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Maker - Product Challenge

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Chemicals crushing

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

Plastic pollution is one of the biggest climate-related problems mankind has. So what are your options? A bioplastic machine can help create an alternative to traditional plastics. Bioplastics, differently from regular plastics, don’t cause environmental contamination. Also, they don’t contain harmful ingredients and additives. Even with these benefits, the annual production of bioplastics is still less than one percent of all plastic making. However, the market is witnessing steady growth due to a rise in demand.

Bioplastics

Calcium carbonate makes up almost one-twentieth of the earth’s crust. But the abundant mineral is found in many living things, including the human body. However, processing calcium carbonate extracts the multi-purpose material from inorganic sediments, namely limestone, chalk, and marble.

Calcium carbonate

Carbon blacks are fine pigment particles that consist mainly of carbon. Its production became popular in the second century with the establishment of paper production. Hydrocarbons such as oil and natural gas are the basic raw materials for manufacturing them. However, the properties of carbon black differ depending on the processes carried out with the use of carbon machinery and production technology.

Carbon black

Cement

A dishwasher tablet is an essential detergent. It consists of a pressed mixture of sodium and potassium salts, surfactant, fragrance, and other filler agents, mixed with the help of tablet making machines. The products’ use in America and Europe is high, unlike in the Asian continent, where the price limits its usage. Its global market size will reach $990 million in 2026 from $475.6million in 2019, according to Grand View Research forecasts.

Dishwasher tablets

Dyes lend color to the things we consume. The foods we eat, the clothes we wear, and even the keyrings that separate your bunch all have a splash of dye added. Historically, colors were extracted from the natural world, but that process has been replaced by processing technology. Dye manufacturing equipment produces colors that are high in definition and consistency.

To make glue, you usually starting from gelatin, which is animal collagen. Glues help in the production of furniture, automobiles, clothing, paper, wood, art and craft, to name a few applications. The production of different glues depends on their industrial use. Different manufacturing processes and glue making equipment make it easier to create the many variations of this useful product.

Glue

Glycerine is a water-soluble liquid mix of alcohol and sugar. It is a by-product of the oil and fats industry that offers added value to various industries. There are three ways to process it: transesterification, saponification, and fat splitting (hydrolysis). In 2020 these 3 forms of glycerine production reached around 4 million metric tons, with a global market of $1.68 billion.

Glycerine

Industry sees a future powered by hydrogen fuel. The chemical element is an excellent energy carrier that could significantly reduce carbon dioxide emissions across sectors without upending economic models. The tricky part, however, is extracting it in its pure form.

Hydrogen

Colors present an enduring philosophical problem that generates lofty debates about subjectivism and consciousness. Meanwhile, ink manufacturing equipment turns colors into physical objects. Perhaps paradoxically, digitalization keeps fueling the use of printing ink. From custom clothing to secondary packaging to aircraft livery, inks are everywhere. Indeed, philosophical discussions are also primarily conducted in ink on paper.

When he was in Haiti in 1493, Christopher Columbus noticed that the natives were bouncing on rubber balls made from the milky sap of Hevea brasiliensis, also known as a rubber tree native to South America. The milky sap was nothing but latex, the source material for natural rubber. Latex processing technology includes equipment for coagulation techniques and rollers for natural latex and a sequence of mixers, pumps, and sieves for synthetic latex.

Latex

Laundry detergents are currently on the rise due to increasing urbanization and the need for automation. The global market will reach $98,139.7 million by 2030 from $61,711.0 in 2020, influencing the demand for laundry detergent equipment. Unlike in Western countries, powdered detergents are more popular in Asia and China because they’re cheaper.

Laundry detergent

Although invented in the early 20th century by Otto Rohm, detergents gained popularity in the 1950s due to the development of modern technology and washing machines which started replacing scrub boards. The liquid detergent manufacturing process involves three key stages: soap premix manufacture, ingredient mixing and enzyme addition.

Liquid detergents

Landline telephones in the 1980s were minimalist gadgets that kept getting slimmer in the 1990s. In contrast, cell phones in the same period were bulky and cumbersome. And once they lost their charge, they turned into a giant paperweight. Then came a revolution in batteries and automation with lithium-ion battery manufacturing equipment. Mobile phones packed more power, recharged faster, and endured more recharge cycles. Above all, they were light and small, making cell phones the inseparable companions they are today. But Lithium-ion batteries power much more than phones. As a result, the world is seeing steady growth in battery manufacturing equipment and lithium-ion production lines.

Lithium-ion batteries

Also known as color concentrates for plastics, masterbatches are plastic granules that contain additives for coloring plastics. Their major purpose is to bring vibrance and improve the final product's appearance. In the process of making them, masterbatch production equipment is used to combine two major constituents—colorants and polymer-specific carriers.

Masterbatches

Growing populations and intensive farming in the last centuries reduced soil nitrate levels. Aware of the risks to food security, chemists Fritz Haber and Carl Bosch developed a way to industrialize synthetic nitrogen fertilizer production. They created the Haber-Bosch process for ammonia synthesis which is still used today. Manufacturers produce over a hundred million metric tons of nitrogenous fertilizers every year.

Nitrogen fertilizer

Oleochemicals

Painting as an integral aspect of the human tradition dates to thousand years ago. Of the many properties of the product, the drying time is important to consumers. The thickness of the paint and environmental factors like humidity affect this parameter. Paint manufacturing equipment must include a humidity test chamber to assess the behavior of paint under different weather conditions.

Paint

Phosphorous is literally at the root of the food industry. An essential ingredient in agriculture, it contributes to plant seed formation and root development. But farmers do not simply give their soil a dose of the chemical element. Instead, phosphorous fertilizer processing equipment blends it with other materials to manufacture effective formulas.

Phosphorus fertilizer

Powder detergent is one of the most widespread washing solutions used in the laundry of fabrics. Since they contain no water, powder detergents are lighter than liquid detergent or pods, which results in cheaper transport and, thus, a more affordable choice for the end consumer. Although manufacturers can formulate their powder detergents differently, the detergent powder production process relies on a combination of builders, surfactants, and enzymes.

Powder detergent

Despite only one letter difference, silicon and silicone are two different things. While silicon is the 14th chemical element on the periodic table, silicone is a synthetic material that, among other chemical elements, contains silicon. Although commonly observed as plastic, technically silicone is rubber. Among others, silicone processing equipment mainly involves several high-temperature machines, mixers and molds.

Silicone

The inventor of the lithium-ion battery predicted that solid-state batteries would become commercially available by the mid-2020s, making them an attractive option for energy storage in a wide range of applications, including electric vehicles. This battery type promises a marked improvement in safety, power, and environmental impact compared to current battery packs that use a liquid electrolyte. However, recent breakthroughs in the lab don’t automatically translate into mass production. The complex processing requires specially-designed manufacturing technology to make solid-state batteries a real solution, especially for the automotive industry.

Solid-state batteries

Sulphur

Unlike natural resins, synthetic resins produced in the industry make up 30 to 60% of plastic composition. Silicone resins, gum arabic, epoxy resins, acrylic resin and carrageenan are some of the different types of synthetic resins that exist. You manufacture them using the chemical polymerization process. Synthetic resin making equipment can help you with that.

Synthetic resin

As traced back to the first half of the 19th century, attempts at synthetic rubber production were simply to reproduce the original material due to the rubber shortage following World War II. Synthetic rubber production processes differentiate between producing the rubber, which can be done via solution polymerization and emulsion polymerization and creating the final product with the help of techniques such as molding and vulcanization.

Synthetic rubber

A toner is a fine powder located in printer and copier cartridges. One peculiar property the product is their ability to act like liquids. Toner manufacturing equipment sees to it that the particle size is between 5 and 30 micrometers to flow through the cartridge.

Toner

The ubiquitous plastic shopping bag was first designed as a reusable carrier. Its inventor, Sten Gustaf Thulin, will have been appalled to see his creation turn into a single-use object. But this disposable tendency is common to all plastic materials, from screw taps to milk carton lining. With plastic recycling equipment, however, plastic waste can be reprocessed and given a second lease of life.

Recycled plastic

Silica sand

Crushing of "plates" on particle sizes < 30 mm

Dust-free coarse crushing

Make clumped materials free-flowing

Continuous milling is a flow production method used to grind materials without interruption. It is often used in the production of foods, cosmetics, pharmaceuticals, chemicals, and minerals. The material to be processed flows in at one end and the milled output flows out at the other in a continuous process. By choosing the right combination of milling technology and processing power you can obtain the desired particle size distribution in an uninterrupted stream.

Continuous milling solutions

Chemical

Metal

Mineral

Crushing Equipment

Crushing is the process of applying an amplified force to a material to break it down into smaller pieces. A crusher is a machine designed to crush large chunks of material into smaller bits or a powder. They are used to reduce mineral rocks to smaller rocks, gravel, or dust. They are also used to reduce the size of waste materials for easier disposal/recycling or to reduce the size of a solid mix of raw materials. Crusher equipment selection depends on the physical properties of the material to be processed, the in-feed size, and the desired output particle size.

Crushing

Connect directly with world leading manufacturers of Crushing equipment and find technology to build or improve your production line.

Crushing &ndash; Making.com

Crushing Equipment &ndash; Making.com

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

We carry dozens of metals around every day. The ubiquitous smartphone is built with no less than 20 metals, each with specific behaviors and purposes. Metals are a pervasive class of materials that have defined entire eras of human development. It is no exaggeration to say that metal processing equipment is the core of our metallic world. But, paradoxically, this manufacturing technology itself is mainly made of metal.

The nearly 5,000 known minerals on earth share some characteristics to be classified as minerals – they are inorganic, solid, naturally occurring elements and have a particular chemical formula and an ordered internal geometric structure. However, minerals are not all the same. One way to divide them is based on their physical characteristics such as hardness, luster, color, and shape. For example, the diamonds we use to make jewelry are very hard minerals while talc is a soft mineral; gold is a shiny mineral while others are less so.

Minerals

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

Process

Continuous

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

Pre-Crusher type PC from Hosokawa Alpine is a Pre-crusher of plates is suited for the first crushing levels before granulation.

With a pre-crusher continuous flakes are made into pieces, before granulation. Proper pre-crushing before granulation Pre-Crusher type PC from Hosokawa

Pre-crusher of plates &ndash; Making.com

We open production technology to everyone

Making.com

Salt

To put into perspective, the average number of peanuts that you use to make a 12-ounce jar of peanut butter is 540 pieces. Peanut butter is widely used as a spread for most bread and biscuits. To make it, use raw peanuts and process them using peanut butter making machines.

Peanut butter

Horizontal grinding area

Screen netting of 0.5 - 10 mm with support material or grinding sheet

Easy, quick screen change and cleaning

Easy disassembly and assembly

Can be made inert

Pharmaceutical

Feed ingredients

Synthetic fertilizers are made of nitrogen, phosphorus and potassium and are often produced as dry pellets or soluble product.

Synthetic fertilizer

The Flake crusher from Hosokawa Alpine offers a gentle milling action which minimizes fines.

Gently crush down brittle, easily broken materials to fine particle size. Gentle milling action for minimum fines generation The Flake crusher from

Flake crusher &ndash; Making.com

<h2>Chemical process equipment is vast and requires proper selection</h2>
Chemicals are often toxic and require extra care for operators (according to acceptable operator exposure level - <a href="https://www.chemsafetypro.com/Topics/CRA/Introduction_to_Operator_Exposure_Risk_Assessment_for_Pesticides.html">AOEL</a>), as well as <a href="https://making.com/technologies/wastewater-treatment-systems">waste water cleaning systems</a>. In this sense, chemical process technology has made production of chemicals easy and less hazardous. When producing chemicals, keeping potential risk in check is mandatory to protect the environment and human health. So using personal protective equipment isn’t all that you need when using the chemical process equipment. Make sure to take account of chemical reaction kinetics and equipment design by doing thorough investigation of the process. The <a href="https://www.alithya.com/hubfs/en/insights/ebooks/Top-4-Challenges-facing-Chemical-Manufacturers.pdf">scarcity of raw materials</a> may be a challenge to manufacturers, who also need to mind strict industry regulations. One of them is the US <a href="https://www.epa.gov/laws-regulations/summary-toxic-substances-control-act">Toxic Substance Control Act (TSCA)</a>, which prohibits the export of five specific mercury compounds.

Chemical reactors are key to producing chemicals. They have a design and configuration that provides proper environment such as temperature and presence of a catalyst for the chemicals reaction to take place. There are two main types of <a href="https://www.essentialchemicalindustry.org/processes/chemical-reactors.html">chemical reactors</a>: the batch reactor and the continuous reactor. The former usually makes products with different reactants, as in production of colorants and drugs in the pharmaceutical industry. The latter consistently produces ammonia and other chemicals in large quantities.

Chemical reactors, the key equipment to produce chemicals

Dry milling is also one of the core processes in manufacturing chemical products, as it controls particle size and removes excess moisture from products. It is advisable to dry at a low temperature because very high temperatures can melt products. You need to monitor the flow of production from the <a href="https://smallbusiness.chron.com/definitions-upstream-downstream-production-process-30971.html">upstream production process </a>(sourcing of raw materials) to the downstream activities, such as purification of chemicals into finished products. This is to ensure good product quality and improve profitability.

<h2>Some chemical products and their industrial applications</h2>
Industries that use big processing plants buy chemical products in order to make intermediate products. Chemical products like toners, dyes, nitrogen fertilizer, synthetic resins, glue, glycerin, fine chemicals and others work as ingredients of these finished products. The materials and the manufacturing process depend on the industry and final consumer of the products. You can use glycerin in the pharmaceutical industry, for foods and soaps. Also, synthetic resins have wide application in the plastic industry. To provide colors to materials in the textile industry, use dyes. The automotive and furniture industries use adhesives in production.

The release of chemicals, whether in liquid, solid or gas states, can pollute the underground water, soil and air, which in turn poses health risks to humans. To tackle this, the European Union has put in place <a href="https://ec.europa.eu/info/business-economy-euro/product-safety-and-requirements/chemicals_en">strategies</a> to ensure the minimal usage and production of harmful chemicals. The strict EU’s regulations aim to put chemical exposure to check from production level to disposal level. They intend to achieve this by phasing out the use of highly toxic chemicals like mercury chloride except their use is essential and promoting green chemistry for sustainability. For example, instead of producing <a href="https://www.unep.org/news-and-stories/story/many-products-still-contain-mercury-these-alternatives-could-replace-them">mercury-based</a> batteries, there are alternatives like alkaline.

EU regulations moving towards green chemistry

Chemical Processing Technology

Find chemical processing equipment and technology and connect directly with leading machine and equipment manufacturers worldwide.

Chemicals &ndash; Making.com

Chemical Processing Technology - Making.com

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Powder containment is the cornerstone of chemical and pharmaceutical manufacturing. Floating particles do not only represent efficiency loss but serious hazards too. Lack of tightness during the powder discharge process leads to cross-contamination and operational health risks.


<h3>Dock transfer systems squarely in place</h3>
The ASBV active/passive valve interface by Andocksysteme locks into position, minimizing exposure of material during powder discharge. The system has two split valves – one active, one passive – that can be easily and reliably centred on each other at a tolerance of ± 14 mm.

Once the units are docked, the valve discs open simultaneously, preventing exposure of the products during transfers. The dust-tight environment achieves contamination values lower than 1µg/m3.

The ASBV solution is fitted with EPDM seals and are optional with a wide range of materials, such as PTFE, offering top-range chemical resistance. All seals are made from FDA-approved materials and can handle a wide range of temperatures as well as explosion-proof executions.

Washing the ASBV interface is simple as the system can be connected to a WIP loop to flush out residual powders. These containment solutions serve applications with an exceptional performance and are easy to be integrated. Moreover, high quality parts and reduced complexity drives simple maintenance.

High containment split butterfly valve

The battery revolution is as old as the industrial revolution. But batteries only emerged as a viable power source with lithium-ion solutions in the last quarter of the 20<sup>th</sup> century. Today, anything from power tools to automobiles runs on batteries, but advances in battery making equipment are eyeing more ambitious undertakings. Will we ever see battery-powered container ships? Will Battery Energy Storage Systems grow grid-scale successfully? Production technology is steadily moving towards this vision.

Batteries

In 2023, the New York City Fire Department mounted a 200-firefighter operation to put out a massive residential blaze. It was only one of 130 fires in a

Material discharge should be no burning issue for battery manufacturers &ndash; Making.com

Material discharge should be no burning issue for battery manufacturers

Nathanael

Imagine being considered the father of one of the inventions that revolutionized the world and being nominated 41 times for the Nobel Prize – yes,

Building a sustainable future by recycling lithium-ion batteries &ndash; Making.com

Building a sustainable future by recycling lithium-ion batteries

Deborah

Adhesives are grouped according to their form, origin - natural or synthetic - and their material joining method. You can make natural adhesives from plant and animal sources such as bones, hide and skin, agar, dextrin. Manufacturers count with adhesive making equipment to produce synthetic adhesives from organic compounds. They include epoxy adhesives, cyanoacrylates (or super glue), acrylic adhesives and so on.

Adhesives

Most people have seen resin in its natural state from various plants. Serving as a layer of protection and defense for certain trees, this viscous liquid

What is adhesive resin? &ndash; Making.com

What is adhesive resin?

We are happy to share our knowledge on making production of organic and inorganic compounds. Send us a message and we will help you solve your production challenge.

Walter

Find production technology for Chemicals crushing, and connect directly with leading machine manufacturers worldwide.

Chemicals crushing

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Pre-crusher of plates

Flake crusher

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