What Is Pneumatic Conveying? A Complete Guide to the Basics

Pneumatic conveying is one of the most efficient, sanitary, and versatile ways to move dry bulk materials through a manufacturing or processing plant. Using air or another gas to carry powders, pellets, or granules through pipelines, pneumatic systems make it possible to transport materials safely, cleanly, and reliably with minimal risk of contamination or product damage, or pipe wear.

At Dynamic Air, we’ve spent decades perfecting this process. With over 15,000 systems installed in more than 75 countries, our custom-engineered pneumatic conveying solutions are built to perform, from food and pharmaceuticals to cement and chemicals.

This guide walks through the essentials of pneumatic conveying, from how it works to how Dynamic Air helps companies design, optimize, and maintain the most energy-efficient systems in the industry.

How Pneumatic Conveying Works

At its core, pneumatic conveying uses compressed gas to move bulk materials through a closed pipeline. 

The system is made up of several key components:

1. Compressed Gas Source – Compressed air or other inert gas provides the power source (through pressure or vacuum) needed to push or pull materials through the conveying pipe.

2. Feed Point – Material enters the system through a feeder, rotary valve, or pressure vessel.

3. Pipeline – Material flows through piping designed for optimal velocity and minimal wear.

4. Receiver / Separator – Material is collected at the end of the system, while the conveying gas is vented to the atmosphere.

 

The process can be configured in two main ways:

• Positive Pressure (Pushing): The conveying gas pushes material from one point to another—ideal for longer distances or higher throughputs.

• Negative Pressure (Vacuum): A vacuum pulls material through the line—ideal for short distances and multiple pick-up points.

 

The Two Main Types of Pneumatic Conveying Systems

Dilute Phase Conveying

In a dilute phase system, materials are suspended in a fast-moving air or other inert gas stream. This method works best for light, non-abrasive, and non-fragile materials like clay, flour, or plastic pellets.

• Conveying Gas Velocity: 5,000–9,000 ft/min

• Advantages: Lower equipment cost and flexible routing

• Best For: Non-fragile materials and shorter distances

Dense Phase Conveying

Dense phase conveying moves materials at a slower velocity in a more compact “slug” or “plug” flow. It’s ideal for fragile, abrasive, heavy bulk solids, and for moisture-sensitive materials like cement, catalysts, or powdered chemicals.

• Air Velocity: 400–2,000 ft/min

• Advantages: Minimal product degradation, reduced pipeline wear, controlled process environment, and lower energy use

• Best For: Long distances, high transfer rates, abrasive, fragile or moisture-sensitive products

 

Designing the Most Energy-Efficient Pneumatic Conveying System

Energy efficiency isn’t achieved by chance, it’s engineered into every system. Dynamic Air’s designs reduce wasted air movement, friction, and product damage through precision control and testing.

What Makes a System Energy-Efficient?

1. Optimized Air Velocity: The right speed keeps material moving without excessive pressure loss. Which gets better gas mileage, an Indy race car or a compact car?  And which gets more miles on a set of tires? Better efficiency leads to lower equipment wear.

2. Accurate Line Sizing: Proper pipe diameter determines the proper velocity at a given rate.  

3. Low-Leak Components: Our carefully engineered system components (valves, couplings, and diverters) minimize energy loss by eliminating leaks.

4. Demand-driven Convey Gas Delivery: Our pneumatic convey systems adjust the amount of compressed gas necessary to do the required job. For example, a system designed for 20 T/h will use half the compressed gas when operating at 10 T/h. Our systems will automatically adjust the compressed gas use to the rate.

Dense phase conveying systems are inherently more energy-efficient than dilute phase because they use lower velocities and require less air volume. In fact, Dynamic Air’s patented technologies can cut energy consumption by up to 50% compared to traditional systems.

 

Custom Pneumatic Conveying System Design & Lead Times

Every material behaves differently. That’s why Dynamic Air doesn’t believe in “one-size-fits-all.” 

Each conveying system is designed based on your specific product (material conveyed), process, flow rates, distance, and plant layout.   

At Dynamic Air, we have a creed that our application engineers abide by: 

First, understand the material to be conveyed AND the customer’s process, and only THEN, develop a solution. If we do not understand your material and process, how can we suggest the best solution for your material and process?

 

Our Dynamic Air Process

1. Material Testing: Your product is tested in our full-scale lab to determine ideal conveying characteristics.

2. System Modeling: Advanced simulation software ensure an accurate design.

3. Custom Fabrication: Components are precision-built to specification.

4. Installation & Commissioning: Our engineers oversee setup to ensure peak performance.

 

Typical Lead Times

Standard Dilute Phase

Design time: 2-3 weeks 

Fabrication: 6-8 weeks

Total estimate: 8-10 weeks

Custom Dense Phase

Design time: 4-6 weeks

Fabrication: 10-14 weeks

Total estimate: 14-20 weeks

Full Turnkey System

Design time: 6-8 weeks 

Fabrication: 12-16 weeks

Total estimate: 18-24 weeks

 

Need a fast turnaround? Dynamic Air can accelerate timelines depending on project scope and material availability.

 

Troubleshooting & System Support

Even the most reliable pneumatic conveying systems can experience issues over time. That’s why Dynamic Air provides full lifecycle support, including system audits, retrofits, and performance optimization.

We have not bought into the throwaway culture that is prevalent today. We understand removal and reinstallation is not only expensive, but it’s horribly inconvenient. Because of this, our equipment is built to last decades, not just 5 years.  

And because we still have systems in operation with 50+ years in service, we offer unlimited spare parts support. If you need to repair 50 year old equipment, we are here to support you!

 

Common Pneumatic Conveying Issues

Even the best-engineered systems can encounter performance challenges over time. 

Here are a few of the most common pneumatic conveying issues and what typically causes them:

• Reduced product transfer rate. There are 3 common causes of this:
  • a) the material changed (particle size, moisture, bulk density)  
  • b) the system adjustment is not optimized.  
  • c) The compressed gas system is not providing clean, dry, compressed gas a the correct pressure

 

• Material build-up is the condition where product builds up on the internal equipment surfaces. This is most commonly seen after a material dryer.  The situation is caused by the saturated air between the material particles condensing on the colder equipment surfaces below the dryer.  The solution is to ensure this saturated air between the particles is removed before discharging to downstream equipment, and this is most commonly achieved with a material cooling process downstream the dryer that purges this saturated air from the material.

 

• Excessive wear usually happens when conveying abrasive materials at high velocity. Switching to a dense phase system can significantly reduce wear and extend equipment life. If you are experiencing high wear with a dense phase system, the system is likely out of adjustment or transferring at a rate much higher than the design rate.

 

• Pressure drops are another common issue, often caused by the addition of non-OEM couplings, bends, diverters, and valves.  

 

Support Services

• On-site diagnostics and repair

• Remote system monitoring

• Preventative maintenance programs

• Spare parts and component upgrades

• Retrofit and performance enhancement

With responsive service and decades of experience, our team helps clients minimize downtime and extend the lifespan of their systems.

 

Why Choose Dynamic Air

Dynamic Air isn’t just a supplier, we’re a full partner in your bulk material handling process.

• 16 different conveying concepts to match your application

• Custom-engineered solutions for every industry

• Global installation and support network

• Proven energy efficiency and process reliability
  

 

Pneumatic Conveying: Key Takeaways

• Pneumatic conveying uses compressed gas such as air or nitrogen to move bulk solids efficiently and cleanly through pipelines.
• The right system type—dilute or dense—depends on your material and process goals.
• Energy-efficient conveying reduces operating costs, wear on equipment, or product degradation.
• Dynamic Air’s custom-engineered systems and full lifecycle support ensure long-term performance and reliability.
• You buy and install a conveyor system once, and you operate it for years. The initial cost is dwarfed by operation cost. As such, the focus needs to be the procurement of a long-lasting efficient system

 

Explore More Dynamic Air Resources

• Resources Overview

 

Ready to design your pneumatic conveying system?

Contact Dynamic Air to start your custom project or schedule material testing at our full-scale facility.