High-Quality Fabrication In Pneumatic Conveying: What Is It And Its Benefits

In the proper functioning of a pneumatic conveying system, its various components, like  pneumatic conveying vessels, diverter valves, vent filters, silo, and hoppers play a major role. For the whole system to work smoothly at an industrial level, high-quality fabrication of individual components is necessary. These systems are used for bulk handling of raw and processed materials in manufacturing plants, and the creation of its parts with the help of high-quality fabrication techniques ensures that the structural integrity of the pneumatic conveyor system remains intact for years. The design and assembly of the components like cyclonic separators, vent filters, and air receivers with high-quality fabrication techniques ensure that the efficiency and performance of the pneumatic conveyor are enhanced overall.

Well-fabricated pneumatic conveyor system components make the system durable and also reduce the chances of raw material degradation. In this blog, the high-quality fabrication of pneumatic conveyor system components and their benefits are discussed in detail.

A] What Is Fabrication? 

For the success of the pneumatic conveying process in an industrial plant, it is important to fabricate and create high-quality system components that assemble to make a high-performance conveying system. The pneumatic conveying system components like pneumatic conveying vessels, diverter valves, vent filters, air receiver, and cyclone separator are complex parts that need to be fabricated carefully and according to industrial design standards. The fabrication of the pneumatic conveying system components includes techniques like metal shaping, cutting, welding sheet metal and assembly of various structures to get the perfect design and functional efficiency for the components. These pneumatic conveying components are then put together to create a highly efficient pneumatic conveying system.

Techniques such as forming and bending help in giving the right form to the components so that there are no chances of material degradation or loss inside the assembled system later on. High-quality fabrication of the components plays a crucial role in meeting specific design standards and creating precise parts that meet the requirements of the industry compliance regulations. Therefore, following proper fabrication techniques and steps of component manufacturing is important for an efficient end result.

B] Benefits Of Fabrication For Pneumatic Systems

In the industrial setting, multiple benefits exist from high-quality fabrication techniques that create pneumatic conveying system components longevity. These benefits include higher efficiency of the pneumatic conveying system components after they are assembled to create functional material transport systems. Read on to learn more about the benefits of high-quality fabrication in pneumatic conveying that professional fabrication services for your pneumatic conveying system can offer. 

1. Better Efficiency

An excellent pneumatic conveying system manufacturer uses high-quality fabrication techniques and tools to create durable pneumatic conveyor components out of high-quality materials. High-quality fabrication of the crucial components can ensure that the system works efficiently once assembled. The precise fabrication and creation of components like Silos, hoppers, vent filters, and cyclonic separators make sure that every step of the bulk material transport process goes on smoothly. Efficiently designed and fabricated pneumatic conveyor system parts can reduce the chances of pressure loss as they maintain the structural integrity of the system together. High-quality fabricated pneumatic system components can also work precisely and optimize energy consumption during the conveying process. The whole system works efficiently and in a resource-optimized way to achieve high productivity levels. The well-fabricated air receivers and diverter valves ensure that there is a consistent airflow and that the material transport happens at the optimal speed at all times.+

2.  System Durability And Longevity

Following high-quality fabrication techniques for the manufacturing of high-quality pneumatic conveying system components can also determine system durability and longevity for years. The pneumatic conveying system is used in an industrial environment where the assembled components are exposed to a number of chemicals and harsh working conditions. The use of high-quality materials and expert fabrication methods can create highly durable and stable parts. These metal parts are resistant to corrosion and factors that lead to wear and tear. Because of the durable nature of the components, the system has also run without any issues for years.

3. Safety of The Workers

The safety of the used systems and workers in an industrial environment is very important to look at and pay attention to. Any system, including a pneumatic conveying system, should be designed with industrial safety standards in mind. High-quality fabrication techniques for the components play a huge role in upholding industrial safety standards. High-quality fabrication of pneumatic conveying system components like pneumatic conveying vessel, silo, hopper ensures that there are no blockages, leaks or structural malfunctions. High-quality fabricated parts avoid chances of major safety hazards and create a safe environment for industrial workers. High-quality fabrication techniques create reliable and safe components that help reduce the chances of industrial accidents and mishaps. Industrial workers can work with the pneumatic conveying system without any safety issues for years.

C] Key Fabrication Techniques Used For Pneumatic Systems 

With knowledge about the multiple benefits of high-quality fabrication techniques, let us delve into the high-quality fabrication techniques used to create crucial components that are assembled to create an efficient pneumatic conveying system. High-quality fabrication techniques and skills help create pneumatic conveying system components that are very durable and reliable.

1. Metal Shaping

 Metal shaping is an important technique in the fabrication of pneumatic conveying system components. Metal shaping happens through rolling, bending and cutting to give shape to the metal sheets. The metal sheets are shaped into different parts of the components with the help of tools that help in cutting, rolling and bending the material. For rolling, the metal sheet is put through a set of rollers so that a cylindrical shape can be achieved. For angled forms and bends in the components, the metal sheets are put through a press brake so that the tool bends the sheet into angular forms. The technicians also use high-grade cutting tools to cut the metal sheets into particular dimensions based on the component design. Proper metal shaping creates smooth and precise components of the pneumatic conveying system.

2. Welding 

Once the metal parts are shaped and cut, the different parts are joined with the help of the welding tools. Welding is done to join the individual pieces to create the final component. High-quality and precise welding of parts is important for the creation of the system as these joints create air-tight seals when welding is done properly. The technicians use the MIG welding technique, TIG welding, and resistance welding to join the components strongly so that the structural integrity of the system remains intact for years. In MIG welding, a wire electrode is used to create strong joints between metal parts. When the same step is done through a tungsten electrode, it is called TIG welding. Resistance welding makes use of electrical resistance and can be very efficient in creating metal welds. Proper welding leaves no space for leaks and creates air-tight spaces inside the conveying system.

3. Coating And Painting

Once the pneumatic conveying system components are assembled, they need to be finished and protected with coatings and paint layers. After metal shaping and welding, the technicians apply a protective coating on the metal parts to finish them so that the parts and the whole system remain resistant to corrosion for a long time.

Technicians first apply a powder coating to create a protective layer on the system, which is then cured with heat. Then, the process of galvanisation continues, which coats the metal parts with a layer of zinc and makes them resistant to corrosive factors. After this, the team paints the pneumatic conveyor system with protective and finishing paint. The technicians then polish the parts to ensure that the outer layers are also smooth and well fabricated.

D] Common Pneumatic Conveying Systems that are fabricated

High-quality fabrication techniques are used to create and finish the crucial components of the pneumatic conveying system. These components, like Silo, hopper, and diverter valves, together make an efficient pneumatic conveyor system. Therefore, efficient fabrication of each part is very important. Here are some of the most common parts of a pneumatic conveying system that are usually fabricated by expert technicians.

1. Pneumatic conveying vessel

The pneumatic conveying vessel is used to transport bulk material inside the conveying system. For this, it is connected to a pipeline that carries compressed air. The vessel is designed and fabricated to ensure that there is a pressure difference between two points within the system so that material can be transported easily.

2. Silo and Hopper

The pneumatic conveying system usually has a silo and hopper, which are used for storing the bulk raw material. The Silo is usually a tall structure which stores a lot of material in one place, while the hopper component is a smaller, sloped container which helps in discharging the material into the system gradually. Both the components are fabricated from high-quality materials to ensure that they are corrosion-resistant.

3. Vent Filters

Vent filters are the components that filter dust particles and other impurities from the air that escapes from the silos and hoppers. The function of vent filters is to reduce the chances of environmental contamination. These are protective filters that avoid pollution and are used in many crucial industries.

4. Air Receivers

Air receivers are metal tanks that are used to store compressed air that is circulated inside the pneumatic conveying system. The air receiver component ensures that there is a steady supply of air inside the system for transport. The high-quality fabrication of this component is necessary to avoid any leaks and pressure drops in the air medium.

5. Different Diverter Valves- 

There are different diverter valves, like plug diverter valves, rotary valves, and flap diverter valves. These valves are designed and fabricated to control the flow of material inside the pneumatic conveying system. This component helps in controlling the flow of different materials and directs them to different destinations in a complex industrial manufacturing flow.

6. Cyclonic Separators

Cyclonic separators are so called because of the vortex and spinning effect they have on air that enters them. These separators filter out dust particulates from the air using the cyclone effect on an incoming air supply. The coarse particles are filtered out using centrifugal force. The removal of particles ensures that the equipment is not exposed to major wear and tear.  

Conclusion 

High-quality fabrication of the crucial components helps in the assembly of a pneumatic conveying system that is resistant to damage and downtime.  High-quality fabrication services create a pneumatic conveying system that is very efficient and durable, carrying out crucial industrial processes for years.

For the creation of high-quality pneumatic conveyor system components, you need a team of expert fabrication technicians who can work with precision. Understanding the process of fabrication and the benefits of high-quality fabrication is important to create components that are sturdy and high-performance. High-quality fabrication plays a huge role in the performance level and overall structural integrity of the assembled pneumatic conveying system. To get high-quality fabricated pneumatic conveying system components like Silo, hopper, vent filters and cyclonic separators, contact Macawber today.