The Ultimate Guide to Pneumatic Conveying: How It Works & Different Types

Pneumatic conveying is a highly efficient method for transporting bulk materials, particularly powders and granules, through pipelines using air or gas. It provides a clean and flexible solution for moving materials from one point to another. This system is widely used in industries such as food, pharmaceuticals, chemicals, and cement, where hygiene, safety, and material handling precision are essential.

So what exactly is pneumatic conveying, how does it work, and what are its different types? Let’s see:

What is Pneumatic Conveying?

Pneumatic conveying uses airflow to move powdered or granular materials through pipelines. The materials are carried by air or gas pressure, offering a streamlined method of transportation.

While mechanical setups depend on belts or screw drives, pneumatic conveying moves materials using airflow within sealed pipelines.

Here are the key benefits of using pneumatic conveying methods:

● The enclosed system design keeps operations clean and prevents contamination.

● It can easily adapt to complex plant layouts and reach difficult areas.

● With few moving parts, it requires minimal maintenance and operates reliably.

● It handles fragile or hazardous materials safely, reducing product damage and exposure risks.

How Does Pneumatic Conveying Work?

At the start of the process, the material is fed into moving air that transports it through the pipeline. Once the materials reach the end of the pipeline, they are separated from the air stream, typically using a separator or filter.

Main Components:

Main components of a pneumatic conveying system include:

1. Air Mover: This includes devices such as blowers, fans, or compressors that generate the airflow required to move materials through the system.

2. Feeding Device: Devices such as rotary valves or venturi feeders regulate how the material enters the moving air.

3. Conveying Pipeline: A network of pipes that carries the material from the feeding point to the destination.

4. Separator/Receiver: At the destination, a cyclone separator or filter is used to separate the material from the air, which ensures clean and efficient collection.

Different Types of Pneumatic Conveying Systems

Pneumatic conveying systems are divided into three main types, each designed for specific materials and production requirements. Here is a quick look at all of them:

Dilute Phase Conveying

This system operates at high air velocity and low pressure. The materials are fully suspended in the air stream and transported continuously through the pipeline.

The dilute phase pneumatic conveying is best suited for light, non-abrasive powders such as flour, sugar, starch, and grain-based ingredients.

Dilute phase systems are simple in design, easy to maintain, and cost-effective. However, they are not ideal for fragile or abrasive materials, as the high velocity may cause particle degradation or equipment wear.

Dense Phase Conveying

Dense phase pneumatic conveying works at a lower air velocity but at a much higher pressure. Instead of suspending materials, it moves them in slugs or plugs along the pipeline.

This method is best suited for materials that are abrasive, dense, or fragile like cement, sand, or plastic granules. The slower movement reduces product damage and wear on the system, making it more efficient for valuable or sensitive materials.

While it offers excellent material protection, dense phase systems typically require higher energy input and more complex controls.

Vacuum Conveying

Vacuum systems use negative pressure to draw materials through the pipeline rather than pushing them with compressed air.

This method is ideal for handling fine, toxic, or temperature-sensitive powders in industries such as food processing, pharmaceuticals, and chemicals.

Since air is pulled through the system, it prevents dust from escaping and minimizes contamination risks. However, vacuum conveying is generally better for short to medium conveying distances and lighter materials.

Here is a head-to-head comparison that will help you better understand the difference between all the types:

● Dilute phase systems are fast, simple, and economical, but not suitable for delicate or abrasive products.

● Dense phase systems protect material integrity and reduce wear, but require more energy and higher maintenance.

● Vacuum systems ensure clean, safe material transfer and are ideal for hazardous or fine powders, though they are limited by conveying distance and capacity.

FAMSUN’s Pneumatic Conveying System

FAMSUN’s pneumatic conveying solutions use fluidization technology to transport powder or granular materials through enclosed pipelines with air pressure.

The system is highly adaptable for industries such as food, pharmaceuticals, chemicals, mining, metallurgy, and energy, offering continuous production, easy maintenance, and space-saving installation. Its airtight design maintains hygiene and protects materials from moisture or degradation.

FAMSUN provides several system types of pneumatic conveying equipment to meet different needs:

● Blow Tank/Vessel Dense Phase: Best for abrasive, moisture-sensitive, or segregating powders.

● Pressure Dense Phase Continuous: Designed for fragile or coated granules needing gentle transport.

● Vacuum Dilute Phase: Ideal for fine or toxic powders where leakage prevention is critical.

● Pressure Dilute Phase: Suitable for hard granules or single-component powders with multi-point delivery.

Each setup ensures high efficiency, safety, and long-term reliability, making FAMSUN’s pneumatic conveying system an ideal solution for modern, clean, and automated material transport.