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agitated-media-mills

Agitated Media Mills

Agitated media mills

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

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

Classifying

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

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

Feed ingredients

Agitated media mills stir the grinding media to break down the target material into ultra-fine particles. The grinding media generally consists of spherical metallic or ceramic beads that are stirred into action by the agitator. Agitated media mills are designed in both vertical and horizontal configurations. The choice of a suitable mill depends on the properties of the material to be processed, the particle size required, the production volume, and the desired grinding time.

Continuous

Industrial

In industries requiring the ultra-fine grinding of hard, temperature-insensitive materials like glass and ceramic, achieving the necessary particle size can be energy-intensive and costly. Engineers often face the dual challenge of high energy consumption and achieving consistent particle distribution.
<h2>Achieve precise ultra-fine grinding with reduced energy demands</h2>
The PULVIS by Hosokawa Alpine is an energy-optimized vertical dry agitator bead mill designed specifically for the ultra-fine grinding of hard materials. This system features an integrated dynamic classifier for steep particle size distributions and sharp top cuts. The compact design makes it ideal for both laboratory and production scales. The milling component, located at the bottom, combines impact grinding and attrition while jets of air cool and transport particles, ensuring efficient operation. The classifier effectively separates fine products from coarser particles, which are reintroduced into the grinding zone. The PULVIS is notable for its ability to achieve particle sizes down to d97 < 1μm with up to 80% energy savings compared to traditional methods. It incorporates ceramic linings and parts for enhanced wear protection, easy maintenance, and quick material changeovers. This makes the PULVIS particularly suitable for grinding applications in the glass and ceramic industries, as well as others that require high purity and minimal contamination.

Ultra-fine dry grinding mill for glass and ceramics

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

Powder

solid

In applications requiring the ultrafine grinding of dry materials, achieving high fineness with minimal energy use is crucial. This is often a challenge in industries like ceramics and minerals, where particle size reduction to sub-2 micron levels is necessary.
<h2>Achieve sub-2 micron fineness</h2>
The ATR (Dry grinding) from Hosokawa Alpine is a dry media mill designed for superfine products with finenesses to approximately 80% <2µm. This vertical agitated media mill features a cylindrical grinding chamber filled with grinding beads, where small feed particles, not exceeding 100 µm, are introduced. The agitator shaft, equipped with arms, rotates at peripheral speeds of 2.5 – 3 m/s, transmitting energy mainly through friction. This process ensures high capacity relative to the approximately 200 kW/m³ bead volume. The mill operates in circuit mode with Hosokawa Alpine Turboplex ultrafine classifiers. Featuring a double-walled mill housing for water cooling and a design that minimizes iron contamination, it is suitable for sensitive applications. The ATR is ideal for processing mineral fillers, glazing raw materials, and non-mineral hard materials such as limestone, quartz, zircon sand, and talc.

Dry grinding mill for superfine products

Size reduction

Pilot

In industrial applications, achieving ultrafine particle sizes in mineral slurries, such as calcium carbonate, often presents challenges. Traditional grinding methods may not provide the necessary fineness, consistency, or continuous operation required, leading to high maintenance and operational costs.
<h2>Achieve ultrafine particle sizes in continuous mode</h2>
The ANR from Hosokawa Alpine is an open-design vertical agitated media mill. It excels in the ultrafine grinding of highly concentrated limestone slurries. The mill's design permits continuous operation with minimal maintenance. Operating in a bottom-to-top flow pattern, the feed material is ground with ceramic grinding beads, such as zirconium silicate or zirconium oxide, ensuring high whiteness and low abrasiveness. The low-speed agitator reduces energy consumption while providing durable wear rates and high service life. The mill includes a mechanical and dynamic separating element to effectively separate the grinding beads from the product suspension. Efficient cooling of the mill stator prevents overheating, and the system can scale from 45 kW pilot machines to large production mills in the MW range, making it versatile for various production needs.

Ultrafine grinding mill for calcium carbonate slurries

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

For industries manufacturing high-quality mineral powders or ceramic materials, achieving ultra-fine particle sizes is often critical. Challenges like achieving consistent fineness and managing energy efficiency can complicate production processes.
<h2>Achieve sub-micron particle sizes</h2>
The Ball Mills and Agitated Media Mills from Hosokawa Alpine are designed to grind powders down to ultra-fine particle sizes. The Super Orion S.O. ball mill is ideal for dry hard crushing as it achieves finenesses of under 10 µm. The Pulvis combines a vertical agitator bead mill with a high-performance classifier and is suitable for grinding hard materials to a fineness of up to d97 = 1 µm. The ATR mill offers a compact design and high power density, achieving fineness of up to approx. 80% < 2 µm. For wet grinding, the ANR vertical agitated media mill is perfect for highly concentrated limestone slurries, typically used in paper production. These mills are suitable for a wide range of hard materials including industrial minerals, metal oxides, and ceramics. Hosokawa Alpine also provides capabilities for both dry and wet grinding, making their equipment versatile for various industries.

Ultra-fine grinding with ball mills and agitated media mills

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 dealing with high-demand wet grinding applications, achieving higher product quality while minimizing energy consumption and reducing costs is a common challenge. Ensuring homogeneous bead distribution and efficient separation is vital to optimize the grinding process.
<h2>Enhance your grinding efficiency and product quality</h2>
The Centex full-volume bead mill by Bühler is designed to provide the highest levels of productivity for your wet grinding needs. The mill utilizes reverse-feeding EcoMizer agitator disks that create homogenous bead distribution, maximizing energy efficiency. This technology supports better overall product quality with a long service life while reducing grinding costs. The smart design ensures no beads are near the screen, allowing the use of smaller beads for more efficient grinding. Additionally, a large screen surface reduces pressure inside the chamber, mitigating temperature issues and enabling higher throughput. Optional sophisticated control options are available for user-friendly operation, ranging from basic controls and alarms to touch screen displays with advanced control algorithms.

Full-volume bead mill for wet grinding applications

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

Batch

A vertical agitated media mill is used for grinding ultrafine particles, in an agitated (or stirred) grinding media action, such as mineral fillers, glazing raw materials and non-mineral hard materials. It comprises a cylindrical grinding chamber that is filled with grinding beads of a few millimeters in diameter.


<h2>Ideal for mineral fillers, glazing raw materials and non-mineral hard materials</h2>
The ATR vertical agitated media mill from Hosokawa Alpine is a vertical agitated media mill that comprises a cylindrical grinding chamber, with a double-walled mill housing to permit water cooling, that is filled with grinding beads of a few millimeters in diameter.

Because of the small grinding beads, the particle size of the feed material should not exceed 100 µm. The agitator shaft with its arms dips into the bed of material and grinding beads and is set into slow rotation by a gear unit connected to a motor.

Typical used for milling mineral fillers, glazing raw materials, and non-mineral hard materials. Examples: limestone, quartz, zircon sand, talc, ceramic colors and frits, titanium dioxide, etc.

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Vertical agitated dry media mill

Powders of extremely high fineness can be produced with ball mills and agitated media mills. Both vertical and horizontal ball mills can be used for the refining of chocolate and other cocoa products. A horizontal ball mill with a high flow rate design can achieve ultra-fine refining below 20 microns (D90).


<h2>Ultimate fine chocolate refining</h2>
The FM-150 Ball mill system from Royal Duyvis Wiener is a high performance horizontal conical agitator ball mill for the refining of compound, coatings, creams and bread spreads in small batches is suitable for both crystal and powdered sugar based recipes.

The horizontal and conical grinding unit has a high flow rate design which allows an ultra-fine refining below 20 microns (D90). The highly wear-resistant materials guarantee the maximum life span of the grinding tools, less wear and the lowest iron intake for the product.

The main feature of the Horizontal ball mill for chocolate refining, is the equal distribution of the grinding balls inside the grinding unit for maximum efficiency and there is no clogging effect.

Horizontal ball mill for chocolate refining

Powders of extremely high fineness can easily be produced with ball mills and agitated media mills. Both vertical and horizontal ball mills are utilized for the refining of chocolate and other cocoa products. A vertical ball mill has the advantage of a smaller footprint and larger cooling jacket.


<h2>Efficient chocolate refining</h2>
The Vertical ball mills for chocolate refining from Royal Duyvis Wiener have replaced conventional labour-intensive production methods, by introducing the versatile Choc-1250 and Choc-1500 machines: convenient and economical solutions for the continuous refining of compounds, coatings, fillings, and spreads.

Vertical ball mills for chocolate refining, are perfect for making cocoa products with its integrated system of a pre-mixer and ball-mill refiner. Both the Choc-1250 and Choc-1500 ball mills guarantee high production flexibility, quick payback time, and great product quality. All ball mills are energy-efficient to ensure a low product temperature.

Vertical ball mills for chocolate refining

Managing the agitation and mixing of high viscosity products poses significant challenges in maintaining consistency, temperature, and homogeneity. Processes involving complex fluid behaviors require specialized agitators to ensure effective mixing and heat transfer, preventing product degradation.
<h2>Optimize mixing and heat transfer for viscous products</h2>
The MCR Counter-rotating Agitator by INOXPA is designed to handle the mixing and homogenization of medium to high viscosity products. It features two coaxial shafts with independent geared motors rotating in opposite directions. The central shaft operates at higher speeds with propellers for dispersing low-viscosity phases, while the outer shaft, equipped with an anchor and scrapers, removes product from tank walls and acts as a deflector for the central propellers. This configuration ensures efficient heat transfer and prevents overheating. It is particularly suitable for processes with variable viscosity, featuring a variable frequency drive for adjustable rotation speeds. Compliant with EHEDG guidelines, it supports CIP and SIP processes, and is configurable with various options including surface finishes and ATEX certification.

Counter-rotating agitator for high viscosity products

Dispersing systems are used to produce emulsions of two immiscible liquids or dispersions of solid particles in a liquid medium. The mixers generally operate on the rotor/stator principle and apply a high shear force on the suspended particles to break them down. The choice of a dispersion mixer depends on the physical state of the material being dispersed, the continuous or batch nature of the process, desired particle size, and the viscosity of the mixture. Dispersion mixers are widely used in the food industry for the dispersion of solid ingredients in oil or water and in the coatings industry for the dispersion of pigments.

Dispersing

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

In winemaking, maintaining uniform temperature and ensuring proper gasification during fermentation are critical. Without the right agitation, these processes can result in uneven fermentation and degraded product quality.
<h2>Ensures thorough mixing and gasification</h2>
The INOXPA CPG Side-entry Agitator is designed specifically for the winemaking industry to facilitate homogeneous mixing, efficient gasification, and proper temperature maintenance in wine tanks. This agitator uses a folding propeller that opens automatically when activated, ensuring efficient mixing even in tanks filled with product. The shaft is equipped with a C/StSt/EPDM mechanical seal that provides reliable sealing. Made from 1.4404 (AISI 316L) stainless steel, the agitator is durable and resistant to corrosion. It incorporates an electric motor available in various configurations, including a manual deaeration valve for easy operation. The agitator can be mounted via a full bore valve, allowing for easy installation and removal without losing product. Additionally, it offers various options, such as a stainless steel trolley, control panel compliance with EC standards, and customizable shaft lengths, to meet specific operational needs.

Wine tank agitator for homogeneous mixing

The fermentation process stimulates enzymatic activity in organic substrates to transform their chemical composition. Fermentation is aided by storying the biomaterials in anaerobic environments, allowing the microorganisms to decompose their nutrient structures. The process is integral to some of the most popular products throughout time such as wine, beer, cheese, and kimchi. But besides the food sector, fermentation is also an important stage in the industrial manufacturing of chemicals, pharmaceuticals, and biofuels.

Fermentation

Maintenance

In the fresh produce industry, ensuring minimal product damage and maintaining sanitary conditions during storage and handling can be challenging. This is particularly crucial during short-term storage of items like potatoes and raw vegetables.
<h2>Streamline storage with gentle handling and flexibility</h2>
The Gentle-Flo Storage and Handling System by Heat and Control is designed to provide a modular and programmable short-term storage solution for fresh produce. Utilizing a shuttling Bin Filling Auger (BFA), the system ensures that products gently descend into storage bins via a lowerator, minimizing damage and the risk of infection. Its open, expandable design prioritizes sanitation, allowing for less time spent on maintenance. The modular configuration means the system can adapt to changing business needs by easily adding extra storage bins. Additionally, the variable speed discharge facilitates synchronization with downstream processes. Ideal for applications involving potatoes, tuber/root vegetables, and raw produce, this system ensures that operations run smoothly and efficiently.

Gentle-flo storage and handling system for fresh produce

Handling

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

In large-scale confectionery manufacturing, achieving a consistent and homogeneous caramelization process is essential. Challenges include controlling temperature and residence time to avoid burning while ensuring high-quality caramel products.
<h2>Ensures uniform caramelization without burning</h2>
The Caramaster® caramelization system from Hänsel Processing employs a double-jacketed, warm-water-heated container to ensure continuous caramelization of the confectionery mass. The process parameters—residence time and temperature—can be individually adjusted, allowing for precise control over the caramelization process. The fill level and residence time are reproducible at any time, guaranteeing consistency. Temperature adjustments are managed via a separate pressurized water circuit. Additionally, the agitator features Teflon scrapers to promote uniform caramelization without burning. Dynamic spray nozzles in the dome cover facilitate quick cleaning, ensuring the system's high availability.

Caramelization system for industrial confectionery production

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

In industries like food, pharma, and cosmetics, preparation processes often involve precise heating, mixing, and blending. Maintaining exact temperatures and homogenous mixing is crucial to ensure product quality, especially in batch cooking scenarios.
<h2>Efficiently cook and blend various materials</h2>
The stainless steel cooking kettle by GPI De Gouwe is designed for applications that require rigorous control over cooking and blending. Ranging from 50 liters to 12.5m³, these kettles are suitable for preparing soups, sauces, creams, and lotions. Efficient heating is achieved through dimple, double wall, or half pipe designs, providing flexibility in heating capabilities. The kettles can integrate various agitators, including gate, anchor, and turbo mixers, ensuring uniform mixing. Options such as tiltable design, integrated control panels, and CIP (clean-in-place) systems enhance operational ease and maintenance efficiency. These kettles are tailored to match specific process and product requirements, making them ideal for diverse applications in the food, pharmaceutical, and cosmetic industries.

Stainless steel cooking kettle for food, pharma, and cosmetics

Blending

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

In the pharmaceutical industry, maintaining the purity and integrity of chemical reactions is crucial. Challenges like reactive media interactions and contamination risk can compromise quality and efficiency. Ensuring reliable agitation within reactors is essential to meet stringent production standards.
<h2>Optimize agitation and ensure process reliability</h2>
The glass-lined mixing systems from GMM Pfaudler are designed to meet the rigorous demands of pharmaceutical processing. These systems utilize glass linings, which are resistant to chemical reactions, ensuring the purity and integrity of your products. They are top-entry systems equipped with components like a pedestal-supported drive system, balanced shafts to minimize vibrations, and a motor drive compliant with European Directive 2014/34/EU for safe operations even in hazardous areas. The glass-lined agitators and baffles ensure optimal mixing and agitation. Probes for temperature, pH, and sampling devices allow precise control of the reaction process. These systems are designed for easy maintenance, with no bottom bearings to avoid issues in larger reactors, ensuring smooth operation and high reliability. GMM Pfaudler provides field services to maintain these systems, enhancing their long-term performance.

Glass-lined mixing systems for pharmaceutical industry

Agitation

Producing high-quality licorice on a continuous production line requires a consistent slurry. This involves mixing ingredients into a homogeneous mass and ensuring a steady feed to the cooking extruder. Maintaining a continuous feed can be challenging without an appropriate preparation system.
<h2>Ensure consistent slurry feed to extruder</h2>
The slurry preparation system by Extrufood is designed to create a homogeneous mixture of ingredients for licorice production. It features two counter-rotating agitators in the mixing tank, ensuring an even blend. The slurry is then transferred via a pump to the cooking extruder for continuous processing. To address the issue of batch processing versus continuous feeding, a day tank is used. Typically holding twice the volume of the mixing tank, this water-heated, jacketed vessel includes an inspection opening, an agitator, and level indicators. This setup provides a buffer, allowing for uninterrupted supply to the extrusion process. Additionally, a double filter station ensures that the slurry remains contamination-free and can be cleaned easily without stopping operations.

Slurry preparation for licorice production

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

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

When developing processes for highly viscous materials, achieving accurate mixing, degassing, and solvent recovery under safe conditions is a significant challenge.
<h2>Optimize mixing and mass transfer processes</h2>
The EKATO Pilot Plant ELA 50 is designed for process development on a 50-liter scale, especially for high-viscosity materials. Featuring a reactor equipped with a coaxial agitator system, this plant allows the operation of both central and close-to-the-wall impellers. The plant includes a vacuum station for efficient degassing and solvent recovery. Installed in an EX-proof area, it is suitable for flammable liquids and operates under well-defined fluid dynamic conditions. It supports a range of processes including batch or semi-batch, single or multiphase, suspension, dispersion, and solvent evaporation. The plant optimizes conditions to minimize mixing times, maximize mass transfer, provide efficient solids suspension, and increase heat transfer.

Pilot plant for highly viscous applications

Dispersion

Evaporation technology is used to reduce or remove the moisture content of a mixture. Considerations for choosing suitable evaporation equipment include the moisture content in the mixture, the boiling point of the solvent, heat sensitivity of the product, and the amount of material to be processed. Evaporators are used for applications such as obtaining fruit and vegetable concentrates in the food industry, concentrating aromas and herbal extracts in the cosmetics industry, and isolating active ingredients in the pharmaceutical industry.

Evaporation

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

Recovery

Producing high-quality fruit-based products such as jams, marmalades, and chutneys demands precision in dissolving pectin, vacuum cooking, and maintaining hygiene standards. Ensuring gentle mixing and controlled heat transfer is essential to preserve the quality of fruit particulates.
<h2>Efficiently produce delicate fruit-based products</h2>
The fruit processing system from Dutch Process Technology is designed for the efficient production of a wide range of fruit-based products. It specializes in hygienic, easy-to-clean processes including pectin dissolving, vacuum cooking, and aseptic production. The system features gentle mixing and controlled heat transfer, critical for processing delicate particulates without damage. Suitable for products such as jam, marmalade, chutney, aseptic fruit for yogurt, high brix fruit concentrates, pie fillings, and apple sauces or compotes. The technology allows flexibility and precision, making it ideal for diverse applications in fruit-based product production.

Fruit processing system for jams and marmalades

In bakery operations, producing consistent and high-quality pre-doughs like wheat and spelt sourdoughs is essential. Traditional methods often lead to lumps and variable results, posing challenges in maintaining product consistency and quality.
<h2>Facilitate consistent and flexible pre-dough production</h2>
The Wheat and Spelt Ecoline by Diosna is designed for the individual production of yeast pre-dough, wheat, and spelt sourdough. This system, available in sizes ranging from 200 kg to 1000 kg, ensures fast, lump-free mixing thanks to its special agitator. The unit is mobile and ready to plug in, with a hygienic and cleaning-friendly design. Control features include a process-optimized program with freely programmable process parameters, except for the W 200 Ecoline model. Its flexibility in operation is enhanced by the RW 500 and RW 1000 models' ability to produce a variety of rye sourdoughs. The single-walled stainless steel fermenter boasts variable fermentation times and stirring intervals, supporting up to 2 tonnes of pre-dough production per day. The system also comes with a PLC control with touch panel or push buttons, and technological coaching for optimal pre-dough quality can be availed through Diosna’s DIOStart products.

Wheat and spelt pre-dough system

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Kneading

In the pharmaceutical and fine chemical industries, precise solids washing and separation are critical tasks. Operators often face challenges such as cross-contamination risk, time-consuming processes, and exposure to hazardous materials.
<h2>Manage solids separation and drying efficiently</h2>
The Agitated Nutsche Filter and Filter-Dryer by De Dietrich Process Systems is designed to meet stringent industry requirements for solid-liquid filtration and drying. This system excels in various tasks including filtration, reslurry washing, and drying under vacuum or convection. It supports multiple filter media options such as cloth, single layer metal screen, and multi-layer sintered metal, enhancing its versatility. A significant feature is the side discharge valve with metal-to-metal seals, eliminating issues with o-rings and ensuring a pressure-tight, cleanable design. The heated filter plate allows efficient heat transfer through all contact surfaces, enhancing drying capabilities. Additionally, the Gas Knife system facilitates total discharge by directing gas streams through small nozzles on the agitator blade. The filter-dryer is constructed from various materials such as 316L stainless steel and Alloy 20 for optimal compatibility with different applications. Designed by De Dietrich, the unit integrates seamlessly into pharmaceutical environments, and is available in configurations to handle highly potent materials with its rigid discharge glovebox and ergonomic design. For processes requiring sterile conditions, SIP capabilities are included to eliminate internal dead spaces.

Agitated nutsche filter and filter-dryer for pharmaceuticals

Industrial filtration equipment separates solid matter from liquid by using a filter medium. The filter allows only the fluid to pass through but retains the solid matter. The choice of filtration equipment depends on the particle size, the consistency of the mixture, and the nature of your product.

Filtration

In the edible oil industry, the removal of impurities such as phospholipids, which can affect the stability and quality of oil, is crucial. Traditional methods can be time-consuming and energy-intensive, creating challenges in both efficiency and output quality.
<h2>Optimize oil purity with versatile degumming techniques</h2>
The degumming process from Crown Iron Works offers a range of methods including water, acid, enhanced, enzymatic, and cold degumming to effectively remove impurities from edible oils. The MultiPure Degumming/Neutralizing system is particularly noteworthy for its flexibility, allowing easy transitions between different degumming methods by adjusting operating conditions or adding components for enzymatic treatment. Designed with an atmospheric reactor that features variable retention time and agitation, the system maximizes precipitation of nonhydratable gums. Temperature control at each step and a high shear variable speed mixer ensure intensive interaction between oil and reagents. Complete with options for water-washing or special sorbents, this process delivers optimal quality and maximum yield with minimal energy consumption.

Industrial oil degumming process

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

Industrial washing systems are used to clean and disinfect a variety of items in research and manufacturing facilities. Industrial washers use solvents and cleaning agents with mechanical action to remove deposits and residues from stainless steel machinery components, empty containers, and other soiled surfaces. The selection of an industrial or commercial washer depends on the type of items and surfaces to be cleaned, the type of deposits/residue that is typically present, whether drying is required after rinsing and the level of sterilization necessary. Manufacturers will have cleaning specifications and as a result, require washers to be engineered to meet these specs.

Washing

In meat processing, ensuring uniform distribution of condiments like olives, cheese, and peppers in emulsion batter is crucial. Traditional methods involve double-back processing, which can overwork the batter, reducing its quality and efficiency. A more effective solution is required to streamline this process.
<h2>Feeds condiments uniformly into emulsion batters</h2>
The Cozzini In-line Condiment Feeder (CCF) is designed to enhance emulsion product processing by accurately mixing condiments with meat batter. The system utilizes a variable speed condiment metering feedscrew, ensuring consistent and even distribution of ingredients such as olives, cheese, and peppers. An agitator in the condiment tub prevents product bridging. Driven by a 20 hp (15 kW) gearmotor, the pump and main 9″ (230 mm) diameter feedscrew provide robust and reliable operation. The recipe-driven PanelView controls allow for precise management of ingredient inclusion. Built in conformity with AMI sanitary equipment design principles, the feeder is USDA accepted and CE approved, making it suitable for a variety of food processing environments.

In-line condiment feeder for emulsion batter processing

In confectionery production, mixing ingredients uniformly and preventing foam when using whipping agents is crucial. This is especially true when handling candy and sugar masses which require consistent quality and texture.
<h2>Ensures homogenous mixing and foam reduction</h2>
The Mondomix Yetmixer from Bühler is a premixer designed to thoroughly mix ingredients in confectionery production. It offers single-walled or insulated tanks to temper masses according to specific product needs. This mixer is equipped with various agitator types like propellers, cutting disks, and shakers to accommodate different mixing requirements. The special Mondomix Yetmixer BPS configuration minimizes the risk of creating unwanted foam when mixing liquids with whipping agents. Additionally, safety features are built into all vessels to provide a safe working environment for both operators and maintenance staff.

Premixer for confectionery masses

Tempering equipment is most commonly used in manufacturing chocolate products as well as bakery products. However, tempering can also be found in the metals industry for processing alloys. The idea behind the tempering process is to heat two or more items to a certain temperature so that they can be blended together easier. Chocolatiers pass the chocolate through a heating cycle and then a cooling tunnel to give their final products a smooth and glossy finish. Tempering machines automate this process, evenly distributing the crystal structure in melted chocolate across the entire production line. Besides enhancing the look and texture of coatings, denser and consistent crystallization also has the benefit of slowing down fat migration in your chocolate-filled products. A vibrating table is an important component for tempering chocolate. First the chocolate mixture goes through a dispenser into the chocolate mould. After which the vibrating table is used to evenly distribute the mixture in the mould so that there are no air bubbles. Thus, creating a smooth and consistent final product.

Tempering

In the food production industry, particularly in the creation of cocoa products, achieving precise color and flavor characteristics is paramount. Traditional methods often fail to offer fine control over pH and color intensity, leading to inconsistent product quality.
<h2>Control ph and color intensity effectively</h2>
The CNA Alkalizing system by Bühler is designed to offer precise control over pH values and process parameters, enabling you to vary the color intensity of cocoa powder to meet market preferences. Using an agitating spiral for gentle mixing, it ensures a homogeneous product through reduced cycle times and increased throughput. The system's capability to function at different pressure-temperature-time profiles allows for the production of a wide color range from red to black hues. Equipped with a mechanical seal, the system is straightforward to maintain and reliably endures the harsh conditions of the alkalization process. Additionally, the built-in options to inject solutions like inverted sugar or salt facilitate enhanced flavor development. This system finds applications specifically within the cocoa processing industry.

Alkalizing system for cocoa powder coloring

For industries requiring efficient solid-liquid separation in hazardous or sensitive environments, traditional methods often pose contamination risks and inefficiencies. Ensuring hermetic processing and high-purity output while managing toxic or sensitive materials remains a significant challenge.
<h2>Perform filtration and vacuum drying efficiently</h2>
The Agitated Nutsche Filter Dryer by Bachiller excels in solid-liquid separation via pressure filtration and vacuum drying. Designed according to cGMP and EHEDG standards, it's suitable for pharmaceuticals, fine chemicals, and food industries. It operates within a hermetic system to prevent contamination, ensuring high-purity outputs. Capable of batch-wise operations, it supports multiple processes like reaction, filtration, and drying within a single unit. Features include a filtering surface ranging from 0.07 m² to 15 m² and operational capacity from 19L to 15,000L. It operates up to 3 bar(g) pressure and 200º C, catering to both heating and cooling needs. Options are available for CIP/SIP systems, different internal finishes, and advanced sealing mechanisms.

Agitated nutsche filter dryer for solid-liquid separation

Entry level

In laboratory settings, ensuring efficient and repeatable solid-liquid separation processes is crucial, especially when working with small batch experiments where precision and scalability are essential.
<h2>Optimize solid-liquid separation and drying</h2>
The GFD®Lab is an automatable benchtop Agitated Nutsche Filter-Dryer from Austar designed to streamline laboratory solid-liquid separation processes. This system combines filtration and drying in one unit, enabling operations such as slurry filtration, washing, re-slurry, vacuum drying, sampling, and discharge. The unique filtration basket facilitates quick media changeover and maximizes product recovery. Adaptable to sector-specific needs, it offers multiple vessel sizes and various product contact materials, making it ideal for fast-tracking process development and scale-up activities. Complete process control with data acquisition and recording features ensures consistent and predictable results in every batch. For larger scale and automated development, the GFD®Lab PLUS allows custom process sequences and recipe optimization to fit specific applications.

Automatable benchtop agitated nutsche filter-dryer

Industrial sampling equipment are systems that allow manufacturers to test (in other words to take a sample of) the products they are manufacturing. This process is generally implemented as a means of quality control but it can also be used as a mean to ensure that production processes adhere to certain regulatory standards. Quality control in your manufacturing process starts with precision sampling techniques. Automated systems deliver consistent samples at a pre-set rate for accurate testing and probing. Sampling technology uses a calibration system involving a series of sensors to extract the material at high levels of reliability.

Sampling

Processes including homogenization, dispersing, suspension, emulsification and dissolving benefit with the addition of a dispersing rotor/stator system to the functionality of traditional overhead stirring equipment.  With traditional equipment, achieving desired results in high viscosity media is often difficult and slow and issues such as sediment formation and air inclusions are common.  Adding a high speed rotor and jet pipe in close proximity to the mixing vane greatly enhances the process and helps avoid many of these issues.
<h2>Fast and efficient agitation of highly viscous fluids</h2>
IKA's Rototron RTS is a line of agitators that uses jet-flow technology to speed mixing processes while avoiding many of the issues seen when more traditional equipment is used.  The jet flow agitators use a high speed rotor and jet pipe in close proximity to the mixing vanes to disperse and circulate products within a vessel while avoiding inefficiency caused by back flow, air inclusions caused by a static whirlpool effect, and the need for flow breakers caused by continuously rotating mixtures.  The circulation mechanism also avoids the common issue of sediment formation when being used to produce emulsions.  The units can be used with open and pressurized vessels and mounting options exist to accommodate a wide variety of vessels and configurations.  With this equipment, no seal material makes contact with the product and food or pharmaceutical grade versions are readily available.  Motor sizes are available from 2,2 to 15 kW with max batch sizes from 1.000 to 20.000 liters.

Jet flow agitator for high-viscosity media

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

Reliable mixing and agitation are essential to any quality production process that involves a fluid. This need is even more acute in the production of pharmaceutical products where utmost precision and consistency are required. Experienced biopharmaceutical manufacturers know that equipment designed for general industry use often falls short of the tight quality and hygienic standards of our industry and that producers who embrace high quality pharmaceutical grade equipment will have an advantage over competitors.


<h2>Precise and powerful magnetically coupled agitation designed for superior hygiene and customized to your vessel and process needs</h2>
Mavag AG is a world leader in production of shaftless magnetic agitators for the pharmaceutical and biotechnology industries. The company's smaller scale and focus on their tradition of Swiss craftsmanship ensuring the impeccable product quality that customers need. The MavaDrive magnetic agitators are a series of agitators made by Mavag AG that use a magnetic coupling between the drive motor which is outside the process vessel and the agitator unit which is inside the containment vessel. The coupling is achieved using powerful permanent magnets attached to the agitator components on either side of the vessel wall. The magnets create a field that travels through the vessel wall and transmits mechanical power from the motor to the agitator without penetrating the wall. Thus removing a potential source of contamination and leakage due to the difficulty of sealing the containment vessel around a traditional rotating shaft. The units use high quality ceramic bearings in the agitator head to limit required maintenance. They are highly configurable with options available for top and bottom mounting to the containment vessel and in available torques from 0.5 to 250 Nm. Many agitator designs are available and Mavag AG can use specialized software and engineering to select the optimal agitator for your vessel and application.

Magnetic agitator

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

Forged metal objects appear seamless, simple items. But as the use of metals changed over time and constructions became more intricate with additive manufacturing, a new way of processing materials surfaced. Metal powder manufacturing replaces the classic blacksmithing techniques, reducing scrap waste in the meantime. The final metal products, however, retain that shiny allure of the archetypal metal pieces.

Metal powder

Just when you think you've seen it all, you come to find out that there's nail polish on the market that costs $250,000. Yes, you got it right; two hundred fifty thousand dollars. And to think that the nail polish was originally a cocktail of beeswax, egg whites, gelatin, vegetable dyes, and gum arabic. Today, however, polymers, pigments and solvents are included in the mixture; when the mixture is ready, you can fill the bottles using nail polish filling equipment.

Nail polish

The most significant decision when making ointments is likely to be the choice between automatic or semi-automatic processes for it. This impacts on individual phases of the ointment cream manufacturing process - the water phase and oil phase.

Ointment

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