Posted by Dedet Panabi on | 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.
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.
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.
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.
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.
Posted by Dedet Panabi on | 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.
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.
Posted by Dedet Panabi on | Comments Off on AirSweep launches new and improved bulk material handling equipment
For decades, half of S&P 500 companies and thousands of SMEs across the globe have used AirSweep to prevent bridging, ratholing and other material build-up. Now AirSweep has gotten even better.
On May 7, 2024 Control Concepts, Inc. rolled out the AirSweep MAX (short for Material Activation Xcellence). It further improves the AirSweep technology to deliver more power and energy efficiency. Laboratory tests found that it delivers up to 52% better performance than its predecessor.
“Our original AirSweep was already in a product class of its own,” said Eric Esselstyn, Director of Sales at Control Concepts. “When fluidizers and industrial vibrators failed, AirSweep could lift and sweep even the stickiest materials into the flow stream without damaging the vessel.” With the new, patented improvements, the AirSweep MAX is poised to become the most powerful and cost-efficient flow aid. Companies can get faster, first in/first out flow with zero manual intervention and less maintenance costs.
Patented design provides more power per pulse
The new AirSweep MAX has 20 patented improvements and six proprietary parts.
This patented design creates more powerful air pulses and a more free-flowing air stream. It can move more material or speed up material flow with the same amount of energy.
Lab tests proved that AirSweep max had 52% more output and pressure 31% more air output than the original AirSweep. For factories or plants that move massive amounts of material each day, this can significantly improve productivity or shorten vessel cleaning times.
Other plants that seek to lower operating costs can also use this technology to lower the operating pressure. They will use less plant air and energy, but still be able to move the same amount of material.
Designed for durability
AirSweep MAX uses aerospace-grade design specs – the highest standard for quality and durability. Each unit is also made and hand-assembled in the United States, following strict quality control standards.
“You can’t copy quality and durability,” said Henry Tiffany, President of Control Concepts, Inc. “We already know how well the original AirSweep works, and now it’s even better performance for the same cost? The MAX will be the last flow aid our customers will ever need.”
Like the original AirSweep, the AirSweep MAX requires preventative maintenance every one million cycles. Control Concepts Inc. also provides a seven-year warranty, the longest in the business.
Easy installation and integration
AirSweep MAX is compatible with the original AirSweep system, so it’s very convenient to upgrade your unit. It is also incredibly easy to install. Workers don’t need special tools or training – anyone can do it. This also makes it ideal for quick field service and assembly.
MAXimize your material flow today
Learn more about AirSweep MAX and how it can help improve your process. Contact us for more information or a custom proposal for your process and material.
Posted by Control Concepts USA on | Comments Off on AirSweep Reduces Cleaning and Maintenance Time
Periodic cleaning and maintenance of vessels can cause significant costs and downtime. However, many companies have found a simple way to streamline this process and further achieve material handling automation. They use AirSweep to improve material flow and flush vessels completely clean.
How does AirSweep help clean the vessels?
AirSweep releases high-pressure, compressed air pulses that can be released in 360-degree or vertical columns. The nozzles can be strategically placed at specific points in the vessel and timed to release in a particular sequence.
Unlike other flow aids that rely on mechanical force or gravity, AirSweep’s air pulses create a powerful, controlled flow within the vessel. It dislodges even the most stubborn materials and ensures that every nook and cranny of the vessel is thoroughly cleaned – leaving no residue behind.
Why should you use AirSweep to streamline cleaning cycles?
While AirSweep is primarily used to prevent bridging, ratholing, and material blocks, many companies use the technology to flush vessels between batch runs.
They use the AirSweep USDA 135, engineered specifically for sanitary applications, and the AirSweep Straight Shooter. The combination of air pulses released at 360 degrees and air pulses released in a vertical column allow them to flush different kinds of vessels – blenders, receivers, sifters and even packaging line vessels.
AirSweep has reduced the time and labor needed to clean after the batch runs were completed. This allowed them to add batch runs and increase production output.
Lower cost and material waste
A leading spice and flavor blends manufacturer with facilities in 25 countries around the world used to manually clean their ribbon blenders by flushing them out with flour. This system was expensive and labor-intensive, and still left some spice residue that could compromise batch uniformity.
After installing AirSweep, they achieved a 62% reduction in flour flush and a 42% reduction in labor, all directly attributed to the AirSweep units. They saved $200,000 a year from flush material reduction alone.
Is AirSweep hard to clean and maintain?
The AirSweep unit itself is designed to shorten cleaning and maintenance times. With the AirSweep Tri-Clover Clamp the nozzle can be dismantled and then reattached within minutes with a few basic hand tools. The nozzle can also withstand corrosive cleaning materials.
Does AirSweep meet sanitary requirements?
Many industries that need frequent vessel cleaning or flushing need sanitary equipment. This includes food, biotechnology, pharmaceuticals, and nutraceuticals. The USDA-accepted AirSweep is designed to meet the strictest sanitary requirements.
AirSweep: the complete solution for lowering factory downtime
AirSweep is the only flow aid that can be used to reduce material blocks and flush vessels clean. This combination of features makes it one of the best ways to improve productivity and reduce downtime.
Contact us to find out more about AirSweep and how it can improve your material handling automation and overall plant efficiency.
Posted by Control Concepts USA on | Comments Off on 4 Companies That Switched to AirSweep and Improved Bulk Material Processing
The right flow aid can make bulk material processing more efficient. It can resolve common problems like bridging and ratholing, and prevent thousands of hours of downtime a year.
However, many flow aids fail to meet expectations. They only partially clear material, or even cause the powders or solids to become more compact. Companies still have to send workers to clean up the mess.
Only AirSweep solves material flow problems completely and efficiently. In fact, many companies shifted to AirSweep after trying out fluidizers, vibrators, and other competing technologies. Take a look at five case studies where companies made the switch and saw remarkable improvements.
Global tire manufacturer: AirSweep more reliable than fluidizers
One of the world’s leading tire manufacturers had frequent delays of carbon black bridging in the hopper. The material residue also led to off-spec batches that had to be discarded.
They tried fluidizers, but these were ineffective and used too much plant air and energy. They wanted a flow aid that created on-demand flow and was less expensive to operate.
The AirSweep difference
AirSweep was the best flow aid for their bulk material processing needs. They installed two AirSweep VA-12 units, which were set up to release pulses in a specific time and sequence. It used less compressed gas than fluidizers that ran continuously and flushed all material from the vessel.
This led to higher production, and lower energy consumption and product waste. The tire manufacturer was so satisfied with the results, that it installed more units in other parts of the plant and in other facilities in the US and Canada.
“The fluidizers were really ineffective. AirSweep has provided us with reliable flow and reliable batch uniformity.”
Food company frustrated by industrial vibrators – gives AirSweep 10/10
A commercial bakery was wasting time and money because of flax oil and cocoa powder bridging in the discharge. They had frequent downtimes and threw away up to 40 pounds of mixture a day.
Other flow aids just made the problem worse. “The vibrators that came installed on the bottom of the hopper above the mixture practically turned the flax into concrete. Then we installed fluidizers, which were terrible.”
The AirSweep difference
The company contacted AirSweep after seeing material flow test videos that demonstrated its effectiveness on wet, sticky materials. They installed the AirSweep VA-06, which was ideal for their small vessel size.
They saw results immediately. AirSweep resolved 90% of the material bridging problems. Their workers didn’t have to manually clear the blocks, and they no longer had to worry about the wasted mixture.
The company was also pleased by the responsive customer service and painless installation. “My experience totally exceeded my expectations—a 10 out of 10!”
Cement company finds AirSweep more powerful than air cannons
Heidelberg Cement, one of the world’s largest manufacturers of building materials, had issues with clinker clinging to vessels and chutes. Clinker is sticky and abrasive, and can’t be activated by fluidizers or vibrators. They thought air cannons–which blast massive volumes of air at material blocks–could solve the problem. But despite using a lot of plant air and energy, air cannons still left a lot of material on the vessel walls. “We were using a bar to [break] the material in the tube.”
The AirSweep difference
Heidelberg replaced the air cannons with two AirSweep VA-51 units – the largest and most powerful model. Each unit can activate the toughest and stickiest materials within a four-foot radius and can even operate in hot or hazardous environments.
“The AirSweeps worked perfectly,” they said. Aside from restoring reliable material flow, AirSweep also used less plant air and did not wear out the equipment. This meant lower operating and maintenance costs than air cannons – not to mention less noise!
Food company stressed out by hammers – AirSweep saves the day
Bunge, an agribusiness and food ingredient company, had issues of rice bran clumping in their hoppers and silos. Workers had to hammer the vessels, but the “solution” was causing delays and factory stress. “The noise was like fingernails on the chalkboard. You wanted to get away from it,” said the maintenance manager.
The AirSweep difference
After reviewing different flow aids, they chose the AirSweep system. Unlike hammers, the nozzle emits a quiet hissing sound that is further muffled by the sound of the material in the vessel.
AirSweep solved other usual pain points, too. Installation was simple and inexpensive: “Any electrician can wire it up.” Maintenance was convenient: “When we needed extra parts, customer service was extremely helpful and fast. If we had to get those parts from China, it may have taken months to get them.”
AirSweep has made bulk material processing faster and simpler. Bunge installed additional systems in the masa flour factory, “In fact, we are looking into expanding to use in other parts of our plant.”
Unhappy with your flow aid? Consider AirSweep.
AirSweep is proven to be more effective than fluidizers, vibrators, air cannons, and other flow aid systems. Find out how you can get better productivity and more cost savings in your bulk material processing.
Posted by Control Concepts USA on | Comments Off on 5 Videos That Prove That AirSweep Works On the Toughest Materials
Do you work with a bulk material that tends to clump, settle, or stick to your vessel walls? Does the poor flow cause hours of downtime or affect the quality of your product? Have you tried other flow aids but still ended up manually clearing out the material blocks?
Learn how to improve material handling quickly and efficiently. AirSweep is a pneumatic flow aid that works on the toughest materials and uses less energy and plant air than other flow aids. It is used in all industries and is installed in thousands of plants around the world.
How does AirSweep work?
AirSweep releases high-pressure bursts of air that dislodges material and sweeps it back into the flow stream.
The AirSweep units are strategically positioned around the vessel and then programmed to release bursts of air in a controlled sequence. This sequence is precisely calibrated to match the characteristics of your material. You get better flow while using less air than flow aids that run continuously.
Unlike vibrators and other mechanical flow aids, AirSweep’s air pulses do not damage vessel walls. You don’t even have to deal with any hammering noises – AirSweep releases a quiet hiss that is further muffled by the material in the vessel. You won’t hear a thing!
But the biggest benefit of AirSweep is that you are guaranteed to get reliable, first-in / first-out flow. Watch these AirSweep videos to see it in action.
AirSweep vs. Liquid Cheese
If you’ve ever tried to grate mozzarella, you know how cheese can get sticky and difficult to handle.
Imagine trying to handle an entire hopper full of melted, gooey cheese.
Other flow aids clearly won’t work. Fluidizers can’t activate such a heavy solid, air cannons will leave cheese residue on the vessel walls, and vibrators will only make the cheese more compact.
Who moved the cheese? AirSweep. You can also read another success story of AirSweep in the cheese industry, and how it improved the material handling of whey protein concentrate.
AirSweep vs. Chopped Tobacco
Chips, fibers, flakes, and shavings are irregularly shaped and have a tendency to clump together. That’s why shredded paper makes great packing material – the individual strands form a nest that protects precious cargo. But it can be a headache if you’re trying to process these materials in your plant.
Once again, AirSweep proves that it’s the best way to improve material handling. It isn’t just used in the tobacco industry. Its particular effectiveness for fibers and flakes makes it a popular choice for the paper and construction industries, or any plant that uses recycled materials.
AirSweep vs. Damp, Compacted Fish Powder
Many processes involve mixing powders and liquids, resulting in a very dense solution that can become compact during handling or prolonged storage. Most flow aids won’t be able to move this sticky paste very efficiently – which is why most plants will need to shut down operations to get workers to clear out the vessels.
Skip the downtime, the hammering noises, and the hassle of having to clean your vessels by hand. AirSweep works even on damp, dense solids. Just turn it on, and walk away to focus on other parts of the plant.
AirSweep vs. Calcium Carbonate
Calcium carbonate is a sluggish powder that is prone to packing and sticking to vessel surfaces. It can clog hoppers, build up inside convey lines and filter bags, and cake in filter bags and cartridges.
There are many powders that exhibit similar properties, like carbon black, acetaminophen, and titanium dioxide just to name a few. But AirSweep helped companies move those materials, just like it moves the calcium carbonate in this video.
AirSweep vs. Cement Mix
While the standard AirSweep releases air pulses in 360-degrees (ideal for silos, hoppers, and other similarly-shaped vessels), the AirSweep straight shooter releases air in a vertical column (ideal for chutes, ducts or specific hard-to-reach areas like pipe elbows).
That’s why many cement and mining/mined materials companies use AirSweep to move materials across different stages of the process.
How to improve material handling of tough materials
At AirSweep, we like to say that ‘the proof is in the flow.” We are trusted by the world’s biggest companies because of our proven effectiveness for all types of materials. We also offer a money-back guarantee and the longest warranty in the industry – which shows our confidence in our technology, and our commitment to your satisfaction.
Contact us to find out more about AirSweep or get a customized proposal for your process.
Posted by Control Concepts USA on | Comments Off on Processing Mined Materials: Challenges and Solutions
Mined materials are used in almost all industries, from construction to consumer goods. However, these materials can be challenging to move and process because of their physical and chemical properties.
Let’s take a closer look at the common problems that can occur while processing mined materials, and how we can help.
Types of Mined Materials
Mined materials range from metallic ores like iron and copper to non-metallic minerals such as potash and gypsum. The World Mining Data names five different categories:
Iron and Ferro-Alloy Metals: Iron, Chromium, Cobalt, Manganese, Molybdenum, Nickel, Niobium, Tantalum, Titanium, Tungsten, Vanadium
Mineral Fuels: Steam Coal (including Anthracite and Sub-Bituminous Coal), Coking Coal, Lignite, Natural Gas, Petroleum (incl. Natural Gas Liquids), Oil Sands, Oil Shales, Uranium
Each of these has unique flow characteristics that present distinct challenges. For instance, metallic ores often possess high density, while non-metallic minerals may be prone to moisture retention.
Challenges in Material Flow
Material flow problems can lead to machine downtime and increased maintenance costs, which decreases profitability. The most common flow issues encountered while handling mined materials are:
Bridging. The material forms an arch above the outlet of a hopper or silo. This slows or even completely stops the flow, causing production delays.
Ratholing. The material accumulates along the vessel walls, forming a channel that restricts the flow. “Old” trapped material also remains in the vessel, instead of first in/first out flow.
Segregation. The materials segregate based on size or density during flow, resulting in inconsistent quality and potential waste of valuable resources.
Dangers of overflow
While material blocks slow or stop the flow, there’s also a danger of overflow–when equipment breaks down, causing tons of material to suddenly spill to the ground.
The material spill can injure workers, release potentially flammable powders into the air, and take days to clean up.
A processing facility may have to completely shut down operations until a material spill is cleared. Workers will also have to manually clear the material, which can pose health and safety risks.
That’s why mining industry regulations require mines and mined materials facilities to have safety devices and protocols in case any equipment malfunctions.
Ensure safe and efficient flow of mined materials
Control Concepts, Inc. provides a complete solution for material flow problems. Our two superstar products, AirSweep and DAZIC, can work together for smooth and safe operations.
AirSweep is a material flow aid that guarantees on-demand, first-in/first out flow. It is used in the mining industry to resolve bridging, ratholing, and segregation–and save a lot of time and money in the process!
AirSweep’s patented nozzle delivers quick bursts of compressed air or gas along the container walls, breaking down bridges and ratholes without damaging the container or the material. It can activate even heavy, wet, or sticky mined materials. (Read more about AirSweep in the mined material industry.)
DAZIC zero speed switches prevent material spills. It monitors the operational speed of rotating, reciprocating, or conveying equipment. It then triggers an alarm or shuts down a system if the equipment is operating at an unsafe or inefficient speed.
DAZIC can be installed on any equipment that has a rotating part, including conveyor belts, bucket elevators, motors, and more. It is inexpensive, durable, and reliable–and used by both global manufacturing firms and small, local businesses.
AirSweep and DAZIC have helped mined materials facilities prevent the toughest material flow problems.
A mineral processing plant took an hour to fill one supersack with mined materials. AirSweep reduced filling time to just two minutes, for a 1200% increase in productivity.
One of the fastest growing mining companies in Africa were concerned about the safety issues and high energy consumption of air cannons – especially since workers still spent up to two hours a day clearing leftover material blocks. AirSweep completely solved the problem, prompting them to say, “You should be on billboards everywhere!”
A global tire manufacturer that uses carbon black installed DAZIC zero speed switches to meet safety standards. A carbon black spill could cause flash fires and breathing problems, and complicated cleaning processes since the material doesn’t dissolve in water and solvents.
A ready-mix concrete plant loads up to 250 tons of gravel an hour into its feeders. “It would be a nightmare if the DAZIC didn’t shut the conveyor belt down. I don’t even want to think about it,” said the plant supervisor. They installed DAZIC zero speed switches nearly 20 years ago–and they are still working! “They have never quit.”
Take charge of the material flow of mined materials
With AirSweep and DAZIC, you’re not just investing in a product – you’re investing in smoother operations, consistent product quality, and ultimately, a more robust bottom line. Contact us to find out more about how to improve material flow in your facility.
Posted by Control Concepts USA on | Comments Off on The Hidden Costs of Poor Material Handling–and How AirSweep Can Help
The Hidden Costs of Poor Material Handling–and How AirSweep Can Help
Bridging, ratholing and other material blocks can have a huge impact on your bottom line. When material doesn’t flow, production stalls and you spend time and money fixing the problem. You also compromise your product safety and quality–and even your business reputation.
That’s why poor material handling should be taken seriously. While it’s true that many materials have challenging flow properties, and it’s “natural” for these to settle during storage or cling to vessel walls, you need to get a reliable flow aid.
Don’t think of flow aids as an expense, but as insurance and investment that prevents bigger, more expensive problems. Here are the hidden costs of poor material handling.
Cost of downtime
Profitability depends on productivity. However, bridging and ratholing in any vessel causes bottlenecks and affects all downstream processes. You may even have to pull workers from other parts of the plant to help clear material blocks–or, equally expensive, pay them to sit around and wait for material to flow properly.
A cement company in Asia, which had to deal with shale clogging the silos, estimated that it lost $12,000 for every hour of downtime. For other companies in countries with higher costs of labor, this figure can be even higher.
Cost of spoiled material
When materials get trapped due to poor material handling, the time and conditions can lead to spoilage, particularly in the case of perishable goods. Compromised batches also need to be thrown away.
When this occurs, you don’t just lose the value of the wasted material itself but also the opportunity cost. Resources and time spent on producing, transporting, and storing these materials go down the drain.
A commercial bakery that had issues of flax bridging in the discharge had to throw away up to 40 bags of wasted material a day and even had to pay to have it hauled away. For a local business, this had a significant impact on their profit margins.
Risk of spoiled products and product recalls
Poor material handling is even more dangerous for the food and pharmaceutical industry, which follows strict regulations on product safety. If a product is spoiled, contaminated, or contains any ingredients that are not declared on the label, then there’s a big risk of product recall.
The worst-case scenario is a product recall. According to Food Safety Magazine, direct costs can reach $10 million, not including litigation costs and lost sales and stock value.
The financial aftershocks could last much longer. One U.S. grocery supplier survey showed that after a large peanut butter recall, 3 out of 4 consumers stopped buying the product for over a year–and it took massive marketing and PR efforts to rebuild public trust.
Risk of safety hazards
Caked whey protein caused a fire in a cheese company’s baghouse. This illustrates how poor material handling can become a safety concern–especially when working with materials that are potentially flammable.
There are other safety risks, too. If workers have to manually clear material blocks, they can inhale powders and dusts, or become injured while climbing into vessels and wielding heavy tools.
If they become injured, companies have to shoulder medical fees and potential fines for asking workers to take on responsibilities that they are not specifically hired or trained to do.
AirSweep: trusted solution for poor material handling
AirSweep is a tested and proven system that virtually eliminates issues like bridging and ratholing. The nozzles deliver quick, powerful bursts of air across the material’s surface, breaking up clumps and ensuring a smooth flow.
Here’s why it’s a game-changer:
Higher productivity. Reduce flushing/cleaning time between product runs
Better product quality. Improve batch uniformity
Lower maintenance costs. Prevent vibration, stress, or wear to container walls
Lower energy costs. Uses less plant air and electricity than fluidizers, vibrators, air cannon, and other flow aids
No material feedback. The patented nozzle design immediately reseals after every pulse, eliminating feedback. This means less damage to the system and pipes, less cleaning, and no risk of cross-contamination
No noise. AirSweep runs with a soft, hissing sound
No safety risks. Workers no longer have to climb into vessels or lift heavy hammers to clear material blocks.
AirSweep is the most powerful, cost-efficient, and safe solution for poor material handling. Read more about how it is used in every industry, and helped thousands of companies increase productivity and lower costs.
You can also contact AirSweep for a personal consultation and custom proposal.
Posted by Control Concepts USA on | Comments Off on The Complete Guide to Flow Aids
All industries need reliable material flow to maintain productivity and product integrity. Any material blocks–like settling of powders in storage, or material bridging in a hopper–cause delays and extra costs.
Unfortunately, most bulk materials will not flow properly without some kind of intervention. This complete guide to flow aids will tackle:
What is a flow aid, and how does it improve plant operations
The different kinds of flow aids, and their pros and cons
What to consider when choosing a flow aid for your material and process
What are flow aids?
Flow aids are mechanisms or devices that encourage the efficient movement of materials inside a container or vessel. They prevent flow issues, such as:
Sluggish flow. Some bulk solids like mined materials or liquid cheese will flow slowly because of their density or the tendency to interlock or cling to vessel walls. Flow aids activate the material and flush it out of the vessel.
Material bridging in the hopper. Bridging, arching, or ratholing is a phenomenon where material forms an arch over the hopper outlet, thus obstructing the flow. Flow aids break up the bridges and prevent them from forming.
Segregation. Mixes made of materials with different shapes, densities, or other physical or chemical properties can segregate during storage or even during processing. Flow aids can activate the material so that the flow (and the proportion of ingredients) remains constant.
What are the different kinds of flow aids?
There are three types of flow aids: mechanical, fluidizing systems, and chemical. Each has its pros and cons.
Mechanical flow aids use agitation or physical force to break up material blocks. Examples include vibrators, air knockers, paddle mixers, and agitators. Mechanical flow aids are relatively inexpensive and easy to source, they’re not appropriate for some vessels or materials.
Mechanical agitation causes metal fatigue, which can damage vessels–especially small vessels with thin walls. It can also make some materials more compact or cause heavier particles to settle. This can worsen material bridging in hopper or material segregation.
Fluidizing systems use air pulses to push material and break up cohesive friction. Examples include fluidizers, air pads, air cannons, and AirSweep.
While all of these use the principle of aeration, they are very different in terms of capability and operating cost.
Fluidizers and air pads use a combination of aeration and gentle vibration. These work on light powders like flour, but will not be effective for sticky, heavy, or moist materials.
Air cannons release more powerful blasts of air, but require more electricity and air to operate. They’re also big, bulky, and produce a lot of “kickback” so they may not be used on some types of process equipment.
Among all the fluidizing systems, AirSweep is the best combination of performance, cost, and flexibility. It releases powerful, controlled air pulses that activate all types of material without damaging vessel walls. The compact nozzle can be installed on any vessel, including silos, hoppers, chutes, pipes, ribbon blenders, or any place where material tends to hang up.
Chemical flow aids change the material properties to material bridging in hoppers. For example, silicone-based agents like magnesium stearate can promote free flow, while anti-caking agents like calcium silicate can prevent lumps and caking.
While chemical flow aids can improve a material’s flow, they can’t break up material bridging in the hopper. Other flow aids must still be installed on the vessel itself to fix material blocks.
Questions to ask when choosing a flow aid
Like any other equipment investment, you need to consider different factors to find the best solution for your needs. Here is a checklist of key questions to ask while reviewing your options.
Material properties
What materials have poor flow properties?
What are the material’s other properties (density, cohesion, particle size, etc)
How do they respond to moisture? Do they become wet or sticky?
Do they tend to clump or settle during storage?
How do they respond to vibration or aeration?
Do any of the materials need sanitary handling to prevent spoilage or contamination?
Vessel characteristics
What type of vessel do you have?
What is the size of the vessel?
Where is the vessel located?
Where does the bridging or material flow problem usually occur?
Do you have blind spots that are hard to reach?
Flow aid features
What kind of materials can it activate?
What is the activation radius?
How much energy and air does it consume?
Does it damage the vessel?
Is it difficult to install? How long will installation take?
Is it safe to use in hazardous environments?
How often do I need to replace parts?
How long will it take to receive replacement parts?
Does it offer a warranty?
Worker experience
Can it automate material flow, or will workers still need to monitor and manually clear material blocks and residue?
How easy is it to clean and maintain the flow aid?
Does it produce a lot of noise?
How to find the flow aid with the highest ROI
The right flow aid can solve material bridging in hoppers and other vessels and improve productivity and cost-efficiency. However, the wrong flow aid can actually increase delays and costs.
Learn more about how AirSweep can solve material flow problems and give the highest return on investment. You can watch this video or contact our sales team for a personalized consultation.
Posted by Control Concepts USA on | Comments Off on Safety and Production Issues? Signs You Need a Conveyor Belt Speed Sensor
Barnes Concrete Co., a manufacturer of ready-mix concrete, handles tons of bulk material a day. They have 12 mixers, with feeders loading up to 250 tons of gravel an hour.
Any equipment malfunction would lead to an avalanche of bulk material which could injure workers and delay production for days. Plant supervisor Joe Kruzewski estimates it would take three people at least three hours to clear one ton. “It would be a train wreck [to be] buried with that amount of gravel.”
Fortunately, the concrete company never had an accident. Twenty years ago, they installed a conveyor belt speed sensor: DAZIC zero speed switch. It would signal whenever there was any abnormal change in the conveyor’s speed, so the team could quickly shut down the process before a pile-up occurred.
How does a conveyor belt speed sensor work?
A conveyor belt speed sensor measures the speed of a conveyor belt by detecting the rotation of one of the belt’s rollers or pulleys.
It is mounted on the shaft of the roller or pulley and generates an electrical signal as the shaft rotates. Then, it converts the signals into a speed measurement, typically expressed in revolutions per minute (RPM) or meters per second.
The DAZIC zero speed switch takes it a step further. Aside from measuring the speed, it sets off an alarm when RPM falls out of normal parameters.
For companies like Barnes Concrete Co., the DAZIC is a simple device that saves them a ton of problems. “It would be a nightmare if the DAZIC didn’t shut the conveyor belt down. I don’t even want to think about it,” Kruzewski said.
What are the benefits of a conveyor belt speed sensor?
Any manufacturing company can benefit from a DAZIC zero speed switch. It can:
Prevent accidents like material spills and pile-ups
Prevent bottlenecks by ensuring consistent equipment speed for synchronized processes
Allow preventive maintenance by identifying potential equipment issues before they become serious problems
Signs you need a conveyor belt speed sensor
If you’re experiencing these issues in your plant operations, consider installing a DAZIC zero speed switch on your conveyors or any other equipment with a rotating shaft (bucket elevators, drive motors, saw blades, etc.)
Frequent machine breakdowns. Changes in speed are often the first sign of other mechanical problems. A DAZIC zero-speed switch can detect these slowdowns in real-time so you can take corrective action, protecting your equipment from further damage.
Safety concerns. Material pile-ups and spills are not the only safety issue when equipment runs at an inappropriate speed. It can lead to overheating, vibration, or other malfunctions which can cause accidents or even fires.
Inefficient production line. When a machine slows down or stops unexpectedly, it can cause disruptions in the production line, affecting the overall workflow. A zero-speed switch enables you to fix the issue quickly to prevent bottlenecks and downtime.
Learn more about DAZIC
A DAZIC zero-speed switch can protect your equipment, improve productivity, and ensure a safer work environment. Contact us to find out more about DAZIC and how it can work in your process.
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