Aerocon

Aero-Mechanical Conveying: The Best of Both Technologies

While pneumatic conveying is by far the most hygienic conveying method for dry bulk powders, there are instances where mechanical conveying may be a better choice: processing facilities with nominal headroom above their equipment; a need for high-speed transfer with minimal energy consumption; and transferring friable materials.

Aero-mechanical conveying (also called aero-conveying) moves material using both pneumatic and mechanical conveying, with the process eliminating most disadvantages of each, resulting in the high volume, controlled, clean transfer of dry materials. It’s an excellent way to quickly transfer product from the source—paper sacks, bulk bags, bag dump stations, silos, feed bins, hoppers, totes, supersacks, mixers, and blenders—straight to downstream processes and packaging lines without any loss of integrity.

Aerocon: A Quick Overview of Features & Benefits

• Versatile: Move powders, granules, pellets, flakes, seeds, beads, beans, and more. Aerocon aero-conveyors can handle an impressively wide range of bulk densities from 5 to 200 pounds per cubic foot, particle sizes from 5 microns to ½ inch, and powder properties from free-flowing to cohesive – all handled by the same aero-conveying system.
• Dust-Free & Sanitary: Aero-conveying is an enclosed system, preventing contamination and ensuring dust-free transfer. The Aerocon also offers Clean-in-Place technology, making it an excellent choice for food processing, pharmaceuticals, biotechnology, cosmetics, and chemical manufacturing.
• Adaptable & Flexible: Low overhead? Need to move material vertically? Around corners? No problem. Aero-mechanical conveyors can handle floor level loading, multi-plane handling (horizontally and vertically), conveying around corners, and any angle from 0 to 180 degrees. Systems can also be easily reconfigured to suit new applications, should the need arise.
• Gentle Handling: Bulk ingredients are conveyed cleanly without segregation, and gently to avoid product degradation. Excellent for mixes, friable, and fragile materials.
• High Throughput: Aero-mechanical conveying is powerful and fast, conveying up to 2000 pounds in 10 minutes, and is ideal for batch conveying.
• Cost & Energy Efficient: Aero-mechanical conveyors are known for being a highly-efficient, cost-effective method of conveying dry solids. They are economical to run and—depending on the design of the conveyor—the cost of a mechanical conveyor can be one third of that of a pneumatic conveyor for the same output.
• Low Maintenance: Aero-mechanical conveying systems are easy to maintain. VAC-U-MAX Aerocon conveyors are engineered with bi-directional tensioning system that is independent of the drive assembly, offering easy clean self-draining housings. Our systems also offer Clean-in-Place technology.

Aerocon: How It Works

An Aerocon Aero-Conveyor is constructed of two parallel tubular housings (typically 3″ or 4″ tubes) containing a continuous loop of steel cable. Polymer discs smaller than inside diameter of the tubes are mounted at equal intervals along the steel cable. One side of the housing is for conveying, and the other is for return. Material inlets and outlets are suitably located for the application.

Two sprocket assemblies, one providing drive and linked to a small motor (typically 2 or 3 hp.) and the other guiding the return, complete a basic system. The versatility of aero-conveying permits additional tubing, sprockets, inlets and outlets, angles, bends, horizontal and vertical configurations, to form a continuous system ranging from 10 feet to about 120 feet. Several systems can cascade to cover greater distances.

Material entering the inlet is moved in a fluidized form, by pockets of air between the discs, further aided mechanically by movement of the discs. Controlling the velocity of the cable assembly determines the nature of conveying and movement of the product.

Densilute

Aerocon has conducted research and tests which enable the user to move certain products at critical speeds, approaching the equivalents of dense or dilute phases in the system. High speed, lean (or dilute) phase conveying fluidizes the material and handles particles more gently than pneumatic conveying. The dynamics of fluidization within the cable-disc configuration, around the corners, causes minimal impact between particles and against the housing. The result is less particle degradation, less conveyor wear, than with dilute pneumatic conveying.

Low speed, dense phase aero-conveying further reduces particle degradation and conveyor wear by controlling the material’s optimum conveying velocity. The use of long-radius bends further reduces particle impact. (Aerocon detailed test results on a wide variety of materials are available on request.) Results permit dense phase aero-conveying of friable materials such as cereals and energy requirements, or capital outlay.

Aero-conveying is economical.

Considering the small motor (generally 2-3hp) which is the only power source needed for either high, low, or variable speed operation, operating costs are modest. In comparison to other forms of conveying, which may require a dedicated supply of high pressure air, filters to retain dust within the system, and suffer from the occurrence of associated maintenance, the cost differential is substantial.

From a continuous operating standpoint, the overall maintenance of an Aerocon system is limited to occasional tightening of the steel cable, and the occasional replacement of a disc and cable assembly. Product retention in the conveyor system is very low with the Aerocon unique housing designs. In many applications a simple cleaning procedure is accomplished in minutes. Of the many operating systems currently being used, the track record speaks for itself.

Safety Features

In keeping with all responsible manufacturers, Aerocon strives to make their products completely safe in operation. For this reason, guards and safety interlocks are provided on potential hazardous areas such as belts, quick access features. Aero-Conveyors are designed to be integrated into the customer’s plant and all safety devices should be in place and operational before running the equipment. Details are contained in, but not limited to, the operating manuals and drawings provided with the machines. Extra copies are available on request.

Specifications & Options

Aerocon Conveyors are available in a variety of sizes, types and materials of construction. These include, carbon steel, 304 or 316 stainless steel. As a standard we provide stainless steel tubing or aluminum with all conveyors, and all carbon steel parts are painted externally with epoxy baked finishes or environmentally safe and durable powder coating. Stainless steel can be bead blasted, brush finished, or mirror polished by hand. We offer a wide variety of disc materials and feature our unique snap-together replaceable discs, or the more traditional three-part assemblies in nylon, polyurethane, polycarbonate, and U.H.M.W. depending on the particular application.

Capacities depend on many factors; however, as a general rule the following guidelines can be used:

Aerocon Conveyor Systems

Basic Up-and-In Series 200

The original and most simple application of aero-conveying! Product is fed into the sprocket end from a controlled feed, then transferred in a straight line to a discharge point where it’s offloaded under centrifugal force. This option offers high volume, high linear velocity, lean phase conveying and is suitable for non-friable products.

Multi-Plane Series 400

For applications requiring both vertical and horizontal conveying, Aerocon 400 Series conveyors are configured with a single drive motor and 90-degree turn sprockets. They can be used for lean or medium phase conveying (employing either sprocket or two-speed systems) and are suitable for semi-friable materials.

Multi-Plane Distribution Series 500

The 500 Series was developed for applications where multiple inlets and/or outlets are required or in tight, obstructed, or angled spaces where the layout does not permit the standard close coupling of conveying tubes. This series can accommodate bag frames, bag dump stations, discharge from mixers, and combinations thereof. It can be used to feed multiple packing machines, hoppers, reactors, and so on. The versatile 500 Series can be set to either lean or medium phase conveying and is suitable for both non- and semi-friable products.

Long Radius Sweep Bend Service Series 300

Particularly useful for handling the most friable of materials. Limited to changes of plane not exceeding 60, this slow speed, dense phase method of conveying still maintains enough velocity to achieve some aeration, yet handles products such as rolled oats, bran flakes, and similar friable products with care.

Combination Systems

VAC-U-MAX Aerocon engineers can tailor aero-mechanical conveying systems to almost any application, balancing the highest possible throughputs with the lowest levels of product degradation. We have created systems for clients worldwide and across all industries, transferring and distributing a wide range of products—including teas, coffee, cake mixes, filter agents, and plastic compounds—to a variety of packing machines, reactor vessels, mixers, and more.

The VAC-U-MAX Advantage

VAC-U-MAX Aerocon conveyors have major advantages over competitive units. Aerocon conveyors are engineered with a superior bi-directional tensioning system that is independent of the drive assembly, offering easy-to-clean self-draining housings. Our units offer Clean-in-Place (CIP) technology, making them excellent for industries that require strict cross-contamination control and sterile processing without equipment disassembly.

Experience matters.

Your project is not an experiment. Partnering with a manufacturer with decades of experience with BOTH mechanical and pneumatic conveying systems, thousands of materials, and a fully equipped test facility ensures that your final system will meet all of your needs. Our depth and breadth of experience across industries—and within highly sophisticated and regulated industries—makes us the ideal manufacturing partner to ensure your system’s initial and ongoing success. We’re with you every step of the way, through installation, startup, operator training, and beyond.

When you partner with VAC-U-MAX, your system will be designed, manufactured, assembled, and configured right here in New Jersey. Once created, your system will be tested and tuned under simulated conditions in our 6,000-square-foot, fully equipped test lab to ensure optimal performance. All equipment will arrive at your facility fully configured and ready to go. And every system is backed by the VAC-U-MAX air-tight performance guarantee.