Industrial Air Blasters / Air Cannons for Silo, Hopper & Chute Blockages
Air blaster (Air Cannon) of high performance for material flow are provided by us at Ubon India . Whether the industry is that of cement, steel, sugar, coal mining, sponge iron, power plant and many more. it does not matter. Our air cannon system prevents blockage and build-up in essential equipment like silos, hoppers, chutes, and kilns, making the material flow smooth and undisturbed.
As a trusted industrial air blaster manufacturer in India, Ubon India provides reliable, advanced solutions to keep your operations running at peak performance.
What Is an Industrial Air Blaster?
Air blaster use 100+ PSI bursts of air to remove obstructions in silos, hoppers, or chutes to provide free flow for cement, coal, and bulk materials. Portable, non-invasive, and chemical-free, they replace hazardous manual clearing.
IoT sensors and AI-enabled models provide new models with automated capabilities, while explosion-proof or corrosion-resistant models provide harsh environment applications. Green and sustainable, they recycle air and eschew chemical cleaners, minimizing waste.
Innovations like low-pressure models accommodate sensitive products, and energy-recovery systems maximize sustainability. With force coupled with finesse, air blaster minimize downtime, maximize safety, and redefine industrial productivity—proving air is the ultimate tool.
Why Air Blaster Are Needed for Your Business
Material handling equipment loses efficiency the moment flow stops. A blocked hopper or a bridged silo doesn't just pause one machine — it backs up everything upstream of it, and every hour spent manually clearing a chute is an hour your plant isn't producing.
- Uninterrupted Output: A blast fires in milliseconds and clears buildup before it can slow the line, so production schedules stay intact instead of being planned around clogging.
- Fewer Manual Interventions: Workers no longer need to enter confined spaces or use rods and hammers to break up compacted material — the air blaster does it remotely and repeatedly.
- Lower Cost Per Ton: Less downtime and less manual labor translate directly into a lower cost of handling the same volume of material.
- Longer Equipment Life: Because the clearing action is a burst of air rather than physical scraping or impact, silo walls, chute linings, and conveyor components see far less wear over time.
- Predictable Maintenance: A properly sized and positioned air blaster system turns an unpredictable blockage problem into a scheduled, low-effort maintenance task.
Schematic Diagram of Air Blaster Installation In Cement Pre-Heater
How Air Blaster Work
An air blaster works in three stages. First, compressed air builds up inside a sealed pressure tank, typically at 4–8 bar depending on the model. Second, a quick-release valve — triggered manually, on a timer, or by a sensor — opens in milliseconds. Third, that stored energy discharges through a nozzle aimed directly at the blockage, breaking it apart on impact.
The tank size and discharge diameter determine how much force is delivered: a PS-2 model with a 50mm discharge suits smaller chutes and feed pipes, while a PS-6 with a 150mm discharge is built for large cyclones and coolers (see the full spec table below).
Most installations run on a pneumatic control panel with a sequential timer, firing multiple blasters in a set order so the whole vessel clears without manual oversight. For plants handling volatile or temperature-sensitive material, we also build explosion-proof and low-pressure variants.
Common Flow Problems in Plants
Material flow problems in bulk material handling systems are common in plants, causing considerable production delays. Some of the common flow problems are as follows:
Arching:
Arching occurs when material builds up and forms a bridge-like structure across the flow path, blocking the movement of material. This creates a complete blockage, halting the flow entirely. Air cannon can break the arch and restore the flow by releasing powerful bursts of air to dislodge the material.
Bridging:
this occurs when material bridges over equipment, thus preventing it from falling freely and also restricting the downward flow. This blockage will cause delays in production because of the restriction of material movement. Blasters can easily dislodge the bridge, clearing the obstruction and allowing the material to flow properly
Funneling:
it is a situation where material flows mainly from the center of the chute or hopper, leaving the material on the sides to stagnate. This type of uneven flow will not be efficient and prevent the equipment from emptying. Strategically placed blasters will ensure even distribution of material flow for smooth operation and maximum utilization.
Rat-holing:
A narrow channel forms in the center of the bulk material leaving the surrounding material untouched. The result is an incomplete material discharge and uneven flow, which are inefficient for the system. Cannons break up the rat hole and encourage a consistent flow of material.
These common flow problems can greatly hinder productivity and efficiency. Using industrial air cannon helps to address such problems and ensure that material continues to flow uninterrupted, reliably maintaining continuous operations in industries such as cement plants, sugar mills, and coal mines.
How Industrial Air Blaster Address the Problems
Strategically placed industrial air cannons for silos, hoppers, and chutes resolve the material flow problem, dislodge trapped material, and allow for continuous flow. See our installation and maintenance services for how we size and position these systems on-site.
The Key Benefits of Air Blaster
- Increased Productivity: Ensure continuous material flow for higher throughput.
- Cost Savings: Avoid costly downtime and maintenance, with ensured efficient work through your equipment.
- Safe Working Environment: Avoid the inconvenience and risk of manual handling to clear blockages.
- Energy Efficient: Consume less fuel while optimizing energy use for airflow.
- Durability: Durable in all industrial operations; our systems are reliable and durable.
Trusted by Plants Across India
Real results from plants that solved their material flow problems with Ubon India air blasters.
“Frequent silo blockages were costing us production hours every week. Since installing Ubon India's PS-4 series air blasters, our downtime from material buildup has dropped significantly and the team no longer has to manually clear chutes.”
“We needed a system that could handle high-temperature zones near our preheater without frequent maintenance. Ubon India's team recommended the right model and handled the full installation.”
Common Material Flow Problems We Solve
The scenarios below are based on typical plant conditions, not specific client case studies — they show how air blasters are applied to common material flow problems.
Hopper Blockage Solution for a Cement Silo
- Industry: Cement
- Problem: Fine cement powder repeatedly bridged just above the silo outlet, stopping discharge and requiring manual rodding to restart flow.
- Typical Solution: PS-4 series air blasters installed at the bridging zone, fired on a sequential timer to clear buildup before it fully blocks the outlet.
- Typical Outcome: Continuous discharge without manual intervention, and no need to open the silo to break up material by hand.
Fixing Hopper Flow Problems in a Coal Bunker
- Industry: Coal / Power Generation
- Problem: Wet, compacted coal formed a rat-hole through the center of the bunker, leaving material stuck along the walls even though the bunker appeared full.
- Typical Solution: Air blasters positioned along the bunker walls at multiple heights to break up wall-adhered material and restore full-volume flow.
- Typical Outcome: Full bunker capacity becomes usable again instead of only the material in the center channel.
When Material Is Not Flowing From a Hopper
- Industry: Sugar Mill
- Problem: Sugar stopped flowing from a storage hopper entirely during humid conditions, with an arch of compacted material forming above the outlet.
- Typical Solution: A correctly sized air blaster fired directly at the arching point, breaking the compacted arch on impact.
- Typical Outcome: Flow restarts without needing to manually break the blockage or stop the line for extended periods.
Air Cannon for Material Build-Up in a Steel Plant
- Industry: Steel / Sponge Iron
- Problem: Ore fines gradually built up on the interior walls of a storage bay, narrowing the effective discharge opening over time.
- Typical Solution: An air cannon for material build-up mounted at the point of accumulation, firing on a set schedule to prevent buildup from accumulating in the first place.
- Typical Outcome: Discharge opening stays clear, avoiding the gradual narrowing that would otherwise require manual cleaning shutdowns.
Clearing Material Build-Up in a Chute
- Industry: Petrochemicals
- Problem: Fine powder stuck to the walls of a transfer chute due to low flow velocity, gradually restricting the passage until flow slowed significantly.
- Typical Solution: Air blasters mounted along the chute wall, angled to clear buildup before it narrows the passage.
- Typical Outcome: Chute maintains its full cross-section for consistent material transfer.
General Material Flow Problems in a Preheater Tower
- Industry: Cement (Clinker Processing)
- Problem: Sticky, high-temperature material accumulated inside preheater cyclones, a common source of material flow problems in clinker lines.
- Typical Solution: Heat-resistant air blasters positioned at known accumulation points within the preheater, integrated with the plant's existing control panel.
- Typical Outcome: Preheater cyclones stay clear without requiring the line to be shut down for manual cleaning.
Applications of Industrial Air Blaster in Different Industries
Because bulk materials behave differently depending on moisture content, particle size, and temperature, the right air blaster setup varies by industry — but the underlying problem is the same everywhere: material that won't move on its own.
- Cement & Clinker Processing: Fine, sticky material tends to pack into preheaters and silo walls; our cement plant solutions are sized for these high-temperature zones.
- Coal & Mining Operations: Wet or compacted coal is prone to rat-holing in storage bins; see how we handle this in our coal mine applications.
- Steel & Sponge Iron Plants: Ore fines and sponge iron dust bridge easily in large storage bays — covered in our steel plant and sponge iron pages.
- Sugar Mills: Compacted sugar buildup in conveyors and hoppers is a seasonal challenge — details on our sugar mill page.
- Power Generation: Feeders and boiler zones need consistent fuel flow to avoid output dips — see our power plant setups.
- Petrochemicals: Bulk powders and granules with specific handling constraints are addressed in our petrochemical solutions.
Not sure which setup fits your material and equipment layout? Talk to our team — we'll recommend the model and placement based on your specific plant.
Solution to Fit Your Plant
We, at Ubon India, provide solutions according to your specific requirements at the plant. Our systems are easy to install, have minimum maintenance, and ensure maximum performance. We also provide professional installation services and periodic maintenance with troubleshooting so that the blasters perform their functions effectively.
Material Flow Problems & Air Blaster FAQs
Common questions we get from plant engineers looking for a hopper blockage solution, sizing guidance, or an explanation of how an air blaster actually works.
What causes material flow problems in silos and hoppers?
Material flow problems — arching, bridging, funneling, and rat-holing — happen when bulk material like cement, coal, or sugar compacts due to moisture, particle size, or pressure inside a vessel. Once this buildup forms, gravity alone isn't enough to move it, and the vessel effectively stops discharging.
What is the working principle of an air blaster?
An air blaster's working principle has three stages: compressed air builds up inside a sealed pressure tank (typically 4–8 bar), a quick-release valve opens in milliseconds, and the stored energy discharges through a nozzle aimed directly at the blockage — breaking it apart on impact.
What is a reliable hopper blockage solution?
For most plants, a correctly sized and positioned air blaster is the most reliable hopper blockage solution — it clears buildup remotely and repeatedly without workers entering confined spaces or using rods and hammers to break compacted material by hand.
What size air blaster do I need?
It depends on your discharge opening and vessel size. As a general guide: 50mm discharge (PS-2 series) suits chutes and feed pipes, 100mm (PS-4 series) suits larger chutes and cyclones, and 150mm (PS-6 series) suits large cyclones, hoppers, and coolers. Contact us with your vessel dimensions for an exact recommendation.
How much air pressure does an air blaster need?
Most models operate effectively between 4–8 bar (roughly 60–115 PSI), supplied by a compressor and stabilized through an air receiver.
Can air blasters be used in explosive or high-temperature environments?
Yes — we manufacture explosion-proof and heat-resistant variants for kilns, preheaters, and other high-temperature or combustible-material zones.
Technical Specifications Of Various Models
| Model | Discharge | Tank Cap (Liters) | Application |
|---|---|---|---|
| PS-2-09 | 50mm | 09 | Chutes, Feed Pipes, Section |
| PS-2-12 | 50mm | 12 | Chutes, Feed Pipes, Section |
| PS-2-20 | 50mm | 20 | Chutes, Feed Pipes, Section |
| PS-2-30 | 50mm | 30 | Chutes, Feed Pipes, Section |
| PS-4-50 | 100mm | 50 | Chutes, Feed Pipes |
| PS-4-70 | 100mm | 70 | Chutes, Feed Pipes |
| PS-4-100 | 100mm | 100 | Chutes, Feed Pipes, Cyclone |
| PS-4-110 | 100mm | 110 | Chutes, Feed Pipes, Cyclone, Riser Duct |
| PS-4-150 | 100mm | 150 | Pre-cyclone, Riser Duct, Cooler, Hopper |
| PS-6-100 | 150mm | 100 | Cyclone, Hoppers, Cooler |
| PS-6-150 | 150mm | 150 | Cyclone, Hoppers, Cooler |
| PS-6-200 | 150mm | 200 | Same as above |
| PS-6-250 | 150mm | 250 | Same as above |
| PS-6-300 | 150mm | 300 | Same as above |
Why choose Ubon India for Reliable Solutions?
- Expertise: Years of experience mean we can offer top-notch solutions to material flow challenges.
- Customization: We tailor the air blaster system according to your plant's specific needs.
- Technology: Our air cannon come with cutting-edge technology for maximum efficiency and durability.
- Complete Support: Our full-service solution includes installation, maintenance, and optimization.
- Global Presence: Serving clients worldwide, Ubon India is your partner for efficient material handling.