Jiangsu Nantong Inorganic Filler Dilute Phase Conveying Case

Case Overview

An industrial manufacturer in Nantong, Jiangsu, specializing in the production of inorganic fillers, faced significant operational challenges in material handling. The facility required a reliable and efficient method to transfer fine powders between production stages while minimizing product loss and equipment wear.

Client Challenges

The client experienced frequent clogging and dust emissions during bulk transfer of inorganic fillers. Traditional mechanical conveyors caused high wear rates and required frequent maintenance, leading to unscheduled downtime. Additionally, the existing system consumed excessive energy and failed to maintain consistent material flow rates, affecting overall production efficiency.

Our Solution

Headpowder designed and implemented a custom dilute phase pneumatic conveying system tailored to the properties of inorganic fillers. The solution features a closed-loop pipeline network that uses low-pressure air to transport materials gently and continuously. Key components include a rotary airlock feeder, a dedicated blower unit, and a cyclone separator with a bag filter for dust collection.

Key Features

The system operates at low velocity to reduce particle degradation and equipment abrasion. An automated control module adjusts air flow and material feeding rates in real time, ensuring stable throughput. The sealed design eliminates dust leakage and improves workplace safety. Installation required minimal modifications to the existing plant layout.

Results and Benefits

After deployment, the client reported a 30% decrease in energy consumption compared to the previous mechanical conveyor. System availability increased to over 98%, with maintenance intervals extended by 60%. Dust emissions were reduced to near zero, meeting local environmental standards. The consistent material flow also improved downstream mixing and packaging processes.