May 31, 2017

How to avoid designing a poor bulk material handling system

When designing a bulk material handling system, a decision must be made as to whether to use a conveyor or a feeder. If you miss using a conveyor for a feeder, especially without a proper interface,it can result in increased power requirements and stagnant regions within the bin.

bulk material handling

Therefore, a professional help in designing of perfect bulk material handling system is mandatory. AAG Engineering Technologies can be your mentor and can design one appropriate system for your needs.

If modulation of flow rate is required, a feeder should be used. While in the case when bulk materials need to be transported over long distances, then a conveyor should be used.

A large variety of feeders are available, and more than one feeder may be appropriate for a particular application. But while making the decision about what kind of feeder is to be used, various factors should be taken into considerations like the kind of material used, space, power and much more.

Here are few issues that should be avoided while designing a perfect bulk material handling system.

Common issues

Inaccurate designing of feeder: While designing bulk material handling system, care must be taken to ensure that the feeder is designed properly in order to provide reliable, uninterrupted flow from the bin above. Care must also be taken to remove material from the entire cross section of the outlet (particularly important if a mass flow pattern is required), and interface with the hopper above such that loads on the feeder are minimized.

The small interface between belt and hopper: Ensure that the interface between the belt and the hopper is large enough to prevent arching in the hopper and to ensure discharge of material over the entire cross section of the outlet.

Hopper outlet is not large enough: It is important to make sure the hopper outlet is large enough to provide the required discharge rate. With fine materials, such as gypsum, fly ash, magnetite concentrate, and titanium dioxide, the discharge rate may be limited if the belt feeder is operating at a speed greater than the bulk material’s critical steady-state rate of discharge.

Insufficient power to operate the feeder: Sometimes the power required to shear material and operate a belt feeder is greater than the available power. This is usually a result of a poorly designed interface in bulk material handling system.

The pressure exerted by the bulk material is not manageable: Structurally design and reinforce the interface to withstand the pressures exerted by the bulk material against it. Otherwise, it will deform in such a way that significantly higher forces are needed to shear the material.

A well-planned and properly designed bulk material handling system can avoid all these issues with a properly designed interface. It requires a professional guidance for an accurate designing of the bulk material handling system.

AAG Engineering has rich experience in not only guiding the design but even in implementing a perfect bulk material handling system. Avail our expertise for your bulk handling system by contacting our sales team at or visit our website at



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