5 Tips To Solve Pellet Tunneling In Hopper

It is frustrating that when you are in the middle of cooking and realize grill temperature has dropped or the pellet grill/smoker shuts down or you get low-level pellet notifications.

One of the reasons for this issue is pellet tunneling in hopper. This article will outline the basics of tunneling/funneling and some good tips to prevent tunneling issues in pellet grill hoppers.

pellet tunneling in hopper

What is Pellet Tunneling in Hopper

When the hopper has fed all the pellets in the center of the grill, but there are still a lot left on the sides, it is called ‘tunneling’. As pellets feed into the augur, they don’t fill in the space above them and form a hole or tunnel in the hopper. This can cause no pellets to make their way into the augur and with no pellets coming in, the fire goes out.

Tunnelling is a common problem in the pellet grill/smokers. The hopper can cause this problem by malfunctioning or by being too full.

New grills have solved this issue, but it could still happen. Sometimes hopper design can be the culprit. If the slopes at the bottom of the hopper are too shallow, this can interrupt the movement of pellets.

If your pellet grill run out of pellet while cooking here is what you need to do.

Here are some ways to solve this problem:

  • One possible reason for pellet grill tunneling that your pellets are clumping together. If your pellets get stuck together or tunnel around, try stirring them with a long spoon or spatula to break up clumps and keep your hand away from the bottom of the hopper. I do make it a habit to open the hopper a couple of times during a long cook and just even out the pellets as they descend in the hopper. It will prevent tunneling.
  • If you notice excessive pellet grill tunneling, the problem might be due to a defect on the inside of the hopper. If you need to replace any damaged parts, be sure to do so carefully.
  • Clean out any debris in the hopper. Saw dust or other forms of debris can lead to tunneling. Clean the firepot and hopper before each cook.
  • Always sift the pellet first before adding them to the hopper. This stops any dust getting in and compressing which could cause problems with feeding the augur and cause tunneling. Yes, it might seem like a little bit more of a hassle than just dropping the pellets in hopper but the benefits of having fewer issues are worth it.
  • Always check the quality of wood pellet and use high quality 100% wood pellet.
  • Keep the pellet fresh and dry. Damp pellets will occasionally turn into clumps and create tunneling or funneling in hopper.
  • Another important tip to prevent pellet grill tunneling is to apply a silicon lubricant to the inside of the hopper wall. This will help to prevent pellet bridging and hulling issues.

How do you keep pellets from bridging or hulling?

“Bridging” or “hulling,” is a common issue faced by the pellet grills. Bridging is when pellets stack up on top of one another, disrupting the flow of material through the auger. This can result in production stoppages and even fires.

Pellets may bridge or hull when they are not properly sized. There are a few steps to avoid bridging, including adding lubricants to the pellets. Lubricants can be either natural or synthetic, with the latter being more effective.

Wrap Up: Pellet Tunneling In Hopper

Both pellet tunneling and bridging are synonymous and lead to inconsistent supply of pellets coming from the hopper. It is vital to shield your pellets from moisture and to keep an eye on the burn pot for any ash that accumulates. Hope this article has helped you solved pellet tunneling in hopper.

Related Articles:

Can You Leave Pellets In The Hopper Between Cooks?

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