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Classifying technologies 

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.

Agitated media mills

Classifier mills combine a grinding/milling system with a particle size classifier which continuously recirculates over-sized particles back into the grinding zone. The classifying action ensures a uniform final product with a narrow particle size distribution. Important considerations for choosing a classifier mill include the desired particle size, the maximum particle size variance allowed, and the physical properties of the material.

Classifier mills

Air classifiers

Screeners

circuit-air-classifier-2

Circuit-air-classifier

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

Fruit

Grains

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

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

Powder

solid

Industrial

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

Batch

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

Achieving precise classification of toner particles and pigments while minimizing the fine fraction can be challenging. These tasks require equipment that ensures accurate cut precision, efficient dedusting, and easy cleaning to maintain product quality consistently.
<h2>Achieves precise particle classification and efficient dedusting</h2>
The TSP and TTSP ultrafine classifiers from Hosokawa Alpine are specially designed for demanding classification tasks, with a high precision of cut and minimized fine fraction. These classifiers are ideal for toner and pigment applications and effectively manage dedusting for powder coatings containing titanium dioxide. The hinged housing design makes cleaning straightforward, reducing downtime. The TTSP model further enhances precision with two consecutive classifying stages, allowing for higher loading factors and increased throughput compared to the TSP model. Both models are available in various sizes with motor power ranging from 3 kW to 18.5 kW and air flow rates from 500 Nm³/h to 7200 Nm³/h, catering to different processing needs.

Ultrafine classifier for toner and pigments

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

In industries such as food processing, recycling, and chemical manufacturing, achieving sharp particle separations is crucial. This is particularly challenging when handling mixtures containing varied particle sizes and densities, necessitating precise and efficient classification methods.
<h2>Achieve precise particle separation with minimal maintenance</h2>
The MZM & MZF Multi-Plex by Hosokawa Alpine are gravity classifiers designed for sharp separations in the range of approximately 0.1–10 mm. Offered in single or multi-tube configurations, these classifiers provide high precision adjustments and low maintenance requirements. Classification occurs with each directional change in the zigzag tube, allowing continuous separation of fines or light materials even under overload conditions. The system can handle throughputs from a few kg/h in laboratory settings to around 200 t/h in industrial applications. Their robustness ensures consistent performance without the need for frequent supervision. Ideal for the separation of cracked soybeans, precious metals from cable scrap, and dust from plastic granules, these classifiers are versatile across various industries.

Gravity classifier for precise particle separation

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

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 various industries such as pharmaceuticals, chemicals, and food production, achieving ultra-fine grinding with precise particle size control is a common challenge. Ensuring that the grinding process is efficient and the end-product meets exact specifications is crucial for quality and safety.
<h2>Achieves high fineness with energy efficiency</h2>
The Zirkoplex ZPS by Hosokawa Alpine is designed to meet the demanding requirements of fine grinding applications. This classifier mill is universal for materials up to a Mohs’ hardness of approximately 3.5 and achieves extremely high end-product fineness values, from < 5 µm to 200 µm, with low energy consumption. It features an impact beater mill with an integrated Turboplex classifier for precise top-size limitation. Its welded design includes grinding elements made of special steel. The ZPS mill's efficient grinding process is facilitated by an impact beater unit and a stationary triangular-ribbed grinding track, ensuring continuous comminution and transportation. The multi-wheel classifier system enhances fineness accuracy, even for sticky products like pigments, wax, and resins. High air flow ensures cool grinding, maintaining product integrity. It’s suitable for industries such as chemicals, food, and pharmaceuticals.

Classifier mill for ultra-fine grinding and precise particle size control

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

In the production of various industrial materials, achieving a specific and consistent particle size distribution is crucial. This is particularly important when working with powders for applications in pharmaceuticals, food, or fine chemicals where precision and product purity are required.
<h2>Achieve precise particle size distribution</h2>
The ACM classifier mill from Hosokawa Alpine combines grinding and classifying in a single unit, making it ideal for ultrafine grinding applications. Powered by a single motor, the mill ensures efficient and cost-effective operation. Capable of achieving a particle size of up to d50 < 10 µm, the ACM classifier mill is suitable for a wide range of applications including pharmaceuticals, food, and fine chemicals. Its durable construction allows for easy maintenance and cleaning, while customization options make it adaptable to various production requirements. The ACM classifier mill operates with a low specific energy requirement and provides a steep particle size distribution curve with minimal oversize particles.

Classifier mill for ultrafine grinding

In industries such as pharmaceuticals, chemicals, and food processing, precise particle classification in slurries is essential for optimal product quality. The challenge often lies in achieving accurate separation cuts while maintaining high throughput and low maintenance.
<h2>Achieve precise particle separation with high throughput.</h2>
The HEINKEL Classifying Centrifuge is a continuous operation device designed for wet classification of fine, ultrafine, and nanoparticles in slurries. Its precise separation cut capability makes it ideal for producing specific slurry qualities required in various applications. Equipped with an electrically operated turbulence blade, the centrifuge ensures efficient and reliable operation. The pneumatically operated siphon discharge system facilitates the easy removal of classified suspensions. The machine's maintenance-friendly design and low complexity make it user-friendly and cost-efficient. Suitable for industries like pharmaceuticals, chemicals, and food processing, the HEINKEL Classifying Centrifuge offers high throughput and simple installation.

Classifying centrifuge for wet classification of fine particles

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

In industries dealing with powdered or granulated products, precise particle size classification is critical. Traditional sifting methods can struggle with large volumes and complex processes, leading to inefficiencies and potential product inconsistencies.
<h2>Classifies particles consistently and efficiently</h2>
The Centrifugal Sifter from Freund is designed to handle large volumes and complex processes, making it a robust solution for industries requiring precise particle size classification. This sifter transports the product via a screw into the sifting chamber. Slightly inclined blades on the shaft push the product toward a nylon sieve on a steel support. Fine particles pass through the mesh, while larger particles are separated and directed to the scrap exit. Notable features include mechanical stainless steel/PTFE seals flowed with air or nitrogen and a design that allows for quick disassembly and reassembly without tools. Available models include the S40, S65, and S85, with capacities of up to 3,000 kg/hr and power ranging from 1.1 kW to 3 kW. Options for pneumatic transport, rotobutterfly valve material loading, and conical mill discharge connection are also available. The Centrifugal Sifter conforms to the ATEX directive for explosive environments.

Centrifugal sifter for particle size classification

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

In pharmaceutical production, ensuring the purity and quality of polymeric microspheres after solvent extraction is crucial. Challenges often include efficient classification, drying, and maintaining sterile conditions while reducing operational costs.
<h2>Classify, wash, and dry polymeric microspheres</h2>
The Microsphere Refiner (MSR) by Austar is utilized for the classification, filtration, washing, and drying (freeze-drying) of polymeric microspheres post-solvent extraction. It offers a high yield of up to 90% and integrates all necessary processes into a single piece of equipment, including classification, washing, drying, sampling, and discharge. The MSR features automated process control and can integrate with a Process Skid for complete automatic production. Its efficient classification is achieved through both horizontal and vertical filtration methods, while drying benefits from jacket heating and cooling. The refined design includes an optimized tilt discharging mode. The MSR is scalable to different production sizes, ranging from laboratory (gram scale) to commercial production (up to 25 kg). Additionally, it can be configured to produce without sterile isolation or freeze-drying systems, lowering operation and maintenance costs.

Microspheres process equipment for classification, washing, drying

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

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

Rinsing

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

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

Recovered Carbon Black (rCB) can be recycled back to the tire production chain and serves as a usable material in the manufacturing of rubber products such as conveyor belts. The main challenge in recycling tires for recovered carbon black of versatile use is refining the pyrolyzed tire materials from various feedstocks to achieve consistent fineness. Typically, an efficient grinding, milling, and classifying system are required to ensure the desired fineness of rCB and increase its value.


<h2>Classifier mill for superfine grinding and classifying process</h2>
The Impact Classifier Mill ICX by NEUMAN &amp; ESSER is suited for dry grinding by combining extra-fine grinding with high-precision classification in a single assembly. During grinding, rapidly moving grinding tools convey feed materials into the liner at variable speeds and crush them. The integrated classifier separates coarse particles carried via airflow. Coarse materials rejected from the classifier re-enters the grinding zone for further reduction. The ICX can achieve particle size top cut from 5 µm to 50 µm. It also enables high throughput rates with high energy efficiency and the capability to process mill capacities ranging from 10 kg/hr to 20,000 kg/hr.

The direct drive uses a VFD-controlled motor; this avoids using a gearbox and oil supply in the rotor. As a result, the ICX can provide easy operation, low maintenance, and low energy consumption by using this design.

When grinding potentially explosive dust such as carbon black, a pressure shock-resistant classifier mill is pressure-resistant up to 11 bar. The NEA ICX is also compatible, and other ATEX-compliant systems can be attached to it.

Classifier mill for recovered carbon black

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

High-quality powder coatings are often required to manufacture equipment, appliances, and vehicles to ensure product durability and longevity. A combined dry grinding and classifying system can significantly help to improve the quality of powder coatings production by providing steep particle size distribution. To achieve the finest uniform powder coatings, the mixture of pigment, polymer resin, and other additives must be finely pulverized.


<h2>Classifier mill to grind brittle material dry, free-flowing, and fine powders</h2>
The Impact Classifier Mill ICM by NEUMAN &amp; ESSER is designed for grinding brittle material to superfine particles such as materials for powder coatings. It combines efficient impact grinding and precise classification technology. During impact grinding, grinding tools throw feed materials into the liner and crush it. The classifier separates coarse particles and sends them back to the mill’s grinding zone for further grinding. It effectively achieves grinding cuts and narrow particle size distribution of 20 μm to 1,000 μm. The throughput of the various mill sizes and designs can range from 10 kg/hr to 20,000 kg/hr. In addition, the large grinding chamber has cooler temperatures that result in lower fines generation.

The ICM employs direct drive technology, a type of permanent-magnet synchronous motor. It removes using a gearbox and oil supply in its rotor, making the mill easy to operate and clean. In addition, the mill is pressure shock resistant up to 11 bar, a must when grinding for powder coatings.

Classifier mill for powder coating

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

Coating

For the classification of delicate granular material, screen tumblers make an excellent alternative where high throughput is still required with gentle handling. This is important to many processes in the chemicals, pharmaceuticals and food industries, where traditional vibratory sieves and graders are too harsh for delicate materials.


<h2>High capacity tumbler for delicate, dry materials</h2>
The Virto VTU 2400 is a purpose-designed high capacity tumbler sieve capable of achieving up to 95% efficiency for particle sizes as small as 20 microns.

Especially suitable for multi-stage separation of fine, lightweight and difficult to screen products, the VTU 2400 uses three-dimensional movement for class-leading performance with powders and granules. The exact nature of the movement can be adjusted to suit your requirements.

The tumbler screen can use meshes down to 20 microns, can be supplied with anti-clogging systems composed of FDA-certified rubber spheres or ultrasound systems to your specification.

All product contact parts are constructed of AISI 304 stainless steel, and ATEX certification and full FDA conformity is available on request.

The VTU 2400 is available with 1 to 5 sieving decks, and offers a total mesh size of 4.5m2 for maximum productivity.

Solidly built for enhanced reliability, the VTU 2400 tumbler sieve is energy-efficient and quiet in operation, making it suitable for a wide range of applications.

Tumbler sieve for classifying and dedusting granular materials

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

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.

&nbsp;

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

In research and development, precise handling of ultra-small batches of powders or suspensions often poses significant challenges. Accurate size reduction, classifying, or mixing of quantities as small as a few grams is required to produce reliable results.
<h2>Process ultra-small batches with modular flexibility</h2>
The Picoline series by Hosokawa Alpine is a modular lab-scale system specifically designed for handling small quantities of powder or suspension. It consists of a platform combined with eight interchangeable function modules and various accessories. The table-top design features a housing made of brushed stainless steel, making it suitable for clean environments like laboratory fume hoods. The touch panel control system, with an integrated microprocessor, allows easy switching and control of different function modules. This ensures that processes can be quickly set up, controlled, and adjusted with visual feedback. The system supports LIMS integration and USB data export. The Picoline series is ideal for laboratories needing to process mini batches for R&D purposes, offering scalable results that can be transferred to larger process equipment with ease.

Lab-scale powder processing system

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

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

Industrial processes often involve drying bulk solids with high moisture content, from slurries and pastes to wet powders. Traditional drying methods can be inefficient and time-consuming, especially when dealing with temperature-sensitive materials that require precise handling.
<h2>Evaporates large volumes with minimal space</h2>
The DMR Flash Mill Dryer by Hosokawa Micron offers an advanced solution for drying bulk solids with varying moisture content. This patented system combines drying, de-agglomeration, and classifying in a single unit, making it highly space-efficient. The DMR ensures precise drying of temperature-sensitive products, achieving rapid drying in just seconds. The drying process involves dispersing wet material into fine particles using a high-speed milling rotor. These particles are fluidized by temperature-controlled hot gas, which can be heated up to 650°C. The system uses 30-40% less energy per kilogram of evaporated water compared to other direct drying technologies and requires up to 50% less space. It can handle materials such as suspensions, slurries, pastes, filter cakes, and wet powders, making it suitable for a wide range of industries including chemicals, food, and pharmaceuticals. The DMR's adaptable parameters, such as classifier speed and outlet temperature, allow precise control over the moisture content and particle size of the end product.

Ultra-fine powder flash drying system

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

Entry level

Pilot

When developing new products with unpredictable grinding properties, the need for flexible systems is paramount. Traditional setups may involve multiple mills and classifiers, taking up significant space and often reducing efficiency during production and research phases.
<h2>Integrate multiple grinding processes seamlessly</h2>
The Multiprocessing System by Hosokawa Alpine offers a versatile solution for flexible production and research requirements. This system integrates multiple mill types into a single compact unit, ideal for rapid changeovers and efficient space utilization. By allowing quick switching between various grinding and classifying modules, it supports small-batch R&D while maintaining compliance with GMP standards. The system is available in sizes ranging from small laboratory setups to large-scale production units. Key features include modular design, optimized dismantling for easy cleaning, and minimal documentation requirements. Ideal for industries such as food, chemicals, pharmaceuticals, and minerals, the Multiprocessing System ensures high flexibility, reduced investment costs, and ease of validation.

Multiprocessing system for flexible research and production

In toner and pigment production, achieving ultra-fine particles with high precision is crucial for optimal product performance. Industrial processes often require rapid cleaning to switch between different products without contamination, and high energy efficiency to minimize operational costs.
<h2>Achieve ultra-fine particles quickly and efficiently.</h2>
The TFG by Hosokawa Alpine is designed to meet the specific requirements of the toner, powder coating, and pigment industries. With its flat-bottom grinding chamber, this jet mill ensures minimal residue at the end of production, facilitating swift and thorough cleaning. Featuring Megajet nozzles and a high-precision classifying wheel driven by a vertical shaft, the TFG allows for precise control over particle size distribution. Its scalable design and compatibility with varied product specifications make it an ideal choice for applications demanding high purity and consistent quality.

Jet mill for toner and pigment industries

Achieving high fineness in powder processing industries, such as minerals and chemicals, often requires advanced technology to overcome limitations like throughput and energy consumption challenges.
<h2>Achieve precise particle sizes with reduced energy use</h2>
The TDG by Hosokawa Alpine is an advanced fluidised bed opposed jet mill featuring a double-flooded classifying wheel, leveraging Vorced Fortex Technology. This innovation allows for the highest fineness values or increased throughput with higher air flow rates while reducing energy consumption. The mill operates using compressed gas that exits through Laval nozzles, accelerating to speeds above the speed of sound. The design ensures efficient particle size reduction through interparticle collisions, with a dynamic deflector-wheel classifier to set fineness. This system is ideal for processing mineral powders, talc, and barium sulphate, and is customizable in materials like mild steel, stainless steel, or wear-resistant Al2O3 ceramic.

Fluidised bed opposed jet mill for fine particle processing

Size reduction

In many industries, producing powders with a precise and steep particle size distribution is crucial. Traditional grinding methods often fall short, particularly with heat-sensitive or abrasive materials that require contamination-free processing.
<h2>Achieve precise particle size distribution</h2>
The AFG by Hosokawa Alpine is a fluidised bed opposed jet mill that offers high-precision grinding. Utilizing grinding nozzles arranged around the periphery of the chamber, it ensures contamination-free grinding with zero machine wear. The dynamic deflector-wheel classifier allows for precise control of particle size. The unique hinge-back and removable classifier top section makes cleaning straightforward. Capable of handling materials from Mohs' hardness 1 to 10, this mill is ideal for both hard and soft powders. It is particularly suited for applications requiring heat-sensitive or contamination-free processing such as pharmaceuticals, ceramics, and high-performance magnetic materials.

Fluidised bed opposed jet mill for ultrafine powder production

In industrial applications requiring ultra-fine particle sizes, achieving precise and contamination-free grinding can be crucial. Traditional mechanical mills may not meet the requirements for purity and fine-grade powders, particularly for applications in pharmaceuticals and fine chemicals.
<h2>Achieve ultra-fine particle sizes without contamination.</h2>
Jet mills from Hosokawa Alpine offer a specialized grinding solution that uses high-velocity gas streams instead of mechanical grinding tools. These mills function by accelerating particles within the grinding chamber, causing them to collide and fragment into finer particles. Notable models include the Aeroplex AS for pharmaceutical applications and various fluidized bed opposed jet mills like the TDG, TFG, and AFG, each tailored for different industrial needs. The TDG model, for instance, incorporates a double-classifying wheel and Vorced Fortex Technology to achieve ultra-fine fineness down to d97 = 1 μm. These mills are suitable for extremely hard or heat-sensitive materials, providing contamination-free grinding with a high degree of efficiency and easy maintenance.

Ultra-fine powder grinding with jet mills

In the field of powder and particle processing, achieving medium-fine crushing of hard materials like ceramics and minerals is essential. Finding a method that combines energy efficiency with precise size reduction is key to optimizing your production process.
<h2>Achieve fine crushing with low energy requirements</h2>
The High-Pressure Roller Mill ECP by Hosokawa Alpine is designed for continuous operation, producing granules with a steep distribution. It operates through counter-rotating rollers pressed together by hydraulic systems. This selective contact creates high inner tensions leading to fractures, ensuring medium-fine crushing with minimal contamination. Its effective milling force allows for compact systems with low energy needs. This versatility makes it suitable for crushing hard materials like ceramics, minerals (5-9 on MOHS hardness), metals, and metal alloys. The ECP can be used in a closed circuit with screening machines or classifiers, achieving throughput capacities ranging from 0.2 to 120 tons per hour. Roller diameters vary from 200 mm to 1,100 mm, with working widths of 50 to 1,200 mm and drive units of 11 kW to 500 kW.

High-pressure roller mill for medium-fine crushing

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

Screening

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 experimental and early-stage product development in various industries, precise control over small quantities of powders and particles is crucial. Researchers and developers often need to perform fine milling, classifying, or mixing on a laboratory scale to test and refine processes.
<h2>Process small powder batches with precision</h2>
The Picoline from Hosokawa Alpine is a compact laboratory system designed for fine milling, classifying, or mixing of powders and suspensions. Comprised of a tabletop platform that can house various function modules, it allows for processing of quantities as small as a few grams. The platform features a brushed stainless steel surface for easy cleaning and can fit inside a laboratory fume hood. Each function module is derived from established product lines, ensuring easy scalability to full production. With an integrated touch panel, users can control the system via a straightforward interface. This makes it ideal for applications in foodstuffs, pharmaceuticals, chemicals, plastics, ceramics, batteries, nanotechnology, and functional materials.

Laboratory system for powder and particle processing

When precision in seed sorting is crucial, a system that ensures consistent calibration and classification is needed. Farmers and agronomists often challenge themselves with achieving uniformity in seed sizes to enhance planting efficiency and crop yield.
<h2>Ensure uniform seed sorting with vibration calibration</h2>
The VCS400 Vibrating Calibration System from Hoopman Equipment is designed to meet exacting standards in seed sorting. The system employs precise vibratory movements to classify seeds by size, offering reliable calibration for a range of agricultural needs. It operates on a vibrating sieve principle, where seeds pass through multiple layers of sieves that segregate them based on dimensions. This method reduces human error and increases sorting accuracy. The VCS400 is ideal for different types of seeds and grains, providing a high-throughput solution with consistent performance. Its robust construction guarantees long-term reliability and minimal maintenance requirements, making it suitable for both small-scale operations and large agricultural enterprises.

Vibrating calibration system for seed sorting

Calibration

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 chemical industry, small-scale testing and pilot plant operations often face the challenge of needing compact, versatile equipment for filtration and sedimentation tasks without extensive setup times or space requirements.
<h2>Simplifies chemical pilot plant processes</h2>
The Vertical Pilot Plant Centrifuge Chemical, from HEINKEL, is designed to meet cGMP requirements and is optimized for use in chemical laboratories and pilot plants. This centrifuge stands out due to its compact, mobile design, allowing easy installation and immediate operation. It includes features such as jacketed baskets for heating and cooling, making it ideal for upscaling from laboratory testing to full production. The centrifuge supports basic tests for filtration, sedimentation, and classifying, with models providing basket diameters ranging from 300 mm to 500 mm. Notable practical specifications include a maximum basket filling up to 38 kg and centrifugal forces up to 2,054 g, depending on the model. HEINKEL ensures high adaptability for various process needs.

Vertical pilot plant centrifuge for chemical industry

liquid

Sorting grains, coffee, nuts, or plastics effectively and ensuring product quality can be challenging, especially when dealing with contaminants or color defects. Accurate sorting technology is essential to maintain high standards in production and reduce waste.
<h2>Detects and removes defects</h2>
The SORTEX A is an ATEX-compliant optical sorter developed by Bühler, designed to sort grains, coffee, nuts, and plastics. This optical sorter is equipped with high-resolution cameras to detect either light or dark color defects and foreign materials, ensuring consistent product quality. Available in up to 5 chutes with sorting throughputs of up to 40 tons per hour, the SORTEX A minimizes waste through its machine learning capabilities, which analyze each grain and classify it accurately. The sorter’s automatic calibration and product tracking reduce setup time and continuous monitoring efforts. Additionally, the SORTEX A is built to withstand hazardous environments, with IP5X-rated sealed components ensuring durability and minimized downtime. Its versatile configuration options allow customization to match different product types, making it a robust solution across various industries.

Optical sorter for grains, coffee, nuts, and plastics

Detection

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

When producing young animal feed such as aqua feed or pet food, achieving ultra-fine granulation of raw materials is essential. Traditional grinding techniques often fail to meet particle size requirements efficiently, leading to uneven blending and energy inefficiencies.
<h2>Achieve ultra-fine particles with low energy consumption</h2>
The Pulverex™ 3 Series by Bühler is a high-efficiency pulverizer designed for ultra-fine applications, ideal for industries such as aqua feed and pet food production. This vertical shaft pulverizer employs the latest technology to deliver the highest throughputs while maintaining consistent quality. Notably, it can produce up to 15 tons per hour for recipes like grass carp feed. Its innovative design features a classifying impeller and deflector hood that minimize air resistance and prevent over-pulverizing, thus reducing energy consumption. The hydraulic opening system for the top cover and two side doors ensures minimal downtime during maintenance. Additionally, particle sizes can be adjusted during operation, ranging from 60 mesh to 200 mesh, maximizing plant uptime and production capacity.

High-efficiency pulverizer for ultra-fine applications

Granulation

Maintenance

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

In milling operations, separating and classifying flour and grist effectively is crucial. Variations in particle size and moisture content demand precise grading and efficient sifting to maintain optimal production and quality standards.
<h2>Sift and classify flour with high throughput</h2>
The Arenit Plansifter MPAV/W from Bühler offers a robust solution for sifting and sorting tasks in wheat, rye, corn, and durum mills. The design features a sturdy cast metal frame ensuring stability and durability for continuous operation. The plansifter provides up to 84 m² of net sieve surface with 26 Nova sieve compartments, addressing the need for high throughput in a compact footprint. Options for wooden or synthetic sieve frames, such as the high-grade NovaTec material, enhance sanitation and food safety. Additionally, the partitions in the compartment channels are well-sealed to prevent dust spread, ensuring product purity. The lightweight motor boosts energy efficiency, with adjustable swing weight settings and minimal maintenance requirements. The integrated stainless steel lining and insulated compartments reduce the risk of condensation and contamination.

Flour sifting and sorting solution for grain mills

Sifting

When processing rice, achieving consistent quality is paramount. The challenge is to efficiently separate impurities and different rice sizes while maintaining product integrity. Using advanced sifting technologies can help ensure high-quality head rice and reduce breakage.
<h2>Classifies rice and removes impurities effectively</h2>
The SuperSift plansifter by Bühler is a compact, high-throughput sifter designed to improve the quality of your rice. This equipment reduces the rice's temperature and moisture content, preparing it for further processing or storage. Multiple sieves, arranged in stacks within a single housing, allow for adaptable separation tasks such as grading different rice sizes or separating large volumes of broken rice. The stainless-steel lining and hygienic design minimize wear and maintenance, while the adjustable balance weights enable precise grading. This ensures that the rice is efficiently classified into large impurities, head rice, mixture rice, and tips, maintaining quality and consistency during processing. The two aspiration connections further enhance product safety by cooling the rice and removing excess moisture, thereby reducing grain breakage. The SuperSift plansifter is ideal for rice and paddy processing industries looking to optimize their sifting operations.

Rice sifter for optimal rice processing

Producing specialized animal feeds, such as aqua feed and pet food, demands finely ground materials. Achieving this level of granulation requires advanced grinding technology to meet the nutritional needs and safety standards of young animals.
<h2>Achieve consistent ultra-fine grinding</h2>
The Pulverex™ 3 Series by Bühler is a high-efficiency pulverizer designed for ultra-fine grinding applications. It is primarily used for processing raw materials in aqua feed, pet food, and other young animal feeds. The system combines feeding, pulverizing, and classifying functions in a compact structure, ensuring a high space-performance ratio. Capable of producing up to 15 tons per hour, it employs a vertical shaft and V-belt drive for robust operation. Key features include a specially designed classifying impeller and deflector hood, which minimize air resistance and prevent over-pulverizing, leading to reduced energy consumption. Maintenance is simplified with two side doors for quick parts replacement and a hydraulic opening system for the top cover. The absence of screen structures allows simultaneous pulverizing and classifying, further optimizing energy efficiency.

Ultra-fine pulverizer for aqua feed and pet food

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

In material recovery facilities, maintaining a high purity level of waste streams and efficiently recovering valuable materials are critical challenges. Traditional methods often struggle to keep up with the diverse and complex nature of waste compositions, necessitating advanced solutions for optimal performance.
<h2>Automates sorting tasks using Ai-guided vision system</h2>
The RoBB is an intelligent and automated sorting robot fully developed by Bollegraaf. It uses an AI-guided vision system built around optical sensors such as NIR (near infrared), RGB, and height cameras to identify and classify items based on material composition, shape, and color. The robot's cognitive computing process relies on deep learning networks that continually improve its sorting accuracy. A strong and robust robotic arm with an advanced air system and patented suction gripper performs real-time object classification and actuation. Designed with modularity in mind, the RoBB can easily be installed in existing sorting lines and tailored to various belt widths. It significantly reduces operational expenses by minimizing the need for human intervention. Ideal for diverse waste streams including plastic, paper, and municipal solid waste, the RoBB ensures high performance, consistency, and profitability in material recovery facilities.

Automated sorting robot for material recovery facilities

In laboratory settings, conducting comprehensive filtration tests requires reliable methods for evaluating filtration behavior under varying conditions. Understanding critical parameters such as thickening, washing, and classification is essential for effective filtration system design.
<h2>Evaluates filtration behavior using crossflow techniques</h2>
The BoCross Test by BOKELA is a laboratory-scale test system designed for dynamic crossflow filtration. Utilizing small sample quantities (1 to 40 liters), it assesses filtration behavior under both continuous and discontinuous operations. The test system supports various filter media including polymer membranes, metal mesh, and ceramic membranes, allowing for versatility in testing different suspensions. The portable design fits into confined spaces like fume cupboards. Key features include the efficient prevention of solid deposits through shear stress effects, rapid change of filter media, and straightforward handling. It operates under pressures up to 10 bar and temperatures up to 170 °C for the complete version. The system captures essential data for filtration evaluations such as pressure, rotor speed, concentration range, and flow rate.

Laboratory crossflow filtration test system

In industries like chemicals and foodstuffs, converting liquid raw materials into solid granules can present challenges such as dust formation and uneven particle size. This calls for a reliable granulation system to ensure efficient conversion and high-quality output.
<h2>Convert liquid materials to solid granules effectively</h2>
The Fluidized Bed Spray Granulators WS-GT from Allgaier Process Technology are designed for efficient production of solid, dust-free granules from liquid starting materials such as suspensions and solutions. By applying the liquid via nozzles to the fluidized bed, the system promotes even particle growth as the drying air evaporates the water content, resulting in dimensionally stable granules with excellent flowability. The granules are then classified by size through a screening machine or sifter, while undersized particles are recycled back into the process. This granulator is particularly effective for producing urea granules, yeast and gelatin granules, and water jars. The system's high performance and possibility for explosion-proof configurations ensure safe and reliable operation.

Fluidized bed spray granulators for liquid to solid conversion

Recycling

Large volume manufacturers demand the most out of their production process, including powder milling. However, not all necessary equipment is available in the same capacity range required to meet different production outputs; therefore, the equipment must have a wide range of capacities for greater flexibility while maintaining maximum product yield.


<h2>Milling powder products using process gas streams for medium and large industries</h2>
The MC DecJet 300/400/500 from Dec, are powder micronization systems for medium and large industries. Each unit has a wide capacity range starting with the DecJet 300 which has a 5 kg to 200 kg/h range, followed by The Decjet 400 with a 10 kg to 400 kg/h range and the DecJet 500 with a 20 kg to 800 kg/h capacity range. The process uses a gas stream inside a chamber where the large powder particles are fed and collide with each other until an acceptable size is obtained by a classifier. The micronized powder can be collected in a cyclone where it is separated from the process gas by a filter. The units feature integrated nozzles to prevent errors during installation, making it easy to assemble. The jet mill is made of high-grade materials such as AISI 316L stainless steel or Hastelloy. The system has an option to use full automation by PLC with batch reporting for added flexibility. The jet mill discharge is also available in top or bottom configurations and a sanitary rotary valve is available for product collection.

Production scale jet mill

Small scale manufacturers that require effective micronization of powders for their process lines may need automated equipment to keep productivity high. When it also comes to scaling up, equipment with a broader range of capacity is necessary to keep up with the expected production output while keeping maintenance costs down.
<h2>Micronizing powder up to 40 kg per hour using an explosion-proof system</h2>
The MC DecJet 200 from Dec, is a powder micronization system best suited for small scale industries. The system has a capacity range of 1kg to 40kg/h. The process uses gas streams inside a chamber where the large powder particles are loaded. These particles will collide until an acceptable size is obtained through a classifier. The micronized powder will then be collected in a cyclone where it is separated from the process gas by a filter. The unit is easy to clean and assemble and it is made of high-grade materials such as AISI 316L stainless steel or Hastelloy. The system has options for better flexibility including full automation by PLC with batch reporting. The jet mill discharge is available in top or bottom configurations and a sanitary rotary valve is available for product collection.

Jet mill micronizer

In a pilot scale level or preliminary study, all the production process steps have to satisfy the small scale production needs. As part of the process, powder milling equipment also needs to be scaled down to match the output of the pilot scale design while maintaining the same efficiency and a wide range of capacity for greater flexibility.
<h2>Micronizing powder through a compact and versatile system for small scale production</h2>
The MC DecJet 100/150 from Dec, is a powder micronization system designed for pilot scale or small scale production. The system has a capacity range of 50g to 5kg/h for the DecJet 100 model and a 500g to 30kg/h for the DecJet 150 model. The process uses gas streams inside a chamber that help break the large powder particles to an acceptable size through a classifier. The micronized powder will then be collected in a cyclone as the process gas passes through the filter.  The unit is easy to clean and assemble and it is made of high-grade materials such as AISI 316L stainless steel or Hastelloy.

Pilot scale jet mill

Manufacturing small quantities of high-value products requires efficient machines that can process these products with minimum loss. In case of milling sticky powder products, caking can cause a massive loss in product yield. Using equipment designed to limit caking of sticky powders maximizes production yield and minimizes product waste.


<h2>Milling powder by process gas stream for laboratory applications</h2>
The MC DecJet 50 from Dec, is a powder micronization system designed to handle powder quantities ranging from 35 grams to 200 grams/ hour. It is an ideal unit for clinical trials and scale-ups. The process begins with the powder going into an inlet that leads to the chamber with a pressurized process gas stream. The gas stream throws the larger particles to the outer edge of the chamber, where they collide with other particles and break up into smaller sizes. As the particles get smaller, they move to the center of the chamber and pass through a classifier going to the cyclone where a filter separates the gas stream and micronized powder.  The unit is easy to clean and assemble and it is constructed of high-grade materials such as AISI 316L stainless steel or Hastelloy.

Laboratory jet mill

Seeds coming from the same plant might have different sizes and shapes. The germination percentage of small seeds is lower than large(r) seeds. Larger seeds often have a higher germination speed than small seeds. For this reason, seeds have to be sorted according to their diameter before processing. For this, a seed sizing machine is needed

<h2>Accurately classifying seeds by diameter using an unbalanced calibration machine</h2>
The CCM-4900 Seed Calibration Machine sorts fine seeds according to their diameter size. The technology is designed by Seed Processing Holland and reaches a size accuracy degree of up to &lt; 3%, making it especially suited for breeding and seed foundation stations. The system separates all kinds of seeds uniformly into anti-static bins and calibrated seeds are separated into four fractions: three lower sizes and one upper size. This machine is slightly different to a gravity separator because it focuses on size/shape instead of weight.

The screen boat of the CCM-4900 holds two screens using a pneumatic clamping system with screen, while its unbalanced motors ensure silent operation throughout. The adjustable vibration function can operate at different time intervals. Meanwhile, integrated dampers prevent the transmission of vibrations to the frame. It is recommended to utilise this piece of equipment on a smooth and flat surface to further reduce any vibrations. Having said that, the dampeners do a great job at absorbing unwanted loud noises.

If you're running a processing plant and looking to maximise the output of any crop you might be growing then this will most help you achieve that. Furthermore, that applies to all crops that are grown from seeds including various types of vegetables, crops and hemp.

If you're growing crops in rows, then using the CCM-4900 will drastically improve the sorting process and allow you to use only the best seeds to ensure a successful harvest.

Machine For Sizing Seeds

Widely used in the construction industry as filling materials, calcium carbonate is usually made from pulverized limestones. As a result, vibration and noise are typical issues during CaCO3 powder production processes, especially during grinding. Therefore, it is essential to have a classifier milling system to ensure low noise and low vibration while achieving the maximum particle fineness required in CaCO3 powder production.


<h2>Mill for fine grinding and drying of soft to medium-hard minerals</h2>
The Pendulum Mill PM by NEUMAN &amp; ESSER is a roller mill used for fine grinding and drying soft to medium-hard materials such as clay, bentonite, limestone, and many other minerals. It is a robust and durable design of combined grinding, de-agglomeration, drying, and classifying system.

The mill consists of a sturdy cast, mill housing, and a rotor with a crosshead. The grinding roller travels on the rings, whose centrifugal action against the grinding ring reduces the minerals into finer sizes. Rotating shovels guide the particles from the mill bottom to the grinding zone. The air system then transports the ground particles to the classifier, where it rejects coarse particles and sends them back to the mill for further grinding. The speed of the classifier can be adjusted to meet the required particle size and distribution. Finally, a downstream collector receives the particles with the necessary final degree of fineness.

The Pendulum Mill PM can achieve narrow particle size distribution with an upper particle size ranging from 10 μm to 1,000 μm (1,250 to 18 mesh). The mill capacity ranges from 0.5 t/h to 150 t/h and can process up to 35% humidity material.

Grinding and drying of CaCO3

After crushing and drying mined bentonite, this clay mineral is usually processed through a grinding mill into powder form. To maximize the capability of bentonite powder in hydration and water absorption, a combined milling and drying system with a higher lifetime of wearing parts is required to achieve desired fineness and product quality.


<h2>Mill for grinding and drying soft to medium minerals</h2>
The Pendulum Mill PM by NEUMAN &amp; ESSER is a roller mill used for fine grinding and drying minerals such as bentonite, clay, limestone, and others. It combines grinding, de-agglomeration, drying and classifying, making it an extremely robust and durable design.

The mill consists of a sturdy cast, mill housing, and a rotor with a crosshead and pendulums whose rollers run against a grinding ring crushing the bentonite material into fine sizes. Air transports the materials to the grinding zone through channels and rotating shovels. Both fine and coarse particles enter the classifier, where it separates coarse particles and sends them back to the mill for further grinding. The classifier speed can be adjusted to meet the requirements that come with the desired particle size distribution. Finally, the downstream collector receives the particles with the required final degree of fineness.

The Pendulum Mill PM can achieve upper particle sizes ranging from 10 μm to 1,000 μm (1,250 to 18 mesh). The various mill capacities can receive input quantities ranging from 0.5 t/h to 150 t/h and process feed material moisture of up to 35%.

Grinding and drying of bentonite

Drying and grinding can be an important feature when trying to process products such as raw and refined minerals, organic and inorganic chemicals, food ingredients and waste streams. It is crucial to maintain particle size and consistent quality of the finished product during such processes. You will need an efficient and abrasion resistant attrition solution to pulverise and dry your product into your required particle size.


<h2>A simplified process while drying and grinding ensuring high product quality</h2>
Atritor’s Dryer-Pulveriser is able to grind and dry the product simultaneously. It is an air-swept mill that uses an air stream to efficiently process the product and controls the final particle size. It is able to process feedstocks of up to 50+mm and production capacities from 100kg/h up to 30t/h with evaporation rates up to 6,000 kilograms per hour.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or waste heat from another process. It can reach an inlet temperature of up to 550ºC. Heat energy from the process can be recovered from the heated air stream. After flash drying, the product is kept cool due to evaporative cooling. The output temperature of the product is maintained accordingly to control the moisture content of the product.

The Flash drying grinder for powders is configured with a combination of variable speed rotor, hammer arrangement and fixed pins. Turbulence inside the grinding area creates attrition to reduce the particle size, which can be controlled for simple deagglomeration of the product. An internal classifier configuration can also be used to further control particle size.

The ‘A’-series is constructed with internals that are resistant to abrasion for applications that can cause high amounts of wearing to the equipment. Where the desired amount of evaporation required far exceeds the grinding duty, the ‘B’-series machine of a lighter weight, fully fabricated configuration permitting higher airflows can be used for non-wearing product or duties, as well as for for applications in which stainless steel contact parts may be necessary.

Flash drying grinder for powders

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

Milling and drying machine for fine powders

In laboratory and research environments, accurately assessing the flow properties and behavior of powder materials is crucial for the development and optimization of various processes. Traditional methods often lack the precision and reliability required for these in-depth analyses.
<h2>Accurate evaluation of powder properties</h2>
The Powder Tester PT-X by Hosokawa Alpine is an advanced tool designed for comprehensive powder characteristic evaluation in laboratory and R&D settings. It offers automated and repeatable measurement of various powder properties such as flowability, compressibility, and cohesiveness. This device stands out due to its ability to provide detailed insights into powder behavior, enabling researchers and engineers to optimize formulations and processes with high accuracy. Equipped with a user-friendly interface, it simplifies the operation and collection of data. The robust build ensures durability and longevity, making it a valuable addition to any laboratory focused on material science or powder technology.

Powder characteristic evaluation

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

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

Industrial production of high-quality powder materials often requires precise control over particle size and composition. Challenges include maintaining consistent quality in mass production and achieving specific material characteristics tailored to end-use applications.
<h2>Optimizes powder synthesis and particle coating</h2>
The Glatt ProAPP® series reactors are advanced synthesis reactors designed to meet the diverse requirements of producing, modifying, or coating powder particles in the nanometer and micrometer range. Utilizing pulsating gas flow in a continuous vertical reaction tube, these reactors allow for tailored adjustments to raw material feed rates and process temperatures. Reactor options range in diameter from 80 mm for small-scale production to 500 mm for larger quantities. The reactors can achieve process temperatures up to 1300°C with electric or gas heating options, and allow for precise product separation via filters and samplers. Suitable for various materials such as battery powders, ceramic powders, catalytic powders, and pigments, the ProAPP® reactors are customizable to fit specific industrial applications. Glatt’s facilities offer lab-scale options for research and pilot-scale reactors for scaling-up production, ensuring flexibility for both small and large campaigns.

Powder synthesis reactors for nanometer and micrometer particles

Blending

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

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.