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Written by Don on Monday, 06 May 2013. Posted in Primasonics Blog

As we know from solving many silo bridging and ratholing problems, the discharge section of a silo or hopper can off be an area of concern for silo operations managers. One thing we have encountered numerous times over the years is a phenomenon called hammer rash.

Ironically it is created in an attempt to actually remedy a problem - when a silo operative uses a metal hammer or iron bar to hit the hopper discharge point to dislodge a blockage such as cement buildup.

If a rubber hammer were used the 'rash' would not occur but often tools like this are mislaid so when a blockage needs dislodging – and plant operators like to tackle these things quickly to avoid downtime – then anything that's handy will be used to hammer against the side of the metal section.

Over time this kind of hammering takes its toll and the metal sections ultimately have to be replaced – an expensive exercise both in terms of materials, manpower and downtime.

The first photograph shows a gypsum silo hopper discharge point with such severe hammer rash that it had to be replaced, despite the installation of a Bin Activator which is supposed to aid material flow.


This second photograph shows a gypsum hopper already damaged by hammer rash but where the plant installed one of our acoustic cleaners in sufficient time to prevent it from being replaced.


The truth is that manual intervention can be avoided by installing acoustic cleaners for hopper cleaning. The audiosonic sound waves generated keep the gypsum material flowing at the maximum discharge rate so there is no buildup, no blockage and no resulting hammer rash and damage to the discharge points.



I am a truly innovative and affable Irishman who has over 35 years experience in a wide range of dry process and storage industries with particular disciplines in project engineering and consultancy.

Faced with a range of material flow and storage problems throughout my career my ambition was to find an affordable innovative and simple solution to prevent material blockages and build up and improve material flow within a wide range of dry process & storage industries.