Application
Dense Phase Conveying of Fragile Food Products
Answer in brief
In food plants dense phase conveying is chosen to protect the product.
Low velocity keeps coated snacks, instant powders and pre-blended mixes intact, which is worth more than the energy saved.
- Match the velocity to the fragility, not to the distance.
- Watch blend segregation as well as breakage.
- Design the line to be cleaned, because it is a food contact surface.
Reviewed October 21, 2026 · Updated October 21, 2026
The problem
High velocity dilute phase breaks fragile products and grinds agglomerates into fines that change dispersibility and appearance.
Pre-blended mixes also segregate in a long dilute phase line.
Desired outcome
A conveying line that reaches the rate over the required distance while keeping the product and the pipework in the condition the process needs.
Process approach
Dense phase or plug conveying moves product as a slow-moving bed, which limits both impact and segregation.
Conveying trials establish the achievable rate and the velocity at which damage begins, and that velocity becomes the design limit.
The line is a food contact surface: crevice-free joints, cleanable bends and a documented cleaning method are part of the specification.
- Trials to establish the damage threshold.
- Crevice-free, cleanable line construction.
- Receiving filter and discharge designed for gentle handling.
Selection factors
- Fragility of the product and the acceptable fines increase.
- Blend composition and segregation behavior.
- Cleaning method and frequency.
- Allergen matrix where lines are shared.
- Dust explosion characteristics of the product.
Common failure modes
- Velocity set by the rate requirement rather than by the product
- Blend segregating between mixer and packer
- Line joints that cannot be cleaned to the required standard
- Agglomerates broken, changing the dispersibility of the powder
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