Process engineering for heavy manufacturing. We audit powder flow metrics, perform physical testing of aggregate-filled industrial resins, and inspect structural integrity of bulk storage silos.
Hausner ratio, Carr index, hopper discharge analysis
Izod/Charpy impact, flexural modulus, filler dispersion
Ultrasonic thickness, magnetic flux, drone visual surveys
Pre-configured audit and testing bundles for process engineers
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Our approach to industrial material compounding and silo inspection is built on measurable precision, not generic consulting.
We measure aerated and tapped density per ASTM D6393, calculating Hausner ratio and Carr index to predict hopper discharge behavior. Our field data comes from actual compounding trials, not lab simulations.
Our physical testing protocols cover Izod and Charpy impact, flexural modulus per ASTM D790, and filler dispersion analysis. We prepare samples with up to 60% mineral filler content and document failure modes.
We use ultrasonic thickness measurement, magnetic flux leakage, and drone-based visual inspection to detect corrosion thinning, weld cracks, and foundation settlement. Reports include repair priority rankings.
Our inspection team has completed over 200 silo audits across polymer compounding plants in the industrial sector. We do not sell equipment or software — only independent engineering assessments with documented procedures and traceable data.
Measurable improvements in material flow, composite strength, and storage reliability — backed by field data.
Our powder flow audits identify bridging and rat-holing risks before they stop production. After a single audit, one compounding line reduced unplanned downtime by 40%.
Physical testing per ASTM D790 and D256 gives you real flexural and impact data for aggregate-filled formulations. We helped a client raise flexural modulus by 18% through filler size optimization.
Non‑destructive inspections catch corrosion thinning and weld cracks early. A recent drone‑based scan at a polymer plant flagged a 2.1 mm wall loss that would have led to a collapse within six months.
Aerated density is measured when the powder is in a loose, settled state, while tapped density is measured after mechanically tapping the container to compact the material. The ratio between these values, known as the Hausner ratio, helps predict flowability during hopper discharge. A higher ratio indicates poorer flow and potential bridging or rat-holing in silos.
For impact strength, we follow ASTM D256 (Izod) and ASTM D6110 (Charpy). Flexural modulus and strength are tested per ASTM D790. Sample preparation for high-filler-content composites requires careful control of particle size distribution and moisture content to ensure repeatable results.
We recommend a baseline inspection upon installation, followed by annual ultrasonic thickness measurements for steel silos and biennial assessments for concrete structures. High-corrosion environments or silos handling abrasive materials may require quarterly checks. Drone-based visual inspections can be performed more frequently to detect surface defects early.
Common methods include ultrasonic thickness measurement for wall thinning, magnetic flux leakage for detecting cracks in steel, and advanced visual inspections using drones with high-resolution cameras. Each method has specific advantages depending on silo material, access constraints, and the type of defect being targeted.
Finer particles generally improve tensile and flexural strength by providing better packing and stress transfer, but they can increase viscosity and reduce impact resistance. Coarser aggregates may enhance impact toughness but can lead to poor dispersion and void formation. Optimal distribution depends on the specific application and processing conditions.
Erratic flow rates, arching or bridging at the hopper outlet, and rat-holing where material flows only through a central channel are typical indicators. These issues often correlate with high Hausner ratios, moisture content above 2%, or improper hopper angle design. Vibration analysis and flow factor testing can help diagnose the root cause.