Air conveyor systems use controlled airflow to move products along a conveying surface without relying on conventional belts or chains beneath the product. This approach is particularly effective for lightweight products that require smooth, controlled movement through production and packaging lines.
By reducing direct mechanical contact during conveyance, air-supported systems can help maintain consistent product flow while supporting accumulation and high-throughput handling requirements. They can also be engineered around different product characteristics, line layouts, and downstream processes, making air conveyance a flexible option within modern conveyor systems and integrated conveyance solutions
An air conveyor system uses a controlled supply of air distributed through a plenum beneath the conveying surface. Air passes through strategically positioned openings in the conveyor deck, creating directed airflow that supports and moves products along the conveyor path.
The airflow pattern, pressure, conveyor surface, and system configuration are engineered around the products being handled and the required production rate. Because product movement is generated by airflow rather than a continuously moving belt beneath the product, products can move smoothly through the system while minimizing friction and mechanical contact.
This operating principle is particularly useful when products need to accumulate. When downstream equipment slows or stops, products can collect on the conveyor while the airflow continues beneath them, helping reduce the backpressure and surface friction associated with conventional continuously moving conveyor belts.
Air conveyor systems can provide several operational advantages when matched to the right product and production environment. Their air-supported conveying method is particularly valuable for applications requiring controlled product flow, accumulation, and efficient movement through automated lines.
Controlled airflow helps move products with less direct mechanical contact, supporting smooth handling of lightweight or damage-sensitive products.
When products accumulate, airflow can continue beneath the stopped products without a moving belt creating continuous friction. This helps reduce backpressure and supports controlled accumulation before downstream equipment.
Air conveyor systems can support continuous, high-throughput product movement between production processes, helping maintain consistent flow through automated lines.
System layouts can be engineered around available space, product characteristics, required throughput, and upstream or downstream equipment.
Because product movement does not depend on a conventional belt or chain beneath the product, air-supported systems can reduce the number of moving conveyor components directly interacting with the product.
Air conveyors can transfer products from one processing stage to another while maintaining controlled movement through the line.
Systems can provide accumulation ahead of equipment that may periodically slow or stop, allowing upstream production to continue for a period without immediately stopping the entire line.
Air-supported conveyance can be incorporated between filling, inspection, packaging, case-packing, and other automated processes where consistent product delivery is required.
Engineered configurations can accommodate production environments where conveyor routing must work around existing equipment and available floor space.
| Design Consideration | What to Evaluate |
|---|---|
| Product Characteristics | Product size, shape, weight, stability, and other handling characteristics that affect conveyance. |
| Throughput Requirements | Required production rate and the volume of products moving through the system. |
| Accumulation Requirements | Required buffering capacity when downstream processes slow or stop. |
| Conveyor Layout | Conveying distance, changes in direction, available space, and equipment positioning. |
| Product Transfers | How products enter and discharge from the air conveyor and transition to connected equipment. |
| System Integration | Upstream and downstream equipment, controls, sensors, and overall line operation. |
These factors should be evaluated together rather than independently. Dillin engineers each system around the product flow and operating requirements of the complete production line.
Have questions about how air conveyor systems work or where they fit in your operation? Below are answers to some of the most common technical questions.
Belt and chain conveyors use a moving mechanical surface to transport products. Air conveyor systems instead use controlled airflow to support product movement, reducing reliance on moving components directly beneath the product. This can be particularly useful for lightweight products and applications requiring low-backpressure accumulation.
Dillin approaches air conveyance as part of the complete product-handling system. Each application is evaluated around the products being conveyed, required throughput, accumulation needs, available layout, and integration with upstream and downstream equipment.
For applications requiring air-supported product transport and accumulation, Dillin’s AIR DECKĀ® conveyor systems provide an engineered solution that can be configured around specific production requirements.
System design considers product characteristics, production rates, accumulation requirements, conveyor layout, and surrounding equipment to develop a solution suited to the application.
Air conveyance can be coordinated with upstream and downstream equipment, controls, and other material-handling systems to support efficient product movement across the production line.
Conveyor layouts and system configurations can be adapted to accommodate different products, operating requirements, equipment arrangements, and available production space.
From initial system design through controls integration and implementation, Dillin works with manufacturers to develop conveyance solutions that support reliable product flow across the production line.
