Dry bulk materials can become compacted during storage. This may lead to bridging, rat-holing, sidewall buildup, and/or inconsistent discharge, which can interrupt processing and require costly—and often dangerous—manual intervention.
Aeration devices are often used to fluidize materials and help them return to a free-flowing state. However, severe compaction issues or challenging materials may require more than air flow to be resolved safely.
The Airbrator® from BinMaster is a proven flow aid that restores material movement by combining aeration and vibration. Its unique, dual-action design helps difficult ingredients discharge smoothly from bins, silos, hoppers, and other storage vessels.
Why Aeration is Necessary in Powders & Bulk Solids
Fine powders and pelleted solids naturally settle in storage applications. As materials become denser, air is trapped between particles and lost. This is how compaction starts, creating complicated flow issues such as:
- Bridges forming over discharge openings
- Ratholes opening, leaving material stuck along vessel walls
- Bulk material compacting within hopper cones
- Material flow becoming erratic or restricted
Without the proper tools for bin aeration, these problems may require workers to enter bins or perform manual cleanout, introducing unnecessary safety risks and resulting in downtime and material waste.
How the Dual-Action Design Works
Mechanical vibrators rely solely on impact to break blockages. Typical aeration tools may not always be able to loosen stubborn materials. To bridge these gaps, Airbrator utilizes both aeration AND vibration to promote efficient flow.
First, compressed air enters the Airbrator from a connected air supply system. Air is blown between the Airbrator’s flexible pad and the bin wall. This airflow creates a gentle vibrating action, which simultaneously helps to fluidize materials and loosen compaction. As adequate flow is restored, bulk solids are able to move freely toward the outlet point.
Using Airbrators often requires fewer units than conventional aeration devices because of this concurrent, multi-functional operation.
How the Airbrator Performs in Tough Environments
BinMaster Airbrators are designed for dependability in demanding industrial operations. This includes outdoor storage installations and harsh processing environments that can reach up to 400°F (204°C).
Another advantage of the Airbrator is its air pressure versatility. The device operates with blower air pressure from 5-60 PSIG for low- or high-pressure output. This also ensures its compatibility with a variety of air supply systems.
Additional features include:
- Options for molded silicone or neoprene pads
- Self-cleaning design
- Built-in check valve prevents materials from entering the air line
- Stainless-steel shaft for a long service life
- Uninterrupted performance in abrasive or corrosive materials
Materials & Industries Improved with Bin Aerators
Because of their resistance to moisture and temperature changes, Airbrator devices are ideal for powders and bulk solids that tend to compact, bridge, or cling to vessel walls.
This also ensures the Airbrator’s performance in a wide variety of agricultural and industrial settings. Typical applications include:
- Agriculture: Grain, seed, animal feed
- Concrete: Fly ash, lime, finished powdered materials
- Chemical Processing: Calcium carbonate, alumina, pigments
- Milling: Flours, milled grains, cornmeal, oats
- Food Processing: Corn, wheat, barley, soybeans, canola
- Mining & Minerals: Sand, gypsum, activated carbon
- Power Generation: Wood pellets, sawdust, other wood products used for biofuels
- Resin Manufacturing: Plastic pellets and resin powders, including PVC, PET, and PP
Ordering Bin Aerators Online
Whether you’re replacing an existing flow aid or solving a persistent material flow problem for the first time, BinMaster makes it easy to purchase Airbrator sensors online.
Airbrators—as well as mounting kits, replacement pads, and related accessories—are available directly from BinMaster for fast ordering and shipment.
Keep Materials Moving with BinMaster
The Airbrator delivers a simple, reliable, and economical solution to improve the discharge of packed materials. By combining aeration and vibration in one compact device, production can run smoothly thanks to seamless material flow. Operators benefit from reduced downtime, save costs due to less waste, and minimize risk involved with manual cleanout.
Find aeration solutions for your bins, silos, and hoppers at BinMaster.com today.
