In the plastics processing industry, masterbatch conveying is a critical step. A company in Ganzhou, Jiangxi, has partnered with Head Powder to successfully implement a complete low-crushing pneumatic conveying project to address frequent breakage issues during masterbatch pneumatic conveying. This project combines material characteristics with on-site conditions, and through systematic design and equipment optimization, has reduced the particle breakage rate and supported subsequent production quality.

Project Overview

This case is located in Ganzhou, Jiangxi, mainly serving the masterbatch production and processing stage. When customers use traditional pneumatic conveying systems, materials collide and rub at high speed in the pipeline, causing large amounts of particle fragmentation, which not only affects product appearance and performance but also increases dust emissions and material loss. Based on a deep understanding of industry pain points, Head Powder has tailored a complete solution for low-crushing pneumatic conveying.

Customer pain point analysis

Masterbatch particles are brittle materials and are extremely sensitive to mechanical impacts during conveying. The customer's original system had the following prominent issues:

• Severe pellet crushing: Crushing rate exceeds 5%, leading to higher defect rates and more complaints from end customers.
• High dust pollution: Crushing produces large amounts of fine powder, polluting the workshop environment and increasing cleaning costs and health risks.
• High loss and waste: crushed materials cannot be reused, directly causing raw material losses and considerable annual waste.
• Low conveying efficiency: crushed particles clog pipelines, causing frequent stoppages for cleaning, which affects overall production efficiency.

Solutions and advantages

To address these pain points, Head Powder optimizes design from multiple dimensions of the pneumatic conveying system, providing a complete set of low-crushing solutions:

• Uses low-velocity, low-pressure conveying processes to reduce the speed and frequency of material collisions within the pipeline.
• Wear-resistant elbows and buffering devices are selected to reduce impact forces at turns.
• Equipped with high-precision gas-solid separation equipment, it helps effectively collect dust and is environmentally friendly.
• The system has excellent overall sealing, preventing material leakage and external contamination.

After the project was implemented, the masterbatch crushing rate dropped below 1%, dust emissions decreased by more than 80%, and production continuity improved. Annual material loss for customers is reduced by about 30%, and overall operating costs have dropped significantly. This case provides a replicable technical path for conveying masterbatch particles of the same type.