Material Build-up

Material build-up can lead to structural integrity issues, operational inefficiencies, and potential hazards. ESS Engineering have a solution.


Bulk material flow through hoppers, stockpiles, silos or chutes can become compacted, and in some cases blocked. Blockage types include rat holes, arches, bridges and clinging material. Material bulid-up in silos, hoppers, and bunkers causes live capacity issues and the reduced amount of material flow from the silo, hopper, bunker and chute, this creates a number of knock-on issues. 

Material Build-up

Risks & Concerns

Material build up reduces plant efficiency as the live capacity is reduced and less material actively flows through the silo, hopper, bunker and chute, and into the plant. 


This means material is more likely to run out and reduces efficiency.
Live capacity also affects product flow in areas like the chute, and it will also change the impact zone. This then leads to increased wear in areas not designed to wear and increases the chance of misalignment. Misalignment leads to spillage and belt damage.


In order remove material build-up,
flow aid devices are used to promote the movement of bulk materials through hoppers, stockpiles, silos and chutes. Air cannons or air blasters use compressed air to create an explosive force that is used to dislodge and prevent build-up, blockages and clinging material from the walls of hoppers, stockpiles, silos or chutes.

material build-up in silo

Vibrators utilise vibrations to shift clinging materials. In some areas, it is appropriate to remove material build-up in a silo or hopper with a silo cleaning device. 


Silo cleaning tools like the bin whip regain live storage capacity and recover lost material. The bin whip machine is an air powered, manually controlled device for the cleaning of silos/bins internal surfaces.

Is your site 100% efficient?

Our company has branches in major mining centres, which can provide you with the necessary technology and expertise to tackle any fugitive material problems you may have. Our ESS service technicians can offer on-site surveying services, troubleshooting, and monitoring of conveyor accessory components. We also provide on-site staff training to help them identify safety hazards and find solutions to them.

Schedule Site Survey

ESS Products & Solutions

to Prevent and remove Material Build-up


To prevent the accumulation of material in storage containers, it is recommended to use flow aid devices such as ESS air cannons and vibrators. These devices use compressed air to dislodge blockages while vibrators shift clinging materials. If material build-up occurs or if material is lost in the container, it is recommended to use silo cleaning devices such as the ESS bin whip to remove the accumulated build-up or recover the lost material.

Call us today on 1800 074 446 for more details about our products and services.

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