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Spent Grain Material Flow Test

Spent brewer’s grain is a by-product from mixing barley malt and other cereals or grains for making wort or beer. Since it has a lot of protein and fiber, the spent grains are dried and sold as animal feed.
The wet mixture of malt and grains is very dense and glutinous. It has a tendency to stick to vessel walls or form large clumps.
Spent brewer’s grain poor flow properties can be seen in this material flow test.
First, 1.3 cubic feet of material was poured into the hopper with a 28” diameter, a 60-degree cone, and a 4” diameter outlet. After the discharge was opened, the material did not flow even when tapped with a rubber mallet. This indicates that Brewer’s grain will not flow readily, if at all, without aid.
Then, four Airsweep VA-06 units were installed on the vessel. Two were placed 180 degrees apart at approximately 4” and 10” above the outlet. The other two were installed 180 degrees apart at approximately 8” above the outlet.
The units were set up to release air pulses starting from the lowest unit, with a pulse duration of 0.25 each and a rate of one pulse every 2 seconds. Material flow increased immediately with the first pulse, and continued to flow until the hopper was emptied entirely.
AirSweep is the most effective pneumatic flow aid for dense, sticky, and compact materials. For this reason, it is used extensively in the pet food industry, including one of the largest pet food manufacturers in North America.

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Sugar Beet Shreds Material Flow Test

All industries need reliable material flow to ensure productivity and product quality. However, the food industry has particularly strict standards – not only because of strict industry regulations but the type of materials that it works with.

Many food materials have challenging flow properties and can become moist and compact during storage and handling. This material flow test shows how sugar beet shreds have plugged the hopper outlet. Even when the discharge was opened, it refused to flow even if the hopper was tapped with a rubber mallet.

AirSweep resolves material blocks and produces on-demand, first-in/first-out flow. The units are also positioned at key areas and pulsed in a sequence to move material in a reliable, cost-efficient way. For example, positioning some of the units near the bottom of the outlet can help start the initial flow of blocked material. 

The AirSweep team tailors each installation according to the material, vessel, and process. Read more about how it is used in different food applications.

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Dried Distillers Grain Material Flow Test

Dried distillers grain and many other materials have a tendency to draw moisture and clump together in storage. This can make it very difficult to move the material, which affects productivity and even the material’s integrity and safety.

AirSweep is particularly effective for damp materials that have a tendency to clump, bridge, or rathole. In this material flow test, the dried distillers grain was mixed with one cup of water, packed down, and left in the hopper for five days. By then, it had formed clumps and begun to adhere to itself.

AirSweep resolved all of these material blocks – breaking up the clumps and flushing all the dried distiller’s grain out of the hopper. It is the proven solution for tough flow problems.

For very difficult materials that sit in the hopper for long periods of time, AirSweep standard units can also be combined with the AirSweep straight shooter, which emits a concentrated column of air.

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Pine Wood Chips Material Flow Test

Pine wood chips (PWC) are used for making paper and composite wood products and are a sustainable source of biofuels. However, it has challenging flow properties and needs a reliable flow aid to prevent material blocks.

This material flow test demonstrates AirSweep’s efficiency and control. At the start of the test, a hopper was filled with half a cubic foot of PWC. The hopper had a 28” diameter and a 4” diameter outlet.

Four AirSweep VA-06 units were installed on the vessel and were programmed to release short air pulses every three seconds.

Without the use of any flow aid, the PWC dropped in slow clumps through the discharge. But from the moment the AirSweep unit released its first pulse, the material began to flow steadily until the hopper was completely emptied.

AirSweep is the most effective flow aid for pine wood chips and other fibrous materials like powdered hemp and organic natural fibers.

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Recycled PVC Plastic Material Flow Test

Recycled PVC plastic is 100% recyclable. It is a sustainable material with a lower carbon footprint than fresh raw materials.

However, recycled PVC plastic can have challenging flow properties. It is dry, lightweight and has a tendency to leave particles on all the surfaces that it touches.

AirSweep is the best flow aid for recycled materials. In this material flow test, a hopper was filled with approximately 0.668 cubic feet of recycled plastic. The material was compacted into the outlet with a 6×6 piece of wood.

Then, two AirSweep VA-06 units were activated. After just seven pulses, the AirSweep swept all the material out of the hopper.

While a thin layer remained because of the material’s stickiness, the flow test proves how AirSweep can effectively solve bridging, ratholing, and other stubborn material blocks. Check out our video library for more material flow test videos.

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Cedar Wood Chips Material Flow Test

Cedar wood chips, a byproduct of the wood industry, are often used in gardening, mulching, smoking meats, and making crafts. It is very light and has a tendency to clump when it is stored or processed.

Wood Chips respond to aeration, but fluidizers don’t have enough power to break apart clumps. It needs a powerful pneumatic flow aid like AirSweep.

In this material flow test, a hopper was filled with .668 cubic feet of cedar wood chips. Four AirSweep VA-06 units were strategically installed at various points of the vessel and set to pulse every four seconds.

At the start of the test, the material was allowed to flow “naturally” without the use of any flow aid. It fell in slow clumps and, in time, would have clogged the discharge completely.

Once the AirSweep units were turned on, it took just a few pulses to move the material completely out of the vessel.

AirSweep is the most effective flow aid for cedar wood chips and other fibrous materials like pine wood chips and powdered hemp.

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Coffee Grounds Material Flow Test

Like many fine powders, coffee grounds have a tendency to clump or flow unevenly when it is transferred or processed. However, vibrators will make it more compact and may produce dust.

AirSweep is the best flow aid for powders that need gentle but effective handling. To demonstrate this, five gallons or 134 cubic feet of coffee grounds were poured into a hopper. After just one pulse, the coffee flowed like a fluid.

AirSweep is trusted by some of the world’s largest food manufacturers to get fast, on-demand material flow. Read more about AirSweep in the food industry.

PVC Powder Material Flow Test

PVC (polyvinyl chloride) is a versatile thermoplastic polymer that is used to make a variety of products. This includes pipes, tubes, roofing, flooring, cables, wires, bottles and other containers, and even shoes.

PVC powder can exhibit poor flow properties and may even form bridges or arches in storage or feeding equipment. AirSweep can resolve these issues – while using less plant air and energy than other flow aids.

In this material flow test, two AirSweep VA-06 units were installed on a hopper at approximately 4” and 10” above the outlet.

The hopper was then filled with 10 gallons or .267 cubic feet of material. Without the AirSweep, the material flowed slowly, dropping in clumps. Once the AirSweep units started to pulse, the flow dramatically increased.

Look at other flow tests on similar materials like PPH (a thermoplastic resin), resin flakes, acetate flakes, and recycled materials.

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.

Shredded Potato Material Flow Test

Potato flakes are a very light, dry material with very challenging flow properties. Without external activation, it tends to settle in the vessel and plug up the outlet. However, it breaks down into a fine powder if it is aggressively handled.

AirSweep is the best flow aid for this type of material. The nozzles release carefully timed, high-pressure air pulses that can move the potato flakes in seconds – without damaging the product consistency.

The material flow test demonstrates AirSweep’s efficiency and control. At the start of the test, the hopper was filled with 5 cubic feet of potato flakes. Note how the material did not flow even after the discharge was opened.

The vessel had one AirSweep unit installed 4 inches above the discharge. The material began to flow from the very first pulse until the vessel was completely emptied.