Clearly define what you want to achieve
Think about the entire process, not just the material.
Are you loading the material into an extruder? Are you loading it into a hopper? Are you loading it into a mixer? Are you loading it into a packaging machine?
Different systems are required for different purposes.
For example:
• If you need dust-free closed-loop transportation, vacuum conveyors are a good choice.
• If you want to handle fragile materials carefully, then transport in a dense phase is suitable for you.
• If the powder needs to be moved over a short distance, then a simple mechanical conveyor is suitable.
You do not choose a system, your powders and the process require it.
Understand the main categories without getting too technical
Most powder transportation methods can be divided into several general categories.
1. Pneumatic conveyor
Uses air as the moving medium for transporting powders.
Two types:
Two common methods include:
• Dilute phase – powders move quickly in the air flow.
• Dense phase – powders move more slowly in compact groups.
Suitable for long-distance operations and indoor environments with low dust levels.
2. Mechanical conveyor
Mechanical refers to the physical force for movement, which includes screws, belts, vibration units, and similar equipment. They are reliable and easy to operate, especially on short routes, although they are generally less closed-loop than pneumatic systems.
3. Vacuum conveyor
A compact and clean method of transportation, suitable for hygienic conditions and short distances. It is often used for its neat layout and automation-friendly design.
Matching technology to your reality
Forget about theory for a moment. Let's talk about real-world limitations:
• Limited space? → Vacuum systems are ideal.
• Long travel paths with many bends? → Pneumatic dilution phase wins.
• Fragile or abrasive powders? → Handle dense phase systems with care.
Want to reduce dust and cleaning? → Closed pneumatic or vacuum feed can be beneficial.
For short and simple cycles? → Mechanical conveyors remain an economical choice.
Choosing becomes much easier when you evaluate based on how your product looks, rather than what is written in a catalog or by a seller.
Think beyond today
Powder systems are a long-term investment. If your production doubles next year or you switch to a different material grade, will your system be able to handle it?
Questions to ask:
• Will you need a higher transport speed in the future?
• Are you planning to upgrade your automation?
• Are you using new powders in your process?
• Will your hygiene or safety standards change?
A flexible design eliminates the need to redesign the entire line later.
Always test with your real powder
No two powders behave the same, even if the specification says otherwise.
Pilot testing is the most underestimated step in the selection process. A good technology partner will help you:
• Run trial versions
• Simulate the real process
• Optimize the parameters
• Show real performance data
• Analyze the flow behavior
This step eliminates guesswork.
Conclusion
Choosing the right system is not only related to the hardware, but also to understanding the whole process.
Once you change your mindset from “Which technology is better?” on “What is suitable for my material and my technological process?”the decision will become clearer.
To summarize, a truly successful powder transportation system is one that:
• Fits the behavior of your powder
• Suitable for your workshop
• Safe for operators
• Stays clean
• Minimizes maintenance
• Grows with your process
You don't need to know every detail of every system.
You just need to know your powder, your goal, and the results you expect.
The technology takes care of the rest.