If you’re thinking of investing in a powder transfer system, you’re probably focused on cost. Once you’ve established your budget for purchase, thinking about ways you can influence a lower total cost of ownership—over time—can result in big savings for your powder handling operation. We break down the basics here.
Understanding total cost of ownership of a powder transfer system
Total cost of ownership (TCO) is a comprehensive approach to assessing the long-term costs associated with a powder transfer system. While the initial capital cost is a significant factor, it’s essential to consider other elements that contribute to the overall expense of owning and operating the equipment. These factors include capacity, cleanability, power consumption, availability, consumables, and maintenance requirements.
By taking a holistic view of your powder handling system’s costs, you can make informed decisions that minimise expenses and maximise efficiency over the life of the equipment. Let’s take a closer look at various types of conveyors and analyse their impact on TCO.
Conveyor total cost of ownership analysis (snapshot)
1. Aero-mechanical conveyor
- Initial capital cost: Moderate to high
- Capacity: Moderate to high
- Cleanability: Excellent, with clean design and easy access
- Power consumption: Low to moderate
- Availability: High, with minimal maintenance
- Consumables: Low to moderate
Aero-mechanical conveyors offer a balance between initial cost and long-term performance. Their efficient design results in low to moderate power consumption, while their minimal maintenance requirements contribute to high availability. With good cleanability and low consumables, aero-mechanical conveyors can be a cost-effective choice for many powder handling applications.
2. Pneumatic conveyor
Initial capital cost: Moderate to high
Capacity: High
Cleanability: Good, with proper design and materials
Power consumption: High
Availability: High, with proper maintenance
Consumables: Moderate to high (filters, wear parts)
Pneumatic conveyors, including dilute and dense phase systems, provide high capacity and good cleanability. However, the high power consumption of these powder handling systems can impact long-term operating costs. Proper maintenance is crucial to ensure high availability, and consumables such as filters, valves, corners and other wear parts should be factored into the TCO analysis.
3. Tubular drag conveyor
Initial capital cost: Moderate to high
Capacity: Moderate
Cleanability: Good, with proper design and materials
Power consumption: Low to moderate
Availability: High, with minimal maintenance
Consumables: Low
Tubular drag conveyors stand out for low to moderate power consumption and minimal maintenance requirements. They offer high availability, low consumables, and low operating costs. Tubular drag conveyors are superior to chain drag conveyors, screw conveyors and pneumatic conveyors for cleanability, making them an attractive option for food processing applications where hygiene is a top priority.
4. Screw conveyor
Initial capital cost: Low to Moderate
Capacity: Low to moderate
Cleanability: Poor to moderate, depending on design
Power consumption: Moderate
Availability: Moderate to high, with proper maintenance
Consumables: Moderate (wear parts)
Screw conveyors have a low to moderate initial cost but may have limitations in terms of capacity, cleanability. and installation routes. Their cleanability largely depends on the design, with some models being more difficult to clean than others. Moderate power consumption and the need for wear part replacements should be considered when assessing the TCO of this powder transfer system.
5. Bucket elevator
- Initial capital cost: Moderate to high
- Capacity: Moderate to high
- Cleanability: Poor to moderate, depending on design
- Power consumption: Moderate
- Availability: High, with proper maintenance
- Consumables: Moderate (belts, buckets)
Bucket elevators offer moderate to high capacity, moderate power consumption and high availability. They can be a suitable choice for many powder handling applications but come with cleaning limitations. Each bucket must be cleaned individually, and cleaning accessibility is poor. The cost of consumables such as belts and buckets should be factored into the conveyor system cost.
6. Flexible screw conveyor
- Initial capital cost: Low to moderate
- Capacity: Low to moderate
- Cleanability: Poor to moderate, depending on design
- Power consumption: Moderate
- Availability: Moderate to high, with proper maintenance
- Consumables: Moderate (wear parts)
Flexible screw conveyors have a low to moderate initial cost but may face challenges in terms of capacity and cleanability. Like traditional screw conveyors, their cleanability depends on the design, with some models being more difficult to clean. Moderate power consumption and wear part replacements are important considerations when evaluating the TCO of these powder handling systems.
7. Belt conveyor
- Initial capital cost: Moderate
- Capacity: High
- Cleanability: Moderate to good, depending on design and materials
- Power consumption: Low to moderate
- Availability: High, with proper maintenance
- Consumables: Moderate (belts)
Belt conveyors provide high capacity and can have good cleanability, depending on the design and materials used. Their low to moderate power consumption and high availability make them an efficient choice for many powder handling applications. The cost of belt replacements should be included in the TCO assessment.
Check out: Comparative Technologies Poster
Cleanability of a powder transfer system: A critical factor in food, agriculture, and pharmaceutical processing
At a recent industry conference, the highest level of feedback centred around the importance of cleanability in a powder transfer system. Attendees emphasised that cleanability is one of the biggest challenges they face, particularly if the system takes an excessive amount of time to clean and dry between batches. This issue is compounded when the equipment is not sourced from a supplier who is familiar with clean design, cleanability, and validation for food processing applications.
Many conference participants shared their struggles with current equipment, citing the significant time required for cleaning and the increased risk of spoilage due to poor designs that are not optimised for food processing. These experiences highlight the critical role that cleanability plays in the long-term cost of ownership for powder handling systems.a
Types of powder transfer system cleaning
- Clean-in-place (CIP): Conveying systems that can be cleaned and sanitised in a fixed plant setting.
- Clean-out-of-place (COP): Conveying systems and equipment must be moved or disassembled to clean and sanitise them.
- Dry clean: Conveyors can be cleaned with air or inert gasses.
- Wet clean: Conveyors require water or liquid for proper cleaning.
Traps to avoid that can increase your total cost of ownership
When selecting a powder transfer system, it’s essential to be aware of potential traps that can lead to increased costs and reduced efficiency. Some of the most common traps include:
- Unplanned downtime—lost production: Equipment breakdowns and unscheduled maintenance can result in significant production losses, impacting your bottom line. One 2022 study showed the average large plant loses 25 hours a month to unplanned downtime, or US$129 million per plant on average.
- Unplanned downtime—demurrage charges/upstream storage: When your powder handling system is down, you may face additional costs associated with demurrage charges or the need for upstream storage solutions.
- Inadequate operator training: Poorly trained operators can lead to inefficiencies, errors, and increased maintenance requirements, all of which contribute to higher long-term costs. If your plant has a high operator turnover, training can quickly become costly. Or worse, operators don’t get the training they need and damage equipment unintentionally.
- High maintenance demands: Powder handling systems that require frequent maintenance or have difficult-to-access components can lead to increased labour costs and reduced availability.
- Excessive downtime for cleaning: Poor clean design can result in extended cleaning times, reducing overall equipment availability and increasing labour costs. Machinery that is hard to access or needs special tools is more costly to operate. This kind of equipment can also require specialised operator training for cleaning which adds to operating costs.
To minimise these risks and achieve a lower TCO, it’s crucial to select a powder transfer system that prioritises clean design, easy access for maintenance, and operator training.
Strategies for lowering total cost of ownership
- Select a powder transfer system that prioritises clean design and easy access for cleaning and maintenance. This will minimise downtime and labour costs associated with cleaning and repairs.
- Invest in high-quality, durable components that minimise wear and maintenance requirements. While the initial cost may be higher, the long-term savings in reduced maintenance and replacements can be significant.
- Choose a system with the appropriate capacity to avoid bottlenecks and lost production. Undersized equipment can lead to inefficiencies and increased cost of conveyor system over time.
- Implement regular training programs to ensure operators are using the equipment efficiently and correctly. Well-trained operators can help minimise errors, reduce maintenance needs, and extend the life of the equipment.
- Work with experienced conveyor manufacturers and suppliers who specialise in clean design and food processing applications. These partners can provide valuable guidance and support in selecting and maintaining a powder transfer system that meets your specific needs while minimising long-term costs.
Conclusión
Investing in a powder transfer system is a massive decision that requires careful consideration of both initial costs and long-term cost of ownership. By understanding the factors that contribute to TCO, such as capacity, cleanability, power consumption, availability, and consumables, you can make informed choices that minimise expenses and maximise efficiency over the life of the equipment.
Cleanability is a critical factor, particularly in food, pharmaceutical, and agriculture processing applications, and should be a top priority when selecting a powder handling system. By choosing a conveyor that offers excellent cleanability, easy access for maintenance, and a clean design, you can reduce downtime, labour costs, and the risk of spoilage.
Consider partnering with an experienced original equipment manufacturer (OEM) who specialises in clean design and is experienced in food processing applications. They can provide valuable support in selecting and maintaining a powder transfer system that meets your needs while minimising long-term costs. By following these strategies and avoiding common traps and hidden costs, you can achieve a lower total cost of ownership and ensure the success of your powder handling operation.
Learn more about reducing total cost of ownership for your powder transfer system
Get in touch with Floveyor for advice on powder transfer systems for your operation. As powder handling specialists with a long history in multiple industries, we can give you advice on total cost of ownership.
