For manufacturers in plastics, food, chemicals, and beyond, bulk material handling is the lifeblood of production. Pneumatic conveying systems move powders, granulates, and additives with speed and precision but they also consume large amounts of energy.
In 2025, this challenge is sharper than ever. Rising energy costs, stricter CO₂ targets, and the push toward sustainability leave little room for inefficiency. The good news? Much of the energy currently wasted in conveying systems can be recovered and reused without compromising product safety or quality.
To understand where energy savings come from, it helps to look at the process:
Each of these steps is essential for consistency. But together, they also create opportunities to rethink how energy is used and how much can be saved.
Every pneumatic conveying process produces heated exhaust air when the vacuum generator compresses air. Temperatures of 150°C to 280°C are typical, and for years, this heat simply disappeared into the atmosphere.
AZO’s heat recovery system captures that energy instead. Here’s how it works:
Key benefits:
Safety comes first, as temperature and pressure sensors continuously monitor the process, eliminating risks of overheating or overpressure.
One overlooked source of waste in bulk solids handling is “bridging.” Over time, powders and granulates can settle and compact, forming bridges that block product flow.
Preventing bridging isn’t just about uptime; it also prevents energy waste. Clogged systems require more conveying pressure, downtime, and even manual intervention. By designing systems for cyclical recirculation, bridging is avoided, and conveying runs at optimal efficiency.
Pumps are among the largest energy consumers in pneumatic conveying systems. That’s why AZO has made pump management a core focus of optimization.
In real-world trials with a leading plastics manufacturer, AZO tested four conveying routes, including one stretching 200 meters with outputs up to 6,000 kg/h. By optimizing pump sizes and airflows, pipeline layouts, and frequency converters, the team uncovered dramatic savings:
And importantly, these optimizations didn’t require a new installation. Upgrading existing systems with smarter configurations delivered major improvements with minimal disruption.
Energy efficiency projects only work if the numbers add up. Here, they did—and quickly:
Once the payback period is over, the savings continue year after year.
Heat recovery, pump optimization, and bridging prevention may sound like small changes, but they add up to big impact:
At a time when both regulators and customers demand measurable sustainability results, these steps show a clear, transparent path forward. Instead of overhauling infrastructure, manufacturers can optimize what they already have and gain both financial and environmental benefits.
In 2025, energy efficiency is no longer optional; it’s required for competitiveness, resilience, and long-term sustainability. By turning waste heat into a resource, preventing inefficiencies, and managing pumps more intelligently, manufacturers can unlock hidden savings once overlooked in their existing plant and process.
Ready to discover how energy optimization drives profitability and sustainability? Download Beyond ROI today.