3 Pneumatic Conveying Hassles Engineers No Longer Need to Worry About

 

When it comes to moving bulk materials, engineers often face a choice: pneumatic conveying or mechanical conveying (most often screw conveyors). Both methods have their place. Pneumatics excel with fine, consistent, or pelletized materials, while screws handle moist, irregular, or heavy materials well.

But for the wide range of “in-between” applications, the decision can come down to past frustrations or lingering perceptions. Many engineers still default to screws because of challenges once common in pneumatic systems. The reality in 2025? Modern technology has solved most of these pain points. Let’s revisit three common hassles and why they no longer need to steer you away from pneumatics.

 

1. Upfront Cost vs. Long-Term Value

It’s easy to assume screw conveyors are simpler and cheaper. And for short, direct routes, they often are. But pneumatic systems have evolved. Compact, self-contained pneumatic units now compete with screws on price for smaller jobs, while large-scale systems still deliver better ROI when long distances or complex routing are involved.

Beyond capital costs, pneumatics typically require less floor space, offer greater layout flexibility, and reduce contamination risks. In an era where energy efficiency and worker safety are front-and-center, pneumatic systems are proving not only feasible but often more cost-effective over the life of the equipment.

 

2. Flow Control and Blockage Prevention

Historically, one of the biggest frustrations with pneumatic conveying was keeping material moving without blockages or damage. Engineers often over-compensated by cranking up air speed, trading one problem for another: product degradation, higher energy bills, and premature wear.

Today, advanced particulate monitoring technology has changed the game. Using methods first developed for emissions monitoring, engineers can now measure actual particle velocity inside the pipeline—not just airspeed. With this real-time data, systems automatically fine-tune air flow, keeping material moving efficiently while preventing both blockages and excess energy use.

Supporting technologies like Flow/No-Flow detectors and More-Flow/Less-Flow monitors further reduce downtime, making pneumatic systems far more predictable and reliable than their legacy counterparts.

 

3. Maintenance and Reliability

At first glance, screws seem like the “low maintenance” choice because they don’t need compressors or blowers. But in practice, screw conveyors come with more moving parts and more opportunities for mechanical wear. Bearings, seals, and augers demand regular upkeep.

Modern pneumatic systems, when paired with intelligent monitoring of both conveying lines and dust collection equipment, can drastically cut downtime. Fewer moving parts, combined with condition-based monitoring, means less unplanned maintenance and greater system longevity.

 

The Bottom Line

Engineers no longer need to let outdated perceptions drive their choice. Pneumatic conveying technology in 2025 is more efficient, more reliable, and easier to justify than ever before. Before defaulting to a screw conveyor, consider how advances in monitoring and system design may make pneumatics the smarter long-term option for your facility.

Want to explore how pneumatic conveying could optimize your process?

Contact Auburn – The Particulate Monitoring Company to learn how our customers across industries are modernizing their bulk material handling.