{"id":6492,"date":"2021-05-14T06:38:50","date_gmt":"2021-05-14T06:38:50","guid":{"rendered":"https:\/\/controlconceptsusa.com\/?p=6492"},"modified":"2021-12-11T00:01:14","modified_gmt":"2021-12-11T00:01:14","slug":"how-to-improve-material-flow-in-silos-and-hoppers","status":"publish","type":"post","link":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/","title":{"rendered":"Material flow: How to improve it in silos and hoppers"},"content":{"rendered":"<p><img decoding=\"async\" class=\"aligncenter wp-image-6594 size-large\" src=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow-1024x201.png\" alt=\"Promoting material flow\" width=\"1024\" height=\"201\" srcset=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow-1024x201.png 1024w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow-600x118.png 600w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow-300x59.png 300w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow-768x151.png 768w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow-1536x302.png 1536w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/04\/Material-Flow.png 1886w\" sizes=\"(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 1362px) 62vw, 840px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">Engineers and plant managers are often tasked to design or recommend the right container for storing and handling bulk solids. They have to weigh several factors \u2014 capacity, storage duration, installation cost, and how well it protects the material from moisture and pests.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">But there\u2019s another factor that greatly affects productivity and can lead to expensive hidden costs: the material flow. Some containers are more prone to bridging and arching, particularly above the discharge. This can affect productivity, product quality, and profit.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Let\u2019s look at the two most common containers \u2013 silos and hoppers \u2013 and how to promote reliable material flow in them.<\/span><\/p>\n<hr \/>\n<h2><span style=\"font-weight: 400;\">Overview: Material flow: How to improve it in silos and hoppers<\/span><\/h2>\n<p>Silos and hoppers are prone to different material flow issues. In the following slide presentation, you&#8217;ll learn the difference between the two and how material flow can help improve their performance.<\/p>\n<p><iframe style=\"border: none;\" src=\"https:\/\/www.slideshare.net\/MarketingControlConc\/slideshelf\" width=\"615px\" height=\"470px\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\" allowfullscreen=\"allowfullscreen\"><\/iframe><\/p>\n<hr \/>\n<h2><span style=\"font-weight: 400;\">What&#8217;s the difference between a silo and a hopper?<\/span><\/h2>\n<p><iframe title=\"Material Flow in Silos and Hoppers Part 1 - Differences between Silos and Hoppers v1\" src=\"https:\/\/player.vimeo.com\/video\/560821973?dnt=1&amp;app_id=122963\" width=\"500\" height=\"281\" frameborder=\"0\" allow=\"autoplay; fullscreen; picture-in-picture; clipboard-write\"><\/iframe><\/p>\n<div id=\"attachment_6596\" style=\"width: 298px\" class=\"wp-caption alignright\"><img decoding=\"async\" aria-describedby=\"caption-attachment-6596\" class=\"wp-image-6596\" title=\"Michael Trolove\u00a0\/\u00a0Grain Silos at Manor Farm\" src=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/Grain_Silos_at_Manor_Farm_-_geograph.org_.uk_-_1706973.jpg\" alt=\"Silos are the oldest storage vessel used by man. \" width=\"288\" height=\"216\" \/><p id=\"caption-attachment-6596\" class=\"wp-caption-text\">Silos are the oldest storage vessel used by man. Credit: Michael Trolove \/ <i>Grain Silos at Manor Farm<\/i><\/p><\/div>\n<p><span style=\"font-weight: 400;\">Silos are used for bulk storage. While the earliest silos were primarily used to store extra grain, modern silos can hold any kind of material: cement, black carbon, plastic resins, wood chips, and more. <\/span><\/p>\n<p><span style=\"font-weight: 400;\">Common types include tower silos, bunker silos, and bag silos.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Hoppers are used for temporary storage or measured feeding systems. They come in different shapes: cones, wedges, pyramids, or a combination of these.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<h2><\/h2>\n<h2><\/h2>\n<hr \/>\n<h2><span style=\"font-weight: 400;\">Common material flow problems<\/span><\/h2>\n<p><iframe title=\"Material Flow in Silos and Hoppers Part 2 - Common Material Flow Problems and How to Solve Them v1\" src=\"https:\/\/player.vimeo.com\/video\/560822034?dnt=1&amp;app_id=122963\" width=\"500\" height=\"281\" frameborder=\"0\" allow=\"autoplay; fullscreen; picture-in-picture; clipboard-write\"><\/iframe><\/p>\n<p><span style=\"font-weight: 400;\">Ideally, any material in silos and hoppers can be discharged quickly and consistently to prevent production delays or accumulation of stagnant material that can spoil or contaminate the next batch. However, many plant managers are plagued with material blocks in their production line.<\/span><\/p>\n<h3>Ratholing<\/h3>\n<p><span style=\"font-weight: 400;\">Material builds up on the vessel walls, restricting the flow and the vessel\u2019s full storage capacity. When the flow channel empties and material flow ceases, it can form a stable rathole that may collapse and block the opening.<\/span><\/p>\n<h3>Bridging or arching<\/h3>\n<p><span style=\"font-weight: 400;\">Materials interlock or bond together to form an arch above the outlet, blocking any flow. The strength of this arch depends on the cohesive strength and internal friction of the particles. Hammering or blasting with an air cannon can break the arch, but this can overload and damage the vessel.<\/span><\/p>\n<h3>Segregation<\/h3>\n<p><span style=\"font-weight: 400;\">If the vessel is filled with different particle sizes, it\u2019s natural for finer particles to collect at the center of the bin, while coarser particles stick to the slope. The variable, inconsistent material discharge can affect product uniformity.<\/span><\/p>\n<hr \/>\n<h2><span style=\"font-weight: 400;\">Factors that affect material flow in silos and hoppers<\/span><\/h2>\n<p><iframe title=\"Material Flow in Silos and Hoppers Part3 - Factors that Affect the Material Flow of Bulk Powders and Solids v1\" src=\"https:\/\/player.vimeo.com\/video\/560822098?dnt=1&amp;app_id=122963\" width=\"500\" height=\"281\" frameborder=\"0\" allow=\"autoplay; fullscreen; picture-in-picture; clipboard-write\"><\/iframe><\/p>\n<div id=\"attachment_6597\" style=\"width: 294px\" class=\"wp-caption alignleft\"><img decoding=\"async\" aria-describedby=\"caption-attachment-6597\" class=\"wp-image-6597\" src=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg-1002x1024.jpeg\" alt=\"An example of a hopper.\" width=\"284\" height=\"290\" srcset=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg-1002x1024.jpeg 1002w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg-600x613.jpeg 600w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg-294x300.jpeg 294w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg-768x785.jpeg 768w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg-1504x1536.jpeg 1504w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/LWq5EmUg.jpeg 1528w\" sizes=\"(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 1362px) 62vw, 840px\" \/><p id=\"caption-attachment-6597\" class=\"wp-caption-text\">A hopper shows hammer marks from workers who tried to clear material blocks.<\/p><\/div>\n<h3>Material properties<\/h3>\n<p><span style=\"font-weight: 400;\">Some materials are more prone to arching, bridging or segregation. Fine powders, small particles and sticky materials have a higher cohesive strength and tend to bridge or compress along the vessel walls.\u00a0\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Other factors include bulk material density, the pressure applied by its weight in storage, permeability, and tendency to retain moisture. Ideally, these <a href=\"https:\/\/www.sciencedirect.com\/topics\/engineering\/material-flow-analysis\" target=\"_blank\" rel=\"noopener\">material flow properties<\/a> are considered while choosing the silo or hopper design.\u00a0<\/span><\/p>\n<h3>Vessel angle<\/h3>\n<p>If the hopper walls are not steep or smooth enough, the material won\u2019t flow down the vessel walls. It will cake and build up, or if it has enough cohesive strength, it can bridge over the outlet or form a rathole as it empties out.<\/p>\n<p><span style=\"font-weight: 400;\">The hopper angle depends on the friction between the powder and the walls, the friction between powder particles, and the shape of the vessel.<\/span><\/p>\n<h3>Vessel shape<\/h3>\n<p><span style=\"font-weight: 400;\">Generally, square feed hoppers work better for bulk materials with uniform pellets. However, when there is a large variation of particle size \u2014 like when virgin material is combined with plastic regrind \u2014 circular hoppers allow for a more gradual compression.<\/span><\/p>\n<h3>Outlet and feeder<\/h3>\n<p><span style=\"font-weight: 400;\">The size of the outlet, the discharge rate, and the interface of the feeder can all affect material flow at the bottom of the vessel. This is particularly problematic for materials that have greater cohesive strength and bulk density, or have a tendency to segregate or spoil.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Steep cones or wedge-shaped hoppers may be able to promote mass flow. Flow aids can also break any bridging or arching above the discharge.<\/span><\/p>\n<hr \/>\n<h2><span style=\"font-weight: 400;\">How to improve poor material flow in silos and hoppers<\/span><\/h2>\n<p><img decoding=\"async\" class=\"aligncenter wp-image-6595\" src=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep-1024x532.jpg\" alt=\"AirSweep Material Flow Aid\" width=\"681\" height=\"354\" srcset=\"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep-1024x532.jpg 1024w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep-600x312.jpg 600w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep-300x156.jpg 300w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep-768x399.jpg 768w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep-1536x798.jpg 1536w, https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep.jpg 1540w\" sizes=\"(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 1362px) 62vw, 840px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">Material flow aids can help break through bridging and arching and promote on-demand flow. These can include:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Mechanical flow aids like vibrators or agitators<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Pneumatic flow aids like fluidizers and<\/span><a href=\"https:\/\/controlconceptsusa.com\/airsweep\/\"> <span style=\"font-weight: 400;\">AirSweep<\/span><\/a><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Chemical flow aids like fumed silica<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Each flow aid will have its pros and cons. Some are better suited for certain types of bulk solids. For example, vibrators can actually compact moist or dense solids like flax or whey protein, while fluidizers are only effective for light powders like flour. (Get a<\/span><a href=\"https:\/\/controlconceptsusa.com\/airsweep-competitive-analysis\/\"> <span style=\"font-weight: 400;\">competitive analysis for different kinds of flow aids<\/span><\/a><span style=\"font-weight: 400;\">.)<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Flow aids can be retrofitted into silos and hoppers. This can be more cost-effective than replacing the bins or having them custom-made. Some of them, like the AirSweep, barely require any modification of the silo or the hopper since they are installed on the wall with a mounting bracket.<\/span><\/p>\n<hr \/>\n<p><span style=\"font-weight: 400;\"><a href=\"https:\/\/controlconceptsusa.com\/video\/airsweep-a-quick-look\/\">Finding the \u201cright\u201d flow aid<\/a> also depends on the type of material, or the size of the silo or hopper. We can provide a customized proposal based on your process.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\"><a href=\"https:\/\/controlconceptsusa.com\/request-a-quote\/\">Contact us<\/a> to find an affordable and reliable solution to arching, bridging and other material blocks.\u00a0<\/span><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Engineers and plant managers are often tasked to design or recommend the right container for storing and handling bulk solids. They have to weigh several factors \u2014 capacity, storage duration, installation cost, and how well it protects the material from moisture and pests. But there\u2019s another factor that greatly affects productivity and can lead to [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":6595,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[90,1019],"tags":[998,1018,1017,1015,1016],"class_list":["post-6492","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-airsweep","category-news-and-information","tag-airsweep","tag-flow-aids","tag-hoppers","tag-material-flow","tag-silos"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.8 (Yoast SEO v27.0) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Material flow: How to improve it in silos and hoppers Control Concepts, Inc.<\/title>\n<meta name=\"description\" content=\"Material flow can affect productivity and cost. 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Find out how you can promote material flow in silos and hoppers with flow aids.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/","twitter_misc":{"Written by":"Control Concepts USA","Est. reading time":"5 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"Article","@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/#article","isPartOf":{"@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/"},"author":{"name":"Control Concepts USA","@id":"https:\/\/controlconceptsusa.com\/#\/schema\/person\/4adf025d9423fe94f784b73a083afb0e"},"headline":"Material flow: How to improve it in silos and hoppers","datePublished":"2021-05-14T06:38:50+00:00","dateModified":"2021-12-11T00:01:14+00:00","mainEntityOfPage":{"@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/"},"wordCount":927,"publisher":{"@id":"https:\/\/controlconceptsusa.com\/#organization"},"image":{"@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/#primaryimage"},"thumbnailUrl":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep.jpg","keywords":["AirSweep","flow aids","Hoppers","Material Flow","Silos"],"articleSection":["Airsweep","News and Information"],"inLanguage":"en-US"},{"@type":"WebPage","@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/","url":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/","name":"Material flow: How to improve it in silos and hoppers Control Concepts, Inc.","isPartOf":{"@id":"https:\/\/controlconceptsusa.com\/#website"},"primaryImageOfPage":{"@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/#primaryimage"},"image":{"@id":"https:\/\/controlconceptsusa.com\/how-to-improve-material-flow-in-silos-and-hoppers\/#primaryimage"},"thumbnailUrl":"https:\/\/controlconceptsusa.com\/wp-content\/uploads\/2021\/05\/airsweep.jpg","datePublished":"2021-05-14T06:38:50+00:00","dateModified":"2021-12-11T00:01:14+00:00","description":"Material flow can affect productivity and cost. 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