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Maker - Food Product challenge

Products

Technologies

About us

Changemakers

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

With the increase in the world population and rising concerns for environmental sustainability, the market for suitable new protein sources is expanding rapidly. Traditional agricultural methods alone can’t deliver sufficient protein to meet the projected food demand over the next decades. Insects provide an alternative source of nutrients. But insect protein does not mean direct insect consumption. Extracting protein and amino acids from farmed insects is more sustainable and efficient. Specialized insect protein processing technology is driving the transformation toward new protein sources.

Insect protein

Pet food is a specialty food mostly based on formulated ingredients for various nutritional and dietary requirements. Pet food formulas are becoming more diverse and complex, considering the special health conditions and needs of young and aging pets that live in cities. The production of pet food is similar to processing food in general when it comes to fresh feedstock and flesh products.

Pet food

Feed ingredients

Liquid

Protein

In Ancient Egypt, starch production was used mainly for coating and gluing the papyrus sheets. Today, the paper industry still uses the same technique even if starch processing equipment has changed immensely. But besides shiny reams, starch has a fundamental place in the food and beverages industry.

Starch

Aquaculture feed is used when rearing marine livestock such as fish, shellfish, and algae. Quality nutrition is needed for healthy growth and reproduction and feed usually consists of fats, carbohydrates, protein, vitamins, and minerals. Extruded aquaculture feed floats on the water surface and pressure-pelleted feed will sink to the bottom.

Aquafeed

Organic fertilizer production has ancient roots, tracing its origins to ancient farmers who used natural materials like animal manure, compost, and crop residues to improve soil fertility. This sustainable tradition of repurposing organic waste for agricultural benefits has endured through the ages, handed down from one generation of farmers to the next. Producing organic fertilizer industrially involves a series of steps such as extraction, granulation, drying, and employs a combination of organic fertilizer production equipment.

Organic fertilizer

Continuous

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

solid

This device is mainly employed for grinding sodium-hydrocarbonate used in flue-gas cleaning.


<h2>Easy cleaning, inspection and exchange of grinding elements</h2>
The Classifier Mill - APP Powderplex from Hosokawa Alpine is a single-rotor classifier mill for powder fineness values of d97 = 20 to 200 µm. It is easy cleaning, inspection, and exchange of grinding elements. It has an integrated air classifier with a high precision of cut for fines with no spatter.

Universal in use for materials with a Mohs’ hardness of approx. 3.5; it is the right solution when powders have to be produced with constant fineness over a long period of time.

Sodium-hydrocarbonate classifier 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

When high cutting forces and high throughput are required, you need a granulator that has proven its reliability under the hardest of tasks.


<h2>High troughput proven economical granulation</h2>
The Ro Rotoplex from Hosokawa Alpine consists in a cross-scissor-cut rotor that offers process technological superiority, saves energy, increases the service life, and improves the material feeding characteristics. These large granulators are capable of extremely high capacities due to our unique design and multiple knife geometry. Besides the classic field of plastics size reduction, Rotoplex large-scale granulators are exemplary for fiber, film, purgings, wire and cable and many more difficult materials.

Characterized by performance capacity, economy, and operating reliability. High-grade spheroidal graphite cast iron ensures that even in continuous heavy-duty operation, the Rotoplex granulators do their job reliably over many years.

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Large granulator

Cutting

Granulation

When working with plastics, film, and other cuttable products, you can benefit from a custom-designed granulator.


<h2>Cost-effective granulation at an attractive price</h2>
CL Compact granulator for cuttable products, from Hosokawa Alpine offers all the integrated technology necessary for the cost-effective comminution of all kinds of plastics. Developed as a universal granulator, it is characterized by a modern and user-oriented machine design as the starting point for custom-designed complete systems.

The universality and the technical features shift the product line right into the center of the customized systems for the recycling of plastic waste and plastic film of all types and shapes as well as other cuttable materials.

Its cross-scissor-cut rotor guarantees optimum material intake and distribution and thus high throughput rates at reduced energy consumption.

The typical materials processed are: PVC, Nylon, HDPE, LDPE, PP, ABS, PET, PC– TPU, PS, Cu, Copper wire, cables and many other materials.

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Compact granulator for cuttable products

When you want to mill soft to medium-hard plastics in the fineness range of several hundred µm to 2 mm, a fine cutting mill can be a good solution for you. Such mills are suitable for the communication of rubber, plastics, and other substances.


<h2>Smooth, cubic shape output with good flow properties</h2>
Fine Cutting Mill AFS from Hosokawa Alpine are commonly used in the size reduction of soft, medium-hard, fibrous and tough materials. A rotor inside the mill revolves at high speed. Different rotor geometries make mills adaptable to different material properties (medium-hard, soft, fibrous or elastic materials).

The feed material, usually between 4 and 8 mm in size, is fed into the grinding zone via the intake chute on the mill door. Size reduction takes place between the axially adjustable stator disc and the rotating grinding disc, which rotates at a high peripheral speed in accordance with the shearing and cutting principle. The actual grinding is effected in stages through a grinding gap which tapers from the inside to the outside. The finely ground product exits the grinding zone through an exactly defined gap.

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Fine cutting mill

If you are shredding very difficult materials, you may need to choose a special construction to avoid the risk that plastic film or fibers winds themselves around the shaft and block your process.


<h2>Even the most difficult material can be shredded without problem</h2>
Shredder - DL DuraLine from Hosokawa Alpine are characterized by a heavy, torsion-resistant support construction, knife shafts made from solid and special perforated screens that permit precise determination of the product.

A menu-guided control system permits variable settings to be programmed and operating modes for different materials (as a function of their specific properties) to be stored in memory. The torsion-resistant shredder can reliably shred even the most difficult material without problem.

Because of the positive engagement of the knife blades with respect to the knives on the opposite side, materials such as plastic film or fibers are stripped reliably and cannot wind themselves around the shaft.

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Torsion-resistant shredder

A shredder is used to reduce the size of various materials through the cutting action of its contra-rotating shredding rollers or knife shafts. Industrial shredders come in many different designs, sizes, and variations. Shredders are best used for the disposal of used tires, scrap metal, car wrecks, garbage, recycling of plastics, paper, and shredding of various foods such as cooked cereals. The choice of a suitable heavy duty shredder depends on the properties of the material to be processed, the desired shred size, the size of the in feed material, and the volume of material to be processed.

Shredding

When you consider shifting pharmaceutical mixing processes from batch to continuous, accurate in-line continuous blending can be a real challenge.


<h2>In-line continuous blender with fast reactivity and minimum residue</h2>
The Modulomix from Hosokawa Micron is a continuous modular mixer and it has been designed to be compact with fast reactivity, minimum residue and rapid start-up and shutdown protocols, very useful in pharmaceutical applications.

It is a very compact blender because you will be able to combine the Modulomix modular mixer with PTS, LIW feeders, continuous blenders, PAT technologies and even downstream processing, like (wet) granulation and/or compact. It is adaptable due to it lets you have two different mixing environments in one single phase, multiple Modulomix mixers can be cascaded in series.

In-line continuous blender

Blending

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

Batch

When you want to mix segregative, free-flowing powders and pastes that require perfect mixing quality and accuracy but require careful treatment, a conical screw mixer is a proven solution.


<h2>Gently mixing with perfect accuracy</h2>
The Vrieco-Nauta® conical screw mixer from Hosokawa Micron is a convective mixer with high mixing efficiency and accuracy for large volumes of up to 100.000 liters, specially designed for segregative, free-flowing powders and pastes. The conical vessel design allows a wide range of filling capacities and the mass flow characteristic design minimizes segregation upon discharge. Because there are no horizontal internal surfaces, products are completely discharged, minimizing product loss and providing for easy cleaning. Suitable for a wide range of processing activities in the pharmaceutical, food, plastic, metals &amp; minerals, nuclear, chemical, pigments and coatings industries.

Conical screw mixer

The conical screw vacuum dryer is particularly suitable for the final drying of powders, granules, pastes and viscous slurries especially when they are brittle and/or temperature-sensitive. It is often used for active pharmaceutical ingredients, pesticides, sterile APIs, chemically produced toner and cocoa.


<h2>Gentle drying of temperature-sensitive products</h2>
The Vrieco-Nauta® conical screw vacuum dryer from Hosokawa Micron is a universal batch dryer, capable of drying volumes ranging from 5 to 22 000 liters, suitable for powders, granules, pastes, viscous slurries, heavy and sticky products. Specially designed for heat-sensitive products or products that contain solvents that are toxic or explosive. It can also be used for vacuum operations such as reaction/crystallization, heating/cooling,
sterilization, liquid/solid separation and de-aeration. Controlling the moisture content by monitoring the weight of condensate or using the Hosokawa sampler for taking samples from the product inside the dryer under vacuum.

Conical screw vacuum dryer

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

When you are looking for a low-speed, indirect drying solution, a disc dryer can be a good option. Suitable for heating and cooling various types of products like filter cakes, powders, viscous materials and granules, it is often used for materials requiring very long residence times or sticky materials with back-mixing.

<h2>Indirect drying with high surface/volume ratios</h2>
The disc dryer from Hosokawa Micron is a low-speed, horizontal, indirect dryer. Using hot air or gas as a drying medium in combination with a heating jacket and heating rotor, which consists of special, heated discs within a cylindrical jacketed housing. It works by combining high heat transfer rates ranging from 85 to 300 W/m²K with high surface/volume ratios. Residence times range from minutes to several hours, making it more versatile than almost any other indirect heat exchanger available today.

Disc dryer

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

For the compression of charcoal powder into briquettes between two counter-rotating rollers, this process is called briquetting.


<h2>Efficient compactor for charcoal briquetting</h2>
Kompaktor HK from Hosokawa alpine was made to compress charcoal powder into briquettes.

Mechanical spring assemblies provide for the elasticity of the swing arm which protrudes due to its light construction. This leads to a very good price-performance ratio for this application.

Hosokawa manufacturers the roller mill for charcoal in two different executions: HK 150 and HK 200, with a roller diameter of 400 and a throughput in of 1 and 2.5 t/h respectively.

Roller mill for charcoal briquettes

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

A Laboratory air jet sieve is used for determining the particle size distribution of powdery and granular materials.


<h2>Intuitive analysis of particle size distribution</h2>
The e200 LS from Hosokawa is ideal for analyzing any kind of dry material. Samples of between 0.3 and 100 grams in weight can be analyzed easily and quickly. The batch weight is dependent on the sieve mesh width and material density. The extraordinarily good dispersion of the material being analyzed by the nozzle jet permits analyses down to 10 µm with the micro-precision sieves.

The only thing that moves the material being analyzed is the airflow. This system makes it possible to do without any and all mechanical means of influencing the sieving process of different materials, such as non-organic or organic granular materials including sands, crushed rock, clays, granite, feldspars, coal, soil, a wide range of manufactured powders.

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Laboratory air jet sieve

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

Sieving machines are available in various designs such as linear sieves, tumbler sieves, and vibrating sieves each employing a different sieving action. The choice of a suitable sieving machine depends on the desired particle size distribution, required amplitude and frequency of vibrations, and the physical state of the mixture. Sieving machines are used for removing dust from granular products and for grading grains. They are also used for the classification of granular material and the separation of solids from a slurry mix in the food processing industries.

Sieving

A laboratory fine impact mill is used for fine and ultrafine grinding, for defibration, and for cutting soft materials.


<h2>Small scale size reduction of soft materials</h2>
The 100 UPZ und 160 UPZ Fine Impact Mills from Hosokawa Alpine are designed for fine and ultrafine grinding, for defibration, and for cutting materials of Mohs' hardness up to 3. Depending on the equipment, powder fineness values range from approx. 100 µm to 1500 µm.

The fine of the final product is adjusted by the selection of the corresponding size reduction elements and as a function of the machine speed.

This mill has many applications in the chemical industry, foodstuffs, and animal feed industry as well as in the pharmaceutical industry.

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Laboratory fine impact mill

Especially designed for flue gas desulphurization, applications in coal fired power plants and waste incineration plants.


<h2>High-quality gypsum with minimal residual moisture</h2>
Gypsum centrifuges from Ferrum are used for the cleaning of the raw flue gas in a wet process with slurry of limestone to form gypsum; this process is called dewatering in desulphurization.

Dewatering is effected discontinuously in a sequence of specific process steps, which are filling, intermediate centrifugation, washing, centrifugation, scraping/solids discharge and residual heel removal.

With this system you will realize trouble-free solid-liquid separation with maximum performance, minimum energy consumption and consistent, reproducible product quality.

Also the gypsum centrifuges can be used in the construction industry instead of being dumped in environmentally harmful landfill sites.

Gypsum centrifuge

Industrial centrifuges are widely used for mechanical solid-liquid separation of components in the pharmaceutical and chemical industries. This is achieved by rapidly rotating the contents within a container to separate fluid of different densities or to remove liquids from solids.

Centrifuging

liquid

A high-impact mixer can help you to produce a homogeneous mixture when you are mixing powders and liquids of different viscosities. High impact mixers are often used the production of detergents, pesticides, water-soluble polymers, fine chemicals, veterinary/bulk pharmaceuticals, milk replacers, instant soups, beverages, and sauces.


<h2>Compact high impact mixer for large volumes</h2>
The Schugi® Flexomix from Hosokawa Micron is a high-impact mixer developed to achieve a highly homogeneous mixture of powders and liquids. It is unlike any other continuous mixer with its vertical cylindrical chamber and vertical rotating shaft and is capable of handling high volumes of product. Its high rotational speed and turbulent mixing keep the mixer chamber clean; it provides accurate dosing of both liquid and solid components and is suitable for even the stickiest of media. Liquids of varying viscosity and steam can be added using atomizing nozzles mounted to the upper part of the chamber just above the upper mixing blades.

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Continuous high impact mixer

When you need to mix cohesive powders with liquids or melt binders and require a homogenous end-product, a high-shear mixer can be used.


<h2>High-speed, intensive paddle mixer and agglomerator</h2>
The Cyclomix® from Hosokawa Micron is a multi-purpose high-shear impact mixer. It combines different processes in one single machine and is the ideal choice for intensive thermal processing of high energy input; high degree of dispersion and homogeneity and ultra-short cycle times.
The mixing vessel is conical shaped and has a central rotor that rotates at a speed up to 30 m/s. The speed of the rotor creates centrifugal forces that push the product to the vessel wall where the shape of the vessel causes an upward movement.

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High-shear impact mixer

An extrusion machine pushes or pulls material through a shaped die to form a continuous length of product with a preset cross-section. The extrusion process is used to produce a large number of commercial products which include plastic tubing, plastic sheets, and many food types.


<h2>Kneading, mixing and extruding in one continuous process</h2>
The Extrud-O-Mix from Hosokawa Micron is an efficient extruder that kneads, mixes, and extrudes in one continuous process; as a standalone unit or in combination with other process equipment. Perfect for mixing solids and liquids into very viscous and homogeneous pastes as well as plastic masses, and moreover it has better particle dispersion in comparison to higher pressure systems, is also less expensive to buy and less expensive to operate. The high shear mixer can be used for a variety of applications like mixing base powders with liquids to form uniform pastes, homogenizing filter cakes, blending wet material with powders or liquids, homogenizing powders with liquids into a plastic mass followed by extrusion and pre-feeding of caked masses.
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Continuous extruder for mixing solids and liquids

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

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

For continuous intensive mixing of fine and cohesive powders, a continuous high-speed paddle mixer offers the advantage of short residence times and accurate temperature control.


<h2>Intense continuous mixing with short residence times</h2>
The high-speed paddle mixer from Hosokawa Micron is a continuous horizontal paddle mixer with paddles located in a single helical or double helical pattern around the rotor shaft. This continuous paddle mixer has been developed for fine and cohesive powder applications. Capacities from 100 kg/h to 100 000 kg/h. Typical residence times range from 1 to 20 seconds. The system can be used for a wide range of applications, such as high-intensity mixing, coating, fine agglomeration or continuous reaction of powders with gases. It is capable of extremely high, heat transfer efficiency due to close contact between the material and the heated inside surface. Units can also be fitted with a heating or cooling jacket depending on the process requirements.

Continuous high-speed paddle mixer

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

A laboratory conical screw mixer is often used in the pharmaceuticals and fine chemicals sectors, in order to investigate or create new compounds. When a gentle mixing action is needed, the low shear agitation results in minimal mechanical product stress and is therefore particularly suitable for homogenizing sensitive bulk powders and solids with very different product characteristics.


<h2>Reliable predictions from only 0.3 liters powder contents</h2>
The Vrieco-Nauta® Minimix lab mixer is a 3-liter conical screw mixer from Hosokawa Micron and has the same advantages as the production size Hosokawa Vrieco-Nauta mixer: High mixing accuracy, gentle mixing, complete discharge and flexible filling range. Already giving reliable predictions from only 0.3 liters powder contents, specially designed for segregative, free-flowing powders and pastes in a batch process. Suitable for a wide range of processing activities in the pharmaceutical, food, plastic, metals &amp; minerals, nuclear, chemical, pigments and coatings industries.

Laboratory conical screw mixer

This label marks innovative technologies that can be used for product development and smaller scale production. Easy access to leading processing know how is necessary for makers to create the products we need for a better tomorrow.

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Empowering changemakers

This classic vacuum dryer comes with extensive product and process know-how at the Hosokawa Micron test center to make a perfect entry level solution for any powder maker. 

The laboratory conical screw vacuum dryer is particularly suitable for the final drying of powders, granules, pastes and viscous slurries especially when they are brittle and/or temperature-sensitive. Useful during research and development when only a few grams of a new substance are available. Ideally suited for testing pharmaceutical products, pesticides, sterile APIs, chemically produced toner and cocoa.


<h2>Test drying processes for sensitive products</h2>
The 5-liter conical vacuum dryer from Hosokawa Micron is used for drying off heat-sensitive materials at typical 10 - 20 mbar absolute pressure in a batch process, this orbital vacuum dryer is the right tool for laboratory-scale experiments. It can handle pasty products, cakes or high viscosity slurries and delivers reliable attempts or simulations of drying and mixing. Suitable for powders, granules, pastes, viscous slurries, heavy and sticky products. Specially designed for heat-sensitive products or products that contain solvents that are toxic or explosive. It can also be used for vacuum operations such as reaction/crystallization, heating/cooling, sterilization, liquid/solid separation and de-aeration.

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Laboratory conical screw vacuum dryer

A Laboratory high shear impact mixer can be used to simulate different processes; from slow speed pre-blending to high-speed coating, agglomeration, and dispersion.
<h2>Experiment with cohesive powders on a lab scale</h2>
The Hosokawa Micron high shear impact mixer 1 liter is a downsized Cyclomix lab model, with a working volume of typical 0.3 - 1 liters powder content, mainly used for cohesive powders. Using frequency control, any mixing process can be imitated on this small-scale mixer: from slow speed pre-blending to high-speed coating, agglomeration, and dispersion.
It is used in the adhesives, chemical, cosmetic, food, pharmaceutical, and plastics industries for emulsification, homogenization, particle size reduction, and dispersion in the batch process.
Combining different processes in one single machine and is the ideal choice for intensive thermal processing of high energy input; high degree of dispersion and homogeneity and ultra-short cycle times.

Laboratory high shear impact mixer

An emulsifier is used to mix two immiscible liquids. Heating or cooling requirements during emulsification, overpressure or vacuum requirements, the need for wall scrapers, design of the mixing head, the viscosity of the liquids, and the desired droplet size are all important considerations when selecting an emulsifying system. Emulsifiers are typically used in the food industry for the production of batters, creams, and sauces, in the pharmaceutical and cosmetics industry for the production of creams and lotions, and in the chemical industry for the production of paint and other emulsions.

Emulsifying

Formulation technologies are an integral process in many industries such as pharma and food. Chemical mixtures require strict handling to combine the separate ingredients into the homogenized recipe that makes your final product. Formulation technology stores, mixes and subjects the elements to a range processing parameters according to your specifications to develop the base material. The resulting formulas are then weighed, formed, packaged, or sent for further formulation.

Formulation

When you have a very limited amount of powder available, you can still test your processes with the Hosokawa Picoline. The Picomix is the mixing module in the Picoline. It is a high-shear mixer that allows you to work with 30ml to 100ml batches.


<h2>Intensive and homogenous mixing on microscale</h2>
The mini Cyclomix from Hosokawa Micron is a high-shear batch mixer for dry powders in a miniature scale. It is the downsized version from the Hosokawa Cyclomix, which combines different processes in one single machine for intensive thermal processing of high energy input; high degree of dispersion and homogeneity and ultra-short cycle times.
Moreover, the speed of this mixer can reach up to 6,000 L /min, the maximum volume it can handle is 20-100mL, and the product batch should weigh approximately 20 g. The result of the unique composition of the mixing element is an intensive homogenous and quick mixing of the powder components.
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Miniature scale high-shear mixer

A mixing &amp; fluid bed granulation system is the combination of a fluid bed dryer and a high Impact mixer. If you have a high-capacity continuous powder process where you need to mix various powders with liquids, agglomerate and then dry the granules, such a combined system may be the best way to go.


<h2>Continuous mixing, agglomerating, drying and cooling</h2>
The Schugi® Flexomix agglomeration system is a combination of two proven Hosokawa Micron technologies: the Flexomix continuous mixer and agglomerator, and the Schugi® fluid bed dryer and cooler. This combined design provides optimal process control and makes this combination the ultimate powder processing solution. The system is controlled using a state-of-the-art integrated control system based on PLC and SCADA systems. It produces instant agglomerates with an open, raspberry-like structure, good solubility and good flow characteristics. Moreover, it has been designed as a stationary unit without any moving parts making it perfect for scaling up to almost any size. The system is suited for powders, granules, agglomerates, and pellets. Often used in the food industry, pharmaceutical and chemistry.

Mixing and fluid bed granulation

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

When you want to predict powder behavior in future and existing installations, possible measures to be taken or for standardized product quality control for incoming goods, you need a good Powder tester.


<h2>Measure flowability and floodability of your powders</h2>
The Powder Tester PT-X from Hosokawa Micron is used to determine the flowability and floodability of dry powders. The model PT-X is the latest design of the Hosokawa Micron Powder Characteristics Tester which utilizes state-of-the-art features to identify the specific characteristics of powdered samples for a wide range of application fields.

Powder tester

Drawing samples and testing them for conformity with preset quality standards allows manufacturing units to produce a consistent quality of the product. In a batch process, sample testing systems ensures that each batch meets the specified standards. In a continuous process, product and materials testing helps in the early identification of quality issues, saving significant time and resources, and preventing a sub-standard product from reaching the market. The selection of industrial testing equipment depends on the identification of key quality parameters. These parameters may include volume, weight, viscosity, hardness, particle size distribution, sterility, gauge and containment, among other parameters. Testing machinery need regular calibration to ensure that the parameters being tested are accurate. Some of the more common testing solutions include thermal imagers, scratch testers, optical inspectors and texture analyzers.

Testing

Mid shear mixers are typically used for processes where high shear leads to product deformation and low shear results in inadequate mixing.


<h2>Combine gentle and mid low shear mixing in one machine</h2>
The Vitomix® from Hosokawa Micron is a mid-shear mixer capable of ultra-short cycle times with up to 8 times more transport volume than conventional ribbon screw mixers. It is also known as a ribbon screw blender, also has a wider range of operation using tip speeds from 0.4 m/s to 6.0 m/s. This multi-functional mixer combines gentle mixing and mid to low shear in one compact machine. It's ideal for the addition of liquids and creates a homogenous mixture without using lump breakers.

Mid-shear mixer

Enable vacuum, atmospheric and pressurized processing of a variety of materials such as powders, filter cakes, pastes and viscous slurries, especially when they are brittle and/or heat sensitive.


<h2>Fast-drying in a compact, multi-functional design</h2>
The Conical Paddle Dryer from Hosokawa Micron is a vertical, centrally-driven dryer that combines extremely fast drying rates with a compact design. This combination of several processes in one vessel offers savings on investment costs, labor and space.
Originally designed for vacuum drying of solid-based materials, but can be used in a wide range of other applications requiring thermal processing or vacuum treatment of solids.
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Vertical paddle dryer

When your product or process is sensitive to humidity, using air dehumidifiers may result in substantial savings on the running costs of your plant.


<h2>Precise humidity and temperature control</h2>
The Air dehumidifiers from Ventilex come in variety of configurations depending upon air volumes, temperature range, available energy and any need for additional biocidal capacity. The systems keep the air at a constant, precise humidity regardless of weather conditions or load variations.

Any manufacturing or processing operation, which is humidity, temperature or micro-organism sensitive, is a natural application for a dehumidification system. Whether your space conditions are 25 ºC and 20% RH, or 5ºC and 40% RH, or even –20ºC and –40ºC dew-point, the system can provide those conditions every day. Result, a better bottom line.

Ventilex Drygenic air dehumidifiers are easy to operate, eliminate airborne micro-organisms and save energy and investment costs.

Air dehumidifiers

Industrial dehumidification involves the process of removing moisture as well as controlling humidity. For example, warehouses that store grains need a controlled climate to avoid mildew and other moisture-related issues that can ruin or spoil the product. Refrigerant and desiccant dehumidifiers are used to reduce or maintain the level of humidity. Refrigerant dehumidifiers pass the air over a cold coil, cooling the air to the point where its water vapor begins to condense. Instead, desiccant dehumidifiers pass the air through a rotor containing a moisture-absorbing material. Commercial dehumidifiers are somewhat similar to their industrial counterpart in terms of function. The only big difference is the scale at which the equipment is being used.

Dehumidifying

A belt dryer typically applies the product through an infeed chamber onto a perforated horizontal belt, which carries the product through the drying area which is divided into several sections.


<h2>Carefully controlled, high through-put, hygienic drying</h2>
The belt dryer from Ventilex is a stainless steel perforated horizontal belt, designed for durability, sanitation; it controls temperature and humidity as required, delivering desired levels even with varying air inlet conditions.

Helping the industry to produce better quality products, controlling temperature / humidity environment while minimizing utility usage and maximizing production rates. Besides the drying of food and agriculture products such as flaked, striped, noodle, cube and granule materials; it can also be used for dehydration of various chemical and pharmaceutical products.

The dryer capacity, size and performance depend on the available heat transfer area and the operating conditions for the specific product. The combination of temperature cycles and drying times can be adjusted to control the final product physical properties.

Hygienic belt dryer

In a Fluid Bed, a product or solid is made fluid by an upward moving flow of gas. The mechanical movement of the Fluid Bed strengthens this effect. Thus, the gas and product are intensively mixed so that high heat transfer and an optimum physical reaction speed are achieved.


<h2>Continuous fluid bed dryer for an energy-efficient drying</h2>
Ventilex Continuous fluid bed dryers apply world-leading fluid bed technology to high-throughput bulk processes. By choosing a good combination of gas speed and mechanical movement, you will be able to process granular products with a wide range of grain sizes while forming a minimum amount of dust.

A whole range of products can be processed in the fluid bed for long residence times, up to two hours per machine are possible. Ventilex Fluid bed dryer can function at temperatures from–15ºC to +600ºC. The gas speed can vary from 0.2 to 3m/sec.

Continuous fluid bed dryer

Electronic net weigher raises the industry’s standards to a higher level with its exceptional performances. This is the system that is used for the high-capacity baggers.


<h2>Electronic net weigh system with strain-gauge load cells</h2>
The E SERIES from PT Chronos is an electronic net weigher that raises the industry’s standards to a higher level with its exceptional performances. The latest generation of the E Series net weighers meets the highest demands for accuracy, reliability and performance. The simple construction and sturdy design ensure safe and accurate operation.

Our precision weighing systems are available in single weigher, double weigher combinations or fully integrated in bagging lines for a weighing range from 5 to 50 kg per weight. Combined with our digital weighing modules SpeedAC NXT, the E Series net weighing system can be used as fully integrated into a bagging line for various applications from the food, feed, pet food, agriculture, chemical, pharmaceutical and minerals industries.

Electronic net weigher for high-capacity baggers

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

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

A checking weigher recognized for receiving and shipping bulk materials, typically in mills and warehouses etc. It is reliable for constant operations.


<h2>Hassle free and high-capacity bulk weighers</h2>
The W SERIES bulk weighers from PT Chronos for receiving and shipping bulk material stand out for their accuracy, performance and reliability. These electronically controlled weighers designed for bulk materials are normally put to use in grain silos, the feed / food industries, mills, warehouses, etc.

The weigher output is dependent on the size of the weigh hopper, which can be up to 10 tons capacity. These High-capacity bulk weighers are manufactured in welded steel and are dust-tight. In feed and weigh hopper are equipped with pneumatically operated (twin) gates. The weigh hopper has an inspection door and frame to place calibration weights.

High-capacity bulk weighers

Industrial inspection equipment is used for checking compliance with health, safety, and quality control standards. For that reason, inspection systems are most commonly utilized in the food and pharmaceutical industry but, they are also used in other industries too. Inspection solutions are often integrated into a production process or production line. Visual inspection systems perform checks to detect variation in size, shape, and color and ensure the presence of labels and closures. Check-weigh systems help ensure that product packages are not under or over-filled. Metal detection systems can help guard against the presence of foreign objects in product containers and X-ray inspection equipment is used to detect physical defects and to ensure high quality package seal integrity.

Inspection

If you are looking for a weigher that is manually controlled for bagging, here it is. It has quick connection junction box, valve manifold and sensors allowing quick installation and easy maintenance.


<h2>Simple but effective open-mouth bagging system</h2>
The E55-MB series from Premier Tech Chronos manual bagging system is a leading edge electronic net weighing system designed to be used as a bagging station in combination with bag clamps, a closing system and a conveyor.

It is designed to operate in a wide range of industries such as food, pet food, feed, seeds, chemicals, salt, aggregates etc. The system can be equipped with different feeding devices (gravity, gravity-agitator, belt, screw and vibratory feeder).

Manual bagger with net weigher

<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

This is a manual bagging set with an electronic gross weighing system to meet international standards. It has rigid support structure in welded steel.


<h2>User friendly weighing controller with multiple display screens</h2>
The E55-MB Gross Weigh SERIES from PT Chronos is a manual bagging system equipped with electronic gross weighing and provide high accuracy and reliability. The simple construction and sturdy design ensures safe and accurate operation. It is designed to operate in a wide range of industries such as food, feed, chemicals and building materials.

It can be equipped with a range of feeding devices (high-speed or standard gravity, belt, screw and vibratory feeder). The system uses our advanced weighing controller SpeedAC NXT.

Manual bagger with gross weigher

For bagging free flowing materials into open mouth bags, this system is ideal. It is a compact design, ideal for restricted packaging rooms and has a fully integrated gross or net weighing system.


<h2>Efficient bagger that fits into limited space</h2>
The Premier Tech Chronos OML SERIES open-mouth bagging systems are designed for bagging free-flowing materials into open-mouth bags for applications between 5 and 50 kg per bag. The systems are ideal for bagging flakes and granules from the Food, Feed, Pet Food, Chemicals and Minerals industries.

The OML SERIES features modular designs in three versions: compact open-mouth bagging system (OML-1080 SERIES, up to 800 bags per hour), high-speed open-mouth bagging system (OML-1120 SERIES, up to 1,200 bags per hour) and high-speed open-mouth bagging system for PE bags (OML-1120 FS SERIES, up to 1,200 bags per hour). Units can be supplied with either gross or net weighing systems for optimum system performance.

Open-mouth baggers for free flowing powders

Many industries that process materials in pellet, powder, or crumble form need a closely controlled drying and/or cooling process to ensure product quality. This line of cooling/drying conveyors provides this function in a highly flexible, modular design configurable to any industry.


<h2>A completely modular line of drying and cooling conveyors</h2>
Amandus Kahl’s line of cooling /drying conveyors is configurable to meet the cooling and drying needs of any industry that deals with pelletized or granular dry bulk material. Process air is drawn through a layer of the customer’s bulk product as it travels along a conveyor. The conveyor bed is either composed of slotted plates attached to driven chains, or a full fabric belt depending on the characteristics of the product being cooled or dried. The belt speed is adjustable and used along with configuration of the overall belt length to precisely determine the product retention time. For enhanced drying, process air can be heated to 200 C, but drying can also be achieved using only air at ambient temperature. Cooling is also controlled and enhanced by the characteristics of the process air and overall product retention time. The modular design of the line allows the use of several layers of belts to be stacked on top of one another and a wide variety of belt widths and lengths are available. Airflow through the array of belts can also be uniquely configured to accommodate a wide variety of process needs.

Belt dryer/cooler for pellets and granules

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

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

Processing of wood and biomass into pellets or other volume reduced products requires careful and consistent moisture level control. This is a line of drying conveyors specifically designed for precisely controlled biomass drying.


<h2>A fabric belt dryer for Biomass</h2>
Amandus Kahl’s Fabric belt dryers use a closely knit plastic fabric belt to both transport a layer of product and allow hot air to pass through it for drying. The fabric belt also acts as an exhaust air filter to ensure limited dust loading as dust particles are trapped in the belt as the air is drawn through it. The dryers are particularly efficient, requiring inlet air temperatures of less than 120 C making them particularly well suited to make use of waste heat from other processes. The dryers operate automatically and relevant process parameters are monitored to ensure optimum and efficient drying.  To ensure a consistent and uniform final moisture content of the dried product even as the input raw materials vary in distribution of moisture content, a product supply system is included which evenly distributes material across the belt and turns it over during the drying process.

Belt dryer for wood

Utilization of biomass for energy and other applications requires consistent and reliable compaction to increase bulk density and provide a consistent an easy to handle input product to subsequent processes such as combustion. This line of pelleting presses has been under development since the energy crisis of the 1970’s and is well suited for today’s renewable raw materials industry needs.


<h2>Robust biomass pelletizers with impeccable pellet quality and high up-time</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of biomass including wood, straw, dried forage, and agricultural byproducts among many others. The presses use pan grinder rollers to compact the biomass and force it through a flat 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 minimized generation of noise and heat.

The grinder roller gap and strand cutter are adjustable for optimized pellet quality for the customer’s particular needs.  The presses are designed for maximized plant up-time and include reinforced press chamber, die supports and cutting knives, oversized and permanently lubricated roller bearings, and active gearbox lubrication. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses. Amandus Kahl has pelletizing presses with capacities from 300 Kg / h to 8,000 Kg / h.

Pelleting press for biomass

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

The production of agricultural feed and pet food products requires machines and plants that supply stable-abrasion resistant pellets tailored to the customer’s needs. A proven, robust press design is required to ensure a consistent, high quality product and efficient operation.


<h2>Robust feed pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of animal feed including compound feeds for all species, raw components, mineral mixtures, dried forage and straw mixtures. The presses use pan grinder rollers to compact the input material and force it through a flat 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 minimized generation of noise and heat. The grinder roller gap and strand cutter are adjustable for optimized pellet quality for the customer’s particular needs. The presses are designed for maximized plant up-time and include reinforced press chamber, die supports and cutting knives, oversized and permanently lubricated roller bearings, and active gearbox lubrication. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses.

Amandus Kahl works with customers to combine pelletizing machines and other supporting equipment including conditioners, coolers, dryers, and a coating system to provide an optimized plant solution for producing the customer’s product.

Pelleting press for feed and petfood

The production of pelletized or granularized food products requires hygienic presses designed for high quality output and robust efficient operation.


<h2>Robust food pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of food products including those with powdery or lumpy input products.  The presses use pan grinder rollers to compact the input material and force it through a flat 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 minimized generation of noise and heat. Temperature is monitored and 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. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses.

The hygienic presses are also designed for easy cleaning and meet GMP guidelines for food processing equipment. Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customers in developing a process that is optimized for their product.

Hygienic pelleting press

Many industries require reliable pelletizing equipment with smaller scale production capacities. These industries include chemicals, pharmaceuticals, synthetic material manufacture, waste disposal and recycling, minerals, and energy where compaction and uniform output are important but high volume production of a pelletized product is not necessarily the industries’ focus.


<h2>Robust smaller scale pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces smaller scale pelletizing presses with proven success for many types of products that often do not require the high volume production of larger presses. This line of presses uses the proven technology of Amandus Kahl’s larger sized presses in a scale more appropriate to the smaller production volumes. The presses use pan grinder rollers to compact the input material and force it through a flat 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 minimized 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 your particular needs.

The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses. 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. Amandus Kahl variable speed proportioning screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Small scale pelleting press

Control the quality of your pelletizing processes using a pellet hardness tester. Pellet hardness is one of the most critical characteristics indicating process quality, and it is essential to ensure a desirable product and efficient downstream processes. The hardness can now be measured right after the pellets have left the cooler.
<h2>Monitor your pelletizing process with a hardness tester</h2>
Amandus Kahl’s pellet hardness tester is a hand-held device that allows the user to quickly and easily monitor the quality of their pelletizing process at the source without the need for laboratory equipment. Hardness/softness is a good measure of overall pellet process quality. Using this device allows the customer to test pellet softness and immediately adjust the process parameters to achieve the desired results without delays and lost production time caused by waiting for more sophisticated laboratory equipment.

The pellet hardness tester allows a simple in-the-field quality control for the pelletizing process. The pellet tester comes in two versions, manual and automatic. An operator can periodically rotate the adjusting screw on the manual version at different speeds to retrieve multiple readings. The automatic unit is motorized and works independently, offering more consistency and better comparison of the hardness values taken by different operators due to potential variation in operator handling of the manual version.

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