During fertilizer production, efficient processing and handling of materials are a major issue because powdered and granular products should continuously flow without any disruption or unpredictability. A significant number of fertilizer manufacturing plants were suffering from inconsistent flow and choking, together with inefficiency in the application process because of using inefficient or older discharge mechanisms.

As the production metrics and the energy prices rose, the plant was to receive a more intelligent type of solution, one that could manage the very high requirements of the material flow of fertilizers as well as help in the future economic one.

Enter AIRSLIP™, the advanced fluidization fabric from Supertech Fabrics Pvt. Ltd. With its engineered permeability, thermal durability, and abrasion resistance, AIRSLIP™ offered the exact solution the facility needed. This case study explores how AIRSLIP™ was implemented, what challenges it overcame, and what measurable improvements it delivered.

The Problem: Complex Flow Dynamics in Fertilizer Production

Working with diverse powdery and granular substances is generally the norm at fertilizer production facilities including phosphate fertilizers, micro and macro elements, and other chemical mixtures. These are dense or sticky or abrasive material and this often causes:

• Unpredictable discharge from silos and hoppers
• Frequent build-up or arching at outlet points
• Manual cleaning and safety risks
• Increased blower pressure demands
• Costly downtime due to clogs and wear

In this particular case, the plant was dealing with excessive downtime, high energy usage from overworked pneumatic systems, and irregular discharge that was affecting batch consistency. The previous technical fabrics used in their air slide systems had reached their performance limit.

Project Objective

The client needed to:

• Restore uniform powder flow through discharge systems
• Reduce operational costs tied to air pressure and cleaning
• Improve equipment lifespan and material discharge efficiency
• Avoid major retrofitting or infrastructure changes

The technical team at Supertech Fabrics recommended the AIRSLIP™ system for its superior performance in handling fertilizer material flow under high-stress conditions.

The Solution: AIRSLIP™ Fluidization Fabric

AIRSLIP™ is a proprietary fluidization fabric developed specifically for dry bulk materials. Unlike conventional technical fabrics, AIRSLIP™ is engineered for both flow optimization and durability—making it ideal for the fertilizer industry.

Why AIRSLIP™ was chosen:

• Even air permeability across the full fabric length
• Abrasion resistance suitable for chemical-heavy, particulate-rich media
• Thermal endurance up to 450°C, depending on the construction and coating
• Self-cleaning effect reducing manual cleaning intervention
• Available in multiple thicknesses and coating options
• Custom-fit implementation with zero structural redesign

Installation Overview

The upgrade process began with a full site audit conducted by the Supertech Fabrics engineering team. Airflow rates, pressure drop points, silo geometry, and material types were carefully evaluated. After assessment, AIRSLIP™ fabrics were custom-manufactured and installed in the following critical areas:

• Air slides beneath blending silos
• Fluidizing zones of intermediate storage bins
• Discharge chutes in packaging lines

Key Technical Specs Used:

• Fabric Type: Woven Polyester (PES)
• Thickness: 5mm and 6mm (application-specific)
• Permeability: Up to 700 m³/m²/h @ 125 Pascals
• Coating: PU-based for abrasion and chemical resistance

The installation was carried out during scheduled maintenance windows and completed without disrupting ongoing production.

Measurable Results

Following the upgrade to AIRSLIP™, the facility began tracking metrics for a 90-day period to assess improvements. The results were impressive:

•  34% Decrease in Air Pressure Requirements

AIRSLIP™ enabled smoother flow with lower blower effort, reducing energy use.

27% Increase in Discharge Speed

Powder flowed evenly and predictably from storage bins and silos, improving production cycle time.

Zero Manual Cleaning for 90+ Days

Self-cleaning properties of AIRSLIP™ eliminated the need for operators to manually intervene.

3x Longer Wear Life (Projected)

Early wear analysis indicated that AIRSLIP™ would last at least three times longer than the fabric it replaced.

Reduced Downtime by 40%

Operators reported minimal clogs, smoother transitions between batches, and fewer shutdowns due to flow issues.

Operator Feedback

Plant operators and engineers noted that, after switching to AIRSLIP™, the entire process felt more predictable and easier to manage. One line supervisor commented:

“We no longer have to stop the line to unclog discharge chutes. The new fabric has made our material flow feel automatic—and that’s a huge operational win.”

Broader Impact

This case was not isolated. As part of a larger optimization program, similar AIRSLIP™ installations have taken place across fertilizer, chemical, and power plants that deal with dense, powdery, or abrasive media. AIRSLIP™ not only enhances discharge efficiency but also helps plant teams focus on production rather than maintenance.

It also supports sustainability goals—by requiring less air pressure and reducing the number of fabric replacements, AIRSLIP™ contributes to energy savings and material conservation.

Why AIRSLIP™ is Ideal for Fertilizer Manufacturing

AIRSLIP™ has proven to be one of the few technical fabrics specifically engineered for complex fertilizer flows. Here’s why it stands out:

• Technical Precision: Custom-woven and coated for the exact operational load
• End-to-End Quality: Fully developed, tested, and produced in-house
• Adaptable Use: Works seamlessly in silos, fluidizing basins, trucks, and bins
• Reliable: Backed by ISO 9001:2015, 14001:2015, and 45001:2018 certifications
• Data-Driven: Performance backed by actual customer use cases

About Supertech Fabrics

Supertech Fabrics Pvt. Ltd. is a premier manufacturer of high-performance technical textiles for industrial applications. With four specialized brands—AIRSLIP™, TEXTROV™, TEXFIL™, and TEXGUARD™—the company serves 22+ sectors and over 250 application types. Their integrated in-house process covers everything from R&D and weaving to testing and quality assurance.

For more details:
🌐 www.supertechfabrics.com
 📧 Email: info@supertechfabrics.com

Final Thoughts

The fertilizer industry is a highly competitive industry where profit margins are too thin and were missed deliveries and lost time cost money. AIRSLIP TM has become an essential upgrade in such an industry. Not all technical fabrics are created equally, and AIRSLIP(tm) is evidence of that with the improved smooth discharge, pressure load, and clean transitions.

If you’re in the business of powder, precision, and performance, AIRSLIP™ is engineered to deliver.