ESS Engineering’s Bin Whip System is helping take risk and waste out of silo cleaning.
The build-up of materials in bulk storage systems is common and presents significant operational challenges by forming obstructions that restrict material flow and diminish overall storage capacity.
As material compacts over time, external flow-aid methods like air cannons and vibrators can become ineffective. In severe cases, full cleanouts become necessary before any flow-improvement measures can be applied effectively.
Traditional silo cleaning methods require workers to enter confined spaces, often involving harnesses, scaffolding, and extensive labour.
That is why ESS Engineering has developed a solution to eliminate the need for confined space entry. The Bin Whip eliminates the need to actually enter the silo itself,” ESS Engineering sales specialist Dan Walker said.
“Instead of relying on confined space entry with rope and harness access, the system is controlled externally by two technicians using a control box.
“From a safety standpoint, workers remain outside the silo, avoiding hazardous environments.”
ESS Engineering Wollongong branch manager Mario Bezzina said the system eliminates the danger of engulfment if material suddenly shifts.
“You’re not at the business end of the silo. The whip operates 10 to 20 metres away from the operator, keeping them at a safe distance,” he said.
“By eliminating the need for scaffolding, confined space permits, and additional labour, costs are significantly reduced. Once the material is dislodged, storage is restored to its original capacity.”
Restoring full storage capacity
Over time, material build-up inside silos reduces storage capacity and disrupts operations. The Bin Whip system restores full capacity by effectively breaking down and removing hardened deposits.
“The Bin Whip clears all build-up, not just at the bottom where bottlenecks occur, but throughout the entire silo. This ensures full material flow from top to bottom, increasing efficiency and preventing future blockages,” Walker said.
The system also avoids the complications associated with water-based cleaning methods.
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“The Bin Whip is air-powered, requiring no chemicals or water. Since it operates as a dry-cleaning system, there’s no slurry or waste that needs disposal, unlike traditional methods,” Walker said.
Unlike water-based methods, which often render materials unusable, the Bin Whip system ensures that dislodged material remains viable.
“Water can damage materials, making them unsuitable for reuse. Since the Bin Whip operates dry, recovered material can be reintegrated into production, generating substantial cost savings,” Walker said.
Industry applications
ESS Engineering sales and service technician Joshua Martin said the Bin Whip system has been successfully deployed across various industries, handling a wide range of materials.
“We’ve used this system in pet food facilities, which require near food-grade standards. We’ve also applied it to coal, concrete, and grain storage,” Martin said.
“Whether dealing with hardened materials or interlocking substances like grain, the Bin Whip proves effective.
“At a pet food facility, traditional methods involving repeated water use led to black mould infestation. This contamination rendered the stored material unusable. The Bin Whip offered a dry solution that effectively removed the build-up without causing further issues.”
Walker said the Bin Whip system is a breakthrough in silo cleaning as industries continue to seek safer and more cost-effective solutions.
“Recently, we used it on a grain storage silo in Western Australia. It’s also been extensively utilised in cement and concrete factories,” he said.
“Essentially, any industry experiencing material build-up in a bin or silo can benefit from the Bin Whip.”