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Material flow problems happen when materials adhere to the wall of a bin or hopper, slowing down production. Industrial vibrators are a standard solution to this issue across manufacturing industries, from concrete, oil and gas production to metal refining and food and beverage processing. Industrial vibrators prevent buildup and blockages in industrial equipment by breaking the cohesion between the material and the wall.

If your plant works with dry or wet bulk materials, implementing a material flow solution like an industrial vibrator can improve production by speeding up material flow in the bin. The various vibrator types, models and sizes can make it challenging to find the right one for your application. This guide to electric vs. pneumatic vibrators explains all you need to know to find the best industrial vibrator for your company.

Electric Vibrators

Electric vibrators, not to be confused with electric hammers, are rotary-type vibrators that use the centrifugal force created by a mass rotating around a central point to dislodge the materials adhered to a bin. Rotary electric vibrators require a solid mount to ensure high force and frequency, promoting efficiency. These vibrators operate on electric power and are ideal for general material flow or specialized for separators, vibration tables, fluidized beds or compactors. 

Electric vibrators provide several benefits to a broad range of industrial applications:

• Low-cost operation 
• A long operating life 
• Low noise output 

 

Varieties 

Electric vibrators come in various formats, sizes and output ratings to optimize material flow across diverse operating environments. Rotary electric vibrator types include the following designs. 

• Heavy-duty rotary electric vibrators: Heavy-duty electric vibrators operate at various frequencies and are durable, enabling continuous operation at total output. Deca Vibrator Industries, Inc. has over 240 models of Series FV heavy-duty rotary vibrators with diverse designs to power you through every application. 
• Micro rotary electric vibrators: Small electric vibrators can be helpful in smaller bins, pipes and chutes. The Series MICRO rotary electric vibrator from Deca Vibrator Industries, Inc. comes in 12 variations to fit your frequency and force needs. 
• Truck vibrators: Mobile or remote operations also need material flow solutions. Clumping or compacting in truck-based bins requires a truck-mounted solution. The Series DC Truck Vibrator is excellent for intermittent use in dump-truck beds, railcars and truck-mounted spreaders. 

Noise Levels

Electric vibrators generally produce lower noise levels. The Occupational Safety and Health Organization (OSHA) requires companies to provide a hearing conservation program for workplaces with 85 decibels averaged or above noise exposure for eight hours. This rule aims to preserve employees’ hearing and inform them about hearing protection devices.

Though electric vibrators are quieter than other types of industrial vibrators, mounting them to equipment typically increases the noise level, mainly while they’re moving materials. Thus, monitoring noise levels is still best to ensure a workplace stays compliant with OSHA noise limits.

Applications 

Electric vibrators are best for applications where materials bridge or rathole within the chute. Manufacturing and industrial applications for electric vibrators include the following.

• Food processing and concrete manufacturing: In plants that deal with fine powders, bulk material handling can lead to clumping and bin-coating. Food processing facilities can benefit from high-frequency electric vibrators, ranging in frequency from 3,000 to 9,000 RPM, to keep small particles moving through the processing system.
• Pharmaceutical laboratories: While all electric vibrators emit low noise, micro-sized vibrators provide the best noise reduction. These small vibrators produce a variety of output forces and are well-suited to pharmaceutical laboratories and other sound-sensitive environments, like packaging lines.
• Mining and quarry operations: Other applications demand high-force output to handle dense materials. High-force rotary electric vibrators can reach outputs of up to 14,000 pounds. 
• Transportation and mobile bulk materials handling: Whether the application is a railcar or concrete mixer, truck vibrators can efficiently empty a load of bulk materials. The Series FVDC Truck Vibrator is watertight and built to withstand rugged applications in punishing outdoor environments. 
• Petroleum refining: The Series Explosion-Proof Electric Vibrators comply with Class I and Class II environment performance requirements and are ideal for use in areas where flammable chemicals or dust create potentially harmful circumstances. 

Whatever your application, rotary electric vibrators can help you speed up productivity and improve workflow. 

Practical Maintenance

Electric-powered vibrators require less maintenance compared to pneumatic options because they have fewer moving parts. To ensure their longevity and reliable performance, the following are basic routine maintenance checks to perform:

• Proper mounting: Always review the manufacturer’s guidelines to ensure the vibrator is mounted correctly. Poorly mounted vibrators can draw excessive amperage that can damage the motor if it lacks sufficient overload protection.
• Electrical connector checks: Regularly inspect electrical connectors for signs of wear or corrosion. Replace loose or damaged electrical connectors to avoid malfunctions. 
• Wiring inspection: Check the wiring for abrasions, cuts and exposed sections. Damaged wires should be repaired or replaced immediately to prevent electrical malfunctions and safety hazards. 
• Noise inspection: While the vibrator operates, listen closely to unusual noises, such as grinding or knocking. If you hear these noises, switch off the vibrator and apply the lockout/tagout safety procedure. Then, visually check the vibrator on the mount for any issues. If you need more help, call your supplier for professional troubleshooting and repairs. 

 

Energy Efficiency

An electric vibrator is generally more energy-efficient and cost-effective than an air-powered vibrator. Electric vibrators efficiently convert significant electrical energy into vibrations. This generates lower energy consumption and reduced power costs compared to vibrators that require air supplies for power. 

An electric vibrator also provides precise control over adjusting vibration intensity. Better control leads to more consistent and smooth operations in industries such as material handling and bulk processing.

However, because electric vibrators use electricity, they have a few limitations. Since they require a stable electrical power source, operating in locations where electricity is unreliable and impractical can be challenging. Though they are versatile, some electric-powered vibrators are not as powerful as heavy-duty hydraulic vibrators, making them less suitable for higher-impact applications. These factors make the electric vibrator vs pneumatic vibrator decision particularly important for operations with specific power availability or environmental constraints.

Pneumatic Vibrators

In applications where electric vibrators are impractical or would wear prematurely due to short on-off cycles, pneumatic vibrators are an excellent option. While some pneumatic vibrators use rotary movement, others use linear vibration, forcing a piston back and forth along an axis to deliver forces. Also called air vibrators, these devices rely on compressed air, typically from a compressor that’s accessible at many manufacturing plants, to dislodge materials from a bin or shoot. Pneumatic vibrators offer these benefits: 

• Low noise 
• Low maintenance costs 
• Air-powered efficiency

Varieties 

Pneumatic vibrators come in rotary ball, roller, piston and turbine varieties to improve material flow in applications where compressed air is readily available.

• Rotary air ball vibrators: Applications that require intermittent operation and low maintenance can benefit from the compact, rugged design and extreme efficiency of pneumatic ball vibrators that use a steel ball rotating on a ring. 
• Rotary pneumatic roller vibrators: Roller vibrators generate vibration through a roller that makes an eccentric motion. 
• Rotary pneumatic turbine vibrators: Silent pneumatic turbine vibrators use a turbine wheel and rotor to generate vibration suited for environments requiring sanitary equipment and low noise. 
• Pneumatic piston vibrators: Some pneumatic vibrators use the back-and-forth motions of pistons to create linear vibration. The Series LPV Slange Mount Piston Vibrator can deliver variable amounts of force and frequency to meet various needs.

Noise Levels

Pneumatic or air vibrators have a range of noise levels. In general, however, they are noisier than electric-powered vibrators. This is because pneumatic systems have more moving parts and thus generate more noise than electric motors.

Air-cushioned pneumatic piston vibrators may produce less noise than pneumatic piston direct-impact vibrators. With an air-cushioned system, these piston vibrators strike a rubber pad or the air in the cylinder, minimizing noise levels. They also deliver single or continuous impacts, applying intermittent blows.

In contrast, pneumatic direct-impact vibrators are designed with pistons directly striking the vibrator’s metallic base. They can generate consistent vibrations through single or continuous impact. Direct-impact vibrators transmit shockwave force to hoppers, bins and chutes, producing higher noise levels than electric-powered vibrators.

Consider using pneumatic turbine vibrators for minimal noise in sound-sensitive environments. They provide high-frequency vibration and efficient air consumption at relatively quiet noise levels. These are suitable for indoor settings that require reduced noise exposure. 

Applications

Pneumatic vibrators are well-suited to various bulk material handling and manufacturing applications.

• Chemical processing: Workers who deal with chemicals must be aware of potential hazards through excess friction in their bulk material handling equipment. The Series DRV Rotary Pneumatic Roller eliminates friction and produces high frequencies through controlled air pressure regulation. 
• Concrete production: When freshly poured, concrete typically forms trapped air pockets that compromise strength, density and longevity. Concrete and cement production requires frequent repositioning of the vibrator and air hose. In these scenarios, the Series 2100 End Inlet provides a swivel for convenient positioning. 
• Food and beverage processing: Food and pharmaceutical manufacturing plants must meet strict sanitary regulations throughout production. The Series DTV Pneumatic Turbine Vibrator keeps materials loosened and maintains a hygienic environment and food and beverage processing plants.
• Feed and grain processing: Agriculture applications need bulk material handling equipment to keep production moving quickly. Deca Vibrator Industries, Inc. carries Series DBV Pneumatic Ball Vibrators and a variety of other rotary air ball vibrators for a broad range of agricultural applications.

Pneumatic vibrators can also be beneficial in numerous other material handling applications, including industrial manufacturing, mining and quarrying, petroleum refining and pharmaceutical processing. 

Practical Maintenance 

Proper maintenance is key to maximizing the life span and efficiency of pneumatic vibrators. Take note of these practical maintenance guidelines:

• Compressor: Use a reliable compressor that supplies clean and dry air to power the vibrator. Dirt and contaminants can cause internal damage, reducing the vibrator’s performance and making it harder to intake clean air. 
• Filter maintenance: Regularly inspect and drain moisture from the compressor’s air filters. Remove debris and dust that accumulates or change the filter once it’s worn with a significant amount of dirt. This helps maintain efficient airflow for smoother operation. 
• Lubrication checks: For pneumatic vibrators that require lubrication, ensure that lubricators are filled and functioning. Lack of lubrication can result in premature wear or cause the vibrator to seize, which may lead to costly repairs or replacement.
• Leak inspections: Check lines and connections for leaks that can lower air pressure. Leaks force the compressor to work harder and exert unnecessary energy. Repair the leaks immediately to ensure efficient operation and prevent unnecessary energy consumption. 
• Pressure optimization: When supplying compressed air, adjust the air pressure to the lowest level that still fulfills performance requirements. This enables efficient energy use for optimum vibrator performance. Avoid using excessive air pressure to prevent premature wear on the vibrator.

Energy Efficiency

While not as energy-saving as electric-powered vibrators, pneumatic vibrators can be energy-efficient when used in appropriate applications. They are specifically effective in environments where electrical power is unavailable or unsafe to use, such as hazardous areas or outdoor operations.

These vibrators offer flexible frequency and force adjustments to meet particular operational requirements. Pneumatic vibrators can also be used in material handling, bulk processing and material unloading in bins and chutes. Using an air supply system can be a practical option, especially for facilities that have limited power infrastructures.

Still, pneumatic vibrators require a steady supply of compressed air, which can increase operating costs due to the need for air compressors. Fluctuations in air quality and pressure can also be challenging, as these factors can negatively impact vibrator performance and efficiency. Finally, connecting to an unreliable air supply system can result in frequent downtimes and reduced productivity.

Choosing a Vibrator for Your Material Handling Application 

Electric and pneumatic vibrators can improve bulk material handling across many industries. Take these steps to determine which type and model of vibrator you need for your specific application.

1. Understand the Problem 

To select the correct electric or pneumatic vibrator for your plant, you must first understand the issues you face. The type of material you handle will direct your choice of a vibrator. Are your materials prone to ratholing or bridging? An electric vibrator is likely your better option. Are your materials loose, wet and sticking to the inner walls of the bin or hopper? Pneumatic vibrators are often best for wetter materials. 

2. Determine Your Power Source 

Choosing a vibrator could be as simple as determining the available power source at your application. For example, if your facility already operates other pneumatic machinery, then you already have the infrastructure for a pneumatic vibrator. However, there are many considerations that determine the best industrial vibrator power source. 

Situations where an electric vibrator might be more appropriate include:

• Your facility does not have access to compressed air
• You work in sound-sensitive environments
• Your applications require precise control
• You prefer machinery with lower maintenance needs

Meanwhile, a pneumatic vibrator may be best if:

• You do not have access to electricity or sufficient power infrastructure.
• Introducing electricity into the work environment would pose a hazard.
• Your application requires short on-off cycling.
• You need to maintain a hygienic or sterile environment.

Having compressed air and electricity gives you a wider range of options. 

3. Verify Moisture Content

If your materials are dry and powdery, a rotary-type vibrator could provide all the vibration you need to thoroughly remove them from the bin. Rotary vibrators can easily overcome the friction between the materials and the bin wall. However, wetter materials like concrete or wet foods could be too adhesive for a rotary electric vibrator, and a pneumatic option using linear vibration would be more helpful. Linear vibration flexes the bin walls, shaking the material loose and sending it down the chute. 

Contact Deca Vibrator Industries, Inc. for Your Industrial Vibrator Needs 

Choosing the right vibrator for your bulk material handling issues can make a significant difference in your operations’ efficiency and productivity. Whether your company handles dry, food-grade powders or wet, compact cement, an industrial vibrator will efficiently solve material buildup. 

At Deca Vibrator Industries, Inc., we are leaders in industrial vibrator engineering and provide expert consultation to assist you with your specific needs. We offer a wide selection of electric and pneumatic industrial vibrators for various applications. Our expertise enables us to design powerful, long-lasting and cost-effective solutions to solve your problems. 

Contact Deca Vibrator Industries, Inc. today. Our engineers are ready to help you find an effective solution.