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.
Posted by Control Concepts USA on | Comments Off on How Does AirSweep Prevent Machine Downtime?
Machine downtime is one of the most common and expensive problems in industrial or manufacturing facilities. According to a Forbes report, companies experience 800 hours of downtime per year, or more than 15 hours a week.
That has a huge impact on revenue. For example, an automotive manufacturer loses about $22,000 for every minute of lost production time. A cement manufacturer loses $12,000 an hour. This doesn’t include the indirect costs incurred:
There are two kinds of machine downtime: planned downtime or the expected time required for routine cleaning and maintenance, and unplanned downtime caused by equipment failure, operator error, and poor material flow.
Equipment failure and operator error are relatively rare and can be avoided through regular inspection and proper training. However, poor material flow can happen every day.
Many bulk powders and solids are prone to bridging and ratholing, which obstructs vessel outlets until the flow slows down or stops completely. The machines must be shut down so workers can clear out the material blocks or scrape away residue on the walls.
This was exactly what happened in the Mexico plant of a regional manufacturer of asphalt products. “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 just to get the factory running again,” said the Sales Manager.
An electricity-generating plant faced similar issues with bituminous coal, a mining by-product used as a clean energy source. The material would plug in the chutes, forcing operators to shut down the process so workers could chip away at the caked-on material. This occurred 15 times during each 12-hour shift, taking 20 minutes each time.
Machine downtime from poor material flow was creating production losses and safety hazards. Fortunately, they found a simple, reliable solution: AirSweep pneumatic flow aids.
Reduce Machine Downtime With AirSweep
AirSweep has helped thousands of plants around the world eliminate bridging, ratholing, and other common causes of machine downtime.
Each nozzle emits a high-pressure, high-volume, 360-degree burst of compressed air to lift and sweep stalled material back into the flow stream – clearing the way for higher factory and material handling efficiency.
AirSweep works where other flow aids have failed. The asphalt manufacturer had tried electric vibrators and air cannons, but workers still had to hammer away at the material blocks. After installing AirSweep, they never encountered material blocks again.
“After four years, we finally have the right solution! We are very happy with the system.” They have saved time, energy, and money from maintenance costs and losses from machine downtime, and are looking to install units in their other plants.
The electricity generating plant reported similar success. AirSweep solved all plugging issues and used less energy than air cannons and other flow aids they had tried. With their higher productivity and lower energy costs, they have already gotten their full return on investment. “AirSweep paid for itself in just two weeks!” said Jeffrey Campbell, Plant Engineer.
Get the AirSweep solution
Contact us to find out more about how AirSweep can restore material flow, increase productivity, and prevent machine downtime.
Posted by Control Concepts USA on | Comments Off on 4 Types of Material Handling Equipment that Improve Factory Efficiency
Material handling equipment can help store, move, and process large volumes of material. It increases production speed and helps prevent some risks of manual processes: injury, human error, or exposure to chemicals and hazardous materials.
There are many types of material handling equipment, and some machines are even customized for particular processes. However, these can be divided into four general categories that serve a specific purpose in the production line.
Bulk material storage equipment
This is one of the most common types of material handling equipment and is used in even the smallest and simplest facilities. As the name implies, it is used to store raw materials before they are transported or used in production.
The most basic storage and handling equipment are drawers, racks, and stacking frames. Larger warehouses may use mezzanines or elevated floor systems that can hold more materials.
The best storage and handling equipment will maximize space, prevent damage to the materials, and make it easier for workers to safely and easily access what they need.
Bulk material handling equipment
This is a broad term for any type of material handling equipment used to move or process bulk powders or solids. Examples include:
Silos: This is a tower used for storing grains and other food products, coal, wood chips, sawdust, sand, metal waste, and more. Interestingly, this is one of the oldest types of material handling equipment—the first stone silos date back to 1700-1800 BC.
Hoppers: This cone-shaped vessel helps funnel material from one stage of production to the other. It is typically used for particulate matter or any material that can flow. However, many materials can become compact because of moisture content, or the size and shape of the particles.
Conveyor belts: This automatically transports materials over several feet, even through steep inclines.
Reclaimers: This has a rotating scoop that gathers loose material and places it on a conveyor belt.
Bucket elevators: This is used to vertically haul powder or free-flowing materials such as grains, sugar, limestone, etc.
Engineered Systems
This works with other types of material handling equipment to automate the storage and transportation of material. This includes Automated Storage and Retrieval Systems (AS/RS), Automated Conveyor Systems, Robotic Delivery Systems, and Automatic Guided Vehicles.
Material Flow Aids
One of the biggest challenges of bulk material handling is how to ensure reliable, first in/first out flow. Many bulk powders and solids can settle and become compact during storage. Others are prone to bridging and ratholing, which blocks the discharge outlet.
Material flow aids break up the material blocks and push material through the vessel. Types of material flow aids include:
Pneumatic flow aids that use air pulses (ex: AirSweep, fluidizers, air cannons)
Industrial vibrators that use mechanical agitation (ex: vibrators, air hammers)
Chemical flow aids that are mixed into the material to change its flow properties (ex: fumed silica, magnesium stearate)
Among all these types of material handling equipment, AirSweep has proven to deliver the best results at lower costs. Unlike other pneumatic flow aids, it can activate even sticky, heavy, and moist materials. It uses less energy and does less damage to vessels than vibrators, and does not compromise the product formula like chemical additives.
Discover the difference between AirSweep and other types of material handling equipment in this in-depth flow aid competitive analysis. You can also contact us to find out how AirSweep can help improve your productivity, product quality, and plant safety.
Posted by Control Concepts USA on | Comments Off on Where Can You Install an AirSweep?
AirSweep pneumatic flow aid systems are used in thousands of plants around the world. Aside from improving material flow, one of its biggest benefits is its simple and fast installation. You do not need special tools or skills to attach the nozzle, and you can use the system on any storage silos and hoppers, chutes, blenders, or any vessel of any size.
AirSweep can even be used in many vessels or environments where other flow aids simply won’t work. Here’s what you need to know about installing an AirSweep—and why it’s the easiest, most effective fix for material blocks.
AirSweep is easy to install
The AirSweep system consists of a nozzle that releases powerful bursts of pressured air. This is hooked up to an air supply through high-flow solenoid valves and an air receiver. An electronic sequence controller sets the duration and frequency of the pulses.
The nozzle is attached to the outside of the vessel. You just need to cut small holes to accommodate the nozzle tip, and then weld the couplings into place. Finally, insert the AirSweep nozzle to the desired depth and then tighten the lock nuts to hold it in place. It’s that simple!
The AirSweep can also be installed without any welding, using the outside of the mounting bracket. We recommend this option if you want to avoid modifying the vessel, or if you need to remove the nozzle often for frequent sanitation and cleaning.
Follow these simple steps on how to install the AirSweep without any welding or special tools:
AirSweep can be used on any vessel
Many flow aids like air cannons or vibrators are so bulky or generate so much metal fatigue that they cannot be used on small vessels or cramped locations. In contrast, AirSweep’s air pulses do not damage the vessels and have a sleek and compact design.
That is why AirSweep is the best flow aid for any vessel: storage silos and hoppers, gravity chutes, cyclones, blenders, pipes, conveyors, and more.
A plastic and chemical manufacturer found that it was the best flow aid for cyclone efficiency. They had frequent production delays because of the build-up of adipic acid. It would coat the upper discharge area, forming a cake-like crust. Bridging over the discharge would lead to complete blockage. The product-laden air would also fail to drop out and return to the baghouse. As a result, good product would get carried to the waste stream.
Vibrators, fluidizers, and other flow aids would not have been able to solve this problem. AirSweep engineers positioned AirSweep units strategically to prevent bridging at critical areas, leading to better flow and fewer operator interactions.
AirSweep can be used in hazardous environments
AirSweep has been fully tested and approved for use in hazardous and explosive environments. It has even received ATEX certification. ATEX (which stands for ATmosphères EXplosibles) is required for all products that are used in explosive environments in the European Union.
An explosive atmosphere can be caused by a variety of substances and chemicals in the air, such as flammable gases, mists or vapours, or fine organic dusts like grain flour or wood. This includes petrochemical industries, underground mining, and food production.
AirSweep can be used in sanitary process environments
Some industries, such as food and pharmaceuticals, must meet strict regulations on sanitary processes and equipment.
The USDA-accepted AirSweep has been developed specifically for this environment. The model incorporates sanitary design and fabrication principles to meet the guidelines set by the USDA. It has flanged connections for simple tool-less removal and easy assembly/disassembly with simple hand tools for inspection and cleaning. All parts are resistant to corrosive products and cleaning/sanitizing chemicals.
Get a custom installation proposal now
Each process, material, and vessel is unique. The AirSweep engineers will analyze your material flow problem, and recommend the best system for your needs—including the best AirSweep model, where to install it on your vessel, and what pulse frequency and sequence to follow.
Contact us if you have any questions about AirSweep and how it can be integrated into your process.
Posted by Control Concepts USA on | Comments Off on 5 Common Bulk Solids Handling Equipment
Bulk solids material handling equipment are used to store, move, and process raw materials and products. They speed up production and ensure that bulk materials can be handled in a safe and sanitary way.
The first bulk solids material handling equipment dates back to 1795: a primitive conveyor belt made of leather and a wooden bed that was used to transport grains and mining materials. Today, the equipment has become faster, more durable, and more precise. The latest automated systems even use machine learning and motion sensor technology and require very minimal human intervention.
Here are some of the most commonly used bulk solids material handling equipment that can be found in almost any processing facility that handles large volumes of material.
Hoppers and chutes
Hoppers and chutes are used to automatically feed material into the production line for further processing. They are usually connected to other bulk solids handling equipment such as conveyors, crushers, mixers, or dryers.
Hoppers are typically set up to allow a controlled feed rate, but material blocks can slow down the discharge or even stop it completely. That is why it is necessary to understand the material flow properties, select the right hopper angle and outlet size, and install a reliable flow aid like AirSweep.
Silos
Silos are used for storing bulk materials. These are typically used for food and agricultural products, but can also hold other bulk solids like cement materials, sawdust, woodchips, metal waste, and chemicals like carbon black and aluminum oxide.
The terms silos and hoppers are often used interchangeably, although there are distinct differences between these two bulk solids handling equipment. Watch this video on silos vs hoppers.
Conveyors
Conveyors are used to transport bulk materials or goods. Most conveyors still use the traditional belt design. Some applications use pulleys or buckets or have cleated surfaces to keep materials secure or evenly spaced.
When choosing the right conveyor (or any bulk solids handling equipment), users must consider the bulk material’s dimensions, weight, and fragility, as well as the plant environment like risk for corrosion and available space.
Conveyors and other bulk solids material handling equipment used for transporting materials such as bucket elevators will always have a risk for material spills. This typically occurs when one of the parts malfunction and cause the conveyor to run faster or slower than intended.
A DAZIC Zero Speed Switch can be installed into the conveyor or transport system to detect abnormal speeds and signal the operator before a spill occurs.
Stackers
Stackers are used to lift and stack heavy loads on warehouses and docks. Some warehouse automation systems combine stackers with autonomous shelf loader robots and shuttles, or systems that track inventory and coordinated routing. (Read our article on Top 5 Technologies for Automated Bulk Material Handling.)
Reclaimers
One of the largest bulk solids handling equipment, reclaimers are used to recover bulk materials from a stockpile. They typically consist of a bucket-wheel, counterweight boom, rocker, and a conveyor system.
Both stackers and reclaimers are used extensively in the mined minerals industry or other applications that have to gather raw materials from piles before redistributing them for shipment or processing.
Protect material flow in bulk solids handling equipment
Materials can often settle during storage, or develop flow problems during transportation and processing. AirSweep can help activate material to prevent material blocks or correct erratic flow.
AirSweep can be installed on any bulk solids handling equipment– silos, hoppers, conveyors, bucket elevators, or any vessel where material can hang up. Contact us to find out more about how to use AirSweep in your system.
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