How to Prevent Clogging and Ice Build-Up During Blasting

Dry ice blasting is an excellent cleaning method - until the machine suddenly stops delivering pellets. The gun goes quiet, the hose feels rock-hard with ice, or the hopper is bridged with a solid lump of clumped dry ice. These interruptions are extremely common, especially after a few months of regular use, and they cost time, money, and patience.

The good news: most clogging and ice build-up issues are preventable with the right focus and habits. Below is a practical, priority-based guide that reflects what actually works best in real-world operations.

Common Signs of Clogging and Ice Build-Up

• Dry ice forms large clumps or bridges in the hopper, preventing consistent feeding
• The feeder (rotor or auger) jams or makes grinding noises
• Ice accumulates inside the blast hose, dramatically reducing flow or blocking it completely
• The nozzle suddenly plugs, with little or no pellet output
• Intermittent delivery - the system works for a few seconds, then stops, then starts again

Recognizing these patterns helps you quickly narrow down where the problem is occurring.

Primary Causes

1. Moisture in the compressed air

This is by far the biggest culprit (responsible for 70–85% of chronic clogging cases). Dry ice at –78.5°C instantly freezes any water vapor in the air that contacts cold surfaces inside the system. Frost builds up quickly and narrows or completely blocks flow paths. The problem is much worse in warm, humid conditions.

2. Poor dry ice quality or improper storage

Inconsistent pellet sizes, excessive surface frost, or dry ice that has absorbed moisture during transport/storage lead to clumping and poor flow inside the machine.

3. Suboptimal operating habits

Leaving residual dry ice in the system after shutdown, keeping long or tightly coiled hoses, running continuously without breaks, and abrupt start/stop cycles all promote ice formation and blockages.

4. High-humidity or hot ambient environments

These conditions amplify moisture-related problems and accelerate frost build-up on external and internal surfaces.

Most Effective Ways to Prevent Clogging and Ice Build-Up

1. Deliver the driest possible compressed air (highest priority)

Nothing else comes close in effectiveness.

Recommended setup:

• Refrigerated dryer (cold dryer) + high-efficiency coalescing filters as a minimum
• Add a desiccant (adsorption) dryer for best results
• Target dew point at the machine inlet: –40°C (–40°F) or lower (many experienced users aim for –70°C)

Real result reported by many operators: upgrading to a –40°C dew point system often reduces clogging frequency from several times per week to once a month or less.

2. Use high-quality dry ice and store/handle it correctly

• Choose dry ice specifically manufactured for blasting (consistent cylindrical pellets, 3–16 mm diameter)
• Avoid crushed, irregular, or low-purity dry ice
• Store in well-insulated containers with vented lids (never airtight)
• Take only what you need for the current job; minimize time outside the cooler

3. Adopt better operating practices (almost zero cost, quick results)

Practical habits that make a big difference:

• Purge the air lines with clean dry air for 30–60 seconds before adding dry ice
• Introduce dry ice gradually at startup (low flow rate first)
• Pause every 20–30 minutes during long sessions to let the system stabilize
• Keep the hose as straight as possible - avoid tight coils and excessive length
• Always purge all remaining dry ice from the hopper, feeder, hose, and gun at the end of every job

4. Perform consistent basic maintenance

Quick daily/weekly checklist:

What to Do When Clogging Still Happens

1. Stop feeding dry ice immediately and observe:

Gradual pressure drop → likely progressive ice in hose or nozzle

Sudden complete stop → probably a hard plug at the nozzle or connection

2. Safe clearing sequence (never poke with sharp tools!):

• Purge with dry compressed air at full flow for 1–2 minutes
• If no improvement, isolate the affected section (nozzle, hose segment, etc.)
• Allow natural thawing in a warm, dry area or use gentle warm air (never hot)
• For hoses: hang vertically and gently flex while purging
• For nozzles: soak in warm water 5–10 minutes, then brush and reverse-blow

3. After clearing, test with low flow for a few seconds before returning to normal operation.

Conclusion

Clogging and ice build-up are almost always moisture-management problems.

The most powerful prevention hierarchy is:

Ultra-dry compressed air > Quality dry ice + proper storage > Good operating habits > Regular maintenance > Equipment anti-clog features

Get the first three right, and you will eliminate the vast majority of interruptions.

If your current setup still causes frequent stoppages, start with an honest evaluation of your compressed air dryness - it's usually the single biggest improvement you can make.

Have you experienced a particularly stubborn clogging issue recently? What do you think caused it? Feel free to contact us via email for advice or to get a quote for affordable and reliable dry ice cleaning equipment.