Selecting a conveying method for food powder handling is rarely a simple decision. Dry ingredients vary widely in physical behavior, sensitivity to handling, and processing requirements, while production environments introduce additional constraints related to plant layout, sanitation practices, and operational efficiency. As a result, conveying systems that perform well in one application may introduce unintended challenges in another.

This paper examines common conveying technologies used in food powder and bulk food ingredient applications through the lens of equipment design and process engineering considerations. Rather than promoting a specific solution, the discussion focuses on how conveying mechanics, system configuration, and operational tradeoffs influence performance. The intent is to provide food process engineers with a practical framework for evaluating conveying options based on application-specific needs and real-world plant conditions.

Understanding Material and Application Reality

Food powders and bulk food ingredients encompass a broad range of physical characteristics, even among materials that appear similar at first glance. Applications requiring gentle handling often include products such as pasta, rice, grains, and coffee beans, where excessive velocity, impact, or friction can result in breakage, fines generation, or product degradation.

Several material properties consistently influence conveying performance. Moisture content can significantly affect flow behavior and adhesion, while fat content may contribute to buildup within the conveying path. Bulk density and particle size distribution play critical roles in determining achievable conveying rates, system stability, and downstream consistency.

In some applications, conveying method selection has led to unexpected downstream issues. Excessive air entrainment or material fluidization during transfer, for example, can negatively impact filling accuracy and weighing performance. These outcomes highlight the importance of evaluating conveying systems as part of the overall process rather than as isolated pieces of equipment.

Overview of Common Conveying Technologies

Food manufacturers typically rely on either pneumatic or mechanical conveying systems for dry ingredient handling. Each approach offers distinct advantages and limitations depending on material behavior, layout requirements, and operational goals.

• Pneumatic Conveying

Pneumatic conveying systems transport material using air flow, typically under pressure or vacuum. Common pneumatic conveying approaches used in food powder handling include dilute-phase pressure systems, dilute-phase vacuum systems, and, in some applications, dense-phase conveying. These systems are often selected for their ability to convey materials over long distances, accommodate complex routing, and centralize material transfer.

However, the reliance on air velocity introduces tradeoffs. Higher conveying speeds can increase particle interaction, which may contribute to product degradation, fines generation, or material fluidization. Energy consumption, system wear, and the influence of air entrainment on downstream filling or weighing processes are also important considerations when evaluating pneumatic conveying options.

• Mechanical Conveying

Mechanical conveying systems move material through direct physical contact using a conveying element within an enclosed or semi-enclosed path. Common mechanical conveying technologies used in food powder and bulk ingredient applications include screw conveyors, cable-and-disc conveyors, belt conveyors, and bucket elevators.

These systems are often applied where controlled product movement, lower conveying velocities, and predictable material flow are priorities. Mechanical conveyors are frequently used for shorter conveying distances, higher conveying rates, or applications where product integrity is a key concern. Design considerations such as system layout, access for inspection and cleaning, and residual material behavior vary by conveyor type and must be evaluated on an application-specific basis.

Key Engineering Tradeoffs in Conveying Selection

• Product Integrity

Conveying method selection directly influences product integrity. Factors such as conveying velocity, impact points, and frictional contact all contribute to the potential for particle degradation or segregation. In applications where maintaining product structure is critical, these considerations often outweigh other design priorities.

• System Enclosure and Environmental Isolation

Enclosed conveying paths are frequently preferred in food powder applications to support consistent material transfer and housekeeping practices. System enclosure can influence dust containment, product exposure, and overall process stability, but must be balanced with access requirements and maintenance considerations.

• Cleanability and Access (Design Perspective)

From a design standpoint, system access and cleanability are influenced by conveying distance, routing complexity, and overall system geometry. In some cases, the amount of time required for cleaning or inspection plays a significant role in determining which conveying technology is appropriate.

Certain design choices can increase the likelihood of material retention or buildup. For example, mechanical conveying systems that rely on screws may retain more residual product within the casing compared to pneumatic systems, which can more fully evacuate material under specific operating conditions. These characteristics should be evaluated within the context of the application rather than viewed as universal advantages or disadvantages.

• Energy Use, Maintenance, and Operational Considerations

Energy consumption varies significantly between conveying technologies and is influenced by factors such as conveying distance, system configuration, and material characteristics. Maintenance requirements, including wear points and component accessibility, also affect long-term system reliability.

Total cost of ownership extends beyond initial equipment cost. Downtime, maintenance frequency, and operational consistency should all be considered when evaluating conveying options for food powder applications.

• System Layout and Plant Constraints

Plant layout plays a critical role in conveying system selection. Space limitations, routing complexity, elevation changes, and existing infrastructure can all influence which conveying technologies are viable. These factors, combined with material flow characteristics and bulk density, help define realistic design boundaries.

In retrofit applications, a common mistake is prioritizing installation convenience over proper conveying circuit design. Selecting the most appropriate route for the chosen technology—rather than adapting the technology to a suboptimal route—can significantly improve long-term performance and reliability.

Conveying flexibility is particularly important in facilities handling multiple products or anticipating future process changes. Systems designed with operational adaptability in mind can reduce the need for costly modifications over time.

Mechanical Cable Conveying as a Design Example

Cable-based mechanical conveying systems represent one approach within the broader category of mechanical conveying. These systems utilize a moving cable and discs within an enclosed tube to transport material at relatively low velocities.

In food powder applications, cable conveying systems may be considered where gentle handling, enclosed transfer, and flexible routing are desired. Their modular design can support routing around existing equipment and accommodate changes in elevation within certain constraints.

As with all conveying technologies, cable systems have practical limitations related to distance, material behavior, and system configuration. Evaluating their suitability requires careful consideration of application requirements rather than assuming universal applicability.

Common Misconceptions in Conveying System Selection

One of the most persistent misconceptions in conveying system selection is the assumption that a single technology can address all process challenges. In reality, conveying performance depends on the interaction between material behavior, equipment design, and operational practices.

Another common misunderstanding involves product evacuation in mechanical systems. In helix-style conveyors, for example, a residual “heel” of material typically remains in the casing once the hopper is empty. Recognizing and accounting for this behavior during system design helps establish realistic expectations and avoid operational surprises.

Expectations, Boundaries, and Engineering Responsibility

Certain claims should be avoided because they depend on variables outside of equipment design alone. Estimated conveying rates, assumed bulk densities, and generalized layout assumptions can quickly lead to misunderstandings if product characteristics or operating conditions differ from expectations. Accurate information regarding how material is received and how it is discharged is essential to defining conveying requirements.

Equipment capability is also sometimes conflated with overall process control. Automated start-and-stop operation based on upstream or downstream signals, as well as interlocking multiple pieces of process equipment, involves control strategy and system integration considerations beyond the conveying equipment itself.

Clear communication of system boundaries and responsibilities supports more successful project outcomes.

Conclusion

Comparing conveying technologies for food powder handling requires a balanced understanding of material behavior, equipment design, and plant realities. No single conveying method is universally suitable for all applications, and effective system selection depends on evaluating tradeoffs rather than seeking one-size-fits-all solutions.

By applying a structured engineering framework and acknowledging application-specific variables, food process engineers can make more informed conveying decisions that support reliable operation, product integrity, and long-term performance.

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Automation has become an essential part of bulk material handling and helps facilities run efficiently, safely, and cost-effectively. Reliable control systems keep materials moving and help teams meet production goals. When these systems are designed with real-world needs in mind, they can boost throughput and reduce downtime while supporting smarter operations.

Many manufacturers face daily operational challenges such as outdated controls, integration headaches, safety compliance, and budget constraints. Hapman addresses these by carefully evaluating each facility’s needs and providing custom automation solutions that go beyond just their proprietary conveying equipment. Whether the requirement is to update legacy controls so they can communicate with Hapman’s latest panels or to deliver a tailored package that incorporates all equipment into a single process, Hapman’s approach ensures no system operates in isolation.

Full-Service Solutions That Work Together

One of the most noticeable trends in the market is the growing demand for automation systems that can control a mix of equipment from different manufacturers, such as mixers or packaging machines. Hapman responds to this by providing full turnkey solutions that keep everything connected and simple for operators. This seamless integration reduces complications and keeps the process moving smoothly.

Hapman’s solutions are especially valuable when existing plant equipment is a complex mix of old and new. For example, Hapman engineers recently unified three separate process steps for a client by bringing disparate systems together in one easy-to-manage control package. This level of integration allows the machinery before and after the Hapman system to operate together without operator intervention, creating a fully integrated and streamlined workflow.

Why In-House Control Packages Matter

Hapman builds control packages in-house rather than relying entirely on third-party vendors. This decision allows for greater quality control, each panel is tested before shipping to ensure dependability for the end user. The hands-on approach guarantees that systems meet Hapman’s standards for consistent performance through every step of the process.

By manufacturing controls internally, Hapman maintains complete oversight throughout the process, from initial design to final testing. Every panel is function-tested in-house before delivery, ensuring full reliability and integration, and giving customers peace of mind that their automation will work as promised right from day one.

Real Advantages for Clients

Choosing Hapman’s full-service, engineered automation systems gives customers several key benefits. Instead of stitching together piecemeal components, clients receive a full turnkey solution where everything works together from the start. This reduces risk, lowers maintenance costs, and helps operators quickly address any issues on the floor, since the system lets them know exactly where a fault has occurred and signals when materials are running low.

Operators also benefit from intuitive panel displays that tell them where any issue has occurred and provide alerts for upcoming process events, such as when additional material needs to be loaded. This advanced notification enables staff to respond quickly, minimizing downtime while supporting safer and more predictable production.

Seamless Plant Integration

Flexibility and compatibility are central to Hapman’s systems. Control platforms are designed to communicate with many types of distributed control systems, as well as programmable logic controllers and multiple communication protocols. Teams can take advantage of Hapman’s automation without abandoning existing infrastructure, creating a more unified and reliable facility.

No matter the industry, whether it is food, pharmaceuticals, chemicals, or agriculture, Hapman collaborates closely with each customer to ensure compliance with all standards. This includes designing panels for hazardous locations and providing solutions to meet or exceed industry regulations. For instance, when a client in the agriculture sector needed to modernize controls, Hapman developed a system that brought all plant operations up to spec, connecting multiple processes together into one platform and greatly enhancing operational oversight.

Built for Smarter Material Handling

Hapman’s commitment to in-house engineering and complete automation ensures every plant can run efficiently and confidently. From testing every panel before it leaves the facility to providing controls that keep workflows smooth, Hapman helps customers optimize their process, minimize downtime, and simplify daily operations.

Whether upgrading a single line or overseeing a plant-wide controls modernization, Hapman’s collaborative, solutions-driven approach provides the backbone for safer, more efficient bulk material handling, today and into the future.

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A leading dairy cooperative in Ontario, Canada processes milk from its member farmers to produce butter, cheese, yogurt, milk powder, and other dairy products. These products are supplied to retail, food service, and industrial markets. To enhance product consistency and texture, the facility incorporates cellulose powder and plant fibers in its dairy formulations.

Understanding the Challenges of Conveying Cellulose Powder

Cellulose powder is a fine, fibrous material commonly used in food processing for its ability to improve texture and stability. However, its lightweight nature and tendency to generate dust create unique challenges in pneumatic conveying systems. The material’s low bulk density makes it prone to becoming airborne, increasing the risk of dust accumulation and explosion hazards. Additionally, cellulose powder is electrostatically charged, which can lead to material sticking to equipment surfaces, causing flow disruptions and maintenance concerns.

Moisture absorption is another key issue. As a hygroscopic material, cellulose powder can clump and build up inside conveying lines, potentially leading to blockages and inconsistent material flow. Because of these factors, effective dust containment, explosion protection, and careful material handling are critical for maintaining system efficiency and compliance with industry safety standards.

Customer Challenge: NFPA Compliance & Dust Containment

The facility had been relying on Hapman filter/receivers installed in 2010 as part of its pneumatic conveying system. However, evolving NFPA safety standards required an upgrade to improve dust containment and explosion mitigation. The customer needed a replacement solution that would integrate seamlessly into their existing vacuum conveying system while meeting the latest safety regulations.

Hapman’s Solution: E-Line Model 24R with Flameless Vent

To address the customer’s needs, Hapman supplied a Model 24R E-Line filter/receiver with a flameless vent. This unit was selected due to its compliance with current NFPA standards, ability to handle fine powder materials efficiently, and compatibility with the customer’s pneumatic conveyor system. Made of stainless steel with a food-grade finish, the E-Line unit ensures hygienic processing. If an explosion occurs, flames and dust discharge into the device and are extinguished as they pass through multiple layers of heat-absorbing stainless steel mesh, thus protecting the people and the equipment.

Why the Customer Chose Hapman

Proven Performance – The facility had successfully used Hapman equipment for over a decade.

Seamless Integration – The new unit fits into the existing process with minimal disruption.

Enhanced Safety – The flameless vent ensures compliance with modern NFPA standards for dust mitigation.

Results & Future Outlook

With this upgrade, the dairy cooperative will enhance workplace safety, improve dust containment, and ensure compliance with updated NFPA standards. By integrating a flameless vent, the system offers superior explosion protection while maintaining efficiency in pneumatic conveying. This investment supports the company’s long-term commitment to safe and effective bulk material handling.

Hapman continues to provide customized conveyor solutions for the food and dairy industry, delivering equipment that meets both regulatory requirements and operational efficiency goals.

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Key Features of Hapman Vacuum Conveyors

1. Regenerative Blower Technology: The core of Hapman’s Vacuum Conveyors is the regenerative blower technology. This innovative approach allows for effective material transport without relying on plant air, significantly reducing operational costs. By minimizing the need for external air sources, these conveyors offer a more sustainable and cost-efficient solution.
   
2. Reverse-Pulse Filter Cleaning System: The conveyors feature a reverse-pulse filter cleaning system, which ensures maximum filter efficiency and minimizes downtime. This system helps maintain optimal performance by keeping filters clean and functional, reducing the need for frequent maintenance.
   
3. Diverse Models for Specific Needs: Hapman offers three distinct models of Vacuum Conveyors, each tailored to meet specific operational requirements:

• MiniVac: Utilizes dilute phase vacuum technology, allowing for flexible installation and operation. The pipe can be routed around obstacles, making it ideal for complex layouts. MiniVac is available in painted carbon or stainless steel, offering durability and resistance to corrosion.
  • LP Series: Designed for tight spaces, this model is perfect for applications where space is limited.
  • E-Line: Emphasizes safety by protecting people and equipment from dust explosions. The E-Line is rated for pressures up to 14.5 psi, ensuring a secure environment for handling potentially hazardous materials.

Benefits of Hapman Vacuum Conveyors

• Enhanced Efficiency: By leveraging advanced technology, these conveyors optimize material movement, leading to increased productivity across various industries.
  
• Cost Savings: The use of regenerative blower technology reduces operational costs by minimizing the need for plant air.
  
• Flexibility and Safety: With models designed for different operational needs, Hapman Vacuum Conveyors offer flexibility and safety features that cater to diverse applications.

Conclusion

Hapman Vacuum Conveyors represent a significant advancement in bulk material handling, combining efficiency, versatility, and cost-effectiveness. With their advanced design and tailored models, these conveyors are poised to enhance productivity and efficiency across multiple sectors. Whether you’re looking to optimize material movement in tight spaces or ensure safety in hazardous environments, Hapman’s Vacuum Conveyors offer a reliable and innovative solution.

For more information on how Hapman Vacuum Conveyors can enhance your bulk material handling processes, visit our Vacuum page or contact our sales team at sales@hapman.com.

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Improving efficiency in batching and blending is simple in concept. All you need to do is produce the most possible product using the least possible resources. That’s easier said than done, but by identifying challenges and applying engineering know-how you’ll find that small steps can lead to great strides in your batching and blending operations.

Efficiency improvements can start small with a single improvement in your process or a design upgrade to a single piece of equipment. A single “win” can get you in the race, be it a way to speed a machine’s changeover, block a material flow obstruction, improve metering accuracy, or remove a bottleneck. Each success leads to another. No matter the scope of your efforts or applications involved, you’ll likely confront some or all these challenges in engineering a solution for you, your process, and your customers:

1.           Inefficient batching process

2.           Poor recipe control

3.           Loss of material

4.           Labor/experience shortage

These challenges are interrelated, and we will discuss them — and solutions to overcome them — below.

1. Inefficient batch processing

Batch processes in any industry share many common efficiency challenges. Inefficient batching can be both the cause and result of production bottlenecks, delays between process steps or machine hand-offs, and overall waste in all its forms.

On the other hand, equipment and process design that addresses the right problems can unlock new levels of process performance. For example, adding a lump breaker can eliminate agglomerations in small-volume metering, or a feeder upgrade can improve dosing accuracy by improving the flow of sluggish granules or powders. (Related reading: Turn Batching Challenges Into a Competitive Advantage.)

In other cases, efficiency can be optimized by rethinking how materials can be moved from Point A to Point B within the constraints of the physical realities of your facility. For example, not all buildings can accommodate mezzanine levels for filling or conveyors to transport materials long distances. In such cases, alternative approaches can provide an efficient solution, as Lawrence Foods, a manufacturer of premium bakery ingredients, learned.

The company needed to pre-weigh bulk bags of powdered sugar from incoming 2,200-pound bags and create two 1,000-pound bags for downstream processing. However, the facility lacked sufficient ceiling height to unload the bulk bag directly into a filler in a single, vertical common frame.

The solution took the form of an integrated system using side-by-side frames incorporating a bulk bag unloader, a 15-foot screw conveyor, and a bag filler to create the 1,000-pound bags of powdered sugar. Weight and process controls ensured accuracy and filling directly onto a pallet enabled easy fork truck removal and transport to production. As a result, the company gained an engineered solution to overcome challenges due to space constraints, bypassing the need to modify its facility. Additional features aid efficiency, safety, dust control, ergonomics, and flexibility for future changes. (Learn the details of Lawrence Foods’ installation by reading  Unload, Convey, Fill, Repeat.)

2. Poor recipe control

Recipe control picks up where batch management leaves off. A lack of comprehensive controls, from accurate measurement to connected digital controls, can lead to many sources of process inefficiency. These include errors caused by manual keying-in recipe parameters, lost time, production bottlenecks, reduced productivity, and increased costs. The solution to these and other weaknesses is digitalization, which enables the additional benefit of recipe management software tools for analyzing accuracy, quality, and other efficiency-related factors.

Many companies rely on manual data entry, which leads to quality deficiencies, product scrap and rework, inefficient labor, and downtime. This can result in losses of $1,000 or more for a 2,000-pound batch. We have seen companies with more than 50 recipes whose operators manually key-in parameters based on information from disparate sources such as clipboards and spreadsheets. In some cases, a vital piece of missing information caused delays, and the lack of efficient tracking documentation during and after processing compromised proper quality control and slowed efforts to improve processing.

Today, process control technology addresses such problems with long-established machine and process control technology. An operator panel connected to the programmable logic controller (PLC) running the equipment stores all recipes. These can be loaded for processing with little more effort than pressing a touchscreen of a menu selection (or even scanning a QR code for a recipe). Improvements can enhance process consistency, product quality, productivity, waste reduction, and more.

Operator interface software also provides alerts and tracks process data for additional uses. These include tracking and trending data for one or more pieces of equipment locally; or using a central workstation to track key performance indicators (KPIs) across a fuller set of operations. Process data can also be presented to multiple users in different roles for different reasons: plant initiatives, vendor remote maintenance services, corporate data analytics, compliance reporting, or any number of good, approved uses. (Click to read an overview of related Controls & Automation solutions.)

3. Loss of material

Material losses can occur anywhere in conveying, handling, and processing — from spills in manual or mechanical handling operations to dust from improperly sealed conveyors. In terms of equipment, bag filling is perhaps the most common source of costly material losses due to excessive overfilling, or product giveaway, to ensure compliance with weight requirements.

In one case, a company was experiencing losses with small, 320-ounce batches of a valuable material costing $1,200 per ounce. To ensure it met weight requirements, the company was overfilling and giving away profits, sometimes by more than two ounces per batch. Once the company identified the problem, the company upgraded to new, more accurate loss-in-weight feeders, precisely controlled overfilling to within 25 grams, and saved approximately $2,000 on each batch.

Loss-in-weight, or gravimetric, feeders are generally preferred for such quality-critical applications, however, volumetric feeders can be used for accurate filling at higher speeds. However, this choice is unlikely if your material’s bulk density varies such as when a hygroscopic material reacts to humidity and/or forms agglomerations. (Related reading: Volumetric vs. Gravimetric Feeder Operation).

Competitive realities typically lead plants to integrate multiple equipment assets with custom engineering and, increasingly, digital automation. One company used both techniques to more efficiently meter controlled amounts of four powdered ingredients. The project included several components including bulk bag unloaders, a dust collector to prevent a separate waste stream and lost product; pneumatic bag agitators to fluidize the material; and a lump breaker to tackle any agglomerations. From there, the powders were ready for loss-in-weight screw feeding

to a slurry tank for processing. The result was that the conditioned materials contributed to the optimal downstream mixing process performance. Process controls and user-friendly monitoring tools further eased the job and reduced labor requirements. (Click for related reading on Bulk Bag Unloading, Pneumatic Conveying, and Material Metering.)

4.Labor/experience shortages

Properly engineered mechanical and automation solutions provide additional benefits for productivity to reduce labor costs and overcome the difficulty of finding and training skilled labor.

Automation brings positive impacts in many ways to overcome labor and productivity challenges. It’s most visible to operators in the form of user-friendly interfaces that ease

tasks and save time. The benefits are also critical for operational continuity as experienced workers exit the workforce, taking their experience and knowledge with them. It also reduces companies’ requirements for up-front training and everyday labor requirements.

When discussing the company that used automation to improve recipe control (Challenge No.2 above), that operation used to require two operators: one to load the batch, and another to manage the recipe. After the automation upgrade, only one operator is needed for that processing station.

Digital automation together with mechanical design features both contribute to labor savings. Material handling equipment that is easy to operate alleviates environmental concerns and promotes health and safety in a processing facility in addition to solving labor challenges. Likewise, today’s equipment designs feature time-saving features that offer easy access for maintenance operations, quick clean-in-place with easy disassembly for cleaning, quick-release features, and more. In turn, digital automation makes it easier for one person to manage more parts of a process, which is essential for companies relying on fewer workers.

In the chemical industry, processors face the ongoing challenge of effectively mixing solids and liquids to blend slurries while minimizing labor (among other factors such as floor space, dusting, and energy usage). This traditionally entailed multiple workers and labor-intensive operations. Examples include workers climbing ladders and opening equipment doors with ingredients/materials in hand; controlling mixer agitators; and incurring risk in potentially caustic or hazardous environments. Today, solutions are available such as sealed conveyors

(e.g., pneumatic, tubular, helix) and automated bag-handling and processing equipment; valves on bag-handling equipment, and self-contained batching/blending equipment offer enhanced worker safety, labor savings, and high throughput. (Learn more by reading Pre-Mix Solutions and Slurries – Effectively, Economically, and Safely.)

Additional technologies offer greater cost-effectiveness and labor savings than ever, including labor-saving automated storage and retrieval systems (ASRS) and autonomous mobile robots (AMR) that shuttle materials across warehouses and production areas. (Learn more by reading: Using Material Handling Automation to Improve Efficiency.)

Efficiency: It’s not a sprint, it’s a marathon

There’s no single solution for any given material handling, batching, or blending application. Significant efficiency improvements require varying degrees of customization to meet your material, processing, and business goals. Asking the right questions of your internal team and your external partners can take you closer and closer to your project’s finish line — and beyond, because the race toward greater efficiency and competitiveness is an ongoing journey.

When it comes to selecting a partner to provide equipment, systems, and engineering services, it’s most important that they have the breadth of expertise and deep knowledge of your needs, This, in turn, can go beyond solving problems to open new opportunities and benefits spanning design, reliability, serviceability, and much more.

About Hapman

We are a global manufacturer of standard and custom bulk material handling equipment and complete material handling systems, with locations in North America, Europe, and Asia. Our process has been proven across 12,000 applications across all major bulk material processing industries in every US state and 56 countries worldwide.

Whether your equipment needs are standard and straightforward or elaborate and controlled, Hapman’s team of applications experts will assist you with any level of support.

Our company culture is driven by new ideas, fresh thinking, and continuous improvement. That’s why Ideas that Move is more than a slogan. It’s an integral part of who we are. We seek to acquire and share new knowledge, build on our experience, collaborate with you and other industry experts, and push perceived process limitations — all while fully embracing disciplined engineering and quality material handling practices.

At Hapman, we are more than a material handling systems provider. We are your business partner. We are dedicated to achieving your highest level of trust and satisfaction and earning your confidence in our commitment and expertise.

Take the next step towards innovation and excellence. Contact our experts at (800) 427-6260 or sales@hapman.com for a personalized consultation.

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A leading pharmaceutical manufacturer needed a vacuum conveying system to transfer finished product from a dryer to a mobile, scale-mounted bulk bag filler for precise batching. The primary challenge was ensuring complete cleanability to eliminate any risk of cross-contamination during product changeovers — a critical requirement in pharmaceutical processing.

Solution

Hapman engineered a Vacuum Conveyor equipped with individually controlled spray wash ports strategically located throughout the interior. This feature enabled automated, thorough cleaning and sanitization without external disassembly.
To further simplify maintenance, the system included a side access door for fast filter cartridge replacement and a clean-in-place rotary valve that could be disassembled, cleaned, and reassembled within minutes.
The entire sanitary assembly was built from 304 Stainless Steel with sealed motors and controls rated for explosive and wash-down environments, ensuring compliance with stringent pharmaceutical standards.

Results

The custom vacuum system met all performance and cleanliness requirements, enabling faster product changeovers, reduced downtime, and improved process efficiency while maintaining the highest standards of product purity.

The post Transforming Pharmaceutical Efficiency with Innovative Conveyor Technology appeared first on Hapman.

At Hapman, we’ve found that the best way to select a conveyor system is to start from a clean slate. By analyzing your process needs from the ground up, we can identify the most effective conveying method for your specific material and operation. This collaborative approach helps ensure that every conveyor system is tailored to meet your performance goals—creating not just a reliable material handling solution, but a trusted partnership.

Below are the six key considerations we discuss with every customer when selecting the right conveyor system.

1. Operation: Conveying vs. Feeding

The first step is to define how the conveyor will operate.
There are two main material movement categories:

• Feeding: Delivering material in controlled amounts, often with greater precision and timing sensitivity.
• Conveying: Moving material from one or more pick-up points to one or more discharge points.

If your process involves batch feeding, it’s important to know:

• How much material must be delivered
• The delivery time and accuracy required
• The idle time between batches

For continuous feeding, define the target feed rate and accuracy tolerance. These details guide the selection of the right feeder or conveyor type to maintain consistent, controlled performance.

2. Material: Understand What You’re Moving

Each material has its own unique handling characteristics, and understanding these fully is critical to selecting the right system.
Key material properties to evaluate include:

• Flowability
• Abrasiveness
• Temperature
• Moisture content

These factors can interact with each other and influence how the material behaves in motion. A thorough material analysis helps prevent challenges like clogging, degradation, or excessive wear on the equipment.

3. Environment: Design for Safety and Performance

Environmental conditions can greatly affect conveyor performance and safety. Consider:

• Potential ignition sources or fire hazards
• Explosion risks in dusty environments
• Corrosive vapors or chemical exposure

In many cases, these conditions combine with material properties to create handling concerns. Identifying them early allows you to design the system with the proper safety measures, containment, and construction materials.

4. Footprint: Fit Within the Available Space

Physical space is often a deciding factor between one conveyor system and another.
When planning an installation, consider:

• Inlet and discharge elevations
• Width, depth, and ceiling height
• Integration with existing systems

Evaluating the footprint early ensures the conveyor layout fits your facility and minimizes costly retrofits later.

5. Cost: Balance Investment and Longevity

Cost is always a major consideration, but it’s important to look beyond the initial purchase price.
Some companies emphasize total cost of ownership, valuing reliability, lower maintenance, and energy efficiency. Others prioritize initial investment to meet short-term budget goals.

At Hapman, we help you evaluate both factors so you can make a decision that aligns with your operational priorities and long-term return on investment.

6. History: Learn from Past Equipment Performance

If you’re replacing an existing conveyor, reviewing its service history provides valuable insight.
Understanding where past equipment struggled—whether with reliability, wear, or throughput—helps pinpoint improvements for your next system.

Simply switching to a new brand doesn’t guarantee better performance. Sharing your maintenance history and performance challenges helps us engineer a more reliable, longer-lasting conveying solution.

Final Thoughts

Selecting the right conveyor system requires more than just comparing specs—it demands a deep understanding of your material, environment, and process goals.

At Hapman, we partner with you to evaluate every consideration and design a solution that performs efficiently, safely, and dependably for years to come.

Ready to find the right conveyor system for your process?
Talk with a Hapman application engineer today to discuss your material, environment, and production goals. We’ll help you design a conveying solution built for lasting performance.

Contact Hapman

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Too often, conveyors are misapplied when facilities try to standardize equipment or minimize upfront costs. While this approach can simplify purchasing, it often leads to reduced throughput, higher maintenance, and unnecessary downtime later on.

To make an informed decision, evaluate your application across these six critical factors.

1. Material

Understanding your material is the foundation of proper conveyor selection. Every material behaves differently — and those differences influence how it moves through a system, what components are required, and how the equipment should be designed.

• Material form: Powder, granule, flake, pellet, or irregular shape.
• Solid composition: The makeup of the material, including density and structure.
• Particle size: Determines the screw, chain, or belt type best suited for handling.
• Flowability: Indicates how freely the material moves or if it tends to bridge or pack.
• Abrasiveness: Impacts the wear life of the conveyor’s internal components.
• Temperature: May dictate material compatibility or component selection.
• Moisture content: Affects stickiness, flow, and potential buildup.

The more detailed your understanding of these characteristics, the better equipped you’ll be to match your application with the right conveyor type and configuration.

2. Operation

The way a conveyor operates within your process is just as important as the material itself. There are two primary functions to consider:

• Conveying: Moving material from one process step to another, often over a distance or incline.
• Feeding: Delivering a controlled, consistent flow of material into another process, such as mixing, blending, or packaging.

Clearly defining how your conveyor will operate helps determine proper drive design, speed, and control options — all of which affect efficiency and product quality.

3. Environment

Environmental conditions play a major role in determining equipment performance and longevity. When evaluating your application, consider:

• Open sources of ignition or potential for a flammable atmosphere
• Corrosive vapors or chemical exposure
• Ambient and material temperature
• Humidity levels
• Dust control or collection requirements
• Pressure or vacuum at inlet or discharge points

In certain cases, compliance with NFPA, ATEX, or other safety standards may also apply. Choosing the right materials of construction and protective features ensures your conveyor operates safely and reliably within its environment.

4. Envelope

“Envelope” refers to the physical space available for installing and maintaining your equipment. Even the best conveyor will underperform if space limitations prevent proper layout or access.

Ask these questions early in the design phase:

• How much headroom or floor space is available?
• Are there obstructions that limit routing or incline angles?
• Can the conveyor be easily serviced or cleaned in place?

By clearly defining your installation envelope, you can avoid unnecessary redesigns and ensure smoother integration into your process line.

5. Cost

Cost always plays a role in equipment selection, but it’s important to consider both initial and long-term costs.

Initial costs cover the purchase and installation of the conveyor. Long-term costs include maintenance, spare parts, energy usage, and downtime. A slightly higher upfront investment in a system designed for your specific material and process can deliver substantial savings over time.

Discussing budget and performance expectations early with your supplier allows for realistic recommendations that balance cost with long-term reliability.

6. History

If the new conveyor is replacing an existing system, analyze the service history of your current equipment. Understanding what has worked — and what hasn’t — can help prevent repeat issues.

Provide your supplier with details on past challenges such as excessive wear, clogs, or throughput limitations. This information helps them identify potential root causes and propose equipment that delivers better performance and durability, rather than simply replacing one brand with another.

Making the Right Choice

Selecting a conveyor for bulk material handling requires a comprehensive understanding of your material, operation, and environment — along with realistic budget and space considerations.

At Hapman, our engineers partner with you to evaluate all six factors to ensure the conveyor system you choose delivers dependable performance and long-term value.

The post 6 Key Factors to Consider When Choosing a Conveyor for Bulk Material Handling appeared first on Hapman.

The proper selection and sizing of a conveyor is critical to successfully meeting production goals. The key factors that should be evaluated when choosing a conveyor are; material, operation, environment, envelope, cost, an history. Taking the time upfront to understand these factors and gather the most accurate data possible related to each component will ultimately make the selection of conveying technology the best for your specific needs and offer the greatest return on investment.

Introduction

Selecting a conveyor system for a bulk material handling application is not always as straightforward as one might think. Moving material consistently, at a rate that is inline with production requirements, and in a manner that does not contribute negatively to the plant operating environment, such as dusting or increased maintenance, can be a challenging endeavor for process engineers and procurement personnel.

Often, conveyor systems are misapplied because of the overall plant’s desire to keep the number of unique pieces of equipment to a minimum while also adhering to spending limits. These factors are critical to consider when selecting a conveyor system for a material handling application; however, they should not be the first, or the only, evaluation metrics used.

The most effective way for a processor to evaluate all of the best options for a material handling application is to consider each material movement requirement from a blank starting point. Looking at an application with the mindset of “What is the best way to satisfy our material conveying need,” will put processors in a better position to make the right equipment selection prior to purchase. Taking this stance, there are several key considerations to evaluate for proper conveyor selection, including material, operation, environment, envelope, cost, and history.

Material

There are several important characteristics that make up the complete material definition, which should be understood in their entirety. Some of these are dynamic and can influence or may be influenced by one or more of the other characteristics, so it is always recommended to look at them together.

1. Name of the material (many materials are known by more than one name)

a. An Esoteric or Trade Name (such as SnoMelt)

b. Generic Name (such as salt) or Chemical formula, which is defined & called by its primary ingredient or ingredients (sodium chloride, NaCl).

2. Material form or state in which it must be handled 

a. Solids (free flowing or semi-free flowing)

i. What is the loose bulk density? (lbs/ft³, g/cc, kg/m³)

ii. Loose Bulk Density is commonly interchanged or confused with Specific Gravity but should not be. They are very different. Specific gravity is the weight per given volume of a substance, usually in its most natural, concentrated, unreduced solid form (no air pockets or interstitial spaces between particles). Loose Bulk density is the weight per given volume of the material in its reduced, free-flowing or semi free-flowing state.

3. Solid Composition 

a. Powder

b. Prill 

c. Granule 

d. Pellet 

e. Fiber 

f. Flake

4. Particle Size a. Symmetrical Solids are usually described in terms of their ability to pass through a screen of a certain size. b. Asymmetrical Solids are usually described in terms of their geometric dimensions, minimum and maximum.

5. Flowability – Flowability is perhaps the most important characteristic of any solid material to understand, yet it lacks a single standardized method of measurement across industrial disciplines

a. Most often it is defined in somewhat arbitrary terms as Very Free Flowing, Free Flowing, Average Flowability or Sluggish.

b. Angle of repose is also frequently used as an indicator of flowability. It is simply the natural angle or rate of incline that is observed when material is metered from a single discharge point without vibration or any effort to settle or distribute the accumulating mound.

c. Some use a 1 to 4 or 1 to 10 indexing system in an attempt to quantify the flowability.

d. We recommended reading the following document to better understand flowability. It’s co-written by James K. Prescott and Roger A. Barnum of Jenike & Johanson and published in the October 2000 issue of Pharmaceutical Technology. It’s downloadable from the Jenike & Johanson website at: http://info.jenike.com/technical-papers/on-powder-flowability

e. If the material is known or suspected to be a challenge because of its flowability, it may be best to send a sample to the equipment supplier for review.

6. Abrasiveness

a. Like flowability, abrasiveness lacks a universal standard definition. However, there are two material factors that tend to determine the abrasive quality. First is the material hardness, which is measurable and can be defined using the Mohs scale or Vickers scale. The second factor is the particle shape. A hard particle having no abrupt edges (a sphere) is less likely to abrade a contact surface than one with sharp edges. Most often, abrasive materials are known to plant personnel, and experience tends to be the most valuable measure. In other words, if a material has been found to erode other plant process equipment, certain parallels can be drawn and educated assumptions made as to the way the material will affect proposed equipment.

7. Material Temperature

a. Usually defined as a range (min. to max.)

8. Moisture Content

a. Usually described as a percentage by weight.

b. Can provide an important clue as to flowability or cohesiveness.

Note: One of the most common misconceptions in regard to materials and their various handling characteristics is that they can be obtained from MSDS (Material Safety Data Sheets). However, this is rarely the case. As the name implies, the document is a declaration of any health, safety or environmental concerns, and while it may offer some vague clues, it seldom enables a sufficient understanding of the way a material is likely to behave while being handled, stored or processed.

Note: There is an excellent resource printed on a web site called http://www.tankconnection.com/ which goes to extensive effort to quantify the most important characteristics for hundreds of common solids, assigning each a code and providing a convenient code chart for interpreting a material’s unique character profile.

That chart may be found at http://www.tankconnection.com/products/understanding-dry-bulk/ material-characteristics/.

Operation

Simply stated, operation refers to the function and performance that you need to satisfy. There are certain aspects of the operation that should include some detail and clarity.

Fundamentally, moving material through a process falls into two main categories. It is important for processors to understand the difference to ensure the right conveyor system is ultimately selected. 

a. Conveying

b. Feeding

1. Conveying is simply moving material (or materials) from one or more pick-up points and delivering certain materials to one or more drop points. The rate at which this is accomplished is usually fixed and the delivery time, while important, fits comfortably within a minimum and maximum range. Conveyor systems are most often used as a refilling device for surge hoppers, feeders or process equipment.

a. Specifying the operation of a conveyor consists of:

i. Defining the amount of material that needs to be moved and the window of time within which it must be moved.

ii. In cases where there may be multiple discharge points, it is necessary to know the demand at each drop point.

iii. Determining what condition will initiate a refill, stop a refill and in the case of multiple discharges, develop suitable logic (or sequence of operation) to establish refill priority, so that the process is not inadvertently starved.

iv. When considering a single conveyor for multiple materials, it is imperative to know whether cross contamination will be an issue.

2. Feeding generally is much more time sensitive and process critical in terms of the amount of material delivered. Material is normally received from a single source and delivered to a single drop point. Because of the precision with which material needs to be delivered, delivery rates usually vary, either to coincide exactly with a continuously fluctuating demand or slowing to creep up on a batch-complete set point, for example.

a. Defining the operation of a feeder consists of determining whether the feeder will be required to deliver in discrete batches or deliver on a non-stop, rate-controlled basis.

i. If batching, it is important to know the amount that must be delivered, the time in which it must be delivered and what level of accuracy will suffice (usually defined as a +/-percentage of the target weight). It is also important to know the idle or at-rest time of the feeder between batches.

Ii. If feeding continuously, the rate needs to be defined, as well as the accuracy (usually defined as a +/- percentage of the instantaneous rate).

Note: One of the most frequently occurring mistakes with regard to conveyor or feeder sizing comes about as a result of confusing material usage with instantaneous demand.

For example, while a process may consume 1,000 pounds per hour of material, the conveyor or feeder may need to deliver at a rate that is 12 times higher if the batch needs to be satisfied in 5 minutes, for example. 

Note: Most automatic means of feeding and conveying are sized according to the equipment’s volumetric capacity. However, the material demand is most often understood and communicated in terms of its weight. Therefore, a reliable value for the bulk density is necessary in order to calculate the volumetric requirement so that the equipment can be properly sized.

Environment

There are a number of environmental factors that must be considered in the proper selection of conveyor equipment. Some of these may combine with material characteristics to cause or exacerbate handling concerns, while others may necessitate added health and safety standards and countermeasures.

1. Some environmental factors may include:

a. Open sources of ignition

b. The potential for a flammable or explosive atmosphere

c. Corrosive vapor

d. High humidity

e. Temperature

f. Vibration

g. Pressure or vacuum (at inlet, discharge or both)

Envelope

The application of one device versus another quite often comes down to envelope – how much room is available to install the equipment or device. This appears straightforward, and yet this is one of the most frequently omitted pieces of information from inquiries.

1. When considering new equipment, particularly when some portions of the system already exist, take care to consider the following:

a. What will the new equipment receive from?

i. What is the discharge elevation of the upstream equipment?

b. What will it discharge into?

i. What is the inlet elevation of the downstream equipment?

c. What is the centerline distance between the proposed inlet and discharge?

d. Is the proposed route in a straight line or must it turn a corner or change elevation more than once to avoid an existing plant feature?

e. How much width/depth is available to accommodate the new device or equipment?

f. What is the ceiling height?

g. Are there any other layout considerations such as the need to temporarily locate pallets of material, etc. or allow maneuvering room for a fork truck?

Cost

Some consider it taboo to have any upfront discussion with suppliers about budgets, and, yet, there is no denying the role cost plays in the feasibility of every project. Understandably, the justification formula is different from one company to the next. There are initial costs and long-term costs. Some companies weigh more heavily the long-term cost of ownership in their justification calculation, focusing more on reliability, reduced energy consumption and maintenance. Others more heavily weigh the initial investment.

When inquiring about potential solutions, therefore, it is in your interest to have the ability to speak with potential suppliers about these factors so as to obtain from them, as soon as possible, whether a particular approach is likely to gain any traction or whether to consider another approach entirely. Considering how lean companies are and how busy everyone is, it can save precious time and energy to have some of this dialog up front.

History

When replacing existing equipment, the importance of service history cannot be overemphasized. Where reliability has been an issue, understanding the difficulties experienced with existing equipment can provide important clues that enable the incorporation of suitable countermeasures. Simply changing brand names is no guarantee that you will end up with a more reliable, longer-lasting piece of equipment. It is far better to provide details in regard to service history and ask the vendor to explain how the proposed equipment will provide a more satisfactory result.

Summary

The selection and sizing of a conveyor are key considerations to make in successfully meeting production goals. The key factors that should be evaluated when choosing a conveyor are; material, operation, environment, envelope, cost, and history. Taking the time upfront to understand these factors and gather the most accurate data possible related to each component will ultimately make the selection of conveying technology the best for your specific needs and offer the greatest return on investment.

The post Moving Material through a Process: A Guide to Selecting the Right Conveyor appeared first on Hapman.

Choosing a Pneumatic Conveying System: Pressure or Vacuum

Because they are efficient and inherently dust-tight, pneumatic conveying systems provide the most practical method for moving large quantities of dry materials, whether powdered, granulated, or pelletized. Pneumatic conveyor systems, which use an air stream to move materials through horizontal and/or vertical piping, come in two forms: pressure or vacuum.

The Differences and Similarities in Pneumatic Conveyors

Pneumatic conveyors can utilize either a pressure system that introduces compressed air at the system inlet in order to push the material through the piping or a vacuum at the delivery end in order to pull the material through the piping. Pressure and vacuum systems can be used for dense (high pressure/ low velocity) or dilute (low pressure/high velocity) phase operation.

Dense phase conveying systems have a low air-to-material ratio. Velocities are below the saltation level, the critical velocity at which particles fall from suspension in the pipe. Dense phase systems, therefore, move the material through the piping in batches, with discrete dunes or plugs of material separated by pockets of air. Valving systems can be adjusted to reduce the air pockets.

Dillute phase conveying systems have a high air-tomaterial ratio. In this type of system, the material is most often fluidized, or suspended in the air flow, and moves at relatively high velocities depending on the particle size and density. Dilute phase systems usually deliver the material continuously. Material is constantly supplied at the pickup point and is conveyed to the receiver without interruption.

Pressure Systems

The basic components of a pressure system are a rotary air lock feeder valve, a high pressure air compressor system or a low-pressure positive displacement blower or fan to serve as the power source. A pressure vessel, the conveying line, and the receiver make-up the balance of the system. Systems using high-pressure compressed air, operate with pressures above 15 psig, usually with a beginning pressure of about 45 psig and an ending pressure near atmospheric pressure. Low-pressure displacement blowers or fans supply a beginning pressure below 15 psig and an ending pressure near atmospheric pressure.

First, the materials is charged into the pressure vessel through the rotary air lock. Once the pressure vessel is filled, the inlet and vent valves close and seal, and highpressure air is gradually introduced into the pressure vessel. The high-pressure air conveys the material to the receiver, where the air and the material are separated by a filter or other system. Valves and sensors control the air pressures and velocities. When the predetermined low pressure setting is reached at the end of the conveying cycle, the air supply is turned off and the residual air volume purges the pressure vessel and the conveying line.

Pressure pneumatic conveying systems are generally preferable when transporting heavier materials longer distances. Pressure pneumatic conveyors can be fairly costly, however, since they require special equipment, like a rotary valve to introduce material into the air stream at the inlet and extra components to remove the air at the discharge end through a vent system.

Vacuum Systems

The basic components of a vacuum conveyor system are the pick-up nozzle, the conveying line, the receiver, and the vacuum generator, which is the power source. The vacuum generator creates the required negative pressure to pull the material through the conveying line and into the receiver. A number of devices, including a regenerative blower, a compressed air driven eductor (Venturi) unit, a plant central vacuum using liquid ring vacuum pumps or low-pressure blowers, or a positive displacement vacuum pump, can serve as the vacuum generator. The maximum negative pressure generated and the overall capability of the system, as well as the system efficiency and general operating characteristics, are determined by the type of vacuum generator used.

The air flow created by the vacuum generator moves the material through the conveying piping and into the receiver. There, gravity causes the material to drop into the receiver hopper. Internal filters separate the material from the air to remove any dust and protect the vacuum generator. Delivery of the material from the receiver to its final destination (e.g., process vessels or a packaging line) may be accomplished using a number of methods dependent on application suitability, including a dumpgate simple slide valves, pneumatically operated dump gates, or air lock rotary valves.

Vacuum conveying systems are usually preferred for transporting materials that may tend to pack or plug in a pressure system. They are also a good choice when space is at a premium; for example, attaching a pressure system rotary valve in the limited space below a hopper rail car may be impractical. However, vacuum conveyors are not a good option if you need to transport materials long distances. Because they operate with pressures at or below atmospheric pressure (14.7 psig), vacuum conveyors are limited to a maximum horizontal distance of 50 feet and a maximum horizontal distance of 200 feet. The effective horizontal distance is also reduced by vertical distances and piping bends.

Which Pneumatic Conveyor Best Suits Your Needs?

You will want to consult with one or more pneumatic conveying system specialists before making your decision. However, you should prepare for your discussion by answering the following questions:

• What kind of material is being transported through the pneumatic conveyor? Is material or piping degradation a concern?
• What is the purpose of transferring your materials in a pneumatic conveying system? Do you simply want to move material? Do you want to transfer more material than your current system can handle? Are you more concerned with reliability and efficiency, or gentleness of transport?

To answer these questions, you need to consider a number of material handling characteristics, including conveyability, optimum air-to-material ratios, buildup tendencies, flowability, and degradation. Figure 1 provides some guidelines to assist you in choosing the right system for the material you need to convey.

Pneumatic Conveying Systems Summary

Pneumatic conveying systems, whether pressure or vacuum, are an excellent choice for providing efficient and dust-free conveying. And while pressure systems are preferred for conveying heavier materials longer distances, vacuum systems are the conveyor of choice for materials that have a tendency to pack or where physical space within the plant is limited. Because of the seemingly limitless variability in system requirements and diverse material bulk densities, designing an optimized system must first begin with identifying these elements with a qualified conveying expert. Taking into account the physical needs of the plant environment, the availability of plant air, and characteristics of the materials being conveyed will ensure that your pneumatic conveying system is the best, most efficient and economical choice for your current and future needs.

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