When it comes to bulk material handling, manufacturers have to make a choice between mechanical vs pneumatic conveying systems and tools in order to optimise the manufacturing process. Here’s a quick rundown of what these systems are:
Mechanical Conveying Systems
Mechanical conveying systems feature a drive motor through a gear and chain reducer that is connected to a drive device such as a sprocket or a roller. In mechanical systems, the energy of the motor is directly transferred to the conveyor that is in direct contact with the material being transferred. Unlike pneumatic conveyors, mechanical conveyors can either be opened or closed to the atmosphere, and consist of hundreds of moving and working parts.
Pneumatic Conveying Systems
Pneumatic conveying systems are comprised of four main components: an air source, a material feed device, a conveying line, and an air-material separator. Pneumatic conveyors are often used by manufacturers to transfer powders, granules, and many other dry bulk materials from one process area to another via vacuum and pressure. Pneumatic powder conveying systems also transfer bulk material within a fully enclosed line, greatly reducing the possibility of material loss and contamination.
Differences Between Mechanical and Pneumatic Conveyors
While mechanical conveying systems may be more practical for niche manufacturing companies that require transfers of heavy, granular materials, pneumatic powder conveying systems feature an entire host of nuanced advantages that make them the preferred choice for most manufacturers when it comes to bulk transfer solutions. Here are the five main advantages of pneumatic conveying systems:
1. Routing
Pneumatic powder conveying systems are much easier to route than their mechanical counterparts. As the conveying line consists only of a simple pipe, pneumatic conveyors require minimal floor space and can be routed in a flow that goes both horizontally and vertically (note: with some limitations). The conveying line of pneumatic powder conveying systems can also be attached to existing structures, columns, or rafters, effectively eliminating the need for special foundations of support frames.
All in all, pneumatic conveying systems benefit manufacturers by reducing floor space taken while allowing for the conveying line to accommodate or go around existing obstructions rather than forcing the manufacturer to remove them entirely, thereby providing significant cost-savings in terms of rental and construction expenses.
2. Cleanliness
Pneumatic powder conveying systems also present an overall cleaner process as compared to mechanical conveying. Pneumatic conveyors can effectively eliminate the risk of spillage for manufacturers, which is especially important for manufacturing companies dealing with sensitive or hazardous materials. As a pneumatic powder conveying system is enclosed, the system not only protects the integrity of a material, but can also protect a company’s workforce and facility from potentially dangerous spills.
The enclosed nature of pneumatic powder conveying systems also mean that FMCG food and beverage manufacturers can alleviate the risk of product contamination, effectively avoiding heavy financial ramifications that can occur as a result of contaminated consumables.
3. Maintenance
With considerably fewer parts than mechanical conveying systems, pneumatic powder conveying systems are a lot easier to maintain. As aforementioned, there are only four main components that make up a pneumatic system, each of which is repairable at the component level without having to move any equipment whatsoever.
Having fewer parts also makes pneumatic powder conveying systems less susceptible to mechanical failure and consequently downtimes, effectively aiding manufacturers to achieve maximum productivity and efficiency at all times.
4. Safety
Pneumatic powder conveying systems also greatly reduce the risk of work injuries happening at your manufacturing facility. Since all its components are sealed to contain pressure or vacuum, the fewer exposed parts of a pneumatic conveying system means that workers are less likely to suffer injury from getting too close to moving components.
Dust explosions are also a lot less likely to happen with pneumatic conveyors, and the quieter system of pneumatic equipment facilitates a safer and more hospitable work environment.
5. Flexibility
Lastly, pneumatic powder conveying systems allow for much more long-term flexibility. Process change is a common occurrence in the manufacturing industry, and expanding a mechanical system to accommodate said change can be extremely costly and time-consuming. When it comes to pneumatic conveying systems, however, manufacturers can simply purchase and install the required added pneumatic equipment parts from suppliers. Buying simple diverter valves, dehumidification systems or additional silos are a lot less costly than purchasing entirely new equipment to add on to existing mechanical conveyors.
Furthermore, because pneumatic powder conveying systems are—as aforementioned—easier to route, the added flexibility in that regard also provides substantial savings in the form of unnecessary expansion costs.
Get the Best Pneumatic Conveying Systems from Pneu Powders
Pneu Powders Systems is the leading supplier of pneumatic conveying equipment and powder handling systems. We also offer systems integration services for manufacturing companies that need it.
Check out our comprehensive and diverse collection of past projects, and get in touch with us today for the manufacturing solutions you need.
