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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

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

Continuous

Manufacturing industries often require precise particle size separation to ensure product quality and performance. Traditional classification methods may fall short in efficiently handling fine powders while maintaining low energy consumption and wear resistance.
<h2>Adjust fineness and process yields with low energy</h2>
The Ventoplex C from Hosokawa Alpine is a circuit-air classifier designed for high-specific fines yield. This classifier features a separately driven classifying wheel and fan, enabling different speeds and extending the fineness range from 24 µm to 200 µm. Unlike its predecessor, the Ventoplex B, this design offers greater flexibility and control over particle size distribution. The Ventoplex C is ideal for industries requiring fine powder processing such as ceramics, minerals, and food products. It provides low wear operation and low specific energy requirements, making it a cost-effective and durable solution. The classifier's design also ensures easy accessibility for inspection and maintenance. Various applications include processing limestone, gypsum, fertilising lime, and more.

High precision air classifier for fine powder processing

Powder

solid

Batch

Industrial

In industries requiring the separation of superfine powders, achieving precise particle size distribution can be a challenge. Applications in the chemicals, food, and minerals sectors often demand consistency and minimal spatter-grain presence in the final product.
<h2>Achieve precise ultrafine powder separation</h2>
The Turboplex ATP by Hosokawa Alpine is a single-wheel or multi-wheel air classifier designed for ultrafine classification. It operates efficiently within a fineness range of d97 = 5 to 10 µm, with advanced models achieving finenesses of d97 = 2 µm. This classifier ensures spatter-grain-free operation throughout the separation range. The device features an integrated coarse material classifier, enhancing cut point accuracy. Its low-wear, horizontally arranged classifying wheel accommodates even highly abrasive materials, extending operational life. The Turboplex ATP is adaptable to various applications, including those in the pharmaceutical industry, where it can be manufactured in stainless steel. Its explosion-pressure-shock-proof design is available for demanding environments.

Ultrafine air classifier for powder separation

Efficient separation of fine powders is critical in industries like chemicals, food, and minerals where uniform particle sizes are necessary. Traditional air classifiers often struggle with energy consumption, precise cut points, and maintenance frequency.
<h2>Enhancing fine powder classification efficiency</h2>
The Calciplex ACP from Hosokawa Alpine is a high-performance air classifier designed to meet evolving market demands. Utilizing the solid body rotation principle, it achieves energy savings of up to 25% compared to older models. The feed material is introduced pneumatically from the bottom, dispersed, and directed to the classifier wheel. Only fine particles can pass through the wheel, ensuring a consistent particle size distribution. The classifier features robust cast iron housing for durability and low pressure drop operation. Ideal for industries requiring precise particle size like chemicals, food processing, and minerals, this classifier offers maximum throughput with fineness ranges d97 = 6 – 40 μm.

Air classifier for fine powder processing

In industries where precise particle separation is critical, achieving high fineness with minimal energy consumption and wear can be challenging. Traditional systems often fail to deliver the required performance within acceptable energy and maintenance costs.
<h2>Classifies particles with high precision and reduced energy</h2>
The Stratoplex ASP II by Hosokawa Alpine is a highly efficient air classifier designed for fine to medium-fine particle separation. This classifier offers reduced wear and lower energy requirements thanks to an optimized design. It operates with an air volume flow ranging from 2,500 to 64,000 Nm³/h and handles particle sizes down to d97 = 10 μm. By utilizing ceramic coatings and improving the separator wheel, this system lowers operating speeds by up to 20%, resulting in less wear and energy consumption. The Stratoplex ASP II is particularly effective for applications involving feldspar, quartz, nepheline, and wollastonite, among others.

Air classifier for fine to medium-fine separation

In industries such as mining and chemical processing, precise particle size distribution is crucial. When dealing with materials like limestone, talc, and calcium carbonate, achieving consistent particle sizes can be challenging due to the varying nature of raw materials.
<h2>Achieve precise particle size distribution</h2>
The Hosokawa Alpine Stratoplex ASP II is an air classifier designed to deliver high accuracy in fine to medium-fine separations. This classifier can handle particle sizes in the range of d97 = 10 - 150 µm with high throughput and efficiency. It operates with low energy consumption, making it cost-effective for large scale applications. The ASP II is particularly suited for the classification of minerals including limestone, talc, dolomite, and calcium carbonate. The system ensures a high yield of fine particles while maintaining minimal oversize. Its robust design and low-maintenance requirements are tailored to both industrial and laboratory environments, offering versatility across different applications.

Air classifier for classifying industrial minerals

In many industries, precise particle size analysis is crucial for quality control and product development. Typical methods can be time-consuming and require extensive manual effort, posing challenges for meeting tight production schedules and maintaining consistency.
<h2>Ensures accurate and fast particle size analysis</h2>
The Air Jet Sieve e200 LS by Hosokawa Alpine is a state-of-the-art particle size analyzer designed for various applications. It provides high reproducibility and comparability of results, thanks to its integrated software packages and automated user guidance. Featuring a high-performance industrial vacuum cleaner, the system ensures efficient sieving. The e200 LS is simple to operate with its user-friendly interface and robust design, maintaining reliability over time. Ideal for industries such as chemicals, food, and minerals, this German-manufactured analyzer enhances precision and efficiency in particle separation and fractionation processes. The scope of delivery includes the main device, vacuum cleaner, software customizations, and various accessories to suit diverse operational requirements.

Air jet sieve for particle size analysis

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

Sorting is the process of arranging items systematically, using a specified criterion, to categorize and group similar items and identify non-conforming items for removal. The choice of a sorting machine depends on the type of item to sort, the sorting criteria, the number of categories that the items need to be sorted into, sorting speed, and accuracy. Sorting machines can be used in the food processing industry for sorting and categorizing fruits, vegetables, empty bottles, crates, and other items; other examples include sorting of tablets and capsules by weight for quality control in the pharmaceutical industry. As well as sorting waste in the recycling industry. Manual sorting is a laborious task however, with the use of specialized equipment, manufacturers are able to automate their sorting at high speeds.

Sorting

In industries such as pharmaceuticals and powdered chemicals, obtaining a precise particle size distribution is crucial for product performance and quality control. Traditional sieving techniques can be time-consuming and inconsistent, leading to challenges in achieving accurate analyses.
<h2>Conduct precise particle size analysis quickly</h2>
The Air Jet Sieve e200 LS from Hosokawa Alpine is designed for the efficient separation, fractionation, and particle size analysis of dry powders. By using an innovative air jet technology, the sieve eliminates the need for manual cleaning, significantly reducing downtime. The unit provides results in just a few minutes and is suitable for use in laboratories or production environments dealing with fine powders across various industries such as pharmaceuticals, chemicals, minerals, and food. It supports sieve meshes ranging from 20 µm to 4 mm, accommodating a wide range of particle sizes. The e200 LS is equipped with an integrated software system that facilitates data logging and analysis, ensuring reliable and reproducible results. The system also features a user-friendly interface with touchscreen controls, making operation straightforward.

Laboratory air jet sieve

Analysis

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

In the grain milling industry, ensuring the removal of dust and low-density particles is critical for product quality and operational efficiency. Traditional aspiration channels often struggle with high energy consumption and inadequate airflow control, leading to increased operational costs and inconsistent cleaning results.
<h2>Adjust airflows for precise grain cleaning</h2>
The air-recycling aspiration channel MVSS from Bühler efficiently removes dust and low-density particles in grain milling applications. What makes this system special is its use of recirculated air and frequency converters, which significantly reduce energy consumption by up to 15% compared to traditional systems. The modular design of the Vitaris cleaning system allows for flexible integration tailored to individual cleaning requirements. Airflows can be adjusted electronically using a rotary potentiometer, enabling product-specific settings directly at the equipment or through a plant control system. With up to 90% less fresh air required during operation, the system not only delivers high energy efficiency but also minimizes the filtration area, resulting in considerable cost savings. The MVSS is a versatile solution for various grain milling applications, ensuring maximum efficiency and sanitation at every step.

Air-recycling aspiration channel for grain cleaning

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

Cleaning

Dust and light particles in grain, corn, and malt processing lines can lead to potential hazards like dust explosions and frequent equipment maintenance issues.
<h2>Remove dust and light particles effectively</h2>
The ASU/ASA air cleaners by Buhler are designed to remove dust and light particles from various food products, including grain, corn, and malt. These air cleaners feature separate discharges for dust and light particles, improving hygiene and reducing explosion risks. The system includes discharge screws that prevent filter clogging by removing contaminants before they reach the filter. The ASU employs a recirculation system, requiring a smaller cyclone and less filter surface for the same throughput, while the ASA uses exhaust air, making it suitable for dusty or oily products. With a compact design and vibrating distribution flap, the cleaner ensures even distribution and maximizes throughput. Optional wear protection enhances the air cleaner’s longevity, making it suited for continuous operation.

Grain air pre-cleaner

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

Many industries require fine and consistent powder for their processes. Producing high-quality powders from various raw materials often presents challenges such as achieving the desired particle size distribution and minimizing contamination.
<h2>Grind powders to precise specifications</h2>
The mills and classifiers by Hosokawa Alpine provide advanced grinding and classifying solutions for powder processing. These machines are engineered to handle a variety of materials, including mineral raw materials, chemicals, pharmaceutics, cosmetics, and foodstuffs. With over a century of expertise, Hosokawa Alpine ensures precise particle size reduction and classification, reducing the need for additional sieving steps. The systems include features like high precision air classifiers which allow for fine control over particle size distribution, and advanced milling mechanisms that ensure minimal contamination. The manufacturing process adheres to stringent quality standards making them suitable for GMP-compliant environments. With flexible capacity options, these mills and classifiers support scalable production needs from small batches to continuous, high-volume manufacturing, ensuring efficient and reliable processing.

Industrial powder grinder

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

When processing fine powders, achieving consistent particle size distribution is crucial. Traditional methods often lack precision and throughput needed in modern industry applications, which can result in inefficiencies and material wastage.
<h2>Ensure accurate particle separation and control</h2>
The MS ultrafine classifier by Hosokawa Alpine is designed to provide precise particle separation with pneumatic product feed. This classifier operates within a working range of approximately d97 = 15 to 150 micrometers, ensuring high throughput while saving energy due to its low classifier speed. Unique features include a belt-driven classifying wheel and steplessly adjustable speed controlled by a frequency converter, enabling easy in-operation adjustments to particle size. Fine particles are gathered via rotor blades and discharged through the main air flow, while coarse particles are rejected and discharged separately, improving cut precision and fines yield. The MS classifier is suitable for processing talc, calcium carbonate, bentonite, kaolin, loam, dolomite, quartz, kieselguhr, and fine-grade chemicals. Available in wear-protected designs for abrasive materials and stainless steel for food and pharmaceutical applications, it can also be operated with a table roller mill or in circuit operation with a ball mill.

Ultrafine classifier for precise particle separation

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

In industries such as food processing, chemical manufacturing, and biofuels, drying large volumes of materials efficiently while maintaining high product quality is a significant challenge. Traditional drying methods often fall short in catering to varying moisture content and ensuring consistent drying results.
<h2>Dry large volumes efficiently with circulating air system</h2>
The Dedert Ring Dryer is an advanced drying solution designed to handle large volumes with a capacity of 179,000 ACFM, capable of evaporating 34 tons of water per hour. This dryer stands out for its manifold classifier, which allows semi-dry solids to circulate internally until fully dry, making the system more energy-efficient. The short residence time helps in maintaining high product quality, exposing materials to high heat for only a few seconds. The Ring Dryer accommodates variations in product moisture content and composition, offering customized configurations like Feed-Type, P-Type, and Full-Ring setups to cater to different resilience levels and drying requirements. The dryer can operate in either Open-Circuit (OC) or Partial Gas Recycle (PGR) configurations for added energy efficiency. Suitable applications include drying orange peel, citrus fiber, calcium carbonate, and high-protein DDG among others.

Industrial ring dryers for high-capacity drying applications

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

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

In the production of high-quality chocolate, one of the critical steps is the accurate separation of cocoa nibs from shells after the beans have been roasted. Inefficiency at this stage can lead to a lower yield and increased waste, directly impacting overall production quality and cost.
<h2>Crush and separate cocoa beans precisely</h2>
The LAB Winnower from Bühler is designed to handle the demanding requirements of cocoa bean processing. This compact and effective system crushes cocoa beans and separates the shells from the nibs with exceptional precision through sieving and air classification. Equipped with a frequency-controlled crusher, the LAB Winnower ensures maximum yield by matching crushing intensity to different bean characteristics, thus producing a low volume of fines. The adjustable air classification process further enhances product quality by enabling precise control over the separation of nibs and shells. With a throughput capacity of up to 150 kg/h, the system allows for continuous quality analysis and control by taking samples from each sieve deck. Additionally, the LAB Winnower's closed design minimizes dust pollution, ensuring a hygienic processing environment that meets high food safety standards through its fully stainless steel processing zone.

Laboratory winnowing system for cocoa beans

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

Crushing

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

In the coffee industry, rising costs for pre-cleaned beans and increasing impurities in green coffee call for in-house treatment solutions. Efficient separation of foreign bodies is needed to maintain the quality of coffee beans.
<h2>Efficient removal of impurities in green coffee</h2>
The green coffee cleaning and sorting systems by IMA Coffee Petroncini are customized plant solutions designed to handle up to 20 tons of green coffee per hour. These systems ensure efficient separation of impurities such as stones, metals, and other foreign materials. The basic cleaning sieve with a magnetic surface removes iron-based impurities, while the densimetric table separates objects with different densities. Additionally, the dry destoner targets heavier foreign bodies like stones and pieces of metal. The integrated dust extraction system and optical sorting machines further refine the process by sorting beans by shape and color. This setup ensures a cleaner, higher-value coffee product, streamlining downstream processing stages significantly.

Green coffee cleaning and sorting systems

In the industrial mineral processing sector, precision in classifying materials such as fillers is vital. High throughput and specific fineness are critical for production efficiency and product quality.
<h2>Classify soft to medium-hard minerals with high efficiency</h2>
The Turbo Twin Double TTD by Hosokawa Alpine is an ultrafine classifier designed for soft to medium-hard minerals. It features a patented classifying wheel geometry that ensures high throughput rates and precise fineness values up to d97 = 3.0 μm. The unit operates with low pressure drop, providing energy savings of up to 25%. In addition to high peripheral speeds of up to 120 m/s, its optimized feed material supply prevents backmixing with already classified coarse material. Maintenance is simplified by the elimination of the need to adjust the classifying wheel gap. Available in six sizes (200, 315, 500, 630, 800, and 1,000), it's suitable for industries dealing with industrial fillers, calcium carbonate, talcum, dolomite, barite, and kaolin.

Ultrafine classifier for soft to medium-hard mineral processing

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

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

Size reduction

When processing bulk materials, maintaining the purity of pellets is essential to ensure high-quality end products. Issues like dust or streamers can compromise product quality and standards compliance, requiring advanced cleaning solutions.
<h2>Effectively remove dust and impurities from pellets</h2>
The Elutriators from Coperion are designed to address the need for efficient dedusting of bulk materials. The Diverting Counter-Flow Elutriator (UGS) offers optimized separating efficiency with its two-stage cleaning process, suited for most pellet types, achieving throughput capacities of 120 t/h or more. The Gravity Rotation Separator (SRS) caters to soft and brittle granular products, dedusting in 1 or 3 stages with capacities up to 100 t/h. The Horizontal Fluidbed Separator (HFS) employs pneumatic separation for up to 40 t/h of granular product, providing intensive and gentle cleaning with a compact design. Finally, the Drum Sieve (TSM) is suitable for separating streamers, functioning both standalone or within a cleaning system, featuring fully automatic sieve cleaning. These elutriators ensure minimal dust generation and optimal product quality through precise design and advanced technology.

Pellet dedusting elutriators

Dedusting is the process of removing dust particles and other undesirable particles from products. Certain products, especially those in the food and pharma industry need to meet strict quality standards. And therefore, fine dust needs to be effectively removed to meet those standards. In order to get started, you will need specific dedusting systems. You can almost think of dedusting as a sort of vacuum cleaning process. Dedusting equipment generally uses compressed air to create a suction that is able to separate the dust from the product. For example, pharmaceutical tablets needs to be dedusted in order for the product to be safe for consumption. Pellets are another common product that require dedusting.

Dedusting

Air classifiers

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