A case study of dilute phase pneumatic conveying project for grass powder at a feed enterprise in Chifeng, Inner Mongolia

Case Study: Dilute Phase Pneumatic Conveying of Grass Meal Powder for a Feed Enterprise in Chifeng, Inner Mongolia

Project Background and Customer Requirements

A feed manufacturing enterprise located in Chifeng, Inner Mongolia, faced significant challenges in handling its primary raw material — grass meal powder. The facility required a reliable, efficient, and dust-free material transfer system to move the fine, fibrous, and low-bulk-density grass meal powder from the grinding area to the mixing and packaging sections. The existing mechanical conveying methods, such as screw conveyors and bucket elevators, suffered from frequent blockages, high maintenance costs, and excessive dust generation, which compromised both product quality and workplace safety. The customer specifically sought a solution that could ensure gentle handling of the material, minimize particle degradation, and provide a closed-loop conveying environment to prevent contamination. After evaluating multiple suppliers, the enterprise selected Shandong Headpowder Engineering Co., Ltd. (headpowder) to design and install a custom dilute phase pneumatic conveying system tailored to the unique properties of grass meal powder.

Product Overview: Grass Meal Dilute Phase Conveying Case

This project is a typical grass meal dilute phase conveying case that demonstrates the effectiveness of pneumatic technology in handling light, fluffy, and cohesive powders. The system was engineered to convey grass meal powder at a controlled velocity using a high-volume, low-pressure air stream, ensuring that the material remains suspended in the pipeline without settling or bridging. Unlike dense phase systems that rely on high pressure, the dilute phase approach is ideal for materials with low bulk density and high air retention, such as grass meal. The entire conveying line, including the feeder, pipeline, cyclone separator, and filter receiver, was designed to operate under negative pressure, further reducing dust emissions and improving hygiene. This case serves as a benchmark for feed ingredient conveying applications where gentle handling and consistent flow are critical.

Technical Solution: Dilute Phase Pneumatic Conveying System

The core of the solution is a complete dilute phase pneumatic conveying system that integrates multiple components to achieve seamless material transfer. The system utilizes a rotary airlock feeder to introduce grass meal powder into the pipeline at a controlled rate, while a roots blower generates the required air velocity. The conveying pipeline is designed with a diameter of 150 mm and a total length of 80 meters, including multiple bends to navigate the existing plant layout. A cyclone separator at the destination separates the material from the air stream, and a pulse-jet dust collector captures any fine particles, ensuring zero emission. The system is controlled by a PLC-based automation unit that monitors pressure, flow rate, and material level, allowing for real-time adjustments. The maximum conveying capacity reaches 8 tons per hour, with a material-to-air ratio maintained between 0.5 and 1.5 kg of material per kg of air, depending on the moisture content of the grass meal. This design not only eliminates blockages but also reduces energy consumption by 30% compared to the previous mechanical system.

Key Advantages of the Dilute Phase Approach for Feed Materials

For feed ingredient conveying, the dilute phase technology offers several distinct advantages over traditional methods. First, the system is completely enclosed, preventing cross-contamination and moisture absorption, which is crucial for maintaining the nutritional value of grass meal. Second, the gentle conveying action minimizes particle breakage, preserving the fiber structure essential for animal digestion. Third, the low maintenance requirement and easy cleaning capability of the pneumatic system reduce downtime significantly. The installation at the Chifeng facility also included a custom-designed inlet hopper with a vibration assist to prevent bridging, a common issue with fibrous materials. The overall system footprint is compact, freeing up floor space for other production equipment. Additionally, the system can be easily scaled up or reconfigured to handle different feed ingredients, such as corn gluten meal, soybean hulls, or alfalfa powder, making it a versatile investment for the feed mill.

Project Implementation and Results

The project was executed in two phases over a period of six weeks. Headpowder's engineering team conducted a detailed site survey to map the existing layout and assess the material characteristics. A pilot test was performed using a sample of the customer's grass meal powder to validate the conveying parameters. After installation, the system was commissioned with a 48-hour continuous run to ensure all components operated within the designed tolerances. The results were outstanding: the conveying rate consistently met the target of 8 t/h, with less than 0.5% moisture loss and no visible dust leakage. The customer reported a 40% reduction in labor costs associated with material handling, and the overall plant air quality improved dramatically. The system has been in operation for over 18 months with zero major failures, and the enterprise has since ordered an additional unit for their new production line. For more details about this grass meal dilute phase conveying case or to discuss your specific feed ingredient conveying requirements, please contact the project manager: Mr. Zhang (Manager Zhang). You can reach him via WeChat at 15662777102.

Company Profile: Shandong Headpowder Engineering Co., Ltd.

Shandong Headpowder Engineering Co., Ltd. (headpowder) is a specialized engineering firm based in Shandong, China, dedicated to the design and manufacture of advanced pneumatic conveying systems for bulk solid materials. With over 15 years of industry experience, the company has delivered hundreds of successful projects across the feed, food, chemical, and building materials sectors. The company's core expertise lies in dilute phase pneumatic conveying systems, which are optimized for handling a wide range of powders, granules, and fibrous materials. Headpowder provides end-to-end services, from feasibility studies and material testing to system design, fabrication, installation, and after-sales support. The company's state-of-the-art testing laboratory allows customers to simulate their specific conveying conditions before committing to a full-scale system. This commitment to precision and quality has made headpowder a trusted partner for feed mills, livestock farms, and ingredient suppliers across China and internationally. For inquiries or to schedule a consultation, please contact Mr. Zhang (Manager Zhang) via WeChat at 15662777102. Headpowder's team is always ready to provide tailored solutions for your powder handling needs.

Conclusion: A Proven Solution for Modern Feed Mills

The success of the grass meal powder conveying project in Chifeng, Inner Mongolia, underscores the reliability and efficiency of dilute phase pneumatic technology for feed ingredient conveying. By replacing outdated mechanical systems with a modern, closed-loop pneumatic solution, the feed enterprise achieved significant improvements in product quality, operational efficiency, and workplace safety. The system's ability to handle low-density, fibrous materials without degradation makes it an ideal choice for grass meal, alfalfa, and similar feed powders. As the feed industry continues to evolve toward higher automation and stricter hygiene standards, the adoption of pneumatic conveying systems from a reputable manufacturer like Shandong Headpowder Engineering Co., Ltd. becomes a strategic advantage. If your facility is facing challenges with material blockages, dust control, or high maintenance costs, consider the proven benefits of a dilute phase pneumatic conveying system. Contact Mr. Zhang at WeChat 15662777102 to explore how headpowder can tailor a solution for your specific application.