Category Archive: Uncategorized

Hoppers

Hoppers store and dispense bulk materials like powders and granules, feeding them into the next stage of processing.

Material hang-up: Bridging and rat-holing are the biggest culprits here. Materials can form a solid arch across the outlet or flow unevenly through a narrow channel. Sticky powders can also cling to hopper walls, disrupting flow and creating bottlenecks.

Silos

Silos store massive quantities of materials, from cement and grains to plastic pellets. They’re essential for large-scale operations.

Material hang-up: Moisture and compaction can cause materials to stick to the silo walls or create blockages. Fine powders, in particular, tend to clump and resist flow, which leads to uneven discharge and wasted product.

Bins

Bins serve as short-term storage vessels for bulk solids, often holding material right before it’s processed.

Material hang-up: Like hoppers, bins suffer from material stagnation. Solids may become compacted or form dead zones, preventing a consistent flow. Dusty materials can also accumulate on bin walls.

Chutes

Chutes transfer materials using gravity, directing them from one stage of processing to another.

Material hang-up: Insufficient slope or the wrong surface finish can cause materials to stick or clump together, especially if they’re damp or adhesive. This results in blockages that stop material movement entirely.

Cyclones

Cyclones separate particles by size or density in pneumatic systems, a common process in industries handling fine powders or particulates.
Material hang-up: Accumulation of fine particles often occurs in bends or outlets, especially in systems that deal with sticky or moisture-laden materials. This can clog the system and reduce efficiency.

Mixing Vessels

Mixing vessels homogenize ingredients, blending powders, liquids, or slurries in food, chemical, or pharmaceutical production.

Material hang-up: Settling and clumping are common issues, especially with viscous materials. Unmixed components can adhere to the walls or bottom of the vessel, reducing the quality of the final blend.

Feeders

Feeders dispense materials in precise quantities, ensuring consistent input for downstream equipment.

Material hang-up: Sticky or fine-grained materials can clog feeder mechanisms, leading to uneven discharge or complete blockages.

Weigh Hoppers

Weigh hoppers measure and dispense materials by weight, a critical function for accurate batching.

Material hang-up: Material bridging or sticking to the hopper walls can result in inaccurate measurements. Over time, residual material build-up can compromise efficiency.

Bag Dump Stations

Bag dump stations transfer materials from bags into processing lines, filtering dust and contaminants in the process.

Material hang-up: Residue from bags can collect on the grids, while powders may clog the transfer points, slowing down production.

Storage Tanks for Slurries or Powders

Storage tanks hold materials for later use, whether it’s liquid, slurry, or powder.

Material hang-up: Sedimentation or compaction at the bottom of the tank is a frequent issue. These blockages make discharge inconsistent and increase clean-up time.

Solve Material Blocks in Processing Vessels

Material flow issues are more than just a nuisance—they can cost your operation valuable time and money. The good news is that these problems are solvable. With the right system in place, you can keep your processing vessels running smoothly, no matter the material.

AirSweep is a pneumatic flow aid system that uses powerful bursts of compressed air to activate stagnant material and restore flow. Unlike vibrators or other mechanical aids that only address surface-level issues, AirSweep penetrates the material column, breaking up blockages at the source.

AirSweep can be installed in all types of processing vessels—whether you’re dealing with a stubborn hopper, a silo that refuses to empty evenly, or a bin plagued by dead zones. It works seamlessly with powders, grains, and even sticky materials, ensuring efficient flow every time. Find out more about how AirSweep works.