Powder fluidization is vital to a successful coating operation. It allows for better transfer and application to the part, resulting in a more even coat.
However, many job shops need help with fluidizer issues that can take time to overcome. Here are a few tips to help you use your fluidizer more effectively:
Keep it Clean
A fluidizer uses a series of rubber discs to promote flow in hoppers and silos. They can be installed inside or outside of the vessel. They work for most dry bulk materials that respond to gentle aeration and vibration. They help prevent rat holing, bridging, and compacting. They often promote discharge from silos, storage bins, and transport containers like dry bulk trailers.
The problem is that they need to be more effective with hygroscopic powders, very dense or moist material, or some unique compound mixes with high fat and moisture levels. They also use a lot of energy and have a limited activation radius.
The best way to get the most from your fluidizer is to inspect and clean it regularly. A fluidizer that is dirty can cause all sorts of issues. Keeping it clean can save time and money. It can also help you avoid powder contamination. Typically, job shops will use separate fluidizers for different chemistries to keep the powders from cross-contaminating.
Keep it Moving
Fluidizers are one of the most common flow aids and are inexpensive, easy to install, and often come pre-installed in vessels. They promote material flow with gentle aeration and vibration, using rubber discs installed inside the hopper that flap and vibrate when air passes over them.
Fluidized beds work well for dry bulk materials that respond to gentle aeration and have a low moisture content, but not for hygroscopic powders that attract moisture or stringy, sticky, or wet powders. They also have less power and a smaller activation radius than other pneumatic flow aids, so more must be installed to achieve adequate coverage.
Even when properly maintained, fluidizers aren’t as effective as they once were due to the nature of the powders they activate. When powder build thickens, it causes problems like orange peel, sagging, and discoloration.
Keep it Cleaner
A fluidizer is a pneumatic flow aid that combines gentle aeration and vibration to keep powder suspended in the hopper. They are inexpensive, easy to find, and often pre-installed in hopper vessels. However, they have a small activation radius, require multiple units to function, and consume much energy.
If the rubber discs trap too much powder, it can cause rat holes that restrict airflow and create a barrier between the part and the coated surface. Also, if the membrane is dirty or oily, it can affect how powder atomizes.
We suggest checking your fluidizer daily and keeping powder levels close to what the manufacturer recommends. By following these tips and doing regular preventative maintenance, your fluidizer can serve you well for a long time. This is especially true if you choose a powerful and effective superplasticizer like Alpha ProTM to reduce water usage.
Keep it Moving
Keeping powder on the surface of the fluidizer is vital for great coverage. A good air supply that is not clogged, damaged, or dirty is also crucial. Bad air will muck up your application and powder coverage, but the fluidizing plates are plastic.
Traditionally, fluidizers prevent ratholing and bridging in storage silos or hoppers or promote discharge from transport containers like dry bulk trailers. They are inexpensive and easy to install, often coming pre-fitted in vessels. Fluidizers have less power and a smaller activation radius than AirSweep and require frequent replacement of rubber fluidizing discs.
The best solution for reducing the need to add water to your concrete countertop mix is to use a high-quality polycarboxylate superplasticizer. The Alpha Pro TM is one of the best, making your definite more fluid without adding water. It is a fine, off-white powder with some black specs that don’t affect the finish.
