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AirSweep in the Cement Industry

The cement industry uses many raw materials that are prone to bridging, ratholing and caking. Unfortunately, slow or sluggish flow can have a huge impact on their productivity and product quality.

That’s why some of the world’s biggest cement companies rely on AirSweep for on-demand flow. Many of them switched from vibrators, air cannons, and air knockers–simply because AirSweep worked better.

Watch the video to find out why AirSweep is so effective for cement materials, and how it has helped companies improve revenue and lower costs.

Aside from the video, you can also visit the AirSweep cement industry page and read cement industry case studies.

AirSweep Return on Investment (ROI)

Bridging, ratholing, and other material flow problems can lower productivity, increase costs, and even cause safety hazards.

Inefficient flow aids can also use more energy and are harder to maintain – costing more money in the long run.

That’s why many companies switched to AirSweep. They saw it was more powerful, cost-effective, and easier to maintain—for a higher return on investment.

Find out what AirSweep can do for your material flow, and your overall business efficiency and profit, with this video on the AirSweep return on investment (ROI). You will learn about:

• Production savings and the true cost of downtime
• Energy savings from electricity and plant air
• Maintenance savings from vessel damage, and cleaning and flushing costs

To calculate your AirSweep ROI, contact our sales team (sales@controlconceptsusa.com) for more information.

USDA AirSweep: Simple, Sanitary Solution for Material Blocks

The USDA-accepted AirSweep delivers powerful material activation and vessel cleaning performance, all in a design specifically made and approved for sanitary bulk material handling processes.

Its features include:

• Air-tight design that guards against material retention and bacterial growth
• Modular construction for easy cleaning and inspection
• Tri-flange mount for tool-less removal

Watch the video to find out how the USDA-accepted AirSweep works, how to remove it for cleaning, possible applications, and the benefits to your business.

How to Install the AirSweep: Proper Nozzle Alignment

The AirSweep® nozzle is installed outside the vessel by cutting a small hole and welding a threaded mounting coupling in place. The nozzle is then threaded into the coupling and positioned inside the vessel at a depth that allows the air flow to sweep closely along the inside walls. A lock nut holds the nozzle in place once it is properly aligned.

In this video, we show how to install the Airsweep nozzle to proper depth in a vessel.

AirSweep vs Fluidizers: Spanish Subtitles

“What is the difference between AirSweep and other pneumatic flow aids?” In this video, Paul the AirSweep guy gives a simple, straightforward answer. He compares the AirSweep with the rubber fluidizing disc, and then shows the difference in a material activation test.

Since the AirSweep® is used in every region, this video provides Spanish subtitles. Visit our Resources section to download brochures and data sheets in Spanish.

Pneumatic Flow Aids: AirSweep vs. Fluidizers

Pneumatic flow aids release bursts of pressured air to dislodge the material blocks. However, even if fluidizers and Airsweep® both use aeration, they have major performance differences. This video tackles:

How they work: Fluidizers use a combination of gentle aeration and vibration, while AirSweep nozzles release powerful bursts of high-pressure air

The materials they can handle: fluidizers are only effective for light powders, while AirSweep can be used with wet, sticky, stringy and bulky materials.

Power and activation radius: It’s like comparing a garden hose and a fire hose. AirSweep has more pressure and volume, and can clear material blocks faster and more efficiently than rubber fluidizing discs. To show the difference, the two pneumatic flow aids are put to test.

AirSweep System Components

The AirSweep® Material Activation System eliminates bridging, ratholing and material build-up. It creates on-demand material flow for almost all materials, and can be retrofit to any vessel, including:

• Silos
• Bins
• Hoppers
• Chutes, pipes and conveying lines
• Blenders and mixers
• Live bottoms
• Cyclones and spray dryers

A typical AirSweep material activation system consists of strategically-located AirSweeps, high-flow solenoid valves, electronic sequence controller and air receiver. This video explains how AirSweep works, the typical components in each system, and how it is installed on the vessel. However, the system will be further customized according to your material, vessel and process.

AirSweep Straight Shooter USDA 135 Activation Radius

The AirSweep Straight Shooters release a focused column of air in front of the nozzle. It can be used to clean troughs and vessels, activate larger material, or promote flow in an inaccessible area. Units can be easily mounted to blast in any direction, using standard pipe elbows or fittings.

The Straight Shooters are available in all standard AirSweep sizes and can be made from either stainless steel or carbon steel. There are also USDA-accepted models for sanitary applications.

This video shows the material activation radius of the AirSweep Straight Shooter USDA 135 model.

AirSweep vs Vibrators: Performance, Costs and ROI

Material blocks: should you shake it, or sweep it? Compare the pros and cons of industrial vibrators with pneumatic flow aids like AirSweep. In this video, you will see how:

• How they work
• The real long term cost and return on investment
• Performance on wet, sticky and stringy products – and their impact on productivity
• Damage to machine, and its impact on maintenance costs
• Effect on work environments

Read about how AirSweep solved material flow issues that couldn’t be solved by vibrators or other flow aids, such as food industries where vibrations compact damp or sticky material, concrete and other construction materials, and more.

How Does the AirSweep System Work?

The AirSweep system prevents bridging, ratholing, arching, and other material flow issues. The powerful nozzles release high-pressure, high-volume, 360-degree bursts of compressed air. These break up material blocks, and sweeps stalled material back into the flow stream.

But how does the AirSweep system really work? This video explains the typical AirSweep system. You will see:

AirSweep components

Look at the parts, what they do, and how they work together to slice through the toughest bulk materials in seconds.

AirSweep installation

The 3D model shows how AirSweeps are positioned on a vessel like silo, bin and hopper. The air pulses are perfectly timed for a first-in, first-out on-demand material flow.

AirSweep efficiency

By the end of the video, you will see why the AirSweep system is especially designed to handle any kind of material—from fine powders to bulk solids.

AirSweep proves that bursts of air, sent at the right place and the right time, can guarantee smooth material flow and higher factory efficiency.