Posted by Control Concepts USA on | Comments Off on 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:
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on 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.
Posted by Control Concepts USA on | Comments Off on How to Prevent Material Blocks in Common Vessels Used in Material Handling
All industrial and manufacturing processes will use storage silos and hoppers and other vessels to hold material before it is sent to the next stage of production. Ideally, these are designed to prevent spoilage and contamination and allow easy maintenance and access.
However, there is another important factor: material flow. During storage or transfer, materials can settle, segregate, form clumps, or develop bridging and ratholing.
In this blog post, we will delve into the common vessels used in material handling and highlight the role of AirSweep in enhancing their efficiency, with insights from real-world case studies.
Silos
Silos are tall, cylindrical containers that store bulk materials, such as grains, cement, or powders. These vessels are commonly used in industries that require large-scale storage. Silos offer advantages such as space optimization, ease of loading and unloading, and protection from external elements.
AirSweep can be installed on silos to ensure efficient material flow. Bunge, an agribusiness and food ingredient company based in the USA, had issues with rice bran bridging in their storage hoppers and silos. Workers had to hammer the vessels, which was ineffective and stressful for everyone in the factory. “It was like fingernails on the chalkboard. You wanted to get away from it,” said John Pappenheim, Bunge’s Maintenance Manager.
AirSweep solved material blocks (and noise!). Installation was also simple and inexpensive: they just attach the units with simple tools and connected them to their existing compressed air and electrical system. “Any electrician can wire it up. I would absolutely recommend it.”
Hoppers
Hoppers are smaller containers typically found at the beginning or end of a material handling process. They are used for feeding materials into a system or collecting and dispensing them. Hoppers are widely employed in industries like mining, construction, and agriculture.
Unfortunately, hoppers can often be the bottleneck in production because of material bridging and ratholing over the outlet. AirSweep can prevent these issues from occurring.
One of the world’s biggest manufacturers of rubber tires had issues with carbon black bridging in the weigh hoppers. The entire process would shut down because the rest of the machines were starved of raw materials. After installing AirSweep, the material flowed freely.
Chutes
Chutes are inclined channels or tubes designed for the controlled movement of materials from a higher to a lower level. They are commonly used for transferring bulk materials such as granules, coal, or sand.
AirSweep technology can be integrated into chutes to eliminate clogging, ensuring a smooth and uninterrupted flow of materials. Heidelberg Cement installed the system on their pipes and chutes to remove cement clinker—a very hot, hard substance that fluidizers, vibrators, or even air cannons couldn’t remove. AirSweep was the only flow aid that worked.
Conveyor Systems
Conveyor systems are widely used in industries to transport materials horizontally or vertically. They consist of belts, rollers, or chains to move goods efficiently.
AirSweep systems can be strategically placed along conveyor belts to tackle material flow issues, such as accumulation or blockages. The pulsating bursts of compressed air from AirSweep devices help dislodge any lodged or stuck materials.
Cyclones
Cyclones, also known as cyclone separators, are vessels used in material handling systems to separate particles from a gas or liquid stream. They are commonly utilized in industries such as chemical processing, power generation, and mining. Cyclones employ centrifugal force to separate solid particles from the gas or liquid flow.
AirSweep is proven to improve cyclone efficiency. A plastic and chemical manufacturer had frequent production delays because of the build-up of adipic acid in their cyclone. It developed a cake-like crust that blocked the upper discharge and restricted material flow. Additionally, the product-laden air failed to separate and return to the baghouse, resulting in valuable product being carried to the waste stream.
AirSweep solved the problem immediately. “The AirSweep was a success! We are already looking at retrofitting more units into a silo with the same material.”
Improve material flow in all your vessels
From storage silos and hoppers to chutes and cyclones, AirSweep technology eliminates flow issues and enhances productivity. Contact us to find out more about how you can incorporate it into your process.
Posted by Control Concepts USA on | Comments Off on 5 Reasons Why AirSweep is Effective for Bulk Product Handling
All industrial processes use bulk product handling equipment. Some are used to transport and supply materials to processing units. Others perform more specific functions like blending, compacting, flushing, grinding, etc.
Flow aids are used to improve the material flow of bulk materials. They perform an important function because when materials don’t flow properly, the entire production line is affected. Without any bulk product handling equipment, workers must hammer the vessels to get the material moving again. This can cause hours or even days of delay.
AirSweep: Bulk Product Handling Equipment for Material Flow
AirSweep provides on-demand flow of even the toughest materials. It eliminates bridging, ratholing, arching and sticky build-up on the vessel walls.
Each AirSweep nozzle directs high-pressure, high-volume, 360-degree bursts of compressed air or inert gas along the inside walls of process equipment, vessels, chutes, and ducts.
The air pulses break the friction between the wall and the material to lift and sweep stalled material back into the flow stream. The unique, sweeping action can even result in the vessel or cone walls being flushed completely clean.
This video explains how the AirSweep system provides reliable bulk material handling.
Built for tough materials
AirSweep works on the toughest materials. The pulses are powerful enough to activate moist, sticky, damp, and wet materials — even with bulk densities up to 200 pounds per cubic foot.
Many companies shifted to AirSweep after becoming disappointed in other flow aids. A commercial bakery had issues with flax bridging above the discharge. “The vibrators that came installed on the bottom of the hopper above the mixture practically turned the flax into concrete,” said the maintenance department head. “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.”
AirSweep resolved 90% of material retention problems—which increased production and eliminated the cost of wasted raw materials. “My experience totally exceeded my expectations—a 10 out of 10!”
Energy-efficient
The AirSweep system uses less plant air and electricity compared to other flow aids. Unlike fluidizers and vibrators, which run continuously, the units are pulsed in a sequence—one at a time—which minimizes overall energy use.
Low maintenance
The AirSweep can be mounted and dismounted from the process equipment without tools. This makes it very easy to remove the nozzle for routine cleaning.
The AirSweep can also run for 1,000,000 cycles before it needs preventative maintenance. Aside from replacing parts that are prone to wear and tear, a system can last for decades without any problem. If there are any issues, customers also enjoy a 7-year warranty—the longest in the business.
Easy installation
One of AirSweep’s key benefits is that it is installed outside the vessel. Drill small holes at the appropriate location, then weld the couplings into place. It can also be retrofitted into existing holes.
Safe for use in hazardous environments
The AirSweep design and materials of construction can withstand high process or material temperatures, corrosive environments and materials, and hazardous area classifications. It is also ATEX-certified, which means that it has been independently tested as safe for use in explosive atmospheres.
Watch AirSweep at work
The proof is in the flow. Watch these material flow videos to see how AirSweep activates different types of materials.
You can also contact us so we can personally explain how the system works, and how it can help you with your particular process.
Posted by Control Concepts USA on | Comments Off on 5 Problematic Materials that AirSweep Can Handle
Most industries need heavy material handling equipment to move raw materials to warehouses and production facilities. However, the problem doesn’t end there. How do they ensure material flow during the process?
Many bulk powders and solids develop flow problems once they are poured into silos, hoppers, or chutes. They can form bridging and ratholing that blocks the vessel outlet until the flow slows down or stops completely. They can stick to the walls or segregate.
These material blocks would take hours to manually clean. Just like plants need heavy material handling equipment to transport materials to different facilities, they need industrial flow aids to move them through different processing stages.
What is the best heavy material handling equipment for material blocks?
There are three general kinds of industrial flow aids, each with its own pros and cons.
Vibrators and air hammers shake the material loose—but at a cost. These consume a lot of energy, can potentially damage vessels, and are very noisy and stressful for workers within the area. Some materials also tend to settle even more when shaken, so this can actually aggravate material flow issues.
Chemical flow aids break down the chemical bonds or change the flow properties. However, adding any material to a formula can affect its quality, consistency, and cost.
Pneumatic flow aids use air pressure to break up blocks or push material. The key is to pick a system aid that uses enough pressure and volume to activate the material. For example, fluidizers that use a combination of light aeration and vibration are only effective for fine powders like flour.
For most materials, you need AirSweep—the trusted heavy material handling equipment for the toughest material flow problems. It can activate bulk solids and powders that don’t respond to fluidizers, vibrators, and air cannons.
The proof is in the flow. Watch AirSweep activate the five most problematic materials used in different industries.
Heavy, sticky materials
It can’t get heavier or stickier than liquid cheese. In fact, many food companies use the USDA-accepted AirSweep to move ingredients used for making chocolate and pastries. This model is specifically designed for use in sanitary environments.
High oil and moisture content
Materials with high oil or moisture content tend to form clumps or bridging and ratholing over vessel walls. Material residue can also spoil and compromise the entire batch. AirSweep guarantees first-in/first-out flow for faster flow and product integrity.
Damp powders
Damp powders can settle during storage and form bridging and ratholing in silos and hoppers. AirSweep has been proven more effective than fluidizers and air cannons—and even uses less energy and air.
Flakes and shreds
These materials have a tendency to interlock and clump together, and won’t respond to agitation and vibration. AirSweep air pulses separate the material and sweep it back into the flow stream.
Heavy irregular particles
Irregularly shaped solids can interlock and aggregate. AirSweep can be used with solids with heavier densities such as mined materials or cement materials.
Find the right AirSweep for your materials
Thousands of plants around the world trust AirSweep for reliable material flow. Contact us for a free consultation on the best heavy material handling equipment for your process.
Posted by Control Concepts USA on | Comments Off on How Different Industries Use AirSweep for Bulk Material Processing
AirSweep is a versatile flow aid that can be used in any industry that requires bulk material processing. It can activate the most challenging material, including sticky pastes, heavy pebbles and mined materials, or rock-hard clumps of powders.
How does AirSweep work?
AirSweep is one of the most cost-efficient ways to improve bulk material processing. Its powerful air pulses break up cohesive friction and sweep material back into the flow stream.
AirSweep has a higher pressure and power than fluidizers, and won’t damage the vessels like vibrators. It also consumes less energy than air cannons and air knockers and uses air more efficiently because of its controlled, sequential pulses.
That’s why many companies trust AirSweep to improve their bulk material processing. Here are some ways they use the system, and how it helps them save money, time, and effort.
Get smooth, on-demand material flow
Slow material flow lowers productivity and can increase manpower hours. In some cases, the plant needs to shut down for manual cleaning, which wastes time and can cause safety hazards because of worker exposure to hazardous material.
A cement company in Southeast Asia needed a flow rate of 20 to 30 tons per hour. However, materials solidified because of plant humidity. Despite using vibrators and air knockers, workers still had to hammer the silos. Each hour of downtime cost them $12,000 per hour. With AirSweep, they were able to solve this problem in just four days.
Reduce material waste
A food manufacturer in the United States handles 6,000 pounds of ground flax and cocoa powder per hour. However, the oil and fat content caused materials to bridge over the discharge and stick to all interiors, all the way to the filter bags. They had to throw away up to 40 pounds of mixture a day and even had to pay to have it hauled away.
They tried other flow aids. Vibrators compacted the material until it was like concrete. Fluidizers failed, and workers still had to hammer the vessels every day. Only AirSweep worked, improving material flow by 90% and eliminating the costs of material waste.
They used a labor-intensive, multi-step process of flushing and manual cleaning. After they installed AirSweep, they cut cleaning time from 40 hours to 10 hours. They pulsed the units during and after the batch runs, which improved blend uniformity and removed residual powders.
Protect factory and worker safety
A cheese company had issues with whey protein concentrate (WPC), which has a very high moisture and fat content and was prone to bridging over the discharge. Unfortunately, this wasn’t just delaying production. The caked material had sparked a fire in one of their baghouses. Bridging had become an urgent safety concern.
They chose the AirSweep USDA-accepted model, which could slice through material blocks “just like an air knife”. The model was also designed for sanitary processes, which was critical for compliance with stricter industry regulations.
Best flow aid for bulk material processing
AirSweep is used in thousands of plants worldwide to achieve on-demand material flow. Our clients include S&P companies and SMEs. Contact us to learn more about how it can be used in your process.
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