By Kevin McGonigal
Silo cleaning is a routine task that will help prevent contamination, blockages, and general safety risks. Silos are somewhat simple in terms of concept and design, yet a surprising number of structural things can go wrong based on how they are used and maintained. Fortunately, almost everything that might go wrong can be avoided or corrected with regular silo cleaning services.
In many cases, you don’t even need an inspection to tell you that something is wrong. When the flow of material out of the silo has stopped or become erratic, or the capacity of the silo has diminished, there is a problem.
The specifics can vary with the material stored in the silo, but common problems with flow include these:
Arching
Bridging
Buildup
Out-and-out blockage
Tunneling or 'ratholing'
Clinging
When these issues occur, it’s time to review how your silo is performing. Whether you’re looking for a DIY solution or professional help, we’ll walk you through the importance of silo cleaning and how it’s done correctly.
Silos that are clogged or running slow as a result of these problems will be detrimental to the efficiency and profitability of a plant. Worse yet, conditions can deteriorate to the point where an emergency cleaning is necessary. And, off-center loading caused by buildup inside a silo can potentially damage the structure due to the non-uniform pressure on the interior walls.
Unsure if it’s time to clean your silo? It’s time if you’re experiencing any of these scenarios:
The bulk material discharges in lumps or chunks
The material discharges off-center
The silo's outlet/discharge plugs discharge regularly
The silo's capacity is diminished – meaning the silo needs filling more frequently and/or the time it takes to fill has decreased.
Naturally, you will also want to clean your silo if the stored material is going to be changed out or the silo is going to be decommissioned.
There are many benefits to keeping your silos clean and operating in top condition:
Material will flow at optimum efficiency
Live storage capacity will be maximized
Productivity will be increased
Downtime will be decreased
Long-term financial savings due to sustained operations
Combustion-generating “hot spots” will be eliminated
The work environment will be safer and cleaner
Immediate benefits of AIRMATIC's silo cleaning service include the fact that material that had been considered “lost” can be recovered. In at least one case we know of, our silo cleaning crews have recovered enough "lost" material to pay for the cost of the cleaning.
Power washing can sanitize silos, prevent cross-contamination, and remove mold, but when the problem is build up, blockage, an erratic flow of material, or when water can't be used, a different approach is required.
For the silo cleaning team at AIRMATIC, the go-to industrial silo cleaning equipment is the bin whip, the bin drill, and the chunk buster. Bin whipping is the most commonly used procedure, but 30 to 40% of the time, conditions require that we start with bin drilling to open a flow channel through exceptionally tough clogs. Bin whipping then follows.
Remember that there’s no need to take on any undue risk to clean a silo. Hazardous techniques like explosives and water and air lances are not necessary. Nor do you need to put personnel inside the silo to clean it – we clean from outside the vessel!
If you want to reduce the need for cleaning professional-level and optimize your efficiency and productivity, consider installing flow-aid devices on your silos. Air cannons, bin aerators, sonic horns, and vibrators are all options to consider. Talk with us for expert advice on what would best serve you and your operation.
Q: Do you need to enter the vessel?
A: No. Our preferred method is always ‘no-entry’ silo cleaning, which keeps personnel out of confined spaces. Using specialized equipment such as Bin Whips and Bin Drills, we restore material flow without placing workers inside the vessel. On occasion, there are build up problems that do require entry. In those circumstances, our plant contact is notified for approval and our confined space entry protocol is presented for acceptance.
No. Our preferred method is always ‘no-entry’ silo cleaning, which keeps personnel out of confined spaces. Using specialized equipment such as Bin Whips and Bin Drills, we restore material flow without placing workers inside the vessel. On occasion, there are build up problems that do require entry. In those circumstances, our plant contact is notified for approval and our confined space entry protocol is presented for acceptance. Close
Q: What power or utilities are needed?
A: Our equipment is pneumatically powered. The compressed air requirement for the Bin Whip is 100 CFM at 90 psi; we also require standard plant power (120V AC) for support tools, eg, lights. If the Bin Drill is needed, we require 220/440V/3Ph/60Hz power. If job site compressed air is limited, we can quote a rental compressor and power distribution accessories.
Q: How fast is the cleaning process?
A: Cleaning time depends on silo size, material condition, blockage severity, and accessibility. Many jobs are completed in hours to a day; severe hard-set product or multiple vessels can take longer.
Cleaning time depends on silo size, material condition, blockage severity, and accessibility. Many jobs are completed in hours to a day; severe hard-set product or multiple vessels can take longer. Close
Q: What happens to the removed / discharged material?
A: As silos are being emptied, material must be removed from the discharge outlet. Depending on its condition, it may be reclaimed or must be disposed of in compliance with local environmental regulations. Some customers manage this process directly, others contract us to arrange collection, transport, and disposal as part of our service.
As silos are being emptied, material must be removed from the discharge outlet. Depending on its condition, it may be reclaimed or must be disposed of in compliance with local environmental regulations. Some customers manage this process directly, others contract us to arrange collection, transport, and disposal as part of our service. Close
Q: How often should a silo be cleaned?
A: Preventive cleaning is recommended annually or bi-annually depending on material flow, climate, and operating conditions. Signs that cleaning is overdue include reduced capacity, slower discharge rates, or arching/rat-holing issues.
Q: Can you prevent the problem from returning?
A: We recommend flow-aid improvements (aeration, vibrators, air cannons, internal liners) and process adjustments (humidity control, fill temperature, material residence time). We can quote options matched to your vessel, material and budget.
Q: What if there is a fire, smolder, or emergency inside the silo?
A: Our crews are trained to recognize and respond to smoldering or fire conditions. Depending on severity, specialized firefighting or inerting methods may be required. We coordinate closely with plant safety and emergency responders in such cases.
We recommend flow-aid improvements (aeration, vibrators, air cannons, internal liners) and process adjustments (humidity control, fill temperature, material residence time). We can quote options matched to your vessel, material and budget. Close
Q: Who do I contact to start service?
Contact AIRMATIC at 215-333-5600, submit a quote request online, or email infocenter@airmatic.com with a completed Application Data Sheet.
Kevin McGonigal is an Account Manager at AIRMATIC and has 12 years of experience in bulk materials handling equipment sales, installation and maintenance services.
Thanks for reading our post. If you'd like to learn more about Silo Cleaning Services or other AIRMATIC Installation and Maintenance Services, please contact one of our experts at +215-333-5600 or at infocenter@airmatic.com.
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