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.
Posted by Control Concepts USA on | Comments Off on 3 Ways AirSweep is Used in the Food Industry
Material handling efficiency is important for every industry, but it is especially important for companies that work with food and beverage, pharmaceuticals, nutraceuticals, and pet food.
These industries work with materials that can spoil and put millions of users at risk for poisoning and other health risks. They also need to make sure that materials are mixed in the right proportions, to preserve the flavor, consistency, and efficacy of their products.
That’s why some of the world’s biggest food manufacturers, as well as local businesses like bakeries and breweries, rely on AirSweep.
What is AirSweep?
AirSweep is a pneumatic flow aid that helps activate material through different stages of the production process. It releases timed, high-pressure air pulses that can break up clumps that form during storage, sweep material through hoppers and chutes during mixing, and flush vessels clean between batch runs.
Unlike other flow aids like vibrators or air cannons, AirSweep does not damage vessel walls or irritate workers with loud, relentless noise. It quietly activates even wet, sticky, or other problematic materials and gets the job done–without any need for manual intervention.
Since the AirSweep nozzles are programmed to release timed, controlled pulses in a strategic sequence–rather than running continuously–it is also more energy- and cost-efficient.
That’s why many manufacturers switched to AirSweep to achieve material handling efficiency. It provides reliable performance and solves common material flow problems with less cost.
Move difficult material with poor flow properties
The food industry often deals with materials that have poor flow properties, such as powdered ingredients, sticky substances, and granulated products. AirSweep’s powerful bursts of air can break up these materials and dislodge them from the sides of processing equipment, ensuring a smooth and consistent flow. This helps to reduce material waste, increase production throughput, and minimize the risk of costly stoppages.
Watch how AirSweep can work with liquid cheese – a particularly challenging material that is too heavy for fluidizers and will settle when vibrated with pneumatic hammers or industrial vibrators.
Flush vessels clean to shorten downtime and cleaning costs
Regular cleaning and maintenance of food processing equipment are crucial to prevent cross-contamination and ensure product quality. However, the cleaning process can be time-consuming and expensive.
An infant formula company was looking for a quick and reliable way to flush vessels clean between batch runs of regular and lactose-free products. However, they had to balance cost-efficiency with safety: even the slightest material residue could pose a significant health risk and lead to expensive product recalls.
AirSweep was the perfect solution. “We went from 40 hours to 10 hours in cleanup time,” said the Company’s Associate Director for Process Technology Application and Productivity. After the initial pilot test in one facility in 2016, they have since added AirSweep units to the other process lines in that plant, and in four other plants worldwide, and are currently adding the system to other plants.
Reduce material waste
Material handling efficiency also reduces waste because of spoiled material or out-of-spec batches. A commercial bakery that had issues with bridging and ratholing had to throw away up to 40 pounds of mixture a day and even had to pay to have it hauled away. As a local business with tight margins, this had a significant impact on their bottom line.
AirSweep was an affordable and cost-effective way to increase productivity and lower waste. They also appreciated the exceptional service and quick response times.
“Customer service has been very helpful. I would call with some ideas and they would work with me on it, and they were right! Installation was awesome and easy, and the units have saved the company a lot of man hours. My experience totally exceeded my expectations—a 10 out of 10!” said the maintenance department head.
Improve material handling efficiency with AirSweep
AirSweep offers numerous benefits to the food industry, from improving material flow to reducing cleaning time and ensuring product safety.
It can help companies face challenges such as increasing demand and stricter regulations, while streamlining their operations and costs without compromising safety.
Contact us to find out more about how AirSweep can help with your plant operations.
Posted by Control Concepts USA on | Comments Off on How to Improve Material Handling Safety: 7 Best Practices for a Safer Work Environment
Material handling can present various safety challenges, including worker injury, exposure to toxic chemicals, flammable environments, and material spills. It’s important to implement safety protocols to prevent health hazards and meet industry regulations.
Read how to improve material handling safety in all plant operations.
Regular Training and Refresher Courses
Training is the bedrock of any safety protocol. All personnel involved in material handling should undergo a comprehensive training program and periodic refresher courses. This ensures that safety protocols remain top-of-mind and are updated with the industry’s best practices.
Limit Manual Handling
Even with the best techniques, the continuous manual handling of materials can lead to musculoskeletal disorders. Wherever possible, automate processes or use machinery.
For instance, a pneumatic flow aid like AirSweep can help move material through silos, hoppers, and other vessels. It prevents bridging and ratholing and eliminates the need for workers to manually clear material blocks with hammers or pick-axes.
Use of Personal Protective Equipment (PPE)
Wearing the right PPE can make a difference between a regular day at work and an unfortunate incident. Depending on the material and the nature of the job, PPE can range from safety gloves, hard hats, safety glasses, to steel-toed boots. Ensuring that the PPE is not just available, but also used correctly, is one of the best ways to improve material handling.
Safety protocols for heavy equipment
Forklifts, conveyors, and other heavy machinery play a significant role in material handling. However, they can also be sources of severe injuries if used incorrectly. Implement measures like designated walkways, clear signage, speed limits, and ensuring that only trained personnel operate such machinery.
Advanced safety features
Incorporate safety tools that monitor equipment and provide real-time feedback.
For instance, DAZIC zero speed switches can detect abnormal changes in speed of rotary equipment like conveyor belts or bucket elevators. If something goes wrong, these switches can trigger alarms or shut down the system, preventing material pile-up and worker injury.
Regular equipment maintenance
Well-maintained equipment is less likely to malfunction, thereby reducing the risk of accidents. Regular checks and preventive maintenance can catch potential problems before they escalate.
Emergency Preparedness
Despite the best precautions, emergencies can still occur. Prepare a well-documented and practiced emergency plan. Regularly conduct drills, ensure that emergency exits are clearly marked and unobstructed, and have first aid kits readily accessible.
Learn how to improve material handling with Control Concepts
Safety in material handling is a multi-faceted approach, from training and PPE to incorporating advanced systems like AirSweep flow aids and DAZIC zero speed switches.
We can help you ensure a safer work environment while also improving efficiency and productivity. Contact us to find out more about how to automate material handling and prevent material spills and pile-up.
Posted by Control Concepts USA on | Comments Off on 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 bulk material hoppers. The bulk 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 bulk 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 material production problems:
Need for manual intervention to loosen the material
Lower productivity and machine downtime
Inconsistent product formulas
Stagnant bulk material that can spoil or contaminate the next batch
Bulk material waste from throwing away spoiled material or out-of-spec batches
What causes bridging in material hoppers?
Know your bulk 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 bulk 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 bulk material’s characteristics. Conical material hoppers with an angle between 50 to 60 degrees, and the right outlet size, can help promote steady material flow.
Consider hopper liners. Using hopper liners made of low-friction materials like Teflon can help reduce bulk material adhesion and bridging.
Use the right flow aid. Many manufacturers use industrial material flow aids to break up bulk 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 material flow aid to get smooth, on-demand flow. AirSweep is a pneumatic material 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 bulk material hoppers.
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on 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.
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.
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