Pressure vessel based batch dense phase and older versions of continuous dense phase systems take a longer time to be fine-tuned during material changeover. ConTran™ is quicker as the fast response air controller automatically adjusts to the conveying parameters.
Material Degradation
With pet food, degradation is minimized when the following interactions are lowered during conveying:
- Particle-pipe (impact and rolling effects)
- Particle-particle (crushing effect)
Particle-pipe interaction is mainly velocity dependent. Compared to dilute phase conveying, virtually all dense phase systems lower particle-pipe interaction because they convey well below saltation velocity.
Particle-particle interaction is dependent not only on material velocity, but also the consistency and type of flow during the entire conveying duration. There are instances where a higher bulk velocity, in conjunction with a more consistent wave-form flow, results in lower degradation.
The majority of all degradation that occurs in dense phase conveying is due to the crushing effect caused by particle-particle interaction. ConTran™ minimizes this effect better for pet food than other dense phase systems for several reasons:
- The fast-response air controller is better able to create and sustain wave-form flow. Unlike the long slugs in full-pipe flow conveying, the shorter and more stable slugs do not disintegrate further down the convey line.
- The air controller lowers the material velocity significantly
- ConTran's™ expansion chamber at the receiving end minimizes sudden, uncontrolled expansion of air .
Degradation also occurs when material slides or rolls on the conveying surface or against other particles. This form of degradation can occur in all types of conveying, but is prevalent in dilute phase and mechanical methods.
Material segregation
Because dilute phase conveying usually occurs at high velocities, certain particles (depending on density and shape) are conveyed faster than others. This leads to significant segregation of mixed pet food products at the receiving end. This is minimized in dense phase systems because conveying occurs well below saltation velocity.
Segregation is also high on vibrating mechanical conveyors, because vibrations treat lighter particles differently.
Future-proofing: System layout flexibility
Flexible routing and less space requirements are benefits all pneumatic conveying systems offer in comparison to mechanical systems. In addition, pneumatic systems are easier and more economical to upgrade in terms of retrofitting additional pick-up or destination points.
Power consumption, operating costs, and initial capital investment
For shorter distances and lower conveying rates, mechanical systems offer the lowest power consumption figures. However, for long and non-linear routes, pneumatic conveying becomes increasingly more competitive in terms of power as well as capital investment.
When compared to other dense phase systems, ConTran's™ power consumption is up to 30% lower. It is more economical than any other dense phase pet food conveying system available.
Maintenance Costs
ConTran™ uses many standard components and sub-components such as blowers, rotary valves, relief valves, sensors, and control hardware. Spare parts are readily available from Horizon Systems, Inc. or directly from the original manufacturers. The original components used are robust and long-lasting. The control software has been extensively field-tested; in the unlikely event of any problems, comprehensive technical assistance is available.
Mechanical systems incur high downtime and labor costs related to cleaning out the line and minimizing cross contamination. ConTran automatically cleans itself.
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