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Maker - Product Challenge

Products

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About us

Changemakers

Ceramics are defined as inorganic and non-metallic materials. Tthey are typically brittle, hard, and elastic as well as resistant to heat and corrosion; in fact, after shaping them into the desired shape, they are heated in an oven called kiln at very high temperatures (1,000 °C to 1,600 °C). Kaolinite and aluminum oxide are the best-known examples of ceramics.

Ceramics

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Continuous

If you are looking for high end-product fineness for suspensions with good flow properties with a steep particle size distribution, a horizontal agitated media mill can be a good solution. Often used for wet materials like chemicals, foodstuffs, metals, pigments, and paints.


<h2>Continuous wet milling of particles down to the submicron range</h2>
The Agitated Media Mill AHM from Hosokawa Alpine is a horizontal, cylindrical milling chamber that is universal in use for the continuous wet milling of particles down to the submicron range. This horizontal milling chamber was especially designed for suspensions with good flow properties where a steep particle size distribution and high end-product fineness are demanded.

Ball mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium. The mill is suitable for both continuous and batch operations, also available in sizes suitable for the laboratory, the testing center or for large-scale production.

Chemicals, minerals, PCC, ceramics, foodstuffs, metals, pigments, paints (mass production), laboratory, nanoparticles, abrasives, pharmaceutics. This mill is suitable for small amounts of product and for development trials, also in the nanotechnology sector. Extremely small grinding beads (&lt; 0.2 mm) can be employed with this mill, and investigations regarding the stabilization of suspensions in the submicron range can be executed.

Horizontal Agitated Media Mill

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

solid

A horizontal rotary ball mill drum can be used for grinding of dry hard materials, such as hard minerals for the ceramic, glass or porcelain industry and processing of soft minerals with abrasive properties.


<h2>Dry ultrafine grinding of mineral powders and ceramic raw materials</h2>
The Super Orion ball mills from Hosokawa Alpine are employed for the dry ultrafine grinding of mineral powders and ceramic raw materials. The ball mill is designed for the dry comminution of hard materials, especially for the ultrafine range &lt; 10 µm in circuit with an ALPINE ultrafine classifier.

Ball mills are giant drums that are filled with between 30 and 40% of their volume with freely moving grinding media, in this case balls. The diameter of the balls is between one and several centimeters to suit the application - smaller balls for fine milling results and larger ones for coarser milling tasks.

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Horizontal rotary ball mill drum

For high throughputs, with a fineness range of approx. d97 = 32 µm - 200 µm. Ideal for use in the mineral powder industry, especially for ceramic powders that need to be produced without iron contamination.


<h2>Stepless fineness adjustment during operation</h2>
The Ventoplex C from Hosokawa Alpine is a circuit-air classifier, which consists of a fan and classifying wheels that are coaxially arranged and driven by means of two separate hollow shafts. This makes it possible for the user to set different speeds and thus permits a significant extension of the fineness range from currently 32 µm to 200 µm.

Thanks to the low-wear design and the possibility of stepless fineness adjustment, it is able of processing different materials such as limestone, quick lime, fertilizing lime, feed lime, bentonite, dolomite, gypsum, chamotte, quartz, feldspar, pegmatite, raw kaolin, ore, phosphor, glass powder, abrasives, rice flour, bone meal, and so on.

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Circuit-air classifier

Classifying

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

Standard classifier for high outputs in the fine to medium-fine separation range of d97 = 20 - 200 µm. Ideal for processing feldspar, quartz, nepheline, wollastonite and so on.


<h2>Even at high feed rates, the quality of classification is maintained</h2>
The ASP Stratoplex from Hosokawa Alpine is a high-efficiency classifier, designed for the fine to medium-fine separation range with a D97 of approximately 10-200 µm. Even at high feed rates, the quality of classification is maintained.

A compact and modular system that permits not only a top performance but also a trouble-free, space-saving system installation. Many sizes are available with feed capabilities of up to 100 tons/hr.

Often used in the Mineral Filler Industry for separating glass (ground), metal oxides, calcium carbonate, zircon flour, kaolin, bauxite and so on.

It is available in wear-resistant construction for even the most abrasive applications. Integration with ball mill circuits is easily accomplished.

High throughput air classifier for minerals

Air-flow classifier (pneumatic product feed) for the fine classification of talc, calcium carbonate, bentonite, kaolin, loam, dolomite, quartz, kieselguhr, pigments, fine-grade chemicals, and so on.


<h2>Precise classifications of even the finest particles</h2>
The Micron MS from Hosokawa Alpine is an airflow ultrafine classifier designed as an air-flow classifier (pneumatic product feed), that works in a range of approx. d97 = 15 to 150 µm and has as feature its high throughput capacity.

Energy-saving because of the low classifier speed at the same fineness in comparison with other classifiers. This also means a low degree of wear.

Depending on the industry, the airflow classifier can be manufactured in a wear-protected design for operation with abrasive feed materials, and for applications in the food or pharmaceuticals industries, the classifier can be manufactured in stainless steel.

Air flow classifier

For ultrafine classifying operations of mineral fillers such as limestone or calcite, dolomite, talc, baryte and perlite, and in the ceramics industry for the classification of quartz, feldspar and kaolin.  The results are superfine powders in the range d97 &lt; 2-20 µm.


<h2>Ultrafine classifying for superfine powders</h2>
The ATP Turboplex from Hosokawa Alpine is an air classifier for ultrafine classifying operations, obtaining with this superfine powders in the fineness range d97 = 5 to 10 µm; with the NG model, finenesses of d97 = 2 µm (d50 = 0.3 µm) are possible. The horizontal arrangement of the classifying wheel reduces wear even with abrasive products and guarantees a long service life.

The ultrafine air classifier operates across the entire separation range without oversize particles and ensures a high yield thanks to the integrated coarse material classifier, which also increases the cut point. With Turboplex multi-wheel classifiers, several horizontally arranged classifying wheels of the same diameter are driven separately. The common speed control is achieved via an adjustable static frequency converter.

Ultrafine air classifier

For medium-sized fines yields in the mineral powder and filler industry.


<h2>Compact and functional design</h2>
The Turbo Twin Single TTS from Hosokawa Alpine is a classifier that belongs to a newly designed series of Single-wheel air classifiers. The development is based on the established ATP/NG technology and it's considered impressive thanks to its compact design. The TTS is designed for medium-sized fines yields in the mineral powder and filler industry. Just as with the TTD, the TTS is characterized by its low-pressure drop and thus reduced energy consumption. Over and above this, its ease of maintenance is convincing.

Ideal for the ultrafine classification of soft to medium-hard materials such as industrial fillers, calcium carbonate (GCC), talcum, dolomite, barite, kaolin and so on.

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Single-wheel air classifier

Ideal for a combined process operation where several process steps are executed simultaneously in one single unit. A product can be simultaneously comminuted, dried, coated and/or mixed.


<h2>Outperform conventional impact mills for maximum fineness</h2>
The Long Gap Mill – LGM from Hosokawa Alpine can be used for various processes, e.g. grinding and drying as well as coating or mixing a product. Several processes can also be carried out at the same time with this machine in one single process step.

It reaches a fineness of maximum 97% &lt; 5 – 500 µm, depending on the product. Either dry materials, slurry or wet cakes can be processed with this mill.

The range of products that can be processed with the LGM is extremely wide. The most common applications are size reduction of mineral powders, plastics and rubber, soya, wheat bran, carbon black, cellulose and derivatives; Impact drying of hydrogels, cellulose derivatives, ceramic slurries and coating of Fine fillers with stearates or silanes.

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Long gap mill

Flash drying refers to the removal of moisture by a stream of hot gas that goes through a stream of small particles that moves in the opposite direction. When drying large quantities of bulk powders, it can be important to better control the output characteristics of the powder. For this, combining drying, milling and classifying steps in one piece of equipment can be beneficial.


<h2>More control in your flash drying system</h2>
The Micron Dryer flash dryer, Drymeister® (DMR-H) from Hosokawa, can dry temperature-sensitive products, safely, even under increased temperatures, in a matter of seconds. Process parameters like classifier speed and outlet temperature can be adapted to control moisture content and particle size of the end product. The drying system is very flexible, handling moisture content fluctuations from a few % up to more than 80% in suspensions, slurries, pastes, dough, filter cakes and wet powders. The Drymeister® requires 75% less space and uses about 30-40% less energy per kilogram of evaporated water than conventional methods. The Flash combines drying system can be used in different industries such as the food industry, the chemical industry with applications in products such as pesticides, inorganic pigments and fish feed.

Flash drying system

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Fluidized bed opposed jet mills rely purely on particle-to-particle attrition in the center of a fluidized bed of material; this is achieved by focusing in compressed gas nozzles into the milling chamber which accelerates the particles to produce collisions where energy is released causing particle breakdown.


<h2>Maximum fineness with the highest product purity</h2>
The Fluidized Bed Opposed Jet Mill AFG from Hosokawa Alpine is used for manufacturing powders with a steep particle size distribution and sharp top size limitation in the range &lt; 5 µm to 200 µm; maximum fineness values at maximum product purity. Such particle sizes can only be obtained in connection with an air classifying step. Fluidized bed opposed jet mills are equipped with a dynamic deflector-wheel classifier.

Even difficult products can be processed efficiently with the AFG jet mills. Heat-sensitive materials such as toner, resin, wax, fat, ion exchangers, plant protectors, dyestuffs, and pigments; highly pure materials where the requirement is contamination-free processing such as fluorescent powders, silica gel, silica, special metals, ceramic raw materials, pharmaceuticals.

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Fluidized bed opposed jet mills

For pre-crushing before fine grinding, non-fine crushing, sharp-edged granules, and narrow granule distribution. With high-pressure roller mills products are produced with a precipitous granule distribution.


<h2>Compact mills for sharp-edged granules</h2>
The high-pressure roller mill from Hosokawa Alpine is also called roller crusher or roller press. In comparison to compaction processes, it uses lower press forces between the rollers because no new adhesive forces need to be created.

With high-pressure roller mills products are produced with a precipitous granule distribution.

Because only the outer particles of the material bed have contact with the surface of the rollers, milling that is almost contamination-free is possible.

Often used in the cases of medium-fine crushing of hard materials such as ceramics, minerals from 5 up to 9 on the MOHS hardness scale metals and metal alloys.

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High pressure roller mill

Tabletop model for the wet grinding of small to ultra-small product batches down to the nano fineness range. Suitable for a wide range of applications such as engineering ceramics, mineral substances, pigments, paints, fine-grade chemicals, pharmaceutical products, dental ceramics, food supplements, abrasives, submicron, and nano grinding.


<h2>For the wet grinding down to the nano fineness range</h2>
The Wet mill 90 AHM from Hosokawa Alpine is a laboratory device for the wet grinding of small to ultra-small product batches down to the nano fineness range. It is suitable for small amounts of product and for development trials - also in the nanotechnology sector. Extremely small grinding beads (&lt; 0.2 mm) can be employed with this mill, and investigations regarding the stabilization of suspensions in the submicron range can be executed.

In contrast to the other AHM mill types, the laboratory version has a variable-speed direct drive; it is easy to fill in, empty, and clean up due to its pivoted support.

Laboratory horizontal agitated ball mill

Batch

The Alpine Picoline is a series of miniature laboratory machines for processing samples down to 1 gram. The Picoline is ideally suited for research and development or for manufacturing expensive materials such as nano-particles, pharmaceuticals, plastics, ceramics, and specialty chemicals.


<h2>Designed for ease of operation, maintenance, and cleanability</h2>
Picoline from Hosokawa Alpine is a new series of eight individual machines specifically designed for the production of very small batches of between &lt;1g and several grams.

The Alpine Picoline equipment maintains, in miniature, the top engineering standards and leading-edge technology. With machines in the Alpine Picoline series for size reduction, classifying, and mixing.

Because the principle of operation of the Alpine Picoline machines is the same as that of large production-scale machines, R&amp;D departments can be confident that the transfer of a manufacturing process developed using a Picoline machine to a production-scale machine will be smooth and problem-free.

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Laboratory mill for small batches

Compaction machines and technologies crush or compress materials and make them denser. Compaction can be used to simply save space or to shape materials into a desired form or format. Tablets, pellets, or briquets are formed by compactors but powder presses also help form cosmetic eyeshadow or face powder.

Compaction

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

Freeze-drying is used for dehydrating high-value products that are too sensitive for conventional drying processes. The product is dried by freezing, subsequently to the sublimation and ice formation, typically with a vacuum and at low temperatures.


<h2>Mixing and freeze-drying in one step</h2>
The active freeze dryer from Hosokawa Micron uses very low temperatures and a vacuum to dry your product and to obtain it in very good quality. Due to the low temperatures usage the damage of heat sensitive products, such as enzymes, flavors, proteins, vitamins and so on is avoided. Hand traditional tray-type freeze dryers are slow and labor-intensive. Hosokawa's Active Freeze Dryer ® eliminates these drawbacks.
Typical applications include pharmaceuticals like antibiotics, collagens, <a href="https://making.com/active-pharmaceutical-ingredients-api/">APIs</a> and electrolytes; Food industry and in special materials like nanomaterials, polymers, ceramics, pigments, fillers, limestone, catalysts, glass powder and salts.

Active freeze dryer

The laboratory-scale active freeze-drying is used for dehydrating high-value products that are too sensitive for conventional drying processes. The product is dried by freezing and subsequent sublimation of ice formation, typically in vacuum and at low temperatures, in a small laboratory and pilot plant scale, enabling a smooth transition to the production plant.


<h2>Start innovating with freeze-drying technology</h2>
The 1-liter laboratory-scale freezer dryer from Hosokawa Micron is quicker and less labor-intensive than traditional tray-type freeze dryers. It offers the possibility of producing loose and free-flowing powder at low temperatures and low pressures, all in one vessel. Ideal for testing and simulating processes, the lab unit is "plug and play", including controls and all necessary equipment for reliable operation in your laboratory environment. Ideally suited for pharmaceuticals like antibiotics, collagens, APIs and electrolytes; food industry and special materials like nanomaterials, polymers, ceramics, pigments, fillers, limestone, catalysts, glass powder and salts.

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Laboratory scale active freeze dryer

Purposely focused on the indirect heating and drying of slurry, filter cakes, powders, pastes and granulates at a high speed - Dispersing liquids quickly and transforming products such as filter cakes and slurries from centrifuges, wet solids from decanters and press cake after press filtration into dry powders are among its striking features.


<h2>Continuous paddle dryer for rapid and effective indirect drying</h2>
This continuous paddle dryer from Hosokawa Micron is a high-speed dryer. It consists of a fixed cylindrical chamber with an eccentric agitator inside and two independent movements, perfectly capable of rotating on its own axis and tangentially to the cylindrical chamber too.

It has a patented jet rotor design, which allows the injection of a gas or liquid through the paddles and into a thin layer of material as it spirals along the cylindrical wall of the unit. This continuous paddle dryer is designed to be utilized with a variety of heat sources and for other numerous applications, not to mention its speed and effectiveness.

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Continuous paddle dryer

Production of certain pelletized products requires working with output products of a pasty consistency. These products include pigments, clay, detergent additives, vitamin products, and many other products where problems of adhesion of fresh pellets are often encountered. Processing of these types of products requires a pelletizing press that allows the fresh pellets to be directly deposited on a gently transporter such as a conveyor.


<h2>A pelletizing press for depositing pellets directly onto your conveyor</h2>
Amandus Kahl produces pelletizing presses with overhead drives that allow pellets to be deposited directly onto a conveyor from above-eliminating the adhesion issues of fresh pellets often encountered with pasty products. This line of presses uses the proven technology of Amandus Kahl’s other pelletizing presses but the drive unit is above the pelletizing die rather than below it allowing gentle direct deposition of the fresh pellets onto a conveyor. The presses use pan grinder rollers to compact the input material and force it through a pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimizing generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs.

Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. A Kahl variable speed proportion screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Pelleting press with overhead drive

Grinders use a spinning blade or rotating abrasive elements to reduce the size of various materials. The specifications, RPM and grit of the engineered grinder, will result in various particle sizes. As a result, what you want to make will determine the type of grinder you need. Grinding is used for improving the texture and flow properties of various products and to enhance the flavor of food products such as coffee, spices, sugar, nuts, sesame, poppy seeds, lentils, wheat, and rice. Choosing the right rotational speed, grinding elements, and processing power allow the grinding and shredding of a wide range of materials into coarse or fine powders. Popular types of heavy duty grinders in food processing include angle grinders, bench grinders and meat grinders.

Grinding

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

Quality of gypsum and stucco products are highly influenced by the quality of the calcining process employed in production. Consistent grinding, purification, and drying of raw mineral inputs prior to their being entrained in the hot gas flow of the calcining equipment ensures efficient calcining and a resultant high-quality final product.


<h2>Grinding, purifying, drying, and calcining from a single piece of equipment</h2>
Claudius Peters’ EM Mill is a calcining system for gypsum and stucco with an integrated grinding mill. The mill uses free moving steel balls rather than stationary rollers which ensures uniform fine grinding while avoiding the need for any bearings inside the mill. The grinding system employed requires very little maintenance and has been known to achieve a service life of over 40,000 hours. At the base of the grinding system, a scraper acts on the ball track conveying foreign material out of the mill into the reject box.

The efficiency of the grinding system allows low material time inside the mill enhancing the controllability of the process and ensuring uniform product quality. After sufficient grinding material is entrained in a calcining gas flow of unusually high temperature which yields lower gas volumes and optimal energy consumption. The constant randomized motion of the ball grinding system ensures even and constant distribution of raw gypsum for exposure to the calcining flow.

Mill for calcining gypsum

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

The quality of gypsum and stucco products is highly influenced by the quality of the calcining process utilized in the production. Post-processing of calcined gypsum can further enhance the product's quality and reduce production costs, all at once.


<h2>Enhanced product quality through better mixing and homogenization under controlled conditions</h2>
Claudius Peters’ Smart Gypsum homogenizer receives a fresh calcined gypsum continuously at a full temperature from the calciner and improves its quality through post-processing. The material is fed through a vertical reactor chamber with a fabric floor which evenly distributes the fluidizing air allowing the gypsum to float freely in the reactor. Additional air is injected through nozzles in a way that ensures complete mixing of the material in the reactor and outflow of a homogenous product. Moisture content of product outflow is also influenced by the characteristics of the fluidizing and additional air streams. The system can be operated at ambient or under pressurized conditions. Careful control of the processing pressure can be used to determine some characteristics of the product's outflow.

Gypsum homogenizer

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

liquid

Quality of synthetic gypsum and stucco products is highly influenced by the quality of the calcining process employed in production. Even feeding into the hot gas flow and well-controlled retention times determine the quality of the process and the final product is stucco, wall-board, or plaster.


<h2>State-of-the-art, direct calcining technology from a single staged process</h2>
Claudius Peters’ Horizontal Impact Calciner can directly process up to 100 tonnes per hour of fine raw materials used in the production of synthetic gypsum. The design is based on Claudius Peters’ successful EM Mill calciner housing, but includes no grinding elements. Instead, fine raw materials are evenly fed to the hot gas flow via an impact plate which crushes any larger or agglomerated particles. Material flow is based on the proven EM Mill calcifier and optimized for ideal retention times and responsive controls.

Horizontal impact calciner

Quality of gypsum plaster products is highly influenced by the quality of the calcining process employed in production. Production of basic and multi-phase plaster products requires carefully controlled high-temperature processing from dedicated equipment.


<h2>Efficient high temperature calcining for plaster production</h2>
Claudius Peters’ Flash calciner is a highly efficient and reliable calciner for the production of gypsum based basic and multi-phase plasters. The equipment uses single or multiple cyclone stages to suspend raw materials for processing at temperatures up to 500 C. Using cyclone technology avoids the need for any internal moving parts and allows for reliable operation with minimal maintenance even at the high operating temperatures. Calcining at these temperatures ensures controlled formation of defined gypsum anhydrite and anhydrite II phases required for the production of plasters with short setting times. A high degree of efficiency is achieved though continuous recirculation of exhaust gasses, reclaiming otherwise wasted heat and reducing energy consumption.

Flash calciner

After the calcining process gypsum products must be cooled from temperatures of 150 C in preparation for further processing. This is a line of quick and efficient cooling systems based on proven heat-exchanger technology.


<h2>Efficient high temperature calcining for plaster production</h2>
Claudius Peters’ Rotary Drum Coolers can process up to 100 tonnes per hour of calcined gypsum products. The hot material is cooled via the counter-current indirect principal in whom cooling air is moved along through a bundle of tubes in the direction opposite the material flow. As material moves through rotating drum its heat energy is indirectly transferred to the air through the tube walls and exhausted from the system. This exhaust airflow can readily be captured and use as pre-heated combustion air for other plant processes greatly increasing efficiency. The rotating action of the drum also serves to mix and further homogenize the output product. Retention time of the material in the cooling unit is carefully controlled to avoid the formation of unwanted by-products like soluble anhydrite and dihydrite.

Rotary drum cooler for calcined gypsum products

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Unacceptably high dust levels can be generated whilst manual emptying and handling of bags, also products can be dangerous if they come into skin contact or are inhaled. Further issues of product wasting and contamination whilst discharging bags can be difficult to eliminate.


<h2>Continuously discharge bags, automatically and dust free</h2>
The TBMA 'Galahad' automatic bag slitter is suitable for the continuous and dust-free handling of all types of single or multi-layered bags. Any size of paper or plastic bag, whether lightly or densely filled with granular or powdered products, can be cut and emptied without problems. Standard operation will handle approximately 20 tons per hour, however, depending on the properties of the product and the condition of the bags, capacities of up to 50 tons per hour can be obtained.

Automatic bag slitter

Bagging is the process of packaging measured portions of a product into bags that protect it from spoilage, enable easy and safe transportation, and secure the product against tampering and pilferage. The choice of bagging equipment depends on the desired mass or volume per bag, the flow characteristics of the product, and bag construction and design. Bags vary in size from small sachets to bulk flexible containers. Bagging systems are often the last processing step that is generally integrated into a production line.

Bagging

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

A reliable and constant supply of industrial gases is essential in producing quality flat glass. The most common gases needed are oxygen for oxy-fired furnaces, and nitrogen and hydrogen for tin baths. However, they are currently supplied by electrolysis and road transportation of liquefied or compressed gas, making the process expensive and time-consuming.


<h2>Recover the hydrogen-nitrogen gas mixtures left unutilized at the end of industrial processes</h2>
To reduce the environmental impact and to provide a more cost-effective and reliable gas supply, HyGear has combined conventional trailer distribution with on-site generation.

The Hy.REC mix system from HyGear recovers the polluted and used mix gas atmosphere from tin baths in float glass production. A significant amount of nitrogen and hydrogen is then recovered, allowing the new reductive gas mixture to be reused.

As the economic return of gas recycling systems depends on their energy consumption and the value of the recovered gas mixture, the Hy.REC mix is engineered to use the lowest possible amount of electricity, resulting in greater economic viability. The post-treatment module is designed with advanced Temperature Swing Adsorption and an ultralow pressure drop to decrease operational expenses.

Depending on the nature and the size distribution of the contaminants, the Hy.REC features either a dry or a wet filtration module. The innovative Condensation Scrubbing Technology further operates at fairly low pressure and reduces the system’s total utility consumption. Moreover, advanced technologies in the conditioning system minimize energy losses and ensure a long-term safe and stable operation.

All in all, the Hy.REC®mix recovers the gas mixtures from tin baths in float glass production. However, by making small changes, the system can be adapted to other applications as well, making it ideal for use in food industries, metal industries, chemical industries, and electronics industries.

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Gas recovery for the glass industry

Industrial cleaning equipment is used to wash or disinfect machinery and the production/warehouse area. It may also be used to sterilize the product, equipment, tools, floor or work surfaces and to purify or clean the product by removing impurities. Choosing a suitable cleaning system depends on the type of product or equipment to be cleaned, the sensitivity of the product to heat, pressure, and chemicals, and the level of sterility desired.

Cleaning

Traditional dosing systems do not have a very long operational life and are hard and expensive to maintain. If you are looking to dose your bulk products like compound feed, mineral premixes, pet food, seeds, plastics, building materials, etc, you need a machine which ensures a relatively lower cost while maintaining high speed and accuracy.


<h2>Low costs with high-performance dosing for macro ingredients</h2>
KSE’s ALFRA GCD dosing and weighing system is configured with a stationary weighing hopper, which is closed for low-dust operation. It can combine ingredients from up to 24 silos automatically.

The traditional screw dosing machines entail a 1:20 dynamic flow range, while KSE’s unique dosing slide has an enormous flow range of 1:1000. The macro ingredient dosing system thus ensures that dosing and weighing is no longer a hurdle in the production process. This workhorse machine is low cost yet has high speed and accuracy leading to a high throughput that showcases its high-performance standards. It can handle products from 1 kg up to 1000 kg. It has a self-learning software which optimizes the flow profile for highest speed and precision ensuring no excess usage of raw materials. This allows the user to save the raw material expense. Upon the completion of a batch, the predetermined weight is discharged into the transport belt, under hopper or the mixer below the machine.

It has very few moving parts which makes cleaning, inspection and maintenance very simple, keeping the operational costs low. Its applications include, dosing of industrial building materials, chemicals, plastic, pet food, compound premixes, gypsum, raw materials for grinding discs, etc.

Macro ingredient dosing system

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Weighing

When you need to produce ultra-fine powders, the milling and drying process employed is what ensures the consistency of your product. To process minerals and chemicals, you need a machine which is powerful, flexible, simple to maintain.


<h2>Versatile and highly efficient milling and drying</h2>
Atritor’s cell mill has been constructed to produce ultra-fine powders. It is able to grind, flash dry, classify and surface coat powders at the same time. Its capacity ranges from 50 kilograms per hour to 15 tonnes per hour, with evaporation rates up to 3,000 kilograms per hour.

The feed can be dosed directly into the machine via a screw feeder or via the inlet air duct. It is then ground in a vertically mounted, multi-stage rotating rotor. Each of the rotor sections is constructed with up to 200 quick-change blades. There is also the possibility for a classifier which is mounted at the discharge section to ensure that oversized feed particles are either discarded or recirculated.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or even waste heat from another process. It can reach an inlet temperature of up to 450ºC. Heat energy from the process can be recovered from the heated air stream and utilized to preheat the intake air. After flash drying, the product is kept cool due to evaporative cooling via the constant exposure of new surface areas of the product created during attrition.

In the case of minerals that require surface treatment, the cell mill provides a range of coatings and surface modifiers that can be added on the side of the machine during the milling process. It has a wide range of applications, from minerals like GCC, clay and limestone to chemicals, dyes, pigments and a wide range of food ingredients and by-products.

Milling and drying machine for fine powders

Ultrasonic spraying technology has the ability to create a thin and uniform nanoparticle coating using a low-velocity spray that realizes a precise targeted spray pattern. The low speed allows for a gentle touch and high controllability of the spray that will lower the waste of expensive material. There are even ultrasonic spraying systems suitable for scientific research institutions and for manufacturers with small volume production.


<h2>Benchtop system for creating uniform coating on fuel cells</h2>
With the UAM4000L, Cheersonic developed a solution that creates a coating using ultrasound technology. The system meets market needs in a wide range of industries and applications for the spraying of glass (e.g., optical lenses, electrochromic glass, flat panel displays or oleophobic coating), fuel cells, solar cells, sensors, PCB (Printed Circuit Board), semiconductors and photoresists.

The machine is provided with a syringe pump that moves the liquid to the ultrasonic nozzle that vibrates longitudinally. Ultrasonic technology converts high-frequency sound waves to mechanical energy, forming standing waves on the tip of the spray nozzle. When the liquid comes out of the nozzle, waves are separated into small droplets. As they reach a critical amplitude, the liquid is sprayed out as a mist. Compared to conventional technology based on pressure nozzles, the ultrasonic coating system has the ability to deposit droplets in a very gentle and accurate way on the substrate due to a low-pressure and low-velocity spray. By using very little pressure, the nozzle doesn’t clog, and the drops bouncing effect is eliminated.

Ultrasonic spraying system for small scale coating and research processes

Biotech equipment is used for cellular and biomolecular processing to develop products that improve our lives and the planet. With the help of specialized lab equipment, the active substance is manufactured or extracted from biological origin materials and typically produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Cell isolation, cultivation, cell banking, and culture expansion are called upstream processes. After harvest, the production process moves into a downstream process to meet purity and quality requirements which is divided into cell disruption, purification, and polishing. Biotechnology equipment makes use of various laboratory machinery such as bioreactors, centrifuges and incubators.

Biotech

To coat your consumer products with color or taste-enhancing substances, specialized technologies are available that ensure all the contents are individually and evenly covered. The process starts with loading your goods onto rotating drums, exposing the products to spray nozzles that treat them with your prescribed coating formula.

Coating

When it comes to expensive chemical solutions and suspensions that need to be applied on a substrate to create a coating, precision and uniformity are watchwords. Achieving this degree of precision is possible with an ultrasonic spraying system that works with easy to control low-pressure, low-speed spray. No more over spraying of material which translates into less material waste and more savings.


<h2>High performance system for depositing thin film coating on solar cells</h2>
The UAM6000 designed by Cheersonic is an industrial-grade spraying system suitable for medium and large-scale producers, where the machine produces the coating with the use of high-frequency sound vibrations. This ultrasonic solution opens up to a broad range of applications like sensors, solar cells, photoresists, PCB (Printed Circuit Board), fuel cells, glass (e.g., optical lenses, electrochromic glass, flat panel displays, oleophobic coating, or touch screens).

The machine is fitted with a syringe pump that moves the liquid to the ultrasonic nozzle that vibrates longitudinally. Ultrasonic technology converts high-frequency sound waves to mechanical energy, forming standing waves on the tip of the spray nozzle. When the liquid comes out of the nozzle, waves are separated into small droplets. As they reach a critical amplitude, the liquid is sprayed out as a mist. The maximum effective spraying area is 500*500mm. One important feature of the UAM6000 is the constant flow of the syringe pump in which the liquid can flow without interruption.

Compared to conventional technology, the ultrasonic coating system has the ability to deposit droplets in a very gentle and accurate way on the substrate due to a low-pressure and low-velocity spray. By using very little pressure, the nozzle doesn’t clog, and the drops bouncing effect is eliminated.

Ultrasonic spraying system for medium and large scale coating

Decoration equipment adds the finishing touch to your industrially-prepared foods by depositing ingredients in a specified pattern on the surface of the products. Your items pass individually under a system of nozzles that lay the decorating formula precisely and uniformly. Popular in confectionery, decoration is used to differentiate products in the market.

Decorating

Bentonite is a clay derived from the alteration of volcanic ash. Bentonite is solid, so after extracting it from the deposits, it has to be crushed and dried to reduce its moisture content up to 15%.

Bentonite

Limestone

Cement

Silica sand

Kaolin, also called china clay, is made from natural rock composed of aluminosilicate clay or kaolinite. Kaolin has wide applications in different industries. Moreover, their classification depends on their industrial use, which includes film formation, fiber extension, polymer extension and chemical composition. Choose a kaolin processing machine to help you make kaolin for beauty products, paper filler, coating, ceramics and even medicine.

Kaolin

Aluminium oxide or alumina is a naturally occurring compound of aluminium and oxygen made from bauxite, a dull and earthy rock with high aluminium content. Bauxite is the most common ore of aluminium and you can find it in tropical areas Most of the bauxite mined end up producing aluminium with specific aluminium oxide equipment. Statistics have shown that Australia and Guinea have the largest bauxite deposits in the world. Countries like China, Brazil, and India also have a large amount of the rock.

Aluminium oxide

Gypsum is a naturally occurring mineral that serves many purposes, with the United States producing the largest crude gypsum in the world. Cover walls, ceilings, plasters, fertilizers, cosmetics and some foods: gypsum’s vast applications granted it the recognition of "wonder mineral". Gypsum making equipment helps in making gypsum powder or board for industrial use.

Gypsum

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