Why AirSweep® Outperforms Other Flow Aid Systems
The Limits of Traditional Flow Aids
Most flow problems come from the wrong flow aid, not the material itself. Plants often start with start with vibrators or fluidisers because they seem simple, but blockages return within months.
Vibrators rely on shaking the vessel to break friction. In practice, they can compact the material instead, worsening bridging or ratholing. Over time, the vibration causes weld fatigue and cracks. They are loud, energy-intensive, and give little control over feed rates.
Air Cannons discharge large blasts of air into the bin. These bursts have power but little control. Air channels through holes in the material, leaving much of it stuck to the walls. Recoil forces and loud noise strain the bin structure and can cause long-term metal fatigue.
Air Knockers use repeated impact against the vessel. The hammering leads to metal wear, high air or power use, and residue left on the bin walls. Frequent cleaning cycles are still needed.
Fluidisers combine gentle aeration and vibration through rubber disks. They work with light, dry powders but fail on sticky or heavy materials. The disks wear down, which can contaminate product and reduce quality. They also consume more energy and have limited activation range.
Each of these systems relies on vibration or brute force. They move some material but not all, often creating new maintenance issues and higher costs.
How AirSweep® Works
AirSweep uses a targeted, high-pressure pulse to lift material directly from the vessel wall. Each nozzle emits a short burst of air that sweeps along the surface, breaking friction and returning material to the flow stream. The nozzle seals instantly to prevent dust or material from entering the line.
Each nozzle covers up to a 2.4m diameter of area, so fewer units are needed for full coverage. The system uses less than 17 m³/h of compressed air per nozzle, providing strong performance with minimal energy use.
Because AirSweep works through internal aeration rather than vibration, it places no stress on the vessel walls. It operates quietly, producing only a quick, ear-friendly “psst” that does not carry through the plant.
AirSweep is effective for powders, granules, sticky pastes, and dense solids. It clears bridging and ratholing and ensures each batch discharges completely for true, first-in, first-out flow.
AirSweep model VA-06 installed on a test bin.
Maintenance and Safety Benefits
AirSweep is built for long service life. The patented nozzle design prevents clogging and typically requires only a brief inspection every six months. Components last more than one million cycles before replacement.
Installation can be done from outside the vessel, removing the need for confined-space entry. USDA-accepted models are available for food and sanitary use.
By removing vibration, loud impacts, and uncontrolled blasts, AirSweep reduces fatigue on equipment and improves safety for operators.
Glossary
Bridging: When material forms a solid arch above the outlet, stopping flow.
Ratholing: When flow occurs only through a narrow vertical channel, leaving most of the material stuck to the walls.
First, first-out flow: When older material discharges before new material enters, preventing build-up and contamination.
Aeration: The use of compressed air to loosen material and restore movement without vibration or impact.
Frequently Asked Questions
What types of material does AirSweep handle best?
AirSweep works with all materials — powders, sticky slurries, grains, minerals, and dense solids. It is effective wherever bridging or build-up occurs.
How is AirSweep different from an air cannon?
Air cannons fire large, uncontrolled blasts that can damage vessels and waste air. AirSweep uses short, controlled pulses that lift material directly from the wall, clearing build-up efficiently with far less air.
Does AirSweep require frequent maintenance?
No. Only a simple inspection every six months is recommended. Components typically last more than one million cycles.
Is AirSweep suitable for food and sanitary applications?
Yes. AirSweep offers USDA-accepted models suitable for hygienic environments and easy cleaning.
How much air does AirSweep use?
Each nozzle uses less than 17 m³/h (10 CFM) of compressed air, depending on the application.
Can it be installed on existing vessels?
Yes. AirSweep can be mounted from outside the vessel, making it ideal for retrofits or upgrades without downtime.
Conclusion
AirSweep replaces brute force with precision. It provides clean, predictable flow while protecting equipment and improving safety. Facilities using AirSweep report less downtime, longer vessel life, and consistent product flow.
The proof is in the flow.
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