Conveyor systems in modern manufacturing
Manufacturers these days have many options when it comes to conveying systems for bulk material handling. Pneumatic conveying systems, in particular, are essential to industrial automation and efficient material handling.
As industries increasingly rely on automation systems for productivity, pneumatic conveyors have proven to be indispensable across multiple sectors.
However, since every industry has its own requirements, engineers and integrators ought to first understand how pneumatic conveying systems work, so they can determine if its versatile features match their industrial needs.
Unsure which system best fits your industry needs? Contact MACTEX for a customised solution or to explore other suitable alternatives.
Here is an overview of pneumatic conveying systems:
Pneumatic conveying systems transport bulk materials like powders, granules, and pellets through enclosed pipelines using gas streams. These systems ensure bulk material travels safely from silo systems where they are stored to their respective destinations in the plant.
They can be broadly classified into two subcategories based on the velocity of air and how materials behave during transport. Both of these subcategories play a major role in industrial automation for bulk handling.
Dilute Phase Conveying: Uses high-velocity gas streams (20-30m/s) to suspend and move materials in the air, ideal for powder handling systems.
Dense Phase Conveying: Relies on low-velocity, high pressure gas streams (5-10m/s) to transport materials in a slug-like form, suitable for handling abrasive or fragile materials.
A key statistic from MACTEX’s case study shows that switching to dense phase conveying in the chemical industry reduced material degradation by 30%, ensuring higher product quality and fewer losses during transport.
Unlike traditional mechanical conveyors, which rely on belts or chains, pneumatic conveyors utilise vacuum pumps, blowers, and compressors to generate a vacuum or pressure system. Other components include long bends, rotary valves, double flaps, and venturis.
This often results in a cleaner, more flexible, and more efficient solution.
The sealed pipelines prevent dust emissions and spillage, ensuring a cleaner workspace and reducing environmental impact. Thanks to the controlled atmosphere, these industrial conveyors also ensure bulk materials are protected from external contaminants.
Take a deep dive into the nitty gritty of pneumatic conveying systems by exploring various components offered by MACTEX.
A further comparison below shows how pneumatic conveyors stand out:
|
Mechanical conveyors |
Pneumatic conveyors |
|
|
Efficiency |
Suitable for short, heavy loads. Requires more energy for long distances. |
Efficient for long-distance transport, especially with powders. |
|
Cost-Effectiveness |
Higher maintenance costs due to wear and tear. |
Lower long-term operational costs due to minimal maintenance and fewer moving parts. |
|
Versatility |
Limited flexibility in routing, best suited for uniform, non-fragile materials. |
Highly flexible and capable of complex routing, can handle a wide range of materials. |
All in all, pneumatic conveying equipment plays an important role in industrial automation, as it leads to efficient bulk material handling, minimising waste and maintaining productivity.
Whether it is moving raw materials in manufacturing or precise powder conveying in pharmaceuticals, these industrial conveyors are designed to integrate seamlessly into modern automation systems.
These systems offer superior efficiency, cost-effectiveness, and flexibility, making them an ideal choice for industries aiming to optimise production processes.
Discover how MACTEX helps manufacturers integrate or upgrade their material handling processes with automation and IoT systems.
From food and pharmaceuticals, to energy and manufacturing, all of these industries can benefit greatly from using pneumatic conveying to automate transporting bulk material.
Take a look at these real-world applications of pneumatic conveying in industrial automation systems.
1. Manufacturing
In manufacturing, pneumatic conveyors transport raw materials like grains, and plastics from storage silos to production lines. MACTEX’s clients in the manufacturing sector reported a 25% increase in production efficiency after switching to pneumatic conveying, including abrasive materials that require gentle handling.
2. Pharmaceuticals
In the pharmaceutical industry, precision and cleanliness are paramount. Pneumatic conveying systems excel in safely transporting delicate materials such as fine powders and tablet granules within a sealed, contamination-free environment. Their integration with automation systems not only ensures precise dosing and batching, but also reduces the risk of contamination, which is critical for maintaining product quality and regulatory compliance.
3. Food & Beverage
In the food and beverage industry, pneumatic systems play a critical role in the hygienic transport of dry food products such as flour, sugar, and spices. These systems provide a sealed, dust-free environment from silo systems to various end points, minimising contamination risks and ensuring compliance with strict hygiene standards. Furthermore, automatic dosing systems can dispense precise quantities according to predefined recipes, minimising waste and ensuring product quality.
4. Chemicals
Chemical industries often deal with hazardous or toxic materials. Pneumatic conveying equipment ensures safe, enclosed handling of these materials, protecting workers and the environment from potential spills, leaks, or exposure. For chemical powders that display poor flow characteristics, conveying systems with smooth internal surfaces and equipment like screw conveyors help minimise flow resistance, improving efficiency.
5. Energy
Pneumatic conveying systems are integral to power generation, where they efficiently transport coal dust, biomass materials, wood pellets, and other alternative fuels within a sealed, automated environment. This reduces the risk of dust explosions, a critical safety concern, while minimising environmental contamination and loss of material. Moreover, the precise and reliable transport capabilities of these systems ensure a continuous fuel supply, optimising combustion processes and improving overall power plant efficiency.
As pneumatic conveying technology continues to evolve, several emerging trends are gaining traction and should be monitored for potential integration into existing systems.
Today, MACTEX continues to pioneer new innovations in pneumatic conveying technology, such as improved energy efficiency, smarter control systems, and advanced materials for pipelines.
Here are a few key trends to follow:
Smart Conveying Systems: These smart systems integrate IoT and real-time monitoring — connecting the plants, facilities, and workers — thereby optimising operations and predictive maintenance.
One of MACTEX’s clients freed up 26,000 sq ft of valuable production floor space after automating their conveying system, allowing them to convert an existing warehouse into an additional production line, fully utilising the available space and increasing production output.
Energy-Efficient Blowers: From roots blowers to screw blowers, these greener components reduce power consumption without compromising on conveying capacity.
Advanced Material Handling: With new, advanced pipelines coatings, pneumatic conveyors are now being designed to last longer while minimising wear, especially in abrasive applications.
MACTEX is at the forefront of advancing pneumatic conveying systems, offering cutting-edge industrial engineering services that cater to diverse industry needs.
From bulk material handling in manufacturing to precise powder handling systems in pharmaceuticals, MACTEX’s innovative designs and engineering expertise are shaping the future of pneumatic technology.
All in all, pneumatic conveying systems offer a versatile solution integral to the success of industrial automation and material handling.
The versatility, efficiency, and safety of pneumatic conveying systems make them indispensable across industries, whether it’s bulk handling raw materials in manufacturing or ensuring the safe handling of hazardous chemicals.
As industries evolve, pneumatic conveyors will continue to adapt, incorporating new technologies and innovations to meet the ever-changing demands of modern production.
From bulk handling material to tailored automation systems, MACTEX delivers the reliability and innovation needed to optimise operations.
For businesses looking to enhance their conveying systems, explore the comprehensive solutions that MACTEX offers today.
