Solve Common Problems When Handling Bulk Materials

bulk material

Every industry uses dry bulk materials—whether it be chemical powders, pellets, flakes, mined minerals, raw materials, food, additives, stabilizers, or preservatives.

Each of these materials has its own properties that can affect how they behave while being stored, transported, or processed. And when you’re dealing with tons of materials, the stakes become higher. Any problems will incur huge delays and costs.

Bulk material handling (BMH) equipment can help prevent dry bulk materials handling issues, and improve production efficiency. The right equipment can even help lower costs, and increase plant safety.

Control Concepts, Inc.: Your Partner in Bulk Material Handling

Since 1951, we have helped companies resolve dry bulk materials handling issues. The patented technologies are used in every industry: mining, cement, food, pharmaceuticals, chemicals, mined minerals, and more.

We offer three products for bulk material handling: AirSweep pneumatic flow aids, DAZIC zero speed switches, and AcoustiClean sonic horns. Each of them addresses particular dry bulk materials handling issues to prevent delays, unnecessary costs, and safety risks.

AirSweep for on-demand material flow

Poor material flow is one of the most common dry bulk materials handling issues—and the most problematic. Sluggish flow (or even no flow) can:

  • Slow down production
  • Compromise batch consistency
  • Cause contamination and spoilage
  • Lower vessel capacity
  • Increase material waste
  • Create flammable environments

AirSweep uses powerful air pulses that break up material blocks and sweep stagnant material back into the flow stream. Unlike other flow aids like vibrators and air cannons (or the old-fashioned method of hitting the vessel with a hammer), it does not cause metal fatigue.

AirSweep has been proven effective for all types of dry bulk materials, including damp powders, plastic flakes, fibers like tobacco, pellets, and irregular particles like mined materials. It also has lower energy and maintenance costs than other flow aids, and can easily be removed from the vessel for cleaning with simple tools.

DAZIC zero speed switch to prevent material pileup

If a conveyor belt or bucket elevator fails, tons of material can spill over and pile up. Workers will need days to clean it up, and companies will need to face production losses and additional manpower costs.

Spilled material can also create safety risks, especially if it is heavy, flammable, or classified as a toxic chemical. That is why OSHA and other safety organizations require plants to take precautionary measures for machine failure and spills.

DAZIC zero speed switches are very affordable but can prevent very expensive and dangerous material pileups. They are attached to equipment to detect any abnormal change in rotation speed. If the equipment speeds up, slows down, or stops completely, DAZIC sends a signal to the operator to shut it down.

DAZIC can be attached to any bulk material handling equipment with a rotating shaft, such as

  • Rotary valves
  • Bucket elevators
  • Belt, drag, and screw conveyors
  • Fans
  • Blowers
  • Saw blades
  • Drive motors
  • Mixers
  • Crushers
  • Agitators
  • Rolling mills

AcoustiClean Sonic Horns to clear light material buildup

Light powders can accumulate on surfaces and hard-to-reach areas. This can cause contamination issues, affect the efficiency of the vessel, or create potentially flammable environments.

AcoustiClean Sonic Horns produce high-energy, low-frequency sound vibrations that disperse dry material. Compressed air is applied to a sound generator, which vibrates a titanium diaphragm. The sound waves clear the material, to clean your material handling equipment.

AcoustiClean can be integrated into the system to automatically clean the surface between production runs. It reduces plant shutdowns, prevents cross-contamination during production, replaces dangerous and expensive manual cleaning, and improves energy/heat transfer efficiency and lifespan of machines.

Bulk Material Handling Solutions

AirSweep, DAZIC, and AcoustiClean can prevent many dry bulk materials handling issues. For more information, or to get a customized quote contact us.

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