This article covers the important uses and common pitfalls of mechanical conveying systems. Each manufacturing scenario is unique and often requires a custom-fit solution. It is important to know the different conveying options available, as well as the necessary, proper care and cleaning to maintain the lifespan of the conveying equipment. This article will help manufacturers learn more about the different types of mechanical conveying systems available for efficient material movement and provide guidance for conveying operators.
The Difference Between Pneumatic and Mechanical Systems
Although both mechanical and pneumatic conveying systems can be effective tools, there are several key differences between the two that can determine which should be utilized for a project.
While pneumatic conveying is a system that uses pressure or a vacuum to transport materials, mechanical conveying is typically an open system which utilizes traditional machinery to transport heavy bulk materials. Mechanical systems can utilize belts, buckets, chains, rollers, or augers to convey material, whereas pneumatic conveying is reliant on the strength of the blower to push or pull the material. As a result, mechanical conveying systems are typically used in industries such as mining, agriculture, packaging, and more, since they are able to withstand the weight of the heavier materials involved.
Another key difference between the two systems is that mechanical conveyors can move wet products, but pneumatic conveyors cannot. This is because wet products are more susceptible to clogging the convey lines. Additionally, although mechanical conveyors are considered to be more versatile since they can run horizontally, vertically, or at an angle, they are only recommended for short distance conveying. This is due to the lack of flexibility and the increased amount of space the equipment takes up.
Why Do a Factory Acceptance Test?
There are many different types of conveyors that are used throughout the manufacturing industry. HaF Equipment can help meet your manufacturing needs with several different mechanical conveying options. HaF has a collection of ready-made designs and can also design custom equipment to fit specific needs.
Screw conveyors are one of the many pieces of mechanical conveying equipment that HaF has to offer. This type of conveyor uses an auger-type motion to move materials. It is often horizontal or at a slight incline. Screw conveyors can move at rates up to approximately 40 tons per hour and can cover over 65 feet. This type of conveyor can be used to move powders and other materials through a process.
A vibratory conveyor has a single trough design that vibrates to move the material upward and forward. This type of conveyor is well-suited for products that tend to clump together. It is also an efficient conveyor for more fragile materials.
Aero-mechanical conveyors use a wire rope with evenly spaced discs that travels at a high speed within a steel tube.
Bucket elevators are designed for vertical handling with dry, free-flowing bulk materials. These buckets are placed on either a single or double chain or belt.
Belt conveyors utilize a wide belt over rollers. This is used for transporting, feeding, discharging, and proportioning.
Drag chain conveyors use a chain and paddle to move the material.
Spiral conveyors are used when bulk solids must be conveyed vertically, both downward and upward.
Tubular Cable Conveyors is the most ideal choice for most fragile materials, as they are designed for gentle handling.
What technology is recommended for a specific application is dependent on several factors like layout, process variables (temperature, moisture, etc.), and material characteristics of the product being conveyed.
Challenges Involved with Mechanical Conveyors
One of the main challenges that can occur when dealing with mechanical conveyors is ventilation, especially in agriculture and industrial industries where creating dust is inevitable. Dust can be hazardous if not properly ventilated since some dust particles can be combustible.
Improper feeding can also create challenges for operators. This can occur when the spout size is miscalculated which can lead to blockages, uneven flow of materials, and increased wear and tear on the system. To avoid these problems, it is important to consider what kind of material is being moved through the system. Size, moisture content, and other physical properties should be considered to ensure proper spout sizing.
Another common challenge that may occur is improper sizing of the conveyor. Often, conveyors will be sized smaller to operate at higher speeds and reduce initial costs. However, this could lead to the conveyor not being able to handle the assigned task which can affect both safety and reliability. Extra measures to ensure safety and reliability include required temperature monitors for belt tracking systems when conveying materials that are classified as combustible, lid switches and motion switches for equipment with moving parts, and wear liners to prevent damage when systems are operating at higher speeds for prolonged periods.
Importance of Cleaning Conveying Systems
How Conveyors Are Cleaned
There are a few different ways that mechanical conveying systems can be cleaned. The three main processes are wet cleaning, drying cleaning, and dry steam cleaning.
The wet cleaning process involves spraying down and washing the conveyor. This requires proper chemicals, an adequate spray and drain system, and an efficient drying system. A good drying system is especially important for this cleaning process because if the belt is not dried correctly, the residual moisture can promote the growth of bacteria in the belts, links, and bearings of the conveyor. This will lead to more cleanliness issues and health risks for the facility and, potentially, legal issues for the company. Wet cleaning is not the solution for every material as this process, when conveying certain materials, can cause corrosion and increase wear.
Dry cleaning is another option that manufacturers can utilize. This process uses compressed air, brushes, or vacuums, and eliminates water usage otherwise required for cleaning. This process prevents the introduction of moisture into the system, which helps prevent the growth of harmful bacteria. In order for this method to be effective, the facility needs proper ventilation to dispose of the resulting dust.
Dry steam cleaning is an additional solution for circumstances that are not well suited to dry cleaning or wet cleaning. The comparatively low moisture content reduces the possibility of mold and bacteria growth and aligns with stringent food safety standards, and the temperatures are still high enough for proper sterilization. This is a favorable choice as it is an effective but gentle cleaning solution.
How HaF Can Help
HaF Equipment has a wide range of equipment options that can benefit manufacturing processes across a wide array of industries. From screw conveyors and bucket elevators to incline flex augers, HaF can offer custom mechanical conveying options to fit the need of any facility’s operations.
About HaF
HaF Equipment designs turnkey systems for projects of all sizes. Our team understands the concerns of our customers and takes the time to listen, develop a plan, and communicate along the way. If you need someone you can trust and want to eliminate the stress of managing all the details of your next project, HaF is Ready To Connect.
CONTACT US today to discuss your next project and how our team can help from concept to system solution.
About The Authors
Ansley Williams
Ansley Williams is a design engineer for HaF Equipment. She has been working as an engineer in the material handling industry for one year, and received her masters degree in mechanical engineering in 2022.
Duncan Marshall
Duncan Marshall has been with HaF since 2023. He has a background in finance and accounting, specifically Accounts Payable. He is currently a Staff Accountant for HaF Equipment.
