Lump Breakers
Break oversized clumps, protect downstream equipment, and keep your process flowing. We offer four proven designs from Atlantic Coast Crushers—Flow Sentry, Flow Sizer, Flow Smasher, and Particle Sizer—each engineered for different materials and output sizes.
From inline protection to high-capacity reduction, these units restore free-flowing material and deliver consistent particle size. Sanitary, abrasion-resistant, and custom configurations available to match your process.
Product Lineup
Flow Sentry
Inline (in-pipe) reducer with rotating blades and a stationary grid to crush oversize as product flows—ideal for liquids, slurries, or pneumatic lines. Common connections from 3″–24″ ANSI or wafer-thin profiles for tight spaces.
Flow Sizer
Dry bulk crusher using a drum with welded blades against breaker bars. Blade sets available for coarse/standard/fine reduction. Sizes from ~6×6 up to 12×30+ with sanitary or industrial builds and easy access panels.
Flow Smasher
High-torque, heavy-duty unit for dense, large, or abrasive lumps. Compact face-to-face design and robust drives deliver aggressive size reduction with minimal footprint.
Particle Sizer
High-speed shafts with spiked blades cutting against a removable sizing cage for precise, finer output. Cage slot sizes ~1 mm to 20 mm; capable of ~30-mesh results depending on material and configuration.
Features & Specifications
Construction & Options
- Materials: Carbon steel, stainless, abrasion-resistant, or specialty alloys.
- Finishes: Industrial or sanitary (polished, cleanable) with end/side access.
- Seals: Lip, powder, or mechanical—matched to product and pressure.
- Drives: Gear-reduction, direct-drive, or belt/sheave; VFD-ready.
Operational Advantages
- Restores flow and protects downstream pumps, airlocks, screens, and feeders.
- Consistent particle size for smoother batching, blending, and conveying.
- Quick-change wear parts (cages, bars, blades) and easy access doors.
- Integrates above/below airlocks, in lines, under bins, and at bag unloaders.
Which Crusher Fits Your Application?
| Model | Best For | Typical Connection / Size | Output Range | Cleaning / Access | Ideal Placements |
|---|---|---|---|---|---|
| Flow Sentry | Inline protection in liquid/slurry/pneumatic flow | 3″–24″ ANSI or wafer-thin face-to-face | Coarse to medium (grid dependent) | Inline pull-out grid; sealed bearings | In piping, before pumps/reactors, above/below airlocks |
| Flow Sizer | General dry bulk reduction of soft–moderate lumps | ~6×6 to 12×30+ (custom larger) | Coarse, standard, or fine (blade set) | Side/end access plates for cleaning | Under bins, at feeders, ahead of screening |
| Flow Smasher | Dense, large, or abrasive lumps; heavy duty | Compact face-to-face; rugged drives | Coarse to medium (high torque) | Heavy-duty wear parts; robust bearings | Under silos, tough reclaim points, pre-crushing |
| Particle Sizer | Finer, more uniform particle sizing | 6×6 up to 22×24; single/double shaft | To ~30-mesh (cage slot ~1–20 mm) | Removable sizing cages for quick change | Downstream of crushers, batching, high-throughput lines |
System Integrations
Combine lump breakers with bulk bag unloaders, feeders, sifters, and conveyors to ensure smooth discharge and uniform flow—even with challenging powders and agglomerates.
Bulk Bag Unloaders
Integrated crushers prevent clumps from entering pneumatic or mechanical conveying systems.
High-Capacity Discharge
Pair with feeders, sifters, and scales for continuous, reliable flow into downstream processes.
Lump Breaker FAQ
How do I choose the right model?
Start with material traits (lump size, hardness/abrasiveness, moisture), target output size, and required throughput. Use Flow Sentry for inline protection, Flow Sizer for general dry bulk, Flow Smasher for tough lumps, and Particle Sizer when you need finer sizing.
What maintenance should I expect?
Inspect and replace blades, breaker bars, or cages on a routine schedule. Choose seal types and materials of construction that match your product. Many models include quick access panels or removable cages to minimize downtime.
Can these be built for sanitary service?
Yes. Sanitary finishes, cleanable designs, and stainless construction are available for food and pharma applications. We’ll align component choices with your validation requirements.
Need help sizing a Lump Breaker?
Share your material, target particle size, and capacity. We’ll recommend the right crusher model, drive, seals, and integration points for dependable, low-maintenance performance.
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