- 08/10/2025
- Article
- Conveying & filling
Conveyor technology for bulk materials: systems, applications, and selection criteria
Whether gravel or flour, plastic granulate or pellets: bulk materials must be conveyed reliably in industry. Depending on the material, distance and process requirements, very different conveyor technologies are required. An overview of systems, their strengths and answers to the question of how to select the right conveyor for an application.
Written by Marius Schaub
Why the right conveyor technology is crucial
Conveyor technology is a central element of industrial bulk material processes. It ensures that materials are moved safely, efficiently, and in compliance with process requirements, whether horizontally, inclined, or vertically. An unsuitable conveyor solution can not only disrupt the material flow, but also lead to product loss, downtime, or increased maintenance costs.
Whether coarse, fine, abrasive, moist, sticky, or temperature-sensitive – the technical requirements vary greatly depending on the bulk material. That is why it is crucial to select the right conveyor system and tailor it to the specific process.
Mechanical conveyors: classic and versatile
Mechanical systems form the backbone of many bulk material processes. They operate reliably, are often comparatively inexpensive, and can be adapted to a wide variety of requirements.
Belt conveyors
Belt conveyors are ideal for continuous material transport over medium to long distances. They are particularly suitable for horizontal or slightly inclined routes and enable high conveying capacities with low energy consumption.
Typical areas of application for belt conveyors include:
- Gravel
- Sand
- Coal
- Grain
- Packaging
Bucket elevators
Bucket elevators are always used when bulk material needs to be conveyed vertically: for example, from a silo floor into a mixer or to a higher process level. They consist of a circulating belt or chain with attached buckets.
Typical areas of application:
- Cement
- Sugar
- Building materials
Screw conveyors
Screw conveyors move material through a closed pipe using a rotating screw conveyor. These systems are well suited for fine-grained, dusty, hot, or pasty materials. Variants such as dosing screws also enable precise quantity feeding.
Typical areas of application:
- Flour
- Sludge
- Chemicals
- Plastic granulates
Chain conveyors
Chain conveyors or scraper conveyors are suitable for particularly demanding applications, such as abrasive or hot materials. Conveying is carried out by means of carriers attached to a circulating chain (often in closed troughs).
Typical areas of application:
- Waste incineration plants
- Cement industry
- Power plants
Pneumatic conveyor technology: flexible and closed
Pneumatic conveying systems transport bulk materials through closed pipes using a stream of air. Depending on the design, a distinction is made between pressure conveying (blowing) and suction conveying.
Advantages include the closed design (ensures dust-free operation), flexible pipe routing, and low mechanical stress on the material. Disadvantages may include higher energy consumption and sensitivity to moist or slow-flowing materials.
Typical areas of application:
- Plastic granules
- Dust
- Grain
- Chemicals
Vacuum conveyors: compact and hygienic
Vacuum conveyors are particularly suitable for sensitive, fine, or hygienically critical materials. They convey smaller quantities under negative pressure and are easy to clean – a major advantage, especially for applications in the food and pharmaceutical industries.
Typical areas of application:
- Milk powder
- Pharmaceutical ingredients
- Additives
- Color pigments
Pipe chain conveyors and aeromechanical systems: for special cases
In addition to established technologies, there are specialized conveyor systems for specific applications. Tube chain conveyors combine closed conveyor paths with gentle material transport. An endless chain with carriers moves the bulk material through a tube system, even over complex routes.
In aeromechanical conveyors, a rotating rope with carriers generates an air flow that pulls the bulk material along. The system is compact, efficient, and low-maintenance, while also offering high conveying speeds.
Typical areas of application for tubular chain conveyors:
- Chemistry
- Food
- Paints and varnishes
Typical areas of application for aeromechanical conveyors:
- Grain
- Plastic granules
- Light powders
Selecting conveyor technology: What matters during planning
Numerous factors play a role in selecting the right conveyor technology:
- Conveying path: horizontal, vertical, inclined?
- Material properties: grain size, flow behavior, abrasiveness, moisture content
- Conveying capacity: continuous or batch, volume per hour
- Process requirements: hygiene, cleanability, explosion protection
- Integration: space requirements, interfaces to other machines
A sound interpretation usually requires practical tests and close coordination with experienced plant engineers.
Trends and developments in conveyor technology
Digitalization is also finding its way into conveyor technology. Digital technologies and processes can bring various advantages for operators:
- Condition monitoring: Sensors detect wear or blockages at an early stage.
- Predictive maintenance: Maintenance requirements are calculated in advance to avoid unplanned downtime and increase plant availability.
- Energy efficiency: Speed-controlled drives and intelligent control systems reduce operating costs.
- Sustainability: The recovery of material losses, reduction of dust emissions, and energy-optimized conveyor routes are also becoming increasingly important.
Conclusion: Diversity in conveyor technology brings advantages for operators
Bulk material handling is as diverse as the materials it works with. From robust belt conveyors and precise screw conveyors to hygienic vacuum systems – there is a suitable solution for every application. The key factors are a well-founded selection and professional implementation that takes both technical requirements and economic aspects into account.
Visitors to POWTECH TECHNOPHARM can experience the entire spectrum of conveyor technology for bulk solids. The list of exhibitors and products, which includes numerous offerings from the “Conveying and Transporting” category, provides a preview.
Are you interested in this topic? Then come to POWTECH TECHNOPHARM and experience this and many other topics live at the trade fair. Get your ticket here with the following code: PTTP25Insights
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