Optimizing Material Handling with Flexible Screw Conveyors: What Works Best?
Flexible screw conveyors truly live up to their name. They can transport materials in multiple directions — vertically, horizontally, and diagonally — offering a versatile solution for various industrial applications. Whether you need to move materials across a production floor or through tight spaces, these conveyors are up to the task.
Besides their flexibility, they provide numerous benefits: they are cost-effective, dust-free, low-maintenance, energy-efficient, and capable of handling a wide range of materials. However, not all materials are equally suitable for flexible screw conveyors. Let’s explore the factors that influence their effectiveness and what products work best.
Key Factors for Material Suitability in Flexible Screw Conveyors
To determine which materials work well with flexible screw conveyors, consider the following six critical factors: size, temperature, moisture, shape, impact on the conveyor, and layout.
1. Size
Flexible screw conveyors efficiently handle materials ranging from fine powders (including sub-micron particles) to larger pellets. However, very large solid particles and dense materials may hinder performance by causing the screw to lock up. In such cases, utilizing a square bar or round wire spiral can help overcome these challenges. If you’re uncertain about compatibility, conducting lab tests can help determine the most suitable conveyor configuration for your specific needs.
2. Temperature
Both hot and cold materials can be transported using flexible screw conveyors. However, extreme temperature ranges may require customized engineering solutions to ensure safe and efficient operation.
3. Moisture
Dry materials are best suited for flexible screw conveyors. High-moisture materials such as sludges and slurries can impede the conveyor’s performance by causing clogging and buildup, which may require additional cleaning and maintenance.
4. Shape
Flexible screw conveyors can handle various material shapes, including powders, crystals, flakes, granules, pellets, and irregular forms. These conveyors are designed to transport materials that tend to pack, cake, smear, break apart, or fluidize, making them ideal for a wide range of applications. When properly designed, they minimize material degradation compared to other mechanical conveyors.
5. Impact on the Conveyor
When choosing a flexible screw conveyor, it’s crucial to consider not only how the conveyor impacts the material but also how the material affects the conveyor. Materials that create excessive friction may strain the motor and lead to mechanical failure if not addressed. Similarly, materials that accumulate on the screw over time can cause blockages and require regular cleaning or design modifications to ensure long-term efficiency.
6. Layout Considerations
Flexible screw conveyors are known for their simple construction, space-saving design, and reliable performance. Their adaptability allows them to be installed into elevated hoppers, bent around obstacles (with a maximum diameter of 4.5 inches), arranged at unconventional angles, and even passed through walls or ceilings. Additionally, they continuously remix materials, preventing segregation of blended products. For materials with high friction or those prone to packing and smearing, it is generally recommended to use a straight conveyor less than 20 feet long without bends.
Conclusion
Flexible screw conveyors offer a versatile and efficient solution for handling a wide variety of materials. However, selecting the right conveyor setup depends on factors such as material characteristics, operational requirements, and spatial constraints. By considering size, temperature, moisture, shape, impact, and layout, businesses can ensure optimal performance and longevity of their conveyor systems.