Case Study: Improved Operator Safety at Chemical Processing Plant

Situation

A chemical processing plant relied on the smooth flow of dense, adhesive powders through hoppers, chutes, and ducts to maintain efficient batch production. Consistent material movement was essential for productivity and safety.

Problem

The plant frequently experienced material buildup—powders would bridge or stick to vessel walls, restricting flow and causing production delays. Operators had to manually hammer vessels with mallets to dislodge the material. This approach was time-consuming, hazardous, and exposed workers to repetitive strain, falling debris, and chemical contact. Additionally, repeated hammering risked damaging expensive stainless steel vessels and piping.

Solution

To address these issues, the company installed MARTIN® PKL® Interval Impactors at key points throughout the plant. These pneumatically driven devices deliver timed, controlled blows to vessel walls, effectively dislodging material without manual intervention. The impactors’ force and frequency can be adjusted for different materials and vessel designs, and operation can be automated or sensor-triggered for optimal efficiency. This resulted in:

• Safer operations with no need for manual hammering
• Reduced risk of equipment damage from uncontrolled impacts
• Consistent material flow with fewer process delays
• Increased uptime since operators no longer stop production to intervene