The aero-mechanical conveyor:
A complete guide to how it works, benefits and applications
What's in the guide
An aero-mechanical conveyor (AMC) is a fully enclosed bulk-material handling system that uses a high-speed rope-and-disc assembly to create low-pressure air pockets inside conveying tubes. Those air pockets suspend and carry powders and granules rapidly, safely and gently from a single inlet to a single discharge point, with minimal product degradation or dust generation. Floveyor invented the aero-mechanical conveyor in Perth, Western Australia, in 1958 and continues to develop the technology today.
What is an aero-mechanical conveyor?
An aero-mechanical conveyor is a class of mechanical bulk-material handling equipment purpose-built for moving powders and granules through enclosed tubes. Unlike pneumatic systems that push material along on an airstream, or screw and drag conveyors that physically push or pull it, an AMC suspends material inside the conveying tube and carries it in that suspended state to a single discharge point. That makes it well-suited to fragile products, pre-blended mixes, and powders that are sensitive to contamination. An AMC is ideal for the food and beverage, chemical, agricultural, manufacturing, and mineral processing industries. A single AMC can handle thousands of different materials, mixes and blends, and the fully enclosed design means it operates dust-free — an important consideration for both product hygiene and worker safety.
How an aero-mechanical conveyor works
The aero-mechanical conveyor working principle relies on a simple physical idea: a series of evenly spaced discs travelling at high speed inside an enclosed tube generates a low-pressure air pocket behind each disc. Material introduced into that airflow becomes suspended within the pockets and is carried along with them to the discharge point, rather than being dragged, pushed or blown. This “fluidised” transfer is what allows an AMC to move material rapidly while keeping contact between particles and the conveyor body to a minimum. At its most basic, the design comprises tubes, a rope, discs, air pockets and speed. The next two sections of this guide cover how those elements operate together and the components themselves.
How does an aero-mechanical conveyor work?
A motor drives an internally circulating rope assembly at high speed inside the conveying tubes. This creates a low-pressure air pocket behind each disc. Bulk material is fed into the system through a single inlet at the feed housing and accelerated into the conveying tubes by the rope assembly. Bulk material is suspended in the air pockets and drawn rapidly but gently to a single discharge point. Aero-mechanical conveyors with FloDisc® Technology have minimal to no material-on-material or material-on-equipment contact. It’s an ideal powder transfer system, even for materials with difficult properties.
Find out more about why FloDisc is essential to aero-mechanical conveying.
Aero-mechanical conveyor components explained
AMC conveyor components consist of:
- Tube: The main conveying tube is a closed-loop system that forms a continuous circuit for material movement.
- Discs: Polyurethane discs are moulded onto the rope at regular intervals. Discs can be manufactured using food-grade construction materials. Polymag discs are also available which have X-ray and metal detection capabilities and have improved resistance to chemicals.
- Rope assembly: Discs are injection-moulded onto the rope assembly in a continuous loop running through the tube. Ropes are manufactured of galvanised steel or stainless steel and can be fully sleeved, along with the discs, to mitigate contamination risks.
- Inlet and outlet: Openings in the aero-mechanical conveyor system where material enters and exits the tube. They are designed to facilitate loading and unloading of bulk materials to and from the conveyor.
- Motor: The drive unit powers the movement of the rope assembly, propelling the discs and material through the conveyor system. It is essential for controlling the speed and direction of material flow.
- Tensioning system: A tensioning system maintains proper tension in the rope to ensure smooth operation of the conveyor. Too much slack or excessive tightness affects performance and can damage the AMC over time.
How does an aero-mechanical conveyor compare to a pneumatic conveyor?
Compared with a pneumatic conveyor, an aero-mechanical conveyor typically uses considerably less energy to move the same volume of material, which lowers both running costs and total cost of ownership.
- A pneumatic system relies on high air volumes and velocities to carry material in an airstream.
- An AMC instead moves material mechanically in suspension, so it is gentler on the product.
That gentleness matters most for pre-blended mixes because an AMC discharges material in the same ratio it was fed. The turbulence of pneumatic conveying can separate blends and damage fragile particles. Both systems are fully enclosed and dust-free. Pneumatic conveying still has the advantage on some very long or highly complex routings, so the right choice comes down to distance, layout and how sensitive your material is.
What are the advantages of an aero-mechanical conveyor?
Aero-mechanical conveyors offer a superior powder conveying system compared to other methods of powder handling. Aero-mechanical conveyors are a popular choice for industries that require efficient and gentle handling of materials with minimal risk of contamination or degradation. When choosing a bulk materials handling conveyor system, consider these key aero-mechanical conveyor advantages:
- Gentle material handling: Aero-mechanical conveyors reduce the risk of degradation or damage to bulk materials. This is particularly important for fragile materials or products that require careful handling.
- High throughputs: An aero-mechanical conveyor can rapidly but safely transfer powders and granules for even the most hazardous materials. Throughput can reach up to 105,000 kg/h (115.7 US tph).
- Versatility: AMCs handle a wide range of materials, including powders, granules, pellets, flakes, seeds, beads and nuts. A single machine can elevate thousands of different materials, mixes and blends. This makes them suitable for a wide range of industrial and food and beverage applications.
- Efficiency in conveying: You can efficiently transport materials at any elevation. This helps in optimising the layout of the production facility and streamlining material flow.
- Fully enclosed design: The enclosed design of AMCs prevents contamination of your bulk materials. This is crucial for industries where hygiene is paramount, like food and pharmaceutical manufacturing. The benefits of a fully enclosed design extend to dusty and explosive materials. It’s a key component of keeping workers safe.
- Low maintenance: Because aero-mechanical conveyors have been engineered with fewer moving parts compared to other conveyor systems, the machinery experiences fewer problems. Regular inspections and basic maintenance ensure maximum uptime and availability.
- Total batch transfers: Minimal product wastage is experienced with AMCs due to little or no residue between batches. Total batch transfers also reduce cleaning time which can make a significant impact on production and operator efficiency.
- Energy efficiency: The aero-mechanical conveyor provides highly efficient conveying, unprecedented availability, and eco-efficiency with minimum energy consumption. AMCs are known for low operating costs.
- Low total cost of ownership: When you factor in energy-efficiency, high availability, low maintenance and cleaning requirements; high reliability; and long-term durability, a Floveyor AMC is often the most cost-effective powder conveyor over time. As a comparison, an aero-mechanical conveyor’s total cost of ownership is 60% lower than a semi-dense phase pneumatic, 62% lower than a bucket elevator, and 37% lower than a flexible auger.
Aero-mechanical conveyor specifications
| Specification | Range / Value | Notes |
|---|---|---|
| Tube diameters available | 76 mm, 102 mm, 127 mm | 3", 4", 5" equivalents |
| Max throughput | Up to 115.7 US tph (105,000 kg/h) | 127 mm tube; material-dependent |
| Maximum conveying length | Up to 20 m (65 ft) per run | Longer runs via intermediate units |
| Operating temperature | 10°C to 70°C (50°F–158°F) | Above 130°C not recommended |
| Moisture content limit | 0%–6% (optimal); up to 15% (marginal) | Above 16% not suitable |
| Max particle size (127 mm tube) | Up to 12 mm (0.48 in) | Larger particles require larger tube |
| Rope assembly service life | 3,000–5,000 operating hours | Correctly installed and operated |
| Hazardous area compliance | ATEX and IECEx options available | Specify at time of order |
What materials and industries use aero-mechanical conveyors?
Aero-mechanical conveyors handle thousands of free-flowing powders and granules, and also manage materials that tend to stick, clump or separate. Their gentle action makes them a strong choice for fragile products, mixes and blends, and they are used across both industrial and food and beverage production.
- Industrial materials, including activated carbon, potash, clay, nickel powder, nylon powder, cement, perlite, cat litter, sandalwood chips, sawdust, soap powder, urea prill, cellulose powder, plastic beads, Ti02, grout mix, resin powder mixes, lithium hydroxide, gunpowder, silica, bentonite, carbon black, and melamine.
- Food and beverage materials, including sugar, icing sugar, egg powder, milk powder, flour, lentils, muesli, salt, green tea, instant coffee, coffee beans, tea leaves, lactose, malt, rice, nuts, grain husk, livestock feed, animal nutrition, pet food, kibble mix, and seed mix.
The industries most likely to use an aero-mechanical conveyor include:
- Food and beverage
- Manufacturing
- Agriculture
- Chemical processing
- Mining and resources
- Critical minerals.
How to choose the right aero-mechanical conveyor
AMCs can be customised to suit any plant. They have a small footprint and come in mobile units so they work equally well in greenfield and brownfield plants. If you’re wondering how to choose an aero-mechanical conveyor, working with a powder handling specialist is the best way to ensure your aero-mechanical conveying system is ideally suited to your operation.
How do I know if my material is suitable for an aero-mechanical conveyor?
An aero-mechanical conveyor can transfer thousands of bulk materials, but a handful of material properties determine whether it is the right fit for yours. Large lumps should be broken up before conveying, and foreign objects such as sacks, tools or fasteners must be kept out, as both can damage the conveyor.
Check the following properties before specifying a machine:
Abrasive materials
An AMC with FloDisc is ideal for conveying abrasive materials like salt, sand, sugar, cement or limestone. Care needs to be taken with highly abrasive materials, and AMCs are generally not advised unless it’s for light-duty applications, at lower throughputs, and with reduced operational hours. Heavy-duty operation using highly abrasive materials causes rapid wear on components, which leads to high ongoing costs.
Particle size
The larger the tube on an aero-mechanical conveyor, the larger the particles it can handle.
- 3″/76 mm tubes – up to 0.25″/6 mm
- 4″/102 mm tubes – up to 0.35″/9 mm
- 5″/127 mm tubes – up to 0.48″/12 mm.
Moisture content
Moisture can be problematic for AMCs. Low levels of moisture work best to ensure there’s minimal build-up in the conveyor. A normal application range would be 0% to 6% moisture content.
Medium levels of moisture can result in clumping, bridging in hoppers and increased internal build-up. When this happens, cleaning requirements need to be assessed. Moisture levels of 7% to 15% are considered to be in the medium-level range.
Materials with high moisture content are not suitable for aero-mechanical conveyor systems. Most powders with high moisture levels will turn into a slurry during handling and continually build up inside the conveyor. Some materials like grains can become more abrasive with increased moisture. Moisture levels of 16% and higher are not recommended.
Watch for stickiness and smearing as signs of high moisture levels.
Hygroscopic and deliquescent materials
High humidity can affect the flow of materials susceptible to moisture. It’s recommended highly hygroscopic materials are processed in a controlled, dehumidified environment for best results. Rigorous inspections and cleaning regimes are recommended whenever shapeshifting materials are being transferred.
Oily and waxy materials
Diligence around cleaning and preventative inspections are essential when handling oily and waxy materials. The materials often smear on internals and chutes during transfer. Build-up can block and stall the powder conveyor, which can be extremely difficult and time-consuming to remedy.
Fragile materials
Friable and fragile materials are handled very successfully with an aero-mechanical conveyor, with no reduction in the integrity of the particle. For larger particles, rubber-lined chutes, spiral discharges to stop freefall impact, and flow-controlled infeeds greatly reduce particle damage.
Hazardous and explosive materials
The AMC is a good choice for materials that can catch fire, like gunpowder or sugar. The fully enclosed, dust-free system allows for safe, rapid transfer of difficult materials. A conveyor can be manufactured with a variety of construction materials and contact surfaces to ensure ultimate safety and hygiene while conveying.
Blended mixes
An aero-mechanical conveyor with FloDisc Technology preserves blend and mix integrity by suspending materials in air pockets and transferring them as a blended unit. The product will not separate during handling and the product will be discharged in the same ratio as it was fed into the machine.
Temperature extremes
A normal range of temperatures for a powder transfer system using an AMC is 10C/50F to 70C/158F. Temperatures lower than this can lead to freezing and internal blocking, especially if moisture is present. Higher temperatures require upgrades for safe materials handling. Temperatures above 130C/266F are not recommended.
What is the maximum throughput of an aero-mechanical conveyor?
An aero-mechanical conveyor has the capacity for high throughputs, which are dependent on the size of the machine and the materials being handled. As a rule of thumb, the following throughputs are achievable:
- 3″/76 mm tubes: 33 US tph/100 – 30,000 kg/h
- 4″/102 mm tubes: up to 66.1 US tph/60,000 kg/h
- 5″/127 mm tubes: up to 115.7 US tph/105,000 kg/h.
What is the maximum conveying length of an aero-mechanical conveyor?
A single aero-mechanical conveyor run is well suited to lengths of up to 20 metres (65 feet). AMCs perform best in straight-line installations and can incorporate 90° corners for combined vertical and horizontal transfer, with bi-directional conveying available where required. Their flanged, modular design and small footprint make them straightforward to install, including as standalone mobile units for smaller plants.
For distances beyond a single run, AMC units can be linked in series; for longer or more complex routes with multiple bends and discharge points, a tubular drag conveyor is often the better choice.
Aero-mechanical conveyor safety and ATEX compliance
An ATEX aero-mechanical conveyor is one of the safest systems for handling powders and granules. The fully enclosed tube design creates a dust-free operation that protects worker health and wellbeing, and its quiet operation adds to a safer working environment.
Is an aero-mechanical conveyor suitable for ATEX or explosive environments?
Yes. Aero-mechanical conveyors can be ordered in configurations compliant with ATEX and IECEx codes for use in potentially explosive atmospheres. The fully enclosed, dust-free design also makes the AMC a sound choice for combustible powders such as sugar or gunpowder, and the machine can be built with specific construction materials and contact surfaces to suit hazardous-area requirements. Compliance ratings should be specified at the time of order, so the conveyor is built correctly for your dust or gas zone.
Dust zones are the most common concern for powder handling. Combustible dust atmospheres (Group III equipment) – the zones we service
- Zone 20: an explosive dust cloud is continuously present, either frequently or for long periods and typically found inside vessels, hoppers, silos, and conveyors.
- Zone 21: an explosive dust cloud is occasionally likely to occur during normal operation, most often around fill/discharge points and inspection hatches.
- Zone 22: an explosive dust cloud does not normally appear in normal operation and is only short-lived if it does occur, generally in areas around dust-handling equipment.
Gas, vapour, or mist atmospheres (Group II equipment not supplied by Floveyor)
- Zone 0: explosive atmosphere continuously present either frequently or for long periods
- Zone 1: explosive atmosphere likely to occur occasionally in normal operation
- Zone 2: explosive atmosphere not likely to appear in normal operation and only for a short time if it does occur.
Under ATEX, equipment is also assigned a category mapping to the zone it can be used in:
- Category 1: very high protection, suitable for Zone 0/20
- Category 2: high protection, suitable for Zone 1/21 (and 0/20)
- Category 3: normal protection, suitable for Zone 2/22 only.
How to clean an AMC
Easy cleaning options with both dry and wet wash downs saves water and energy costs. Compared to conveying technologies like bucket elevators, a Floveyor AMC is quick and easy to clean and requires no tools for access.
Floveyor aero-mechanical conveyors can be Clean In-Place (CIP) or Clean Out-of-Place (COP) and come with three cleaning options:
- Dry cleaning – an AMC can be cleaned with air or inert gas to return any settled residue to the main product stream.
- Inert purging – Inert materials such as granular salt or broken rice can be used to clean the aero-mechanical conveyor and flush out residue. For example, a bakery may use flour to purge the additive residue of a previous run and ensure there’s no wastage in the recipe.
- Wet cleaning – A Floveyor AMC can convey liquids at high speeds for a recirculating wash cycle to clean the conveyor internals. Watch How to wet clean a Floveyor to see how straightforward it is to maintain a genuine Floveyor AMC.
What does an aero-mechanical conveyor cost to run?
A Floveyor AMC delivers strong performance in powder conveyor type comparisons across a range of duties. The following three examples show the performance of a Floveyor aero-mechanical conveyor that is typical of the technology being compared.
Total cost of ownership: aero-mechanical conveyor vs pneumatic
In this application, an AMC is compared with a semi-dense phase pneumatic conveyor.
20 tph (22 stph) granulated sugar
- Infeed: Silo outlet
- Inlet: Adapter for process connection
- Discharge: Liquid mixing vessel inlet at 18 m elevation
- Throughput: 20 tonnes (22 short tons) per hour
Aero-mechanical conveyor
- 4″ conveying tubes
- Stainless steel 304 contact materials
- Painted mild steel structure
- 65′ (19.8 m) long
- c/w washing accessories
Semi-dense phase pneumatic conveyor
- 4″ conveying tube
- Stainless steel 304 contact materials
- Painted mild steel structure
- 86′ 7″ (26.4 m) long c/w 90° elbows
- c/w blower to suit installation
Over 10 years, a Floveyor aero-mechanical conveyor has a total cost of ownership of around US$178,000, compared with roughly US$447,000 for a semi-dense phase pneumatic conveyor handling the same application, or about 60% lower overall.
The largest contributors are:
- power consumption (around 4x lower)
- unplanned downtime (around 7.5x lower)
- planned downtime (around 2.5x lower).
Capital costs for an AMC are roughly half that of a semi-dense phase pneumatic conveyor. Maintenance consumables are the one line item where the AMC costs slightly more, but the operating-cost savings far outweigh it.
Comparing AMC vs pneumatic when conveying 20 tph (22 stph) granulated sugar
Total cost of ownership: aero-mechanical conveyor vs bucket elevator
In this application, an AMC is compared with a bucket elevator conveyor.
80 tph (88 stph) urea prill
- Infeed: Truck unloading feeder
- Inlet: Adapter for process connection
- Discharge: Storage silo inlet at 15 m elevation
- Throughput: 80 tonnes (88 short tons) per hour
Aero-mechanical conveyor
- 5″ conveying tubes
- Stainless steel 316 contact materials
- Stainless steel 316 structure
- 55′ (16.8 m) long
- c/w dry cleaning accessories
Bucket elevator conveyor
- Chain-driven, replaceable buckets
- Stainless steel 316 contact materials
- Stainless steel 316 structure
- 55′ (16.8m) long
- c/w structural supports
When compared to a bucket elevator, an aero-mechanical conveyor requires significantly less maintenance man-hours.
Over 10 years, a Floveyor aero-mechanical conveyor has a total cost of ownership of around US$163,000, compared with roughly US$432,000 for a bucket elevator handling the same application — about 62% lower. The largest contributors are:
- maintenance manpower (around 6.7x lower)
- unplanned downtime (around 9x lower)
- planned downtime (around 5.5x lower).
The Floveyor is lower on every individual cost line shown.
Comparing AMC vs bucket elevator when conveying 80tph (88stph) urea prill
Total cost of ownership: aero-mechanical conveyor vs flexible auger
In this application, an AMC is compared with a flexible auger (screw conveyor).
8 tph (8.8 stph) animal nutrients
- Infeed: 25 kg disposable bags
- Inlet: Integrated bag dump station
- Discharge: Mixer inlet at 5 m elevation
- Throughput: 8 tonnes (8.8 short tons) per hour
- Materials: Animal nutrients – dicalcium phosphate, magnesium oxide, Acid Buf, zinc sulphate monohydrate, salt, copper sulphate
Aero-mechanical conveyor
- 3″ conveying tubes
- Stainless steel 304 contact materials
- Painted mild steel structure
- 20′ (6.1 m) long
- c/w integrated bag dump station
Flexible auger (screw conveyor)
- 4″ conveying tube
- Plastic contact materials
- Painted mild steel structure
- 20′ (6.1 m) long
- c/w integrated bag dump station
A Floveyor aero-mechanical conveyor outperforms a flexible auger on total cost of ownership. Over 10 years, a Floveyor AMC has a total cost of ownership of around US$93,000, compared with roughly US$148,000 for a flexible auger handling the same application, amounting to about 37% lower.
Capital cost is essentially the same between the two machines. The gap between an AMC and a flexible auger is in operating cost:
- unplanned downtime (around 6x lower)
- planned downtime (around 50% lower).
The flexible auger is slightly cheaper on consumables and power, but the downtime savings far outweigh those line items.
Comparing AMC vs flexible auger (screw conveyor) when conveying 8 tph (8.8 stph) animal nutrients: dicalcium phosphate, magnesium oxide, Acid Buf, zinc sulphate monohydrate, salt, copper sulphate
What maintenance does an aero-mechanical conveyor require
Aero-mechanical conveyors require minimal maintenance. Regular, preventative maintenance eliminates costly, unplanned downtime during production. The manufacturer will recommend inspection and adjustment intervals for:
- Rope assembly
- Sprocket assemblies
- High-speed bearings
- High-speed seals
- Internal housing surfaces
- Fastener tightness
- Other seals.
Maintenance intervals vary depending on application, materials handled and hours of operation. The Floveyor AMC provides quick access to areas requiring frequent cleaning, inspection or maintenance. When well-maintained, Floveyor AMCs can operate up to 24 hours per day. A rope assembly will last 3,000–5,000 hours of operation when the conveyor has been installed and operated correctly. It’s normal for a Floveyor AMC to operate for decades with minimal downtime and high availability rates.
Custom solutions and configurations
Bulk material handling equipment is available to complement the aero-mechanical conveyor, including:
- Tubular drag conveyors
- Mobile systems
- Truck loading
- Reusable bulk bag discharger
- Disposable bulk bag discharger
- Bulk bag unloading screw feeder
- AMC screw feeder
- Trough screw feeder
- Dosing screw feeder
- Rotary lump breaker
- Bulk bag conditioner.
As the original inventor of aero-mechanical conveying, Floveyor has extensive experience custom-designing powder handling systems to complement the AMC. This entails:
- Discovery and solution modelling
- Applying expertise to guide concept through to reality
- Global support
- Reliable, after-sales support.
Floveyor powder handling specialists
Custom solutions may include application-specific chutes, hoppers and transfers to integrate standard Floveyor AMCs and powder handling equipment with existing plant or third-party supplied components.
If a fully customised solution is required, Floveyor can design and build structural, mechanical and electrical solutions to meet your exact requirements.
When is an aero-mechanical conveyor not the right choice?
There are aero-mechanical conveyor limitations, making it not always the best choice for every application:
- Lengths more than 30m/100ft where a single run is more economical
- Moisture content above 16% w/w
- Waxy, fatty, sticky or oily materials
- Materials that bind under compressive loads.
A tubular drag conveyor can be a better choice for:
- Complex routes with multiple corners and/or bends
- Multiple planes
- Multiple inlets and/or discharge points.
Conclusion
An aero-mechanical conveyor is the workhorse of powder conveying systems all over the world. Its versatility, durability and low total cost of ownership make it an attractive option for myriad industrial applications and food and beverage manufacturing operations. When you consider its ability to rapidly transfer thousands of materials safely and gently with a single machine, an AMC is the best choice for powder handling.
Floveyor invented aero-mechanical conveying in 1958 in Perth, Western Australia, and continues to evolve powder conveying equipment. As powder handling specialists, we can help you discover the best powder conveyor for your plant, to ensure your performance expectations are being met.
Our materials matcher will help you discover the best AMC for your operation.
Get in touch with Floveyor for advice on powder handling and learn how to optimise your operation for maximum yields and profit.
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