Have you ever stood in front of a hopper, watching production grind to a halt because the material inside simply refuses to move? Or perhaps you’ve dealt with a product that looked perfect at the start of the line but arrived at the packaging station separated and inconsistent. If you work in manufacturing, these scenarios probably sound all too familiar.
Handling powders and granules can be tricky. Unlike liquids, which generally behave predictably, bulk solids have a mind of their own. They can cake, arch, flood, or separate, leading to costly downtime and frustrated teams. But here is the good news: flow problems aren't a mystery. They are physics problems, and they can be solved.
At Material Flow Solutions, we believe that understanding the science behind your material is the key to reliable production. Whether you are in the pharmaceutical, food, or chemical industry, optimizing your handling process is the best way to ensure efficiency and profitability. Let’s explore how the right testing and design can turn a headache-inducing process into a smooth operation.
The Challenge of Bulk Solids Handling
Bulk solids handling is a critical part of operations for countless industries, from bio-fuels to pharmaceuticals, or even mining production. Yet, it remains one of the most common sources of production bottlenecks.
When a system isn't designed with the specific material properties in mind, several issues can arise:
- Arching: Material forms a bridge over the outlet, stopping flow completely.
- Ratholing: Material flows only from the center, leaving stagnant product on the sides which can spoil or cake.
- Flooding: Fine powders become aerated and flush through the system uncontrollably like water.
These aren't just annoyances; they are economic drains. They waste time, ruin product quality, and can even create safety hazards. The solution starts with moving away from guesswork and moving toward data.
Why You Can’t Guess with Powders
Many production facilities rely on "rules of thumb" or generic equipment designs. The problem is that sugar doesn't flow like salt, and pharmaceutical powders don't behave like agricultural granules. Even small changes in moisture content or particle size can drastically change how a material moves.
To build a robust system, you need to know exactly what you are working with. This is where scientific analysis comes into play.
The Role of the Particle Properties Test
Before you can design a silo or a feeder, you need to understand the individual particles. A particle properties test looks at the fundamental characteristics of your material. We examine things like particle shape, surface friction, size distribution, and density.
Is your material jagged and interlocking? Is it smooth and spherical? These physical traits dictate how particles interact with each other and with the equipment walls. By characterizing these properties early, we can predict potential issues before they cause a line stoppage.
Understanding Movement with a Powder Flowability Test
Once we know what the particles look like, we need to know how they move as a group. A powder flowability test measures how the material reacts under pressures and stress levels in your process.
In a storage bin, the material near the transition from the cylinder to the cone is under immense pressure or stress. While the material near the bin outlet is under much less pressure or stress. If your powder is cohesive, that pressure may turn it into a solid block (caking) or cause it to support its own weight over an outlet (arching). Flowability testing gives us the “flow function” of the material. This data tells engineers exactly how steep hopper walls need to be and how large the outlet must be to prevent arching, or how large the active flow channel must be to ensure gravity does its job and prevents stable rathole formation.
Preventing Separation with a Powder Segregation Test
One of the most insidious problems in bulk handling is segregation. This happens when a blend of ingredients separates back into its original components. For example, if you are making a drink mix, you might end up with all the sugar at the bottom of the bag and all the flavoring at the top.
Segregation often happens during discharge or transport. Heavier or smaller particles might sift through the lighter or larger ones. Materials with different repose angles may separate as they form a pile. A powder segregation test helps us identify if your material is prone to these behaviors. If it is, we can design handling systems that minimize patterns that cause separation, ensuring your final product is consistent from the first batch to the last.
Engineering Solutions That Work
Testing is vital, but data alone doesn't move mountains (or powders). The next step is applying that data to engineering design.
At Material Flow Solutions, we don't just hand you a report and wish you luck. We use the insights from the bulk material flow test to create conceptual designs that work. This might mean retrofitting an existing bin with a new insert to change the flow pattern, or it might mean designing a completely new feeding system from scratch.
Our approach is grounded in sound scientific principles. We look at the friction between your material and the wall liner. We calculate the critical arching dimensions. We analyze the compressibility of the solid. We test the segregation tendency of the mixture.
By basing the design on measured properties rather than generic assumptions, we help you achieve:
- Reliable Flow: Material goes where you want it, when you want it.
- Process Optimization: Faster throughput and less downtime.
- Economic Goals: A better bottom line thanks to reduced waste and maintenance.
A Partner in Your Success
We know that dealing with technical flow problems can be stressful. You want your plant to run smoothly, and you want satisfied customers. We want that for you, too.
Material Flow Solutions was incorporated in 2001 in Gainesville, Florida, but our roots go much deeper. Dr. Kerry Johanson, a leader in the industry, brings over 50 years of experience to the table. We have spent decades solving the toughest problems in powder and granule handling.
Our mission is simple: we help you achieve your goals. Whether you need a quick troubleshoot, a complex retrofit, or a new product development strategy, we are here to support you. We view our relationship with clients as a partnership. We listen to your needs, analyze your specific challenges, and provide robust, economic solutions.
Let’s Get Things Moving
You don't have to accept poor flow as "just the way it is." With the right expertise and the right tests, you can revolutionize your bulk operations.
Whether you are dealing with a new product formulation or trying to fix a legacy system that has never worked quite right, we are ready to help. Let’s use science to make your production process efficient, reliable, and successful.
Are you ready to optimize your operation? Reach out to us today and let’s discuss how we can get your materials flowing.
