Aero Mechanical Conveyors

Ideal for vertical or angled conveying of a wide variety of products, even fragile, fibrous or cohesive ones. High throughput & total batch transfer.

Our Aeroflow aero mechanical conveyor has a tubular design where a cable assembly, with evenly spaced polyurethane discs, move at high speed.  The cable assembly runs in specially designed sprockets at each corner and each end of the conveyor.  The action of the cable assembly traveling at high speed creates an air stream running at the same velocity.  As the material is fed into the airstream, it is fluidized and conveyed to the outlet where it is centrifugally ejected.

Features

  • Proven Design
  • Operates at any angle from 0-90°
  • Transfers Materials Vertically & Horizontally
  • Easy to Clean
  • Total Transfer
  • Gentle Conveying Action
  • Multiple Inlets & Outlets
  • Mobile
  • Conveys Difficult Materials
  • Maintains Mixtures
  • High Throughput
  • Totally Enclosed for Total Containment
  • Dust-free Conveying
  • No Dust Collection System
  • Low Power Consumption
  • HOW IT WORKS & BENEFITS
  • APPLICATIONS
  • CONFIGURATIONS
  • MODELS & SPECIFICATIONS
  • COMPONENTS & OPTIONS
  • TYPICAL MATERIALS
  • BUYER'S GUIDE

HOW IT WORKS & BENEFITS

Aeroflow aero mechanical conveyors offer processors many advantages

Proven Design

As the leading provider of aero mechanical conveyors, Spiroflow has provided these conveying systems operating throughout the world.

Totally enclosed for containment & dust-free conveying

All conveying takes place in a totally sealed tubular system which ensures the dust-free transfer of even the finest powders.

Operates at any angle

Aero mechanical conveyors can convey materials at any angle from 0° and 90° without loss of capacity. The range of configurations is almost limitless. This enables the widest choice of system layout options, using standard components, to optimize available factory space.

Goes around corners

Aero mechanical conveyors can be supplied in a variety of configurations enabling them to transfer materials vertically and horizontally within the same unit.  These conveyors can also be linked together allowing one aero mechanical conveyor to feed another.

Easy to clean

Because of the total transfer capability of aero mechanical conveyors cleaning is not necessary for most applications.  To avoid cross-contamination of product it is often sufficient to simply purge the conveyor with a sacrificial quantity of material.  Safety interlocked cleaning/inspection hatches can be fitted to both the conveying tubes and the sprocket housings.  Additionally, aero mechanical conveyors fitted with wash gates and drains can be washed through with water or another cleaning fluid.

High throughput

Aero mechanical conveyors can operate at speeds up to 36 ft3/min or 2,160 ft3/hour / 1 m3/min or 61 m3/hr, with many products such as flour. They are capable of conveying rates in excess of 160,000 lb/hr / 72,600 kg/hr but this rate will vary according to the bulk density of the product.

Conveys difficult materials

Virtually all materials can be conveyed in an aero mechanical conveyor ranging from the finest of powders to granules, pellets, flakes, and flocks.  We have been particularly successful with titanium dioxide which is a notoriously difficult material to convey.

Low power consumption

Pound for pound conveyed, aero mechanical conveyors are one of the most efficient conveyors available.  Users benefit by their minimal power requirements and associated energy savings.

Gentle conveying action

Materials are suspended in a cushion of air within the conveying tube as it is displaced by the discs traveling at speed.  This makes for a gentle conveying action that minimizes damage to fragile finished products.

Mobile

Spiroflow aero mechanical conveyors can readily be mounted on a wheeled frame complete with controls and a power connection.  This makes it possible to use one conveyor to serve several processes or to remove it to a remote wash-down area for cleaning.  Optional height adjustment on mobile units is also available when they have to pass under low doorways or when they must discharge at differing heights.

Maintains mixtures

Given that product is metered into aero mechanical conveyors at a controlled rate, there are almost identical amounts in each pocket between the discs. The conveying action itself is gentle and therefore tends not to disturb mixtures.  The combination of these two factors means that the integrity of mixtures is maintained during conveying.

No dust collection system

With an aero mechanical conveyor no additional air is added to convey material so there is no excess air at the outlet to filter for dust.  Any material that is not ejected at the outlet is simply carried around the enclosed system until it is.

Total batch transfer

It’s simple. What is fed into the conveyor at the inlet is discharged at the outlet.  This makes the aero mechanical conveyor ideal for transferring pre-weighed batches of bulk and/or minor ingredients.

Multiple inlets & outlets

The concept lends itself to multiple outlets so that one conveyor can deliver material to a series of silos for example.  Multiple inlets are possible as long as only one is operational at a time.

Principle of operation

Our aero mechanical conveyor has a tubular design where a continuous wire rope assembly with accurately spaced polyurethane discs move at high speed. At each end of the conveyor, the cable assembly runs around specially designed sprockets, one of which drives the cable assembly and the other tensions it. The drive assembly can be located at either the inlet or outlet of the conveyor depending on its length or to meet plant requirements.

The action of the cable and disc assembly traveling at high speed sets up an airstream running at the same velocity. As material is fed into the airstream, it is fluidized and conveyed to the outlet where it is centrifugally ejected. High capacities are possible with low energy requirements and with minimal product degradation and separation.

APPLICATIONS

Aero mechanical conveyors are designed for a variety of applications.

Consistent performance and operational reliability have endeared our aero mechanical conveyors to a wide audience of industries. From the seemingly simple task of transferring food ingredients to the abrasive and corrosive nature of conveying chemical industry products, Spiroflow aero mechanical conveyors are well-equipped to handle many kinds of products with ease.

Titanium Dioxide

Aero mechanical conveyor designed for handling titanium dioxide – one of the few effective methods of handling this type of product.

Feeding Additives

Inclined and horizontal aero mechanical conveyors feeding additives to either of 2 tanks.

Elevating Material

Aero mechanical conveyor elevating material from a transition hopper fed by two bulk bag dischargers via flexible screw conveyors.

Around Corners

Aero mechanical conveyor elevating material from a transition hopper fed by two bulk bag dischargers via flexible screw conveyors.

Multiple Inlets

Aero mechanical conveyor elevating material from a transition hopper fed by two bulk bag dischargers via flexible screw conveyors.

Mobile Conveyor

Mobile aero mechanical conveyors are used extensively both in and out of factory environments.

Tanker Loading

No bulk handling tasks are more arduous than in mineral and ceramic applications. Spiroflow equipment is robustly built to meet the most exacting demands.

Application Suitability
Layout Constraints
of a single conveyor
PC3 Up to 65 ft (20m)
PC4 & PC5 Up to 82 ft (25m)
Only 90° corners
Multiple units can be directly connected without venting
MaintenanceThe cable must be tensioned periodically & replaced every 2,000 - 6,000 hours of operation
Cable tensioning is critical
Installation CostsLayout dependent
Energy ConsumptionLow energy consumption
Dust Control/Air DisplacementAir is not displaced at the discharge point, though some venting is required when discharging into a holding vessel
Conveyor is mechanically dust tight
Can be nitrogen purged
Residual MaterialNear zero residual
DegradationVery low shear
Can be used with extremely fragile materials such as tobacco, coffee beans, pelletized fertilizer, etc.
Fragile ProductsRecommend material test
Maintaining BlendsIdeal for maintaining blends
Hygroscopic MaterialsRecommend material test
Moist MaterialsSuitable
Cohesive MaterialsExcellent
Hot MaterialsVery good
Handles material temps up to 300°F (149°C)
SludgeNot suitable
SlurriesNot suitable
Fine ParticlesVery fine particles, including sub-micron, are easily fluidized, though capacity may be reduced by as much as 50%
Avoid particles that are wedge shaped (i.e. limestone)
Running EmptyCan be run empty for extended periods
Starting & StoppingCannot be stopped with material in the tubes because the solids will fall out of the air stream & settle to the lowest point

Check out our Conveyor Comparison Chart

This document compares our conveyor offerings based on application suitability, configurations, specifications, options & cleanability. Our engineers will assess your application needs & recommend the optimal conveyor system.

CONFIGURATIONS

Some of Spiroflow’s basic aero mechanical conveyor configurations are shown here.
Many other layouts can be designed to meet customer requirements.

Check out our Conveyor Comparison Chart

This document compares our conveyor offerings based on application suitability, configurations, specifications, options & cleanability. Our engineers will assess your application needs & recommend the optimal conveyor system.

MODELS & SPECIFICATIONS

Aeroflow Aero Mechanical Conveyors are offered in 3 sizes.

ModelTube Size (OD)Maximum Conveyor LengthMaximum Cable SpeedTypical Capacity Up To
PC3Tube Size (OD)3" / 75 mmMax Conveyor LengthUp to 65’ / 20 mMax. Cable Speed750 ft/min (230m/min)Typical Capacity Up To9 ft3/min (0.25m3/min)
PC4Tube Size (OD)4" / 100 mmMax Conveyor LengthUp to 82’ / 25 mMax. Cable Speed1,000 ft/min (300m/min)Typical Capacity Up To18 ft3/min (0.5m3/min)
PC5Tube Size (OD)5" / 125 mmMax Conveyor LengthUp to 82’ / 25 mMax. Cable Speed1,200 ft/min (365m/min)Typical Capacity Up To36 ft3/min (1.0m3/min)

Specifications

Standard Construction & Components

  • Tubes: 304 stainless steel
  • Cable: Carbon steel (mild steel)
  • Discs: Polyurethane
  • Manual Inlet Baffle
  • Manual Cable Tensioner

Electrical Requirements

2 - 7.5 HP / 1.5 - 4 KW Motor

Pneumatic Requirements

60 - 80 psi

Inlets, Outlets & Feeding

  • Multiple inlets & outlets
  • Must be stream fed
  • Inlets can be fitted with baffles, lids, hoppers, agitators, etc.
  • Custom designs available

Check out our Conveyor Comparison Chart

This document compares our conveyor offerings based on application suitability, configurations, specifications, options & cleanability. Our engineers will assess your application needs & recommend the optimal conveyor system.

COMPONENTS & OPTIONS

Aero Mechanical Conveyors - Components & Options

For your reference the following table displays a list of components available for our aero mechanical conveyors.  Our engineers will evaluate your requirements and make a recommendation for a complete conveying system.

Standard Components
Tubes304 stainless steel tubes with a 3" (75 mm), 4" (100 mm) or 5" (125 mm) nominal outside diameter
CableCarbon steel (mild steel) material of construction
All cables used in our cable assembly are constructed from MIL-spec aircraft quality steel cable. The cable assembly is a multi-strand steel cable with one-piece molded discs secured at fixed intervals.
DiscsPolyurethane Construction: 175°F (79°C) max.
Manual inlet BaffleFor introducing material into the conveyor
Manual Cable TensionerTo maintain appropriate cable tension
Drive Motor2 – 7.5 HP / 1.5 - 5.5 kW
Motor selected based on application requirements.
Options
Inlet SupportA carbon steel (mild steel) or 304 stainless steel floor mounted support base for the inlet housing.
Corner HousingA twin housing assembly enables a 90° bend of the conveyor which allows quick access to the corner and/or discharge housing and sprocket.
Hinged Housing Access CoversThis allows quick access to corner and/or discharge housing and sprocket.
Hinged Inlet Chute Access CoversThis allows quick access to the inlet housing and sprocket.
XP SwitchFor the Americas: A NEMA 7 switch can be provided for use with the hinged access covers in place of the standard NEMA 4 switch.
Inlet VibrationElectric or Pneumatic: Used to aid the flow of materials that can bridge in the hopper.
Tube Mounted InletUsed to introduce product to the air stream via the tube instead of or in addition to the inlet housing.
Tube Mounted OutletUsed to discharge product from the air stream via the tube instead of or in addition to the discharge housing.
Tube ValveA pneumatically operated slide gate valve can be connected to the conveyor tube outlet.
Extended Capacity ChuteAn extended capacity chute can be supplied with a square grid and support frame.
Dust Hood AssemblyDust hood and plastic strip curtain with vent connection can be provided for use with the Extended Capacity Chute.
Splash GuardA rear and side perimeter guard for the Extended Capacity Chute can be used to prevent the spillage of material when not fitted with a lid.
Lid for Inlet ChuteA lid with an inlet and a vent connection is available.
Pneumatic Inlet BaffleA pneumatically operated inlet baffle aids in control of product into the air stream.
Rotation Sensor AssemblyA Zero Speed Switch assembly can be mounted on the slave shaft to detect the motion of a non-driven sprocket and the switch monitor.
Air Purging for HousingThese Introduce a burst of air into four (4) points positioned inside the housing to remove the presence of any product accumulation.
Level IndicatorsA capacitance sensor can be mounted through the side of the chute/discharge to indicate a low and/or high solids level.
Mobile BaseCarbon steel (mild steel) or 304 stainless steel frame support can be provided with casters and support for the complete conveyor.
Wash Gate DrainThe unit is provided with a shut off gate for isolating the system for complete Clean-In-Place.
Grounding Lug SystemConductive equipment can be inter-connected to keep the same potential between parts and prevent sparking.
Suitable grounding is required.
Patented Dynamic Automatic Rope TensionerThe automatic tensioner applies a constant pre-load to the conveyor’s cable and disc assembly & compensates for the natural change in length of the cable during its life cycle.

A pneumatic actuator, anchored at one end, applies a linear force to the free moving aero mechanical housing mounted on 2 linear bearings fitted with ‘O’ ring seal assemblies where it interfaces with the 2 conveyor tubes.

A manually adjustable precision filter regulator is employed to ensure that there is never too much pressure applied to the actuator and this limits the linear force (tension) applied to the conveyor.

The pneumatic circuit prevents the total loss of linear force and tension if the air supply is interrupted.
Patented Dynamic Automatic Rope Tensioner (Bottom Mounted, Includes Support Frame)The automatic tensioner applies a constant pre-load to the conveyor’s rope and disc assembly & compensates for the natural change in length of the rope during its’ life cycle.

A Pneumatic Actuator anchored at one end applies a linear force to the free moving aero mechanical housing mounted on 2 linear bearings fitted with ‘O’ ring seal assemblies where it interfaces with the 2 conveyor tubes.

A manually adjustable precision filter regulator is employed to ensure that there is never too much pressure applied to the actuator and this limits the linear force (tension) applied to the conveyor.

The pneumatic circuit prevents the total loss of linear force and tension if the air supply is interrupted.
Clean dry plant air at a minimum pressure of 60PSIG is required for reliable operation.
ControlsControl panels can be provided as per customer requirements.
  • Motor Starter Control Panel
  • VFD Control Panel
  • Loss-in-weight Control Panel
  • Gain-in-weight Control Panel
Explosion Proof Options
  • Static grounding (Earthing)
  • Explosion proof motor
  • Purged control panels
  • Available to meet NEMA 4 or 7 standards
  • Available to meet a variety of Atex standards
Hygienic Design Options
  • Hygienic materials of construction available
  • Hinged housing covers
  • Air purge in housings
Cleanability Options
  • Can be cleaned by dry scouring (running an abrasive product) or air purging
  • Scavenged dust is directed out through discharge outlet
  • Can be also wet washed/CIP
  • Cable can be removed for cleaning/drying remotely
  • Wash gate & drain
  • Cable can be removed for cleaning/drying remotely

Check out our Conveyor Comparison Chart

This document compares our conveyor offerings based on application suitability, configurations, specifications, options & cleanability. Our engineers will assess your application needs & recommend the optimal conveyor system.

TYPICAL MATERIALS

Conveys Difficult Material

Almost all materials can be conveyed making the aero mechanical conveyor the ideal medium for transferring products from the finest of powders to granules, pellets, flakes and flocks.

Maintains Blends

Given that product is metered into aero mechanical conveyors at a controlled rate, there are almost identical amounts in each pocket between the discs. The conveying action itself is gentle and therefore tends not to disturb mixtures. The combination of these two factors means that the integrity of mixtures is maintained during conveying.

Typical Throughputs

The tables show estimated conveying rates in tons per hour based on continuously metered feed. When feeding from a bag dump station the rate may reduce by 10% – 40% depending on material flow characteristics.

Aero mechanical conveyors can transport a multitude of materials.  Here is a very short list of materials generally considered for this type of conveyor.  Our engineers will carefully assess the properties of your material and likely perform a material test to ensure your conveyor performs exactly to your expectations.

ProductModel PC3 Tons/Hr (Tonnes/hr)Model PC4 Tons/Hr (Tonnes/hr)Model PC5 Tons/Hr (Tonnes/hr)
BarleyModel PC3 Tons/Hr (Tonnes/hr)16Model PC4 Tons/Hr (Tonnes/hr)33Model PC5 Tons/Hr (Tonnes/hr)66
Carbon BlackModel PC3 Tons/Hr (Tonnes/hr)6Model PC4 Tons/Hr (Tonnes/hr)12Model PC5 Tons/Hr (Tonnes/hr)24
Coffee BeansModel PC3 Tons/Hr (Tonnes/hr)6Model PC4 Tons/Hr (Tonnes/hr)12Model PC5 Tons/Hr (Tonnes/hr)24
Desiccated CoconutModel PC3 Tons/Hr (Tonnes/hr)3Model PC4 Tons/Hr (Tonnes/hr)6Model PC5 Tons/Hr (Tonnes/hr)12
FiberglassModel PC3 Tons/Hr (Tonnes/hr)7Model PC4 Tons/Hr (Tonnes/hr)14Model PC5 Tons/Hr (Tonnes/hr)28
FlourModel PC3 Tons/Hr (Tonnes/hr)6Model PC4 Tons/Hr (Tonnes/hr)12Model PC5 Tons/Hr (Tonnes/hr)24
GypsumModel PC3 Tons/Hr (Tonnes/hr)15Model PC4 Tons/Hr (Tonnes/hr)30Model PC5 Tons/Hr (Tonnes/hr)60
Iron PowderModel PC3 Tons/Hr (Tonnes/hr)10Model PC4 Tons/Hr (Tonnes/hr)20Model PC5 Tons/Hr (Tonnes/hr)40
Hydrated LimeModel PC3 Tons/Hr (Tonnes/hr)5Model PC4 Tons/Hr (Tonnes/hr)10Model PC5 Tons/Hr (Tonnes/hr)20
Milk PowderModel PC3 Tons/Hr (Tonnes/hr)5Model PC4 Tons/Hr (Tonnes/hr)10Model PC5 Tons/Hr (Tonnes/hr)20
OatsModel PC3 Tons/Hr (Tonnes/hr)10Model PC4 Tons/Hr (Tonnes/hr)20Model PC5 Tons/Hr (Tonnes/hr)40
PolyethyleneModel PC3 Tons/Hr (Tonnes/hr)12Model PC4 Tons/Hr (Tonnes/hr)24Model PC5 Tons/Hr (Tonnes/hr)48
PVC PelletsModel PC3 Tons/Hr (Tonnes/hr)10Model PC4 Tons/Hr (Tonnes/hr)20Model PC5 Tons/Hr (Tonnes/hr)40
PVC PowderModel PC3 Tons/Hr (Tonnes/hr)13Model PC4 Tons/Hr (Tonnes/hr)26Model PC5 Tons/Hr (Tonnes/hr)52
SandModel PC3 Tons/Hr (Tonnes/hr)24Model PC4 Tons/Hr (Tonnes/hr)48Model PC5 Tons/Hr (Tonnes/hr)96
Sodium CarbonateModel PC3 Tons/Hr (Tonnes/hr)9Model PC4 Tons/Hr (Tonnes/hr)18Model PC5 Tons/Hr (Tonnes/hr)36
Granulated SugarModel PC3 Tons/Hr (Tonnes/hr)20Model PC4 Tons/Hr (Tonnes/hr)40Model PC5 Tons/Hr (Tonnes/hr)80
TeaModel PC3 Tons/Hr (Tonnes/hr)6Model PC4 Tons/Hr (Tonnes/hr)12Model PC5 Tons/Hr (Tonnes/hr)24
Titanium DioxideModel PC3 Tons/Hr (Tonnes/hr)5Model PC4 Tons/Hr (Tonnes/hr)10Model PC5 Tons/Hr (Tonnes/hr)20
WheatModel PC3 Tons/Hr (Tonnes/hr)33Model PC4 Tons/Hr (Tonnes/hr)66Model PC5 Tons/Hr (Tonnes/hr)132
Zinc OxideModel PC3 Tons/Hr (Tonnes/hr)6Model PC4 Tons/Hr (Tonnes/hr)12Model PC5 Tons/Hr (Tonnes/hr)24

BUYER'S GUIDE

Download Your Buyer's Guide on Everything You Need to Know About Aero Mechanical Conveyors