November 2026
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Inside the November Issue |
Safely Clearing Silo, Hopper,
and Chute Blockages
BY BRAD PRONSCHINSKE
The signs of a clogged silo, hopper, or
chute are obvious. Nothing is discharging
from the spout. Material is compacted, or
there’s spillage from either overflow or
conveyor backup. When production
stops, workers get creative, hitting the side
of the vessel with tools or strapping on a
harness to go inside, both creating safety
hazards. In response, air cannons have
become a viable alternative across bulk
handling sectors, offering greater safety,
less labor, and significantly reducing
downtime.
Martin Air Cannons clear and prevent
clogs to promote material flow. The first
step is to understand how, where, when,
and why clogs occur. The second step is
to remove worker involvement in clearing
the clog. The third step is to monitor the
flow aid system to maximize efficiency.
Why Do Silos, Hoppers,
and Chutes Clog?
• Weather – Humidity and temperature affect
how the material flows and builds up.
• Material weight/size/shape – Gravity
is both friend and foe to bulk flow. With
materials of variable shapes and sizes
and different flow rates/characteristics,
obstructions happen.
• Structural design – Choosing a square or
round vessel for optimal flow is based on
the material characteristics. Material Flow
Analysis software helps in modeling flow.
• Load speed/volume/distribution –
Speed and volume should not exceed the
vessel’s specifications, or clogs will occur.
To avoid buildup and eccentric load
stress, discharge distribution should
match the geometry of the vessel.
Unsafe Practices for Silo,
Hopper & Chute Clearing
Once a clog has been detected, there are
several unsafe practices that, at the time,
may seem harmless but frequently cause
serious worker injuries or fatalities year
after year.
Beating the vessel walls with objects to
loosen adhered material creates bumps
and ridges on the wall, forming ledges that
promote greater accumulation. This solution
also puts workers near the spout,
exposing them to sudden surges.
Poking or lancing underneath the clog
at the discharge point causes a surge of
material, burying or crushing the worker(s)
below.
Confined space entry is a major cause
of worker injuries and fatalities when
clearing obstructions. Bridging material
could pull the worker into the cavity.
Material buildup on the sides of the vessel
could release from above, resulting in
serious injury or burial. Full story »
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