Preventing Bridging and Ratholing with the ActiFlow™ Bulk Solid Activator

9 Apr 2026  |
The Coperion K-Tron ActiFlow™ Bulk Solid Activator is an advanced solution designed to prevent bridging and ratholing in bulk materials discharged from a hopper by a feeder during industrial manufacturing processes. Many bulk solids-particularly fine, cohesive powders do not flow consistently from supply hoppers, which can make accurate feeding difficult and disrupt process efficiency. Poor flow can cause ratholes, where material flows only through a narrow vertical channel while the rest remains stagnant, or bridges, where material flow is completely blocked across the hopper outlet. Both conditions reduce feeder performance, limit material discharge, and can lead to process interruptions.

Unlike traditional vertical agitators, which require additional headroom and can be difficult and time-consuming to clean, the ActiFlow™ system offers a more efficient and user-friendly alternative. It is a non-product-contact device made up of the ActiFlow unit and the ActiFlow Control unit. The ActiFlow device is mounted externally to the rear wall of the extension hopper, above the feeder, where it continuously activates the material inside the hopper using optimized frequency and amplitude settings.

A key advantage of the ActiFlow™ system is its self-tuning capability. The control unit constantly monitors operating conditions and automatically adjusts the frequency and amplitude to compensate for changes in hopper fill level and material flow behavior. By proactively maintaining optimal material movement, ActiFlow helps prevent bridges and ratholes before they develop, ensuring more reliable discharge, improved feeding accuracy, and smoother overall process performance.

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Coperion is a global industry and technology leader in compounding and extrusion systems, size reduction, washing, separating, drying, agglomeration, feeding, weighing, material handling and pneumatic conveying systems, as well as milling, mixing, thermal processing, dust...