Dilute phase vs. dense phase pneumatic conveying: How to select the right system for your material and avoid costly design mistakes

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Summary

Selecting the wrong pneumatic conveying mode can lead to excessive product degradation, line plugging, high energy consumption, and costly production disruptions. Yet many facilities still struggle with one of the most fundamental design decisions: Should this material be conveyed in dilute phase or dense phase?

In this practical, engineering-focused webinar, Jack Hilbert, principal consultant at Pneumatic Conveying Consultants, will explain the key differences between dilute phase, dense phase, and intermediate conveying modes, and how material properties ultimately determine which approach works best.

The session will walk through the critical factors that influence conveying behavior, including particle size and shape, density, abrasiveness, fragility, and flow characteristics. Attendees will also learn how system geometry, conveying distance, and solids throughput affect overall system selection.

Special attention will be given to multi-ingredient and recipe-based processes, where multiple materials with very different properties must move through the same conveying system. These situations often create hidden challenges that can significantly impact reliability and product quality.

Participants will leave with a clearer understanding of how gas–solid dynamics influence conveying performance, along with practical insights into the advantages, limitations, and real-world tradeoffs of each conveying mode.

This webinar is designed for engineers, plant managers, technical leaders, and operations professionals working with powders and bulk solids in the food, chemical, pharmaceutical, plastics, and related processing industries.

Attendees will learn:

• The fundamental differences between dilute phase, dense phase, and intermediate conveying

• How material properties determine the most suitable conveying mode

• The advantages and limitations of each conveying approach

• Why multi-ingredient conveying systems require special consideration

• Practical guidance for avoiding common pneumatic conveying design mistakes

Bring your pneumatic conveying challenges

During a live Q&A session following the presentation, Jack will answer attendee questions and discuss real-world conveying problems submitted by the audience.