Poor material flow affects every part of food production—quality, hygiene, sanitation, and operating costs.
A single hopper or silo with bridging can compromise an entire batch. Stagnant material may spoil, and uneven flow leads to variations in flavour, texture, and consistency.
Material Flow Challenges in Food Manufacturing
Problematic Flow Properties
Powders can compact and form arches that block flow. High-fat ingredients like flax or cocoa may cake and clog pipes or filters
Humidity and Temperature
When materials absorb moisture, they compact and become difficult to discharge.
Contamination
Trapped residue becomes a breeding ground for bacteria and mold.
How Material Flow Affects Cost, Time, and Safety
Material blockages create extra cleanup work, leading to delays, safety risks, and higher operating costs.
Material Waste
A flax processor was discarding 40 pounds of mixture each day—and paying disposal costs on top of it.
Manpower
A spice producer lost hours each week manually cleaning ribbon blenders by flushing them with flour.
Workplace Risk
Caked whey protein caused bridging in a cheese plant’s baghouse, leading to a fire and serious safety risk.
AirSweep: Proven Solution for Tough Material Flow Problems
These food manufacturers solved their material flow challenges with the AirSweep® system. AirSweep uses powerful, high-volume air pulses to cut through buildup—just like an air knife. It clears stagnant material and restores consistent, first-in/first-out flow.
AirSweep is Trusted by Leading Food Manufacturers Worldwide
It is Proven Effective for:
Cheerios Material Flow Test
Cornstarch Material Flow Test
Whey Protein Material Flow Test
Why AirSweep Outperforms Other Flow Aids
Some flow aids can worsen material blocks or cause more problems than they solve.
The vibrators that came installed on the bottom of the hopper above the mixture practically turned the flax into concrete. Then we installed fluidizers, which were terrible. We still had to use hammers and sticks, and spent an hour a day to clean and keep things flowing.
— Head of the maintenance department at a flax-based bakery
However, AirSweep® was able to solve 90% of their material flow problems. Aside from reducing wastage and improving production speed, they no longer need to climb equipment to dismantle and clean the ingredient receiver.
Engineered for Hygiene and Food Safety Compliance
Designed to meet USDA requirements, AirSweep systems ensure full compliance with food safety standards.
Prevent Material Pile-Ups with DAZIC®
DAZIC speed switches—available in electromechanical, electronic, and inductive proximity models—alert operators when equipment runs too fast, too slow, or stops completely.
They’re ideal for conveyors and other shaft-driven systems, and can be interlocked to automatically shut down operations if equipment speed falls outside safe limits.
AcoustiClean® Sonic Horns Prevent Dust Build-Up and Contamination
Fine powders such as flour can coat vessel walls or enter air ducts, contaminating the process and reducing air quality.
This buildup can also affect worker safety and equipment performance—trapping heat, disrupting temperature control, and causing long-term wear.
AcoustiClean® prevents this by stopping powders and particulate matter from accumulating on surfaces.
AcoustiClean Sonic Horns use high-energy, low-frequency sound waves to remove dry material buildup.
Compressed air activates a sound generator that vibrates a titanium diaphragm, releasing sound pulses that dislodge and clear dust from vessels—keeping equipment clean and efficient.
Gain Control Over Your Food Processing
AirSweep® and DAZIC® integrate seamlessly across your plant to boost efficiency and cut operating costs. Request your free tailored proposal today.
[contact-form-7 id="8a12c69" html_class="custom-cf7-form"]
ISO 9001:2015 Certified
Built in WA, delivered worldwide.
