Why Powders Don’t Flow: Practical Troubleshooting for Powder & Bulk Solids Handling Systems
March 24th, 2026
2:00 PM ET / 1:00 PM CT / 11:00 AM PT / 7:00 PM GMT
Duration: 1 hour
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Summary
When powders and bulk solids stop flowing the way they should, production stops with them. Issues such as arching, ratholing, erratic discharge, segregation, flooding, and buildup can quickly disrupt throughput, create quality problems, and increase operating costs across food, chemical, pharmaceutical, and other processing industries.
In this one-hour expert panel discussion, sponsored by Hapman and Carrier Process Equipment Group, leading bulk solids specialists will share practical strategies for diagnosing and solving the most common material flow problems in bins, hoppers, feeders, and conveying systems.
Rather than theory alone, the panel will focus on real-world troubleshooting approaches used in operating plants — how to quickly identify root causes, what warning signs to look for, and which design or operational changes can restore reliable flow. Panelists will also discuss how factors such as particle size distribution, moisture, equipment design, and process conditions interact to create unexpected handling challenges.
Attendees will gain actionable insights into:
- Identifying the root causes of arching, ratholing, and inconsistent discharge
- Troubleshooting flow problems in mechanical, pneumatic, and vibratory conveying systems
- Preventing segregation, flooding, and material buildup before they disrupt production
- Determining when operational adjustments can solve the problem, and when equipment changes may be required
- Best practices for designing and operating powder handling systems for consistent, reliable flow
Whether you are responsible for plant performance, process design, or day-to-day operations, this interactive panel will provide practical guidance to help you reduce downtime, improve reliability, and keep your powders moving.
Who Should Attend:
- Plant managers and operations leaders
- Process and project engineers
- Maintenance and reliability managers
- Production supervisors and technical specialists
- Professionals working with powders and bulk solids in food, chemical, pharmaceutical, plastics, and related industries
Participants will also have the opportunity to submit their own flow challenges for discussion during the live Q&A.
Speakers
Jeff Flees
Director of Engineering
Hapman
Jeff Flees has more than 10 years of experience in bulk material handling and mechanical conveying systems at Hapman. His work focuses on the specification, installation, and commissioning of conveying equipment used in food, chemical, and industrial manufacturing. Flees supports system integration, factory and site acceptance testing, and the development of engineering standards and operational documentation that help ensure reliable material handling performance in process facilities.
Dr. Kerry Johanson
Chief Operations Officer
Material Flow Solutions Inc.
Dr. Kerry Johanson is Chief Operations Officer at Material Flow Solutions Inc., the consulting firm he founded in 2001, and a researcher at the University of Florida Particle Engineering Research Center. He began his career in powder flow and material handling as a summer lab technician with Jenike & Johanson in Billerica, Massachusetts during his high school and undergraduate years. After receiving his BS in 1985, he spent 14 years with JR Johanson, Inc. in San Luis Obispo California, finally serving as their Chief Technical Officer. He received his Ph.D. in chemical engineering from Brigham Young University in 1994. He has published 50+ technical papers, has developed a course for teaching powder flow and technology to graduate students, and has mentored five doctoral graduates at the University of Florida. Johanson has presented numerous industry seminars on the topic of powder flow in industrial applications. He holds PE licenses in both Florida and Utah and is an active member of AAPS, ACC&CE, AIChE, ASME, and ASTM.
Moderator
Nate Todd
Senior Editor
Processing Magazine
Nate Todd, senior editor, has been covering powder & bulk solids handling and processing for 12 years. Prior to joining Processing, he was the chief editor of Powder & Bulk Engineering and Tablets & Capsules. He lives near Minneapolis, MN.
