At an aerogel material production base in Ganzhou, Jiangxi, to address the frequent scattering issues of lightweight powders during transportation, feeding, and packaging, Head Powder undertook this anti-fly material engineering project. Due to its low density and high specific surface area, aerogel powder easily generates dust in the air, which not only causes material waste but also poses a lasting impact on the production environment, equipment operation, and operator health. Based on in-depth analysis of powder properties and process conditions, Head Powder has designed and implemented a systematic anti-fly material solution, effectively controlling dust escape and improving on-site cleanliness and operational efficiency.

Customer pain point analysis

At the early stage of the project, the main issues faced by the client focused on three aspects: first, severe material loss. Due to the extremely light weight of aerogel powder, the loss rate of flying jackpots was high under traditional packaging and conveying methods; Second, excessive dust concentration in workshops, with fine particles suspended for long periods increasing equipment wear and electrical safety hazards; Third, compliance pressure is increasing, with increasingly stringent environmental and occupational health standards, and current working conditions can no longer meet emission and hygiene requirements. The client urgently needed an engineering solution that could efficiently prevent flying materials without disrupting the original production rhythm.

Head Powder Solutions

To address these pain points, Head Powder offers integrated services covering equipment selection, system integration, and on-site renovation. The core of the solution includes: adopting a closed airflow conveying system to replace open transfer and reduce powder scattering at the source; High-efficiency filtration and dust removal units are added at key feeding inlets and packaging stations, reducing dust concentration in workshops below national standard limits; Combined with automatic control technology, it achieves smooth adjustment of powder flow and avoids localized splashing caused by rapid currents. At the same time, the project team rationalized the site layout and optimized personnel workflows, greatly reducing the risk of powder leakage while improving production efficiency.

Project effectiveness and value

After the renovation was completed, dust concentration in the customer's workshop dropped by about 85%, material loss rate dropped to within 3%, and a single shift saved over ten thousand yuan in powder costs. The operating environment has significantly improved, and employee health and equipment maintenance pressure have been reduced simultaneously. Starting from this Ganzhou project, Head Powder has continuously accumulated experience in aerogel lightweight powder anti-fly material engineering projects, providing more powder companies with reusable technical pathways.