​Gentle Conveying Solutions by YINCHI: Protect Your Powder Materials from Breakage

When high-value ceramic powders worth thousands per ton turn into waste due to excessive breakage, or pharmaceutical companies face batch recalls due to fractured active ingredients—these staggering losses often stem from a hidden culprit: harsh conveying methods. Discover how YINCHI’s gentle conveying technology safeguards your material integrity and boosts profitability.

Material Breakage: The Hidden Profit Drain in Powder Industries

Quantifying the Impact of Breakage

According to the Journal of Powder Technology (2024), fragile materials can suffer 15%-40% breakage rates under improper conveying.

Example: A lithium battery anode production line handling 10,000 tons/year could save $2 million annually by reducing breakage by just 5% (at $4,000/ton).

Critical Moments When Breakage Occurs

High-speed impact: Particles collide at 30 m/s (108 km/h) in pipe elbows.

Shear friction: Micro-cracks form from wall abrasion.

Pressure agglomeration: Particles crush under excessive compaction.

Expert Insight:

"Brittle powders are like potato chips—traditional dilute-phase conveying is like blowing them with a fan. What you need is a steady hand to transport them safely."

YINCHI’s 4 Core Technologies for Gentle Conveying

1. Speed Control: From Racing to Walking

Dense-phase conveying reduces speed to 3-8 m/s (vs. 18-30 m/s in dilute-phase).

Case Study: A silicon carbide powder producer cut breakage from 22% to 3.2%.

2. Air Cushioning Technology

Minimizes particle-wall contact with optimized airflow.

3. Precision Pressure Control

Dual-pump + sensor feedback keeps fluctuations <0.05 MPa (vs. 0.3 MPa in standard systems).

4. Path Optimization

3D laser-scanned pipelines eliminate 90° sharp turns.

Ceramic-lined bends (radius R≥10D) ensure smooth flow.

3-Step Selection Guide for Optimal Conveying

Step 1: Material DNA Testing

Step 2: Distance-Based Optimization

<50m: Low-pressure dense-phase (40% energy savings).

50-200m: Tank-based dense-phase.

>200m: Multi-stage pressure control.

Step 3: Special Requirements

Sterile: 316L mirror-finish pipes + CIP.

Explosive: Nitrogen inerting + vent valves.

Pro Tip:

Conveying speed must stay below the critical breakage velocity (Vc):

Vc = √(2E/ρ)

(E: Elastic modulus, ρ: Density)

Success Story: Pharma API Breakage Reduced by 94%

Challenge: A cancer drug API ($280M/ton) lost 18.7% potency due to breakage.

YINCHI’s Solution:

Inert gas-protected dense-phase system.

Mirror-polished pipes (Ra≤0.4μm).

Real-time particle size monitoring.

Results:

Breakage dropped to 1.2%.

$65M/year saved.

Passed FDA audit.

The Future: Smart Gentle Conveying

AI Dynamic Adjustment: Learns material traits, adjusts parameters in <50ms.

Digital Twin Simulation: Predicts breakage with 93.5% accuracy.

Industry Trend:

Process Engineering (2025) forecasts 60% adoption of smart conveying in advanced materials.

Protect Your Powders with YINCHI!

🔗 Explore our Dense-Phase Conveying Systems

📞 +86-18853147775 | ✉ sdycmachine@gmail.com