Efficient bulk material handling is critical for industries such as food processing, plastics, chemicals, and pharmaceuticals. Choosing the right conveying system can impact product quality, operational efficiency, and maintenance costs.
At AMH Technologies, we provide tailored solutions for both pneumatic conveying and pipe chain conveying. This case study highlights the applications, challenges, and outcomes of both systems in industrial scenarios.
Pipe chain conveying system for gentle material handling
Pneumatic conveying system for efficient material transport
Project Background
A client in the food and beverage industry needed to transport flour and sugar from storage silos to multiple production lines across a facility. The key requirements were:
- Minimise product degradation
- Reduce dust and contamination
- Maximise system reliability
- Provide flexible routing through complex plant layout
AMH was tasked with evaluating pneumatic conveying and pipe chain conveying to determine the most suitable solution.
Solution 1: Pneumatic Conveying System
System Type: Dilute phase pressure conveying
Design Features:
- Material: Flour and sugar
- Conveying distance: 80–100 meters
- Pipeline: Stainless steel with multiple bends
- Feeding: Rotary airlock valves at silo outlets
- Discharge: Cyclone separators to feed production lines
- Airflow control: Blowers designed for optimal velocity (15–25 m/s)
Advantages:
- Enclosed system reduces dust exposure and contamination
- High flexibility for complex layouts
- Can feed multiple production lines from a single silo
- Minimal maintenance on moving parts
Challenges:
- High velocity may cause minor product degradation
- Requires precise air volume and pressure control
- Energy consumption higher for long distances
Outcome:
The pneumatic system successfully delivered consistent, controlled material flow to all production lines. Dust exposure was minimised, and production efficiency improved by 12% compared to manual or gravity-fed systems.
Solution 2: Pipe Chain Conveying System
System Type: Mechanical pipe chain conveyor
Design Features:
- Material: Flour, sugar, and plastic pellets
- Conveying distance: 100–120 meters with elevation changes
- Pipeline: Enclosed steel tube with continuous chain and flights
- Feed: Gravity feed from silos
- Discharge: Screw or rotary feeders into production lines
Advantages:
- Gentle on fragile or abrasive materials; minimal degradation
- Lower energy consumption than high-velocity pneumatic systems
- Handles a wide range of bulk densities and particle sizes
- Simple operation with low maintenance of motor-driven chain
Challenges:
- Less flexibility for complex routing
- Cannot easily split material flow to multiple lines
- Higher initial investment compared to simple pneumatic systems
Outcome:
The pipe chain system provided zero degradation for fragile powders and pellets, and reduced energy costs by 18% compared to a comparable pneumatic system. However, routing limitations required additional design considerations to feed multiple production lines.
Comparison Summary
| Feature | Pneumatic Conveying | Pipe Chain Conveying |
|---|---|---|
| Product degradation | Minor for fragile materials | Zero degradation |
| Dust control | Excellent - enclosed system | Good - enclosed tube |
| Flexibility in routing | High - complex layouts | Limited - careful design needed |
| Energy consumption | Higher for long distances | Lower - 18% reduction |
| Maintenance | Minimal moving parts | Low - motor-driven chain |
| Material types | Wide range - powders/granules | Wide range + fragile materials |
Client Feedback
Pneumatic System:
"The enclosed system greatly reduced dust in the plant and allowed multiple production lines to operate simultaneously. Maintenance is minimal and easy to manage."
Pipe Chain System:
"Material arrives intact with no degradation. Energy consumption is noticeably lower, but the system requires careful planning for layout changes."
Key Takeaways
Pneumatic conveying is ideal when:
- Dust control is critical
- Complex routing or multiple pickup/discharge points are required
- Moderate product degradation is acceptable
Pipe chain conveying is ideal when:
- Fragile or abrasive materials must remain intact
- Energy efficiency is a priority
- The plant layout is simple or moderately complex