How to Select the Right Pneumatic Conveying System for Your Material Type

Choosing the right pneumatic conveying system is critical for efficient, safe, and cost-effective bulk material handling. But not all materials are created equal—and neither are the conveying systems that move them. The wrong setup can lead to product degradation, energy waste, excessive wear, or even system failure.

In this guide, we’ll break down how to choose the best pneumatic conveying system based on the type of material you’re handling. Whether you're moving powders, pellets, or granules, understanding your material is the first step to building a high-performance conveying solution.

What Is a Pneumatic Conveying System?

In industries where bulk materials like powders, granules, and pellets are handled daily, material movement must be efficient, hygienic, and safe. That’s where a pneumatic conveying system comes in—a powerful solution for transporting dry bulk materials through pipelines using air or gas pressure.

In this article, we’ll explain what a pneumatic conveying system is, how it works, its types, and why it’s widely used in modern manufacturing and processing industries.

Why Material Type Matters

Every material behaves differently in motion. Some are fine and free-flowing; others are sticky, abrasive, or fragile. These characteristics determine which type of pneumatic conveying system will work best.

Key material properties to consider:

• Particle size and shape

• Bulk density

• Flowability

• Abrasiveness

• Fragility or sensitivity to pressure

1. Dilute Phase Conveying – For Light, Non-Abrasive Materials

Best for: Sugar, flour, plastic pellets, starch, grain

In dilute phase conveying, materials are suspended in high-velocity air and move continuously through the pipeline. It works well with light, free-flowing materials that are not fragile or abrasive.

Pros:

• Fast transport

• Cost-effective for basic applications

• Suitable for most food and plastic materials

Avoid if: Your materials are easily breakable or highly abrasive, as the fast-moving air can cause damage or wear.

2. Dense Phase Conveying – For Fragile or Abrasive Materials

Best for: Cement, silica, coffee beans, chemicals, powdered metals

Dense phase conveying uses low-velocity, high-pressure air to push materials in slugs or waves. It minimizes air turbulence, making it ideal for delicate or abrasive materials.

Pros:

• Gentle handling

• Reduces product degradation

• Less wear on pipes and bends

Avoid if: You need fast, lightweight conveying over short distances—it may be more than what’s needed.

3. Vacuum Conveying – For Hygienic or Compact Applications

Best for: Pharmaceuticals, food powders, fine chemicals

In vacuum conveying, negative pressure pulls materials through the line. It’s commonly used where hygiene, containment, or space-saving is a priority.

Pros:

• Dust-free and sanitary

• Ideal for enclosed, multi-point transfer

• Safe for toxic or sensitive materials

Avoid if: You’re handling heavy materials over long distances; it may require more power or a hybrid system.

Additional Factors to Consider

Before making a decision, evaluate these operational details:

• Distance and layout: Long, complex routes may need dense phase or hybrid systems

• Capacity requirements: High throughput needs systems built for volume

• Environment: Food and pharma industries require stainless steel, GMP-compliant systems

• Maintenance needs: Systems with fewer moving parts reduce downtime

Final Thoughts

Choosing the right pneumatic conveying system starts with understanding your material. By evaluating its behavior—such as how abrasive, fragile, or dense it is—you can select a conveying method that maximizes productivity while protecting your product and equipment.