Benefits Of Industrial Lump Breaker And How To Select One

The modern manufacturing industries are using technology and mechanics to drive their production procedures faster while maintaining quality to get better income. Therefore, many automation are integrated into the production industries these days, and one of those revolutionary machinery is the industrial lump breaker.

Its versatile use is critical in various sectors, including chemical manufacturing, mining, food processing and pharmaceuticals. The equipment helps improve food processing, mining, medicines, and chemical production. It facilitates downstream operations by breaking down big materials into smaller or fine-sized particles.

Since it is not a viable option to deliver lumped materials to the buyer, a lump breaker will ensure the material property is free-flowing with efficient conveyance. When there are not many lumps in the materials, they are easy to handle on a mechanical & pneumatic conveyor.

It is essential to learn the role and beneficial points of the lump breakers and their selection criteria to achieve desired outcomes. Read on to learn the importance of the industrial lump breaker and make informed decisions when selecting the right solution for your operational needs.

A] What Are Industrial Lump Breakers

Industrial lump breakers are sturdy devices that are made to break up big clumps of materials into smaller and easy-to-handle pieces. The primary role of using lump breakers is to reduce the solid lumps of industrial materials i.e. chunks or clumps of materials into smaller particles or granules.

It enhances the quality of the final product processing effectiveness and material handling. You can find various types of industrial lump breakers that are effective for various manufacturing processes as they work through different mechanisms and have different capabilities.

• Hammer Mills

This lump breaker type has a rotating hammer crusher that pounds and crushes the mass of big materials, which are ideal for coarse grinding materials in food, chemical and agriculture industries.

• Impactors

Impactors are used for crushing brittle materials like minerals, ores, and aggregates. It puts high-speed impact pressure on the construction and mining materials to break apart the lumps.

• Jaw Crushers

Jaw crushers are another form of lump breaker that is mostly used in mining and construction applications to break down large rocks into smaller ones.

Read More: Difference Between a Lump Breaker vs Hammer Mill

Diverse use cases of Industrial Lump Breakers:

• The effective lump-breaking process makes the machine indispensable in the pneumatic conveying process in various industries.
• It is essential in pharmaceutical production to crush big granules into smaller ones, which can be combined and compressed in tablets easily.
• To crush ingredients like sugar or spices in the food process to make uniform mixing.
• These instruments are essential in mining operations for crushing big rocks or ores in smaller pieces for further processing.

B] Advantages Of Lump Breaker

1. Multifunctional Use and Extraordinary Processing Capabilities

There are many advantages of lump breakers as the equipment can have many functions, such as breaking lumps, speeding up mixing, granulating minerals and keeping lines smooth, offering uniform consistency in the production process. Apart from being multi-functional, its versatile application can process various materials such as chemicals, coal, sugar, minerals, plastics, gypsum, ammonium nitrate, etc. A reliable Lump Breaker Manufacturer in India can customise the equipment as per the required designs and sizes to ensure its optimal performance and efficiency for your industry.

2. Deagglomeration After Prolonged Storage or Transport of Materials

After being stored, dry bulk materials compress, forming big lumps of compression. Big lumps can cause air pockets that lead to collapse. It can happen in super sacks, silos, rail carriages, IBCs, day bins, etc. These lumps can become harder due to exposure to moisture or humidity. You can solve this issue by installing a lump breaker right underneath these silos to break down the material. It will effectively prevent any clogging to restore the flow of the materials for consistent processing downstream.

3. Creation of More Efficient Conveyance

Using pneumatic conveying to move large lumps of material can be challenging. To improve conveyance efficiency and minimise equipment failure, a lump breaker must be installed to produce materials with the ideal “Material to Air ratio”. The conveying vessel, screw feeders, rotary valves and vibrating feeders and other equipment in the system will operate more smoothly with the use of a lump breaker.

4. Protect Your Screening Equipment

In order to minimise damage from big lumps and agglomerates, lump breakers are crucial to the maintenance of mechanical screening equipment. While using the screening equipment in the industrial manufacturing procedure, keep the big particles out of the process. It will lower the possibility of unexpected downtime and increase your production efficiency. Add it into your maintenance strategy to ensure smoother operation and longer equipment lifespan.

C] What To Consider Before Selecting a Lump Breaker?

• Physical properties of the product

Understand the properties of the materials you will be processing, such as their hardness, rough texture, moisture content, and temperature sensitivity, to ensure effective processing. See if the product is soft while selecting a lump breaker. Check how tough or sticky the material is to decide which lump-breaking equipment can best fit your material use.

• Determine the production capacity and output

Take into account factors like material flow rate, batch size and how much output size you require while choosing your lump breaker machine in your production requirements. Check if the machine can offer consistency and manage the load capacity as per your current requirement and for future requirements.

• In which operating environment do you want it to be installed? 

You can check for the lump breaker machine manual to assess its operating condition, which ensures that the equipment can run at its optimal efficiency. Check for temperature, humidity, and potential material exposure to determine the ideal operating environment for the equipment. It will help you select the right machine that uses the right building materials and with protection measurements. Moreover, check how much the machine emits dust or noise and choose the product that matches the recommended amount for efficient dust and noise management.

• Any system connectivity capabilities

If you want your manufacturing lines to handle and process materials efficiently, choose lump breakers that are compatible with the latest machinery and process automation systems. Make sure to put in the proper system type with the correct orientation to get the best results.

• Sealing and bearing of the equipment

Make sure to check the manufacturer’s manual for information on the lump breaker’s sealing and bearing systems that ensure its durability and dependability. It will help you choose a machine that is robust and offers prolonged use.

• Maintenance requirement

Check the requirements for lump breaker maintenance, which may include cleaning, lubrication, and routine inspections. Choose equipment that is simple to use and has easy access to its parts to ensure reliable performance and less downtime.

Conclusion 

Industrial lump breakers are essential equipment in the automation process in various manufacturing sectors as they increase productivity and provide better material handling that guarantees higher product quality. This equipment can separate materials and make conveying easier to secure your other machinery equipment from damage in the production line, further improving the production processes.

Make sure to consider the essential selection factors to ensure the product you are selecting fits perfectly into your manufacturing requirement procedures. Evaluate your own unique demands and lump-breaking needs in the production line to determine the number and type of lump-breaker machines you require. If you are looking for a pneumatic conveying systems manufacturer in India or have any further inquiries to make regarding your lump breaker selection, contact us today!