Using the Smart Elbow® from process equipment manufacturer HammerTek Corp, global ceramics manufacturer Carbo Ceramics has slashed maintenance costs and recaptured lost productivity by eliminating troublesome leaks from its pneumatic conveying line. When moving calcined kaolin to storage in 10 different silos, the Eufaula, AL facility's traditional long radius elbows were no match for the highly abrasive material and quickly wore through, requiring patching and replacement as often as every week, along with a daily maintenance check.

After a successful test with a single elbow, Carbo Ceramics replaced its 12 leaking elbows with the 6 in., tungsten carbide-coated HammerLast 300 Smart Elbow, which deliver a robust surface hardness of RC 69-70. None have needed to be replaced since their installation four years ago and the maintenance team's daily elbow inspections have been practically eliminated, along with costly line downtime and maintenance and cleanup expenses.

The Smart Elbow combines an innovative rounded chamber on a tight radius elbow in a single, rugged unit that causes conveyed particles to gather inside in a slowly-rotating, self-renewing ball of material and air. Material is gently absorbed as it enters and gradually released to continue on its way through the conveying line.

"There are cost savings, but more importantly, you can't place a high enough value on the peace of mind," says Tom Sorensen, Carbo Ceramics' maintenance manager. "Installing Smart Elbows is an easy call for anyone processing ceramics or other abrasive materials."