At Thayer Scale, our engineers have a deep understanding of material flow properties and challenges which is why we have numerous models and customizable options available on much of our equipment. When it comes to bin or hopper flow challenges we are no different and have two preferred options that handle most situations;
- The Thayer Scale Bridge Breaker® Material Flow Aid
- A Bin Activator
So, what is the difference between a Bridge Breaker and a Bin Activator?
Both address material discharge challenges, but they act on different areas of the hopper or bin and are best suited to different flow problems.
The Bridge Breaker® material flow aid is designed to eliminate problematic bridging within a hopper wherever it may occur. Rather than attempting to transmit energy through the vessel walls, as external knockers or vibrators do, it uses internally mounted screens that act directly on the material where stable arches may form. Units can be installed individually or at multiple locations, then automated or operated on timers when restricted flow conditions are detected or anticipated.
A bin activator takes a different approach. A suspended discharge cone is mounted at the bottom of the hopper or silo and vibrated to promote flow through the lower section of the vessel. This motion can reduce ratholing and stagnant material zones, encourage more uniform drawdown, and initiate discharge on demand. Designs vary by manufacturer and application, including cone geometry, suspension, drive arrangement, seals, baffles, and outlet configuration.
Our engineers are available to help evaluate bulk material flow challenges and recommend the right material flow solution for your situation. If you’re ready for that step, let us know.
But because we know you might be an engineer too – and enjoy doing your own research before reaching out to us – we created this evaluation guide.
Bridge Breaker Flow Aid vs. Bin Activator
Best For
Localized bridging and inconsistent flow
Installation Location
Inside the hopper at multiple levels as required
Equipment Modification Required
Minimal
Uses Existing Hopper Cone?
Yes
Vibration Location
Localized agitation at BridgeBreaker location
Retrofit Friendliness
Excellent
Large Silo Applications
Good
Best For
Poor overall flow patterns, ratholing, stagnant zones, and flow-on-demand needs
Installation Location
Bottom of the hopper, replacing part of the cone
Equipment Modification Required
Moderate to significant
Uses Existing Hopper Cone?
No
Vibration Location
Suspended discharge cone or lower vessel section vibrates near the outlet
Retrofit Friendliness
Moderate
Large Silo Applications
Excellent
When the Bridge Breaker Material Flow Aid Is the Right Solution
The Bridge Breaker flow aid is designed to eliminate bridging wherever it may occur in a hopper or silo, allowing material to continue to flow towards the outlet. Rather than attempting to transmit energy through the vessel walls, it acts directly on the material where stable arches may form.
You May Need a Bridge Breaker Flow Aid If You Experience:
- Material sitting in the hopper while the feeder runs empty
- Operators hitting the hopper to restart flow, especially after shutdowns
- Frequent hopper blockages
- Sudden surging after a delay
- Inconsistent feed rates
- Poor batching accuracy
- Downtime caused by material hang-ups
Typical Materials
- Titanium Dioxide (TiOâ‚‚)
- Zinc Dust
- Carbon Black
- Cement
- Flour
- Starch
- Hydrated Lime
Advantages
- Eliminates bridging at its source
- Predictable, consistent discharge
- Minimal vessel modifications
- Low structural stress on the vessel
- Excellent retrofit solution
When a Bin Activator Is the Right Solution
A bin activator uses a vibrated discharge cone or lower vessel section to promote material movement near the outlet. This approach can improve drawdown, reduce ratholing and stagnant zones, and help initiate flow on demand. Performance depends on proper sizing and on matching the activator design to the vessel geometry and bulk material properties.
You May Need a Bin Activator If You Experience:
- Poor control of material discharge through current feeding device
- Material forming ratholes
- Large amounts of stagnant material
- Poor overall flow patterns
- Large silos that do not empty completely
- Material segregation
- Inconsistent discharge from large storage vessels
- Need to be able to initiate flow on demand (discharge control device)
Typical Materials
- Fly Ash
- Limestone Powder
- Talc
- Sand
- Plastic Pellets
- Wood Flour
- Mineral Powders
Advantages
- Promotes mass flow
- Reduces stagnant material zones
- Helps eliminate ratholing
- Reliable discharge from large vessels
- Effective on a wide range of difficult powders
The Right Solution Starts with the Right Diagnosis
At Thayer Scale, we believe in recommending the technology that best fits the application—not forcing every problem into a single solution.
Whether the answer is a Bridge Breaker Material Flow Aid, a bin activator, or another flow-aid technology, our goal is simple:
Keep material flowing reliably, consistently, and efficiently.
Not sure whether you’re dealing with bridging, ratholing, or both? Contact our engineers to discuss your application.