Mechanical Conveying Systems

Mechanical conveying systems transport large amounts of product horizontally, vertically or at an incline through a powder processing system. Generally speaking, there are a number of moving parts within a mechanical conveying system, with belts, buckets, chains and trays often being utilized to move product at a quick pace.

At Powder Process-Solutions, our team of engineers works with our customers to design mechanical conveying systems are tailored to their unique needs to ensure efficiency, safety and sanitation.

Advantages of Mechanical Conveying

Mechanical conveying systems have been part of manufacturing and production for decades, and offer several advantages over pneumatic conveying systems:

  • More energy efficient. By some estimates, mechanical conveying systems require 10 times less horsepower than pneumatic systems, saving energy and money.
  • Smaller dust collection systems. Mechanical conveying systems don’t need to separate material from an air streams, so a more modest dust collection system does the trick.
  • Increased safety for combustible bulk solids. Conveying bulk solids poses deflagration and other fire hazards—which can lead to dust explosions . Since mechanical conveying systems use a more conventional method of transportation, rather than an air stream like pneumatic conveyors, the risk of an explosion is greatly reduced.
  • Well-suited for dense, heavy, granular and sticky materials. Typically, mechanical conveying systems make it easier to transport sticky materials that could cause pipeline blockages in pneumatic systems or heavier material that can’t be easily moved using an air stream.
  • Lower price point. Mechanical conveying systems are often less expensive to design and install than pneumatic conveying systems, making it a more cost-effective option for small and mid-sized businesses.

Of course, mechanical conveying systems aren’t a good fit for every powder processing plant. These systems typically require more floor space than pneumatic conveying systems, as well as more maintenance due to having more moving parts.

Mechanical Conveying Types and Applications

Mechanical conveyance of bulk powders can be achieved in a variety of different ways. As mentioned above, mechanical conveying systems are often used to convey dense, sticky or granular products, such as sugar and wheat. In addition, these systems are most often used in situations where product needs to travel shorter distances.

Below are three of the most common types of mechanical conveying systems that Power Process-Solutions designs for our customers:

Screw Conveyor

Screw conveyors are perhaps one of the most popular and cost-effective ways to mechanically convey product. This type of system, which can be installed horizontally or inclined, is often used for:

  • Discharging small hoppers.
  • Unloading bulk bags or hand dump stations.
  • Adding minor amounts of powder.

Vibrating Conveyor

Vibrating conveyors are a highly sanitary and gentle option for conveying sensitive bulk powder material. This type of system is often used to:

  • Convey dry, wet, warm, greasy, frozen, hygroscopic, oxygen absorbing or abrasive products.
  • Convey with simultaneous spreading, cooling, heating, draining, distribution, unification, dusting, grading or drying.

Differential Motion Conveyor

A differential motion conveyor uses a horizontal, slow-advance, quick-return motion to gently convey product and practically eliminate conveyor-imposed product damage.


Mechanical conveying systems are a good choice for many industries that handle or manufacture dry or wet bulk powders. Some industries that benefit most from mechanical conveying are:

  • Food
  • Dairy
  • Chemical

How to Select a Mechanical Conveying System

Choosing the right mechanical conveying system for your business should be based on a number of factors including the type of material being handled, the space you have to work with in your facility, conveying rates, distance product needs to travel, and other process requirements. In addition, thinking about the service life your conveyor must provide, as well as how the energy and maintenance costs fit into your operating costs, are worth consideration, too.

Powder Process-Solutions has the industry and manufacturing knowledge that can only be attained after 40 years of active and successful engineering within the industry. We have an on-site test lab that can be used to gain solid information when handling new products with unfamiliar properties. Our experienced engineers will work with you to design a system that gives you with the most efficient, safe, sanitary and quality process solution.

Contact Us Today

To discuss your needs or learn more about whether mechanical conveying is a good fit for your powder processing facility, contact us today.