How to compare the actual durability of pneumatic conveyor solutions?

Procuring a pneumatic conveying system is a long-term investment whose true value is only revealed after years of operation. When comparing solutions from different suppliers, a superficial comparison of technical data easily leads astray: two systems can look almost identical on paper, but their actual durability in demanding process conditions can differ significantly. In this article, we go through the factors that enable you to evaluate pneumatic conveying solutions real performance and durability at a strategic level.

Factors determining actual durability

The durability of a pneumatic conveying system does not depend solely on material choices or structural strength. It stems from how well the system is designed to meet the exact requirements of the application in which it operates. In metallurgy, the energy sector, and the minerals industry, bulk material handling places exceptional stress on equipment: high temperatures, abrasive materials, and continuous round-the-clock operation make compromises expensive.

One key distinguishing factor is the choice of conveyance method in relation to the material. Dense phase plug flow uses a lower gas velocity and larger material volumes in the pipeline. In practice, this means that abrasive materials cause significantly less wear on the pipeline and components than in the dilute phase method, where the material moves at a high velocity. A correctly chosen conveyance method can multiply the service life of the system in demanding conditions.

Materials and component structure

The most critical components of the conveyor system, such as valves and pressure vessels, largely determine how long the system will operate without significant maintenance. Carbon steel, wear-resistant steel and acid-resistant stainless steel are suitable for different applications, and the correct choice of material always depends on the process conditions. A system whose critical components are designed and manufactured in-house offers better quality control than a solution where the components come from several different subcontractors.

Also, taking ATEX requirements into account during the design phase directly impacts the long-term operational reliability of the system. Systems operating in potentially explosive atmospheres where safety requirements have been integrated into the structure from the outset are significantly more reliable than retrofitted solutions.

Life-cycle costs and maintenance needs in comparison

The lifecycle of a conveyor system and its total cost of ownership are the metrics that distinguish true solutions from superficial ones. The purchase price tells only a fraction of what the system will cost over ten or twenty years.

When comparing the life-cycle costs of a pneumatic conveyor system, it is worth looking at three main components:

• Energy consumption: Compressed air generation is energy-intensive. Dense phase conveying consumes less compressed air than dilute phase conveying, which is reflected directly in operating costs. A well-dimensioned system can deliver significant savings on an annual basis.
• Service life of wearing parts: Systems operating at a low material velocity cause less wear on pipelines and valves. This means fewer spare parts purchases and shorter maintenance shutdowns.
• Operational reliability and unplanned downtime: One unexpected production shutdown can exceed the cost of the entire year's planned maintenance operations. The structural reliability of the system is therefore more important than merely the maintenance interval.

Another way to approach lifecycle costs is to look at how the supplier has designed the system's upgradability and customisability. Process requirements change over time, and a system that can be upgraded to meet new needs without replacing the entire hardware offers a clear financial advantage. Dense phase conveyors, which can be used with both dense phase and dilute phase methods with minimal software changes, are a good example of this flexibility.

Testing and materials knowledge as part of reliability

A supplier's ability to test the behaviour of different materials before the final sizing of the system is one of the most underestimated factors affecting durability. Every bulk material behaves differently in pneumatic conveyance, and incorrect sizing quickly leads to premature wear or process disruptions. A supplier with in-house testing capacity and an extensive reference history is able to provide sizing based on real data rather than just calculated estimates.

Application of evaluation criteria in supplier selection

When the factors described above are translated into practical comparison criteria, supplier evaluation becomes significantly more concrete. Alongside technical specifications, questions arise that reveal the supplier's true level of expertise and how well the solution has been designed specifically for your process.

In a practical comparison, it is worth paying attention to the following matters:

1. References for comparable process conditions: Does the supplier have documented deliveries of similar materials and operating conditions? A long reference history is not merely a marketing argument, but a concrete demonstration that the system has proven to work in comparable environments.
2. Manufacture of critical components: Does the supplier manufacture the most critical parts of its system itself, such as valves? In-house manufacturing enables better quality control and a quicker response to potential issues.
3. Scope of lifecycle services: Does the supplier's quote cover design, installation, commissioning and long-term support? A supplier that commits to the entire lifecycle of the system is motivated to design it to be sustainable from the start.
4. Documentation of energy efficiency: Can the supplier provide comparable data on their system's energy consumption in different operating scenarios?
5. Adaptability to process changes: How does the system adapt if the material properties or capacity requirements change?

Applying these criteria at the invitation to tender stage forces suppliers to provide concrete justifications for their claims. A supplier that answers these questions clearly and with documentation is likely the one whose system will also withstand practice.

Here at Kopar, our nearly 50 years of experience in the design, manufacture and life-cycle services of pneumatic conveying systems has taught us that every project is unique. That is why we approach every new challenge with the same care as our very first projects. If you would like to evaluate how a pneumatic conveying system could fit your process, explore our solutions or Contact our experts, so we will go through your situation together.