Pneumatic Conveying Systems

Overview

Pneumatic conveying is by far the most hygienic conveying method for dry bulk powders. Because they can be made to USDA sanitary standards, pneumatic conveying systems are popular in the food, cosmeceutical, nutraceutical. pharmaceutical, and chemical industries.

Pneumatic conveying systems are extremely versatile and can move product long distances, around corners, and vertically.Applications can include loading mixers, tablet presses, volumetric or gravimetric feeders; feeding into a packaging machine; or any other application where bulk dry powders need to be introduced into your process.

VAC-U-MAX specializes in the design and manufacture of custom, semi-custom, and off-the-shelf pneumatic conveying systems, vacuum receivers, control panels, and peripherals to automate all powder and bulk material handling processes.

Learn more about pneumatic conveying technology →

How it Works

Pneumatic conveying (aka vacuum conveying) is the process of moving bulk dry materials from place to place using suction. Material is transferred from the pick-up point (or source), through a network of tubing to the vacuum receiver, and on to the customer’s process.

Every VAC-U-MAX vacuum conveying system begins with a pick-up point, a vacuum receiver, a vacuum producer, and a control panel. From there, it can be customized and optimized depending on the needs of the customer.

Most vacuum conveying systems transfer product to the vacuum receiver based on a timed interval. At the end of the timed sequence, the discharge valve opens and the conveyed material discharges into the process.

There are two types of pneumatic conveying. Dilute phase conveying and dense phase conveying.

• Dilute Phase Vacuum Conveying: As the name suggests, the material is entrained in the air stream (suspended in air) and is almost equal parts air and product. This method is excellent for conveying almost any type of non-abrasive powder, like sugar or flour.
• Dense Phase Vacuum Conveying: In dense phase conveying, the material is transferred in slugs (clumps or plugs) within the convey tubing. The material moves more slowly, making it an excellent choice for delicate, friable product or blends of powders.

Learn more about the fine points of vacuum conveyor design →

Features

FEATURES & BENEFITS

While pneumatic conveying has a higher initial capital expenditure than mechanical systems, the return on investment is substantial. The flip side of the cost of a good pneumatic conveying system is the savings you will enjoy on the other side – reduced downtime, increased production, product reclamation, and more.

• Cost savings. Pneumatic conveying has an incredible ROI, with significant savings on labor, reduced downtime, increased production, increased product quality, reduced housekeeping costs, a healthier workforce, and a longer lifespan for capital equipment.
• Efficient. Pneumatic conveying offers you greater control, precision, and consistency, and can often handle a higher volume of material. There is minimal waste, contamination is eliminated, and it opens the door to product reclamation.
• Flexible & Versatile: Pneumatic conveying systems can be routed horizontally, vertically, and around existing equipment and other obstacles, and they can handle thousands of materials, from the finest silica fume to reactive metal powders, from delicate friable foods to bottle caps, and more.
• Dust-free transfer of powder. As opposed to positive pressure conveying where leakage is outward, vacuum conveying pulls inward, keeping the dust within the system, minimizing dust, and preventing product loss. Pneumatic conveying is the NFPA’s preferred technology for transporting combustible dusts.
• Sanitary. Pneumatic conveying is by far the most hygienic conveying method for dry bulk powders.
• Easy to clean. VAC-U-MAX vacuum conveying systems are designed to be easy to disassemble – no tools needed.
• Small footprint. When using a vacuum conveyor, the tubing or hose takes up little or no floor space within your facility, allowing you to maximize your space and freeing up the floor.
• Easy to install. All VAC-U-MAX systems are pre-assembled and shipped for easy installation when they arrive at your factory. Most VAC-U-MAX vacuum receivers are also equipped with a suspension frame that allows for support from above or below.
• Low power consumption. When designed properly, pneumatic conveying is very energy efficient. Just like a performance car on a Dyno, we test and tune every system for maximum performance.
• Improved ergonomics. Pneumatic conveying can protect workers and save on injury costs by eliminating the need for heavy lifting, scooping, and climbing.

Pre-Engineered Conveying Packages

In addition to our custom pneumatic conveying solutions, VAC-U-MAX offers a premier collection of pre-engineered vacuum conveying packages that can be configured to seamlessly integrate into a broad range of applications in the food, pharmaceutical, nutraceutical, chemical, nonwovens, and plastics industries.

VAC-U-MAX’s Signature Series™ pre-engineered vacuum conveyor systems feature varied finishes, body designs, and discharge configurations, and can be tailored to your process needs.

Each package includes a vacuum conveyor, vacuum producer, flexible hose, pickup wand, and control panel. Your system will arrive fully preconfigured and ready to integrate into your line, eliminating complex installation and minimizing downtime.

Signature Series™ packages come in two main sizes. The 1500 Series is rated to move up to 1500 pounds (680 kg) per hour, and the larger 3500 Series handles up to 3500 pounds (1600 kg) per hour. Both series are highly customizable with standard and sanitary options, offset cone and tube hopper receiver variations, venturi- or electric-powdered vacuum producers, and a control panel configured for your process and ready to go on arrival.

Learn more about the Signature Series™ line of pre-engineered vacuum conveyors →

The VAC-U-MAX Advantage

CAPABILITIES

• Direct charge loading of blenders, mixers, reactors and other vacuum tolerant vessels
• Automatic weighing & batching of multiple ingredients
• In-line check sieving while conveying product
• Dust-free transfer to tablet presses and capsule fillers
• Conveying tablets, gel caps, empty or filled capsules
• Delivering product, containers, and closures to filling and packaging machines
• Integration & automation of material transfer & controls
• CIP-able designs
• Hand polishing to mirror finish
• In-House Passivations and Dye-Penetrant Testing
• In-House Engineering for Approval Drawing Submittal

OUR PROCESS

Every vacuum conveying system design—whether it’s a sophisticated, custom-engineered system or a turnkey package—begins with a blank page. We begin by consulting with you about your process—equipment, plant environment, materials, volume, and so on. Once created, your system will then be tested and tuned under simulated conditions in our 6,000-square-foot, fully equipped test lab to ensure optimal performance.

All equipment is pre-wired, pre-plumbed, and tested right here in New Jersey before shipping to minimize assembly at your facility. Most importantly, we provide an air-tight performance guarantee. We’re with you through installation, startup, operator training, and beyond.

THE VAC-U-MAX DISTINCTION

• Faster processing time
• Cleanable designs & FDA-approved materials of construction
• Easy, quick-clean & take-apart features
• Minimal footprint
• Made in the USA
• Local product support
• Performance Guarantee
• Maximize regulatory compliance including (FSMA) sanitation and OSHA (Walking/Working Surfaces)