacity.

What causes ratholing?

Like bridging, ratholing is caused by material properties like cohesion and particle size distribution, and vessel geometry. It tends to happen in cone-shaped hoppers with walls that aren’t steep enough to encourage flow. If the material is even a little cohesive, it sticks to the walls.

What materials are more prone to ratholing?

Ratholing is a flow issue that affects specific materials, often characterized by their cohesive and interlocking properties. Some common materials that are prone to ratholing include:

• Cohesive powders like flour, cement, coal, pharmaceuticals, or food ingredients like coffee
• Granular materials such as fertilizer granules or prilled chemicals
• Minerals, ores, and fine sands with high cohesive strengths and fine particle sizes
• Plastic pellets with strong cohesive properties
• Chemical powders with strong cohesive properties
• Flaky or elongated particles can form preferential flow paths
• Animal feeds with pellets or ground materials

Solve problems in material handling with AirSweep

Thousands of plants around the world use AirSweep flow aid systems to solve bridging, ratholing, and other material flow problems. The nozzle releases highly pressurized air pulses to promote on-demand, first in and first out flow.

AirSweep breaks up material blocks and sweeps the vessel walls clean. It is the only flow aid that can handle problematic powders and even sticky and moist solids without damaging the vessel or consuming a lot of energy.

AirSweep can even be used on thin or small vessels, or installed in hard-to-reach areas.

Tell us about your problems in material handling and get a customized proposal for your process.

Improve Mining Equipment Safety and Efficiency With DAZIC

The mining and materials processing industry uses various tools and equipment to extract, process, and handle mined materials. These machines can carry from a hundred to over a thousand tons of material in one load. It speeds up the process—but also has risks.

Any equipment malfunction or abnormal change in speed could cause a material spill. Workers could get injured, and the material pile-up would take days to clean up. That’s why it’s important for mining equipment to have alarms or sensors to detect a problem even before it breaks down.

In this article, we’ll look at the common mining tools and equipment, and what you can do to prevent malfunctions and material spills.

Types of mining equipment

• Excavators. These are used to extract minerals and ores from the earth. They are equipped with buckets or hydraulic attachments to remove overburden or dig into the ground.
• Bulldozers. These push large amounts of soil, rock, or other materials to prepare the site for mining operations.
• Conveyors. These transport bulk materials like minerals or ores within mining and processing facilities.
• Crushers. These break down large rocks or ores into smaller, more manageable sizes. It includes jaw crushers, cone crushers, and impact crushers.
• Grinding mills. These grind or pulverize mined materials to achieve the desired particle size or extract valuable minerals from ores.
• Agitators and mixers. These are used for blending and mixing substances in tanks or vessels.
• Vibrating screens. These are used to separate particles, or sort and classify materials according to size.
• Concentrators. These separate valuable minerals from the mined ore through processes like flotation, gravity separation, or magnetic separation.
• Pumps. These help with transporting slurries (mixtures of water and solid) during mineral extraction and processing, removing excess water from a site, transferring fuels or other chemicals from storage vessels to different parts of the mine, or transferring tailings and other waste material.
• Fans and blowers. These are used for ventilation, dust control, or material movement.

The role of speed switches in mining operations

DAZIC zero speed switches can be attached to mining equipment to improve efficiency and safety.

A speed switch monitors the speed of rotating machinery or equipment. When it detects that equipment is running outside of normal speed parameters, it sends an alarm so the operator can stop operations or adjust equipment settings.

This has numerous benefits and applications in the mining process:

• Prevent material spills and downtime
• Prevent equipment damage and repairs
• Protect worker safety
• Synchronize multiple machines used in complex processes
• Identify bottlenecks or issues caused by variations in speed to adjust and optimize the process
• Comply with safety regulations that may be mandated for certain types of mining equipment

Common mining equipment that uses zero speed switches

DAZIC zero speed switches can be attached to any equipment that has a rotating shaft. This includes:

• Conveyor systems. DAZIC can be installed on conveyor drives or tail pulleys to monitor the belt’s rotational speed. It helps detect belt slippage, jams, or unexpected stops.
• Crushers and Grinders. DAZIC quickly flags speed deviations that could indicate overloading or equipment failure.
• Agitators and Mixers. DAZIC can be installed on the shafts to monitor the rotational speed.
• Fans and Blowers. DAZIC can indicate issues such as motor failure, belt slippage, or obstructions in the airflow system.
• Pumps. DAZIC detects speed changes caused by impeller damage, cavitation, blockages, or motor failure.

Get the right speed switch for your equipment and process

DAZIC has a full range of zero speed switches for different process requirements such as shaft input speeds, mounting styles and housing material, and more. Tell us about your project and we can recommend the best DAZIC zero speed switch.

How to Improve Material Handling Efficiency in the Food Industry

The food industry follows strict industry and government regulations for quality control and product safety. If your business fails to comply, you could face stiff fines and penalties and suspension of license. In cases when authorities feel that there’s a risk to consumer health, you may be required to recall all your products at your own expense.

Many of these industry regulations – such as the Good Manufacturing Practices (GMP), Hazard Analysis and Critical Control Points (HACCP), and the Codex Alimentarius – set standards for material handling efficiency.

For example, they require proactive, preventative measures against material spoilage and contamination. The food industry uses many materials that quickly degrade or develop mold or microorganisms. In addition to prioritizing safety and following proper handling practices, it is crucial to prevent your material from becoming stagnant and adhere to the FIFO principle.

First-In, First-Out (FIFO) Flow

In a nutshell, FIFO ensures that the oldest material is used first. It maintains the freshness, integrity, and even nutritional value and consistency of the material and the final product.

FIFO starts in the warehouse. Clearly label products with their production or expiration dates and establish proper inventory rotation procedures. Regularly monitor stock levels and adjust replenishment orders accordingly to maintain optimal inventory turnover.

However, FIFO is also important during the production process: when material sits in silos and hoppers. Many bulk powders and solids have a tendency to segregate or stick to vessel walls. Others are prone to bridging and ratholing.

Bridging occurs when a solid bulk material forms an arch or bridge over an opening, obstructing the material flow, while ratholing happens when material funnels through a central flow channel.

In all these cases, stagnant material is left inside the vessel. This increases the risk of spoilage and contamination and compromises the quality and safety of the entire batch run.

Achieve material handling efficiency and safety with AirSweep

AirSweep is an innovative flow aid system that can help achieve a First-In, First-Out (FIFO) flow during material handling.

AirSweep releases bursts of compressed air to dislodge and activate material that may have become stagnant or formed bridges or ratholes in storage vessels.

By installing AirSweep units at key points within the storage vessel or hopper, the system effectively breaks up material bridges and ratholes. Material can flow freely and consistently.

AirSweep is effective for all materials, including damp and sticky powders and solids used in the food industry. Watch how it works on corn grits that have been soaked in water and left in the hopper for three days. The air pulses break up the hard, cakey mixture in minutes.

AirSweep promotes material handling efficiency and food safety by:

• Facilitating FIFO or the removal of older material first before accessing fresh or newer material
• Preventing material segregation and stagnant zones
• Resolving bridging and ratholing
• Ensuring that the material flows uniformly and maintains its proper distribution within the storage vessel or hopper

AirSweep in the food industry

AirSweep systems are widely used in the food industry to improve material handling and ensure efficient flow in various applications.

• Silos. AirSweep can dislodge grains, flours, powders, and granules that have settled and become compact during storage.
• Hoppers. AirSweep ensures consistent discharge, maintaining proper ingredient flow and preventing material stagnation.
• Conveyors and chutes. AirSweep prevents material build-up and blockages to facilitate the smooth transfer of food materials between processing stages.
• Mixing and blending equipment. AirSweep promotes uniform material flow and prevents ingredient segregation, ensuring thorough blending and consistent product quality.
• Packaging and filling equipment. AirSweep maintains a consistent flow of food products for fast and accurate packaging operations.

USDA-accepted AirSweep

The USDA-accepted model is specially designed for the food industry and other industries requiring sanitary equipment and frequent cleaning.

• Only the nozzle tip comes in direct contact with the material, preventing contamination
• The flanged connections allow quick removal and re-installation with simple hand tools
• The surfaces are also resistant to corrosive products and industrial-grade cleaning chemicals

Watch the video to see why AirSweep USDA-accepted model is the best choice for achieving material handling efficiency and safety in the food industry:

Trusted by food manufacturers worldwide

AirSweep is used by some of the world’s leading food manufacturers, local businesses, and SMEs. Read more about AirSweep in the food industry or contact us for a customized presentation and proposal.

The Role of Flow Aids in Bulk Material Processing

Bulk material processing is a critical aspect of many industries, including manufacturing, mining, agriculture, and construction.

However, many materials—powders, granules, and pellets—have challenging flow characteristics that can slow down processing operations. Flow aids can overcome these challenges to improve productivity and overall efficiency.

Common flow challenges in bulk material processing

A material’s physical properties can affect its flow patterns. These include particle size, shape, moisture content, and cohesive tendencies.

Particle size

Smaller particles tend to be more prone to cohesive forces and can easily clump together, leading to flow problems such as arching and bridging. That’s why fine powders like titanium dioxide and carbon black can be very challenging to work with, especially when they pass through feeders and hoppers.

Larger particles, on the other hand, have a tendency to interlock, impeding flow through hoppers or chutes. This is a common problem in the cement and mined materials industries.

Particle Shape

Irregularly shaped particles may interlock or form arches, hindering material flow. One mineral processing plant that worked with pebbles and crushed materials took over an hour to fill a supersack, with operators frequently stepping in to hammer the vessels.

Moisture Content

Moisture can increase particle cohesion and create adhesive forces between particles, leading to material agglomeration and blockages. On the other hand, excessively dry materials may become powdery and prone to dusting, which also causes flow issues.

This frequently occurs in the food industry. Many raw ingredients like butter or whey either have an inherently high fat and oil content. Others, like sugar or cocoa, have a tendency to attract and retain moisture.

The food industry also uses dry powders like preservatives, spices, and nutritional additives. These have to be added in very precise amounts, so even the slightest irregular flow can compromise an entire batch.

Cohesive Tendencies

Cohesive materials have a natural tendency to stick together due to intermolecular forces such as surface chemistry or electrostatic charges. This is common in the chemical, cement, and pharmaceutical industries which use binding agents, solvents, lubricants, and disintegrants.

These properties can cause common flow problems such as arching, bridging, ratholing, and segregation. These issues can lead to material blocks, uneven discharge, lower production, and increased downtime.

Flow Aids used in bulk material processing

Flow aids enhance material flow by breaking up cohesive masses, preventing material build-up, and promoting consistent discharge.

• Pneumatic flow aids. These use compressed air to break up cohesive friction and loosen material blocks. Examples include fluidizers, air cannons, and AirSweep.
• Vibrators. These use vibrations to loosen compacted materials, similar to shaking or hitting a ketchup bottle. Some plants still employ workers to hit vessels with a hammer; others use industrial vibrators or air knockers.
• Mechanical Agitators. These use gyratory forces rotating blades or paddles to break up material clumps and prevent bridging. Like vibrators, they use continuous agitation to dislodge stagnant material.
• Bin Activators. These combine vibratory or gyratory forces to dislodge compacted material.

Each flow aid has its pros and cons. Fluidizers, which use gentle aeration, are cheap and often pre-installed in vessels. However, gentle air pulses are usually only effective for light powders like flour.

Vibrators, mechanical agitators, and bin activators provide more power, but use a lot of electricity and can damage the vessel. Some powders or irregular particles can also become more compact when agitated.

AirSweep: best flow aid for bulk material processing

AirSweep is a unique flow aid that uses high-pressure air pulses that are more powerful and cost-efficient than vibrators, mechanical agitators, and bin activators. It can break up bridging, arching and ratholing, and promote first-in/first out flow.

AirSweep’s unique design and operation provide several advantages for bulk material processing:

• Versatility. AirSweep can be used in a wide range of industries and applications, including silos, hoppers, chutes, conveyors, and other material-handling equipment. It is proven effective for various materials, including powders, granules, pellets, and even sticky or cohesive substances.
• Reliability. AirSweep is made of high-quality materials and hand-assembled in the USA following strict quality control measures. It requires minimal maintenance and is designed to withstand the harsh conditions commonly encountered in industrial environments.
• Energy-efficiency. AirSweep’s controlled, sequenced pulses use less air and energy than other flow aids, which run continuously and have a limited activation radius. Thus, you need fewer units and resources to activate more material—and get more continuous material flow.

AirSweep improves overall plant efficiency

An AirSweep system can help you increase productivity and lower costs. Here are some key advantages that make it a worthwhile investment.

• Get on-demand flow. Preventing ratholing, bridging, and other material blocks that can affect material flow and operations. This leads to increased throughput, reduced downtime, and higher production rates.
• Lengthen machine lifespan. Unlike other flow aids, AirSweep prevents vessel and equipment wear and tear and extends the lifespan of machinery. This minimizes maintenance and repair expenses.
• Reduce waste. Material buildup and inconsistent discharge often lead to product waste. With AirSweep, all materials are properly discharged and utilized.
• Protect worker safety. AirSweep automates material flow. Workers don’t have to enter confined spaces, be exposed to potentially hazardous materials, or use manual methods that can lead to accidents or injuries.
• Comply with regulations. Consistent flow can help a process meet environmental regulations, health and safety standards, and quality control guidelines.

Optimize bulk material processing with AirSweep

AirSweep increases productivity, enhances equipment efficiency, and minimizes operational costs and material waste. Find out how AirSweep can help improve your process. Tell us about your material flow challenges, and get a free customized proposal.

How to Prevent the Most Common Causes of Machine Downtime

Unplanned machine downtime can disrupt operations, cause unnecessary costs and affect downstream processes. Find out about the most common causes of machine downtime, its effect on your revenue, and proactive strategies that can improve equipment efficiency and reliability.

Mechanical Failures

Mechanical failures can include issues such as component breakdowns, wear and tear, malfunctioning parts, or equipment reaching the end of its service life.

Solution: Regular maintenance can help identify potential mechanical failures and address them before they get worse. Maintenance activities can include visual inspections, testing, lubrication, calibration, and replacement of worn or damaged parts. Predictive maintenance techniques, such as vibration analysis or thermal imaging, can also detect early signs of impending failures.

Dust and other material residues can also lower equipment efficiency, clog components and eventually cause malfunction and failure. Periodic cleaning with AcoustiClean sonic horns can remove particle accumulation and prevent machine downtime.

Poor material flow

Unlike occasional equipment failures, poor material flow can happen every day. Stagnant material can lower the vessel capacity and block the vessel outlet. This can lead to reduced throughput and increased downtime. It can affect downstream processes or equipment and require operators to stop the process and assign workers to manually clear the material blocks.

The most common causes of poor material flow are bridging and ratholing.

• Bridging happens when material forms an arch or a bridge across the outlet of a storage bin, preventing the free flow of material. It occurs when the material’s cohesive or interlocking properties cause it to adhere and form a stable structure.
• Ratholing occurs when a hole or tunnel is formed within the stored material in a bin or hopper, leaving a void around the outlet area. This happens when a funnel-flow pattern develops: the central material column flows freely, but the material surrounding the perimeter remains stationary.

Solution: AirSweep promotes on-demand material flow to prevent material blocks. The powerful air pulses can move damp powders, sticky solids, and other challenging materials that are prone to bridging and ratholing.

Human Error

Operators or maintenance personnel can make mistakes that result in machine downtime. This can involve incorrect operation of the equipment, improper maintenance procedures, or mistakes during repairs or adjustments.

Solution: Proper training, clear operating procedures, and effective communication can minimize the occurrence of human errors.

Cleaning and other regular maintenance

Regular cleaning of machinery and equipment is essential to ensure optimal performance and meet industry sanitation requirements. However, it does contribute to overall machine downtime.

Solution: Clean-in-Place (CIP) technologies are automated systems and processes used in various industries to clean and sanitize equipment and piping systems without disassembling them. It removes product residues, microorganisms, and contaminants to prevent cross-contamination between batches and reduce the risk of microbial growth or product spoilage.

Aside from CIPs, AirSweep can also be used to flush the vessels clean between batches. An infant formula uses AirSweep to flush vessels between batch runs, cutting cleanup time from 40 hours to 10 hours.

Material spills and pile-up

When conveyor belts, bucket elevators, or other material transport equipment malfunction, there’s a big chance that material will spill over. If this occurs, companies face two problems: repairing the equipment, and cleaning up the mess.

Solution: For some companies, any material pile-up can lead to days of downtime. A concrete company estimates that its feeders load about 250 tons of gravel per hour, or 4 tons a minute. Even just a 10-minute malfunction could result in 30 hours of downtime. To prevent machine downtime and its catastrophic results, it installed DAZIC zero speed switches that could alert the operator of any abnormal changes in equipment speed.

Cost of unplanned machine downtime

Equipment downtime affects productivity and costs. Calculate how much your company is wasting whenever your equipment malfunctions or operates at lower efficiency.

Unplanned Downtime = (Time Asset is Down / Total Time) x 100
The cost of downtime can depend on factors like the size and complexity of the affected operations and the number of workers who are affected. You can use this formula to start your calculations, but you may need to add other variables depending on your particular process.

Cost of Unplanned Downtime = Average Hourly Wage x (Time Asset is Down/Total Time) X Number of Employees Affected

Protect your equipment and your revenue

Control Concepts, Inc. has helped thousands of plants improve their bulk material handling. Our products—AirSweep, DAZIC, and AcoustiClean—are used by companies of every size and industry. Work with us to improve productivity and reduce machine downtime.

Pneumatic Flow Aids: Benefits and Comparisons

Many production facilities have problems with poor material flow. Powders or other bulk materials cake on the hopper or bin walls and block the vessel outlet. But instead of reaching for the nearest hammer, many are now turning to more powerful, automated solutions—like pneumatic flow aids.

What are pneumatic flow aids?

Pneumatic flow aids are bulk solid handling equipment used specifically for improving the flow of material while it is transported or processed. They use compressed air to break up the cohesive friction that causes material blocks, and then propel the material down the vessel or pipes.

Pneumatic flow aids are often used in industries that handle dry, granular, or powdered materials, such as manufacturing, food processing, pharmaceuticals, and mining. Many of these materials are abrasive and fragile and can degrade if over-handled. The compressed air minimizes direct contact, unlike vibrators and other mechanical flow aids.

What are the different kinds of pneumatic flow aids?

• Fluidizers. Fluidizers are small discs attached inside the vessel wall. As the discs move, they push air down the vessel wall to loosen the material. While fluidizers are inexpensive and may even be pre-installed on some vessels, the gentle aeration can only activate light powders and can’t fix most bridging and ratholing problems.
• Air cannons. These large devices release single, powerful blasts of air to break up material blocks. The nozzles are carefully embedded in the vessel wall and hooked up to a system that automates the firing sequence. While it can activate sticky material, it uses a lot of electricity and can damage vessels. If not installed properly, the material can also accumulate inside the nozzle edges and cause sanitation and contamination issues.
• Pneumatic knockers. These are pistons that hit the vessel at variable intervals, much like an automated hammer. Unlike other pneumatic flow aids, a knocker doesn’t use air to activate the material—instead, the air powers the piston. Despite its name, its mechanisms are more similar to industrial vibrators or agitators.
• AirSweep. AirSweep is a unique pneumatic flow aid that resolves many of the issues found in fluidizers, vibrators, air cannons, and pneumatic knockers. The patented nozzle releases powerful bursts of air that can activate all materials, from light powders to very sticky and moist solids. It does not damage vessel walls and is installed outside the vessel for easy cleaning and maintenance.

How does AirSweep work?

The AirSweep system is uniquely designed to create on-demand, first-in/first-out material flow. Unlike pneumatic flow aids which run continuously, you can control exactly where and when the air pulses are released. It can also activate tougher materials, break up tough material blocks, and sweep the vessel walls completely clean. No material residue is left behind.

The role of pressure and volume

While all pneumatic flow aids will use compressed air, they achieve varying degrees of material activation—because of the simple principles of pressure and volume.

Think of it as a garden hose versus a fire hose. While they may both use water and have similar structures and mechanisms, a fire hose has more power and range. You can’t use a garden hose to put out a big fire, and you can’t use a weak pneumatic flow aid to solve tough material flow problems.

Get the right flow aid for your process

Choosing the right flow aid involves many factors like efficiency, cost, installation and maintenance, and more. We can help you weigh the pros and cons, and find the right solution for your needs. Contact us for a free consultation, and a custom proposal from our engineers.

5 Ways AirSweep Boosts Productivity and Streamlines Operations

Efficient material flow has a huge impact on productivity, costs, and even plant safety. Companies can lose thousands of dollars a day because they had to stop operations to clear out a clogged silo or hopper. They may even have to throw out contaminated material or pull workers from other tasks to hammer away at the material blocks.

AirSweep can solve dry bulk materials handling issues and ensure efficient, reliable material flow. It is used in thousands of plants around the world and can handle materials that other flow aids can’t. In fact, many companies shifted to AirSweep because they saw that it was more powerful and cost-efficient than their current system.

Here are five ways AirSweep enhances material flow and paves the way for higher productivity and streamlined operations.

AirSweep: Bulk Product Handling Equipment for Material Flow

Bridging and ratholing are two of the most common dry bulk materials handling issues. In both cases, the material forms a solid mass that blocks the vessel discharge outlet. Material flow becomes slow and uneven, and “old” material remains in the vessel. This can become a safety issue for food or pharmaceutical companies that use materials that can spoil.

AirSweep breaks up bridging and ratholing and pushes the stagnant material back into the flow stream. The powerful air pulses work on damp, sticky, or problematic powders that don’t respond to other flow aids, such as titanium dioxide or flax and cocoa.

Enhance silo and hopper efficiency

Many dry bulk materials handling issues occur in silos and hoppers, where bulk materials are stored before being transferred to the next stage of the production process.

Material blocks can reduce storage capacity and speed of discharge. In fact, surveys show that most silos and hoppers only operate at 80% capacity because of poor material flow.

AirSweep can be installed on silos and hoppers to dislodge blocked material. The nozzles are strategically placed at the right points and then set to release air pulses in a specific pattern. This prevents slow flow, overflow, bottlenecks, uneven feeding, and material segregation.

Reduce cleaning and maintenance time

Cleaning and maintenance tasks can take up valuable time in manufacturing and industrial processes. AirSweep can be used to flush vessels completely clean between batch runs. It costs less than using flushing material and is safer and faster than manual cleaning.

AirSweep is so reliable that one of the world’s biggest infant formula companies uses it to prepare equipment between the production of regular and lactose-free milk. They installed it on their blenders, vacuum receivers, sifters, and packaging line vessels, and significantly cut down their turnaround and cleaning time.

The AirSweep unit itself is also very low-maintenance and can be removed for cleaning with simple hand tools. This is very convenient for processes that follow strict sanitation standards.

Minimize manual intervention

Sometimes, companies have to send workers to resolve dry bulk materials handling issues. They climb into a vessel with hammers and pick-axes to dislodge material blocks—a solution that takes too much time and puts them at risk for injuries and unnecessarily exposes them to materials.

Worker safety organizations discourage plants from giving any tasks that the worker is not specifically trained to do, or leads to prolonged contact with powders or substances that can cause irritation, respiratory problems, or other long-term health problems.

AirSweep is a safer, faster, and more effective way to solve material blocks. Not only does this reduce the risk of worker injury, but it also allows them to focus on more productive tasks.

Increase productivity

The biggest and clearest benefit of the AirSweep system is that it increases productivity and output. When material flows, so does the rest of your process. Here’s just one example: a minerals processing plant was able to cut down the filling time of its supersacks from two hours to just a few minutes. Production increased so much that they had to hire more people—a “problem” that most plants would like to have.

Improve your plant efficiency with AirSweep

AirSweep offers a reliable and simple solution to dry bulk materials handling issues. Contact us to find out more about how you can use it to improve productivity, reduce maintenance time, and streamline your production processes.

What is Bulk Material Handling Efficiency?

In all industries, the efficient movement and storage of materials play a vital role in smooth operations and increased productivity. If the material flow stops, so does production—and every delay incurs costs and risks.

This is where bulk material handling comes into play. This field of engineering looks at the fundamental principles of managing tons of material, and the best strategies for achieving reliable material flow.

In this blog post, we will look at what is bulk material handling, its key components, and various methods used in different industries and applications.

What is Bulk Material Handling?

Bulk material handling is the process of moving, storing, and managing large quantities of dry or granular materials. These are in their loose or bulk state, rather than packaged goods. Examples include powders, grains, minerals, chemicals, and aggregates.
It encompasses various stages:

• Unloading: Materials are removed from trucks, railcars, or other transportation vessels
• Conveying: Materials are transported from one location to another through a network of belts, pipes, or other systems
• Storing: Materials are stored in bins, silos, or warehouses for easy access and inventory management
• Blending: Materials are mixed together in precise proportions to create desired product formulations
• Loading: The final product is transferred to trucks, railcars, or other means of transportation for distribution to customers or further processing.

What is Bulk Material Handling Efficiency?

The goal of bulk material handling is to effectively manage the movement and flow of bulk materials throughout the handling process.

Efficiency in bulk material handling encompasses various aspects, including:

• Smooth Material Flow: Materials flow smoothly and continuously from one stage to another without interruptions, blockages, or slowdowns. This is achieved by using the right equipment, designing the right material flow paths, and applying the right strategies to prevent material blocks.
• Minimized Downtime: Efficient material handling minimizes the time required for maintaining equipment, clearing blocks, or resolving material flow problems.
• Optimal Equipment Utilization: Equipment should operate at full capacity and potential. It’s important to use the right equipment for the specific application and maintain it properly to avoid bottlenecks and idle time.
• Cost Reduction: Efficient bulk material handling can help lower costs by preventing material waste and lowering energy consumption. And if material flows efficiently, this usually allows for better inventory management.
• Safety Enhancement: Any bulk material handling process must include safety protocols and proper training to lower the risk of accidents or incidents caused by poor material flow or equipment failure.
• Data Monitoring and Analysis: Bulk material handling efficiency identifies stages in the process that can be improved or optimized. It is useful to monitor and analyze data like flow rates and equipment performance, then use these insights to make informed decisions.

What are the best practices for bulk material handling?

Every company will have unique bulk material handling challenges, based on the materials and processes they use.

While there is no “cookie cutter” approach to perfect material flow, these practices can help prevent the most common problems.

• Do regular equipment inspections: Inspect silos, hoppers, conveyor belts, and other equipment to identify and correct any issues before they become bigger and more expensive to fix.
• Follow preventative maintenance: Cleaning, lubricating, and replacing worn-out components can keep equipment at optimum performance, and prevent blocks caused by mechanical failures or inefficiencies.
• Know the material’s characteristics: Carefully consider the characteristics of bulk materials and use the appropriate equipment and handling techniques. For example, use filters to remove impurities that can cause blockages, or optimize material flow rates to prevent overfilling storage bins.
• Use the right flow aid: Flow-aid systems such as AirSweep promote consistent material flow and prevent blockages.

Improve Bulk Material Handling Efficiency with AirSweep

AirSweep is a highly effective bulk material handling system that promotes smooth, on-demand material flow.

It uses strategically placed nozzles that release powerful air pulses that disperse and dislodge materials without requiring mechanical force.

Unlike traditional methods that need manual intervention or costly equipment modifications, AirSweep offers a simple yet robust solution.

• Efficient material flow: AirSweep ensures consistent and unrestricted material flow by breaking up bridging, ratholing, and other material blocks. This leads to improved productivity, reduced downtime, and increased overall efficiency.
• Higher savings: By preventing blockages and material buildup, AirSweep reduces the need for manual labor, equipment downtime, and maintenance costs. Unlike vibrators and air cannons, it does not cause metal fatigue—thus reducing maintenance and replacement expenses.
• Versatility: AirSweep systems can be installed on hoppers, silos, chutes, bins, conveyors—or any equipment where material can pile up. It has been used in practically every industry, including cement, food processing, mining, power generation, and more.
• Easier installation and maintenance: AirSweep can be installed with simple tools and can be retrofitted into existing equipment with ease. It also has low maintenance requirements, ensuring uninterrupted operations and saving time for maintenance personnel.
• Fewer safety risks: AirSweep helps prevent material buildup, which can lead to hazardous conditions such as collapsed bridging, fires, and explosions.

Improve your material handling efficiency today

Whether you are dealing with powders, grains, or other bulk materials, consider AirSweep as part of your material handling strategy. Contact us to learn more about what we can do for your process.