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Continuous chocolate line with vertical ball mills

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

Feed ingredients

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

Insect protein

Do you have a sweet tooth, or are you more into a warm loaf of bread for a savory lunch? The bakery shop window displays something for everyone, from baguettes over croissants to muffins. Bakery products are a wide range of baked goods prepared from flour or meal derived from grains. These undergo mixing, fermentation, and baking processes with the help of bakery processing equipment such as a series of low- and high-speed mixers, fermentation tanks, and baking chambers.

Bakery

With over one-third of the population consuming it daily in different forms, coffee is one of the most popular processed beverages worldwide. Not only serving as drinks, but coffee is also often regarded as a culture. Coffee manufacturing is a knowledge-intensive industry. Coffee beans from different regions will reveal different tastes, while the level of caffeine could also be different. When it comes to coffee bean processing, the range of roasts varies from light golden brown all the way to dark. The method of tasting coffee differs between countries, habits, and tools.

Coffee

<span style="font-weight: 400">Cocoa production and the cocoa industry uses industrial processing technology to process and manufacture high quality cocoa products in many different forms. Did you know that cacao cultivation goes back centuries - to be specific, about 5300 years? </span><span style="font-weight: 400">This plant, with its long history, is also known for its versatile usage. From </span><span style="font-weight: 400">cocoa nips to cocoa butter, cocoa becomes a base to produce multiple products, ranging from food products to cosmetics. As you may already know, chocolate products are all made from cocoa as well. Hence, depending on what you intend to produce as the end product, as well as your recipe, your cocoa processing equipment line may change.</span>

Cocoa

There is a pasta type for every mood. Curly, straight, ridged, or smooth, pasta has quickly grown into a staple food. The simple combination of milled wheat and water is transformed by pasta making equipment into a rainbow of shapes, colors, and sizes. But producing pasta with the right firmness, elasticity, and color profile is as intricate a process as preparing an authentic lasagna.

Pasta

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

Organic fertilizer

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

Continuous

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

Vertical ball mills for chocolate refining

solid

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

Horizontal ball mill for chocolate refining

A pre-refiner is commonly utilized to refine and calibrate the sugar crystals in the chocolate batch and get the it ready for the refining process.


<h2>Preparation for optimal fine refining</h2>
The Two Roll chocolate pre-refiner, from Royal Duyvis Wiener, are optimized for the highest productivity, designed to refine and calibrate the sugar crystals to a fineness of 120 to 180 microns. Extremely durable and resistant to wear, with its specially designed components: hydraulic controls, gap adjustment, and drive technology, effortlessly produce pre-ground chocolate batches, ready for the subsequent refining process.

Two Roll chocolate pre-refiner

For mixing, rubbing and fine grinding in the production of chocolate mass, filling materials and a vast range of rework products.


<h2>Flexible mixing, rubbing and fine grinding with Three-Roll chocolate refiner</h2>
The versatile Three-Roll chocolate refiner, from Royal Duyvis Wiener, is quite simply the most innovative solution for a flexible production process, designed to perform multiple tasks in the chocolate production process. The hydraulic Three-roll refiners are optimized for mixing, rubbing and fine grinding in the production of chocolate mass, filling materials and a wide variety of rework products.

Three-Roll chocolate refiner

When you want to produce high quality traditional chocolate, a 5 Roll Refiner gives you complete control of your product quality. For frequent recipe changes, individual roll drives and advanced automation will help you master your process.


<h2>Fully automated 5 Roll refining</h2>
The 5-Roll Refiner from Royal Duyvis Wiener is the most hygienic 5 roll refiner available. With its fully automated functions, controlled by the PLC buffer, the five-roll refiner maximizes your production up to four batches /hour. Versatility of your production line is ensured, by adjusting the roll's revolution speed and friction ratio.

Particle size management is the answer when undesired product fluctuations jeopardize your production. Installed on top of the 5th roll, the particle size management device directly measures the particle size at two locations on the roll (center and side), without using an indirect layer thickness. Every 20 ms, the cocoa, chocolate and white mass are measured automatically and at the same time the settings of the 5-roll refiner are controlled.

Five Roll chocolate refiner

For mixing and refining cocoa liquor, cocoa powder, sugar, and lecithin, several methods can be utilized, such process can be easily accomplished through the use of horizontal ball mills and liquid conching.


<h2>Fine processing of chocolate masses</h2>
The EMA-Choc 1000 and EMA-Choc 2800 are lines of high performance horizontal conical agitators ball mills for the refining of compound, coatings, creams and bread spreads in continuous process; with a processing time/capacity between 1200 to 3200 Kg/h. The innovative approach combines a pre-mixer with ball mill refiners, for intermediate and/or fine grinding results in an efficient and sustainable production process.

The Continuous chocolate line with horizontal ball mills is suitable for both crystal and powdered sugar based recipes. The horizontal and conical grinding unit has a high-flow rate design which allows to get an ultra-fine refining below 20 microns (D90). The highly wear-resistant materials guarantee the maximum life span of the grinding tools, less wear and the lowest iron intake for the product.

Continuous chocolate line with horizontal ball mills

Conching is a critical step in the manufacturing of chocolate. In this phase, your chocolate mix is agitated and superficially scraped by a conch, allowing the cocoa butter to separate amalgamated particles and distribute your cocoa butter more evenly. The heat generated by the process volatilizes acids improving the texture and aroma of the finished product. Early machines used vessels in the shape of a conch shell, giving the equipment its name.

Conching

After roasting and cracking chocolate beans (without husks), the following process is the grinding. Grinding is the process of going from the cocoa nibs into cocoa liquor, obtaining with this pure cocoa mass in liquid form.


<h2>Accurate temperature control during the cocoa grinding process</h2>
This cocoa grinding machine from Royal Duyvis Wiener keeps the cocoa grinding process as simple as possible whilst paying close attention to every single detail.

The cocoa grinding process begins by feeding cocoa nibs into the chamber via a screw.

Knives then commence their work, and the ground material leaves the machine through a specially designed sieve. The sieve on the cocoa grinding machine can be adjusted. Making it possible, to alter the fineness of the final product during the cocoa grinding process.

The management of temperature is paramount during cocoa grinding process, due to grinding nibs in large volumes requires large amounts of energy, where heat is produced; for this reason the airflow within the cocoa-grinding machine is controlled accurately in order to stabilize the temperature.

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Cocoa liquor grinding line

liquid

If you are looking for high end-product fineness for suspensions with good flow properties with a steep particle size distribution, a horizontal agitated media mill can be a good solution. Often used for wet materials like chemicals, foodstuffs, metals, pigments, and paints.


<h2>Continuous wet milling of particles down to the submicron range</h2>
The Agitated Media Mill AHM from Hosokawa Alpine is a horizontal, cylindrical milling chamber that is universal in use for the continuous wet milling of particles down to the submicron range. This horizontal milling chamber was especially designed for suspensions with good flow properties where a steep particle size distribution and high end-product fineness are demanded.

Ball mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium. The mill is suitable for both continuous and batch operations, also available in sizes suitable for the laboratory, the testing center or for large-scale production.

Chemicals, minerals, PCC, ceramics, foodstuffs, metals, pigments, paints (mass production), laboratory, nanoparticles, abrasives, pharmaceutics. This mill is suitable for small amounts of product and for development trials, also in the nanotechnology sector. Extremely small grinding beads (&lt; 0.2 mm) can be employed with this mill, and investigations regarding the stabilization of suspensions in the submicron range can be executed.

Horizontal Agitated Media Mill

Batch

Agitated media mills are media mills that employ an agitated (or stirred) grinding media action for grinding of the ultrafine particles. In this case, a ceramic grinding media grinds mineral, metal, or chemical powder. The most typical application is the manufacture of GCC slurries used for the production of paper, but also ultrafine limestone slurries, such as calcium carbonate, limestone, and marble.


<h2>Cost-efficient grinding of highly concentrated limestone slurries</h2>
The agitated media mill ANR from Hosokawa Alpine is designed for the cost-efficient ultrafine grinding of highly concentrated limestone slurries. The operating mode and the design permit the production of extremely high qualities with regard to fineness, degree of whiteness, and abrasiveness.

The mill design ensures low-maintenance continuous system operation with no expensive downtime periods. The flow pattern goes from bottom to top, whereby the feed material is ground to the required end fineness with the aid of ceramic grinding beads (zirconium silicate or zirconium oxide).

Efficient cooling of the mill stator removes the heat generated during grinding.

The agitator elements and the grinding chamber wall are made of wear-resistant hardened materials.

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Vertical agitated wet media mill

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

A horizontal rotary ball mill drum can be used for grinding of dry hard materials, such as hard minerals for the ceramic, glass or porcelain industry and processing of soft minerals with abrasive properties.


<h2>Dry ultrafine grinding of mineral powders and ceramic raw materials</h2>
The Super Orion ball mills from Hosokawa Alpine are employed for the dry ultrafine grinding of mineral powders and ceramic raw materials. The ball mill is designed for the dry comminution of hard materials, especially for the ultrafine range &lt; 10 µm in circuit with an ALPINE ultrafine classifier.

Ball mills are giant drums that are filled with between 30 and 40% of their volume with freely moving grinding media, in this case balls. The diameter of the balls is between one and several centimeters to suit the application - smaller balls for fine milling results and larger ones for coarser milling tasks.

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Horizontal rotary ball mill drum

Standard classifier for high outputs in the fine to medium-fine separation range of d97 = 20 - 200 µm. Ideal for processing feldspar, quartz, nepheline, wollastonite and so on.


<h2>Even at high feed rates, the quality of classification is maintained</h2>
The ASP Stratoplex from Hosokawa Alpine is a high-efficiency classifier, designed for the fine to medium-fine separation range with a D97 of approximately 10-200 µm. Even at high feed rates, the quality of classification is maintained.

A compact and modular system that permits not only a top performance but also a trouble-free, space-saving system installation. Many sizes are available with feed capabilities of up to 100 tons/hr.

Often used in the Mineral Filler Industry for separating glass (ground), metal oxides, calcium carbonate, zircon flour, kaolin, bauxite and so on.

It is available in wear-resistant construction for even the most abrasive applications. Integration with ball mill circuits is easily accomplished.

High throughput air classifier for minerals

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

Universal in operation for the size reduction of soft materials in the range 50 µm to 5 mm. Most applications are to be found in the chemicals industry, foodstuffs and animal feed industry, as well as in the pharmaceuticals industry.


<h2>Generously dimensioned mill door for easy cleaning and exchange of grinding elements</h2>
The Fine Impact Mill Ultraplex UPZ from Hosokawa Alpine is a versatile size-reduction system with exchangeable grinding elements such as beater disc, pin discs, swing beaters and plate beaters, sieves and grinding tracks.

It is featured by offering an end-product fineness in the range 50 µm to approx. 5 mm in accordance with the grinding equipment installed.

Alpine Ultraplex UPZ fine impact mills offer versatility in use combined with simplicity in operation. The overall result is a host of practice-oriented and perfectly coordinated equipment combinations.

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Fine impact mill

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

Developed especially to meet the requirements of sugar grinding, it is also suitable for similar applications within the food industry.


<h2>Meet all safety and accident prevention regulations</h2>
The Fine sugar grinder Impact Mill - Sugarplex SX from Hosokawa Alpine is a versatile size-reduction system with exchangeable grinding elements for sugar with a high grade of fineness in the range 50 µm to approx. 5 mm in accordance with the grinding equipment installed.

The Fine sugar grinder was developed exclusively for the food industry, it meets all basic safety and health regulations of the EC Machine Directive 98/37 EC Annex II and all safety and accident prevention regulations of the Federal Republic of Germany.

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Fine sugar grinder

Particularly designed for humid, oily, and greasy products.


<h2>Ultrafine pill mill proved to process even sticky materials in a wide chamber housing</h2>
The Contraplex Wide Chamber Mill - Contraplex CW from Hosokawa Alpine is an ultrafine pin mill, with two driven pin discs. Designed aiming to achieve high-power fineness values at a range of approximately 10 to 500 µm.

The fineness can be adjusted by altering the fine pin mill disc speeds. The centrifugal forces acting on both discs allow the processing of humid, greasy, and sticky products, primarily as a result of the utilization of the design within the wide chamber housing.

The feed material stands out for being embrittled by intensive mixing with liquid nitrogen. Ultrafine Pin mills are considered among the most reliable and versatile equipment currently available in the materials processing market. It features a generously dimensioned mill door that can be attached wide-open, for easier cleaning.

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Ultrafine pin mill

Ideal for a combined process operation where several process steps are executed simultaneously in one single unit. A product can be simultaneously comminuted, dried, coated and/or mixed.


<h2>Outperform conventional impact mills for maximum fineness</h2>
The Long Gap Mill – LGM from Hosokawa Alpine can be used for various processes, e.g. grinding and drying as well as coating or mixing a product. Several processes can also be carried out at the same time with this machine in one single process step.

It reaches a fineness of maximum 97% &lt; 5 – 500 µm, depending on the product. Either dry materials, slurry or wet cakes can be processed with this mill.

The range of products that can be processed with the LGM is extremely wide. The most common applications are size reduction of mineral powders, plastics and rubber, soya, wheat bran, carbon black, cellulose and derivatives; Impact drying of hydrogels, cellulose derivatives, ceramic slurries and coating of Fine fillers with stearates or silanes.

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Long gap mill

Suitable for the comminution of numerous products and it's utilized in every branch of industry. It is also suitable for the fine and ultrafine grinding of soft to medium-hard products.


<h2>Most versatile size reduction equipment available on the market</h2>
The Mikro ACM Air classifier mill from Hosokawa Alpine is one of the most versatile types of size reduction equipment available in the market. Size reduction is a result of the feed product impacting against the rotating grinding elements and against the stationary liner. At beater tip speeds of up to 140 m/s, fineness values of d97 = 10 µm are achieved.

The fines pass through the classifying wheel and exit the mill. The cut point is a function of the classifying wheel speed, which can be adjusted even during operation.

The most common applications of the Air classifier mill, are materials for powder coatings, cosmetics, food, pharmaceutical, chemical, and Mineral industries.

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Air classifier mill

For grinding soft products up to a Moh´s hardness of 3.5. The end products are free from oversize particles and have a steep particle size distribution and an exact top cut.


<h2>Designed for processing sticky products that tend to deposit</h2>
The Classifier Mill - ZPS Zirkoplex from Hosokawa alpine is a universal classifier mill for materials to a Moh´s hardness of approx. 3 when the requirements call for extremely high end-product fineness values at the lowest possible energy consumption.

It works by rejecting the particles that are too coarse by the classifying wheel and are comminuted by the beater unit until they can pass through the classifying wheel and thus correspond to the required fineness as specified by the classifying wheel speed.

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Classifier mill for soft products

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

Sodium-hydrocarbonate classifier mill

Gently crush down brittle, easily broken materials to fine particle size.


<h2>Gentle milling action for minimum fines generation</h2>
The Flake crusher from Hosokawa Alpine offers a gentle milling action that minimizes fines; which means that the Flake Crusher is often used in hazardous dust areas. Typically the circumferential speed is around 1 m/s.

The material to be crushed is strained through a screen with a horizontal rotor. The crushing movement of the rotor can take place both in an oscillating and rotating manner.

The most common applications of this device are crushing of lumped salts and hygroscopic substances, deagglomeration after drying and mixing, crushing of flakes to granulate, recycling of tablets, and dust-free crushing.

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Flake crusher

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

For the gentle crushing of soft to medium-hard substances. Widely used in food industries for size reduction, pulverization, deagglomeration or delumping before they become a finished product.


<h2>Gently crush soft to medium-hard substances</h2>
The Bexmill from Hosokawa Alpine is a Conical gentle crusher, used to crush soft to medium-hard substances.

The mill can be charged both continuously and discontinuously.

Due to its conical form, the Bexmill can be operated in contrast to the classic Flake Crusher at higher revolutions. Through these larger throughputs, a higher fineness can be achieved.

The product spectrum ranges from wet to dry feed material.

This Conical gentle crusher is often used in processes of homogenization of mixtures, after mixer agglomeration, the disintegration of agglomerates, after fluid beds and kilns, and in the finishing of granulates.

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Conical gentle crusher

With a pre-crusher continuous flakes are made into pieces, before granulation.


<h2>Proper pre-crushing before granulation</h2>
Pre-Crusher type PC from Hosokawa Alpine is a pre-crusher of plates quite suited for the first crushing levels before the granulation and production of clumped materials for free-flowing.

The crushing takes place with counter-rotating grinding rollers which are either equipped with bars or discs, that reach particle sizes up to 30 mm, dust-free coarse crushing in the preliminary crushing of flakes

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Pre-crusher of plates

A hammer mill crushes aggregate material into smaller pieces; the most common applications can be found in food, chemical, plastic and cosmetic industries.


<h2>Grinding, mixing and homogenization in one single process</h2>
The Mikro Pulverizer MP from Hosokawa Alpine is a hammer mill for the gradual crushing of soft to medium-hard products. This unit comes with three operations such as grinding, mixing and homogenization.

Easy to clean and maintain, the MikroPulverizer MP grinds, mixes and homogenizes in one single processing step. The system is well-proven in combined grinding and drying systems, as well as in cryogenic and inert gas systems.

Different rotors, liners, screens and grinding elements are available for a wide range of applications and products, e.g. carbon black, iron oxide, casein, melamine, sugar, urea, etc.

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Hammer mill

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

Cutting

Granulation

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

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

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

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

Shredding

When it comes to the low-dust and cost-effective comminution of mouldings, blow mouldings and sprues and flashes, polymer line granulators are your best choice.


<h2>Cost-effective size reduction of polymers</h2>
The Granulator - PL polymer line from Hosokawa Alpine was specially designed for the cost-effective size reduction of mouldings, blown containers, sprues, flashes and other polymers. They are a synonym for a wide range of different mill designs intended for use as auxiliary and main mills.

This series features three various models, each engineered with dual-scissor-cut rotor mechanisms, an efficient product feeding apparatus, noise-suppressing elements, and a compressed and sleek architectural design.

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Polymer line granulator

Jet mills are frequently used in the pharmaceutical industry and also for the production of fine-grade chemicals. Jet milling uses highly compressed air or other gasses to reduce particles into powders with dimensions as small as one micron across.


<h2>Milling with high purity and minimal contamination</h2>
The Spiral Jet Mill - AS Aeroplex from Hosokawa Alpine is used to manufacture fine-grade chemicals for ultrafine size reduction of dry materials with a crystalline structure up to a Mohs hardness of 3.

Because it has no rotating components, there are consequently no bearings and shaft seals, and thus no lubricants are used. Contamination from these sources is therefore impossible.

This device is frequently used in the pharmaceutical industry to manufacture fine-grade chemicals, to create polymer powders for the plastics industry, adhesives, cosmetics, paint and ink compounds, pharmaceuticals, and more.

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Spiral jet mill

Fluidized bed opposed jet mills rely purely on particle-to-particle attrition in the center of a fluidized bed of material; this is achieved by focusing in compressed gas nozzles into the milling chamber which accelerates the particles to produce collisions where energy is released causing particle breakdown.


<h2>Maximum fineness with the highest product purity</h2>
The Fluidized Bed Opposed Jet Mill AFG from Hosokawa Alpine is used for manufacturing powders with a steep particle size distribution and sharp top size limitation in the range &lt; 5 µm to 200 µm; maximum fineness values at maximum product purity. Such particle sizes can only be obtained in connection with an air classifying step. Fluidized bed opposed jet mills are equipped with a dynamic deflector-wheel classifier.

Even difficult products can be processed efficiently with the AFG jet mills. Heat-sensitive materials such as toner, resin, wax, fat, ion exchangers, plant protectors, dyestuffs, and pigments; highly pure materials where the requirement is contamination-free processing such as fluorescent powders, silica gel, silica, special metals, ceramic raw materials, pharmaceuticals.

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Fluidized bed opposed jet mills

Pharmaceutical granulators are often used with active substance mixtures to be processed into granulates, a process also known as compaction.


<h2>Dry granulation of pharmaceutical powders</h2>
With the Pharmapaktor® Serie (Pharmapaktors series L, K, and C 250) from Hosokawa Alpine, active substance mixtures are processed into granulate.

For this, the powder is first pressed into flakes/pellets. These are often crushed with a Flake Crusher into granulate.

Compaction (dry granulation) is understood to be the compression of powder between two synchronized, counter-rotating rollers. The powder is fed to the counter-rotating rollers in a regulated manner. Here, adhesive forces between the product particles are created under high pressure between the rollers.

For capsule or sachet filling the granulate must be de-dusted in a screening machine. The sieved fines can then be directly fed to the Pharmapaktor again

Pharmaceutical granulator

Compaction machines and technologies crush or compress materials and make them denser. Compaction can be used to simply save space or to shape materials into a desired form or format. Tablets, pellets, or briquets are formed by compactors but powder presses also help form cosmetic eyeshadow or face powder.

Compaction

For pre-crushing before fine grinding, non-fine crushing, sharp-edged granules, and narrow granule distribution. With high-pressure roller mills products are produced with a precipitous granule distribution.


<h2>Compact mills for sharp-edged granules</h2>
The high-pressure roller mill from Hosokawa Alpine is also called roller crusher or roller press. In comparison to compaction processes, it uses lower press forces between the rollers because no new adhesive forces need to be created.

With high-pressure roller mills products are produced with a precipitous granule distribution.

Because only the outer particles of the material bed have contact with the surface of the rollers, milling that is almost contamination-free is possible.

Often used in the cases of medium-fine crushing of hard materials such as ceramics, minerals from 5 up to 9 on the MOHS hardness scale metals and metal alloys.

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High pressure roller mill

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

A Laboratory hammer mill in pharma design for the comminution of pharmaceutical and chemical products. Depending on the project, the mill can be delivered integrated into an isolator.


<h2>Easy to clean pharmaceutical grade hammer mill</h2>
The Laboratory Hammer Mill 20/10 from Hosokawa Alpine is a laboratory device to perform size reduction and disintegration of agglomerates and lumps of pharmaceutical and chemical products with an achievable end-product fineness of &lt; 500 µm with minimum fines.

It is easy to dismantle, this results in easy and effective cleaning of all product-contact components. The inside of the machine can be cleaned with the beater unit removed and a special cover installed to protect the bearings.

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Laboratory hammer mill

When creating new products whose grinding properties cannot always be predicted in advance are constantly being developed, maximum flexibility is quite imperative.


<h2>Reproducibility and accuracy for scaling up to production-scale equipment</h2>
The Laboratory multi-processing systems, from Hosokawa Alpine offer process reproducibility and the possibility of scaling up at a later date to production-scale equipment.

This is where so-called multi-processing systems have established themselves as veritable all-rounders: it takes only a few minutes to exchange the following modules: fluidized bed opposed jet mill, ultrafine classifier, classifier mill, spiral jet mill, and fine impact mill.

To ensure the highest degree of resistance to chemical attack and against corrosion, all product-contact surfaces of Alpine's multi-processing systems are made of rust- and acid-proof stainless steel.

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Laboratory multi-processing systems

Ideal for the ultra-fine size reduction on a laboratory scale of dry materials up to Mohs' hardness 3 and powder fineness of 5 µm to 40 µm. Suitable for high-grade pharmaceuticals and fine-grade chemicals.


<h2>Ultrafine size reduction of mini-batches</h2>
The laboratory spiral jet mill, 50 AS from Hosokawa alpine is used for ultra-fine size reduction of dry materials with a crystalline structure up to Mohs hardness of three and production of a powder with a high ultra-fine portion between 0.5 and 30µm.

Often used for processing pharmaceutical active substances like parenteralia, DPIs (dry powder inhalants) and other active substances.

This compact and portable design meets the highest pharmaceutical standards and is ideal for the operation in an isolation containment device.

Laboratory spiral jet mill

Tabletop model for the wet grinding of small to ultra-small product batches down to the nano fineness range. Suitable for a wide range of applications such as engineering ceramics, mineral substances, pigments, paints, fine-grade chemicals, pharmaceutical products, dental ceramics, food supplements, abrasives, submicron, and nano grinding.


<h2>For the wet grinding down to the nano fineness range</h2>
The Wet mill 90 AHM from Hosokawa Alpine is a laboratory device for the wet grinding of small to ultra-small product batches down to the nano fineness range. It is suitable for small amounts of product and for development trials - also in the nanotechnology sector. Extremely small grinding beads (&lt; 0.2 mm) can be employed with this mill, and investigations regarding the stabilization of suspensions in the submicron range can be executed.

In contrast to the other AHM mill types, the laboratory version has a variable-speed direct drive; it is easy to fill in, empty, and clean up due to its pivoted support.

Laboratory horizontal agitated ball mill

Form pellets with the uniform length for a dust-free, cylindrical granulate, pellets with smooth surface and high stability of the granulate.


<h2>Stable pelleting with uniform length</h2>
The Gear pelletizer from Hosokawa Alpine is also known as the low-pressure extruder or pelleting machine. This process is known as extrusion, and helps to get stable pellets with uniform length are formed. The extrusion takes place by a pair of counter-rotating hollow toothed rollers. The product is drawn in by the rollers and pressed by nozzle bores or press nozzles.

The compression is determined by the relationship of the nozzle diameter to the nozzle length. The nozzle diameter is within the limits of 1 to 10 mm.

The Gear Pelletizer can be run dust and gas-tight. Operation with inert gas and solvents it’s possible without any problem.

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Pelleting machine

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

Table roller mills are robust and time-proven mills for soft to medium-hard mineral raw materials and industrial bulk materials. The advantages of the table roller mill are the simple fineness adjustment and fast product change. Table roller mills are used wherever a high degree of production flexibility is demanded.


<h2>Flexible production of large amounts of fines</h2>
The Table Roller Mill AWM from Hosokawa Alpine operates in accordance with the principle of pressure comminution, making them suitable for brittle but elastic feed products to deliver end-product fineness values of between approx. 10 µm and 100 µm.

A fundamental feature of Alpine's table roller mill is the optimized kinematics of the grinding rollers and grinding table to permit the production of large amounts of fines

Table roller mills are used wherever a high degree of production flexibility is demanded, for example for limestone, gypsum, dolomite, talc, petroleum coke, bentonite, quick lime, and so on.

Table roller mill

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

Pelleting press for biomass

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

Pelleting press for feed and petfood

The production of pelletized or granularized food products requires hygienic presses designed for high quality output and robust efficient operation.


<h2>Robust food pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of food products including those with powdery or lumpy input products.  The presses use pan grinder rollers to compact the input material and force it through a flat pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimized generation of noise and heat. Temperature is monitored and the grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses.

The hygienic presses are also designed for easy cleaning and meet GMP guidelines for food processing equipment. Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customers in developing a process that is optimized for their product.

Hygienic pelleting press

Many industries require reliable pelletizing equipment with smaller scale production capacities. These industries include chemicals, pharmaceuticals, synthetic material manufacture, waste disposal and recycling, minerals, and energy where compaction and uniform output are important but high volume production of a pelletized product is not necessarily the industries’ focus.


<h2>Robust smaller scale pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces smaller scale pelletizing presses with proven success for many types of products that often do not require the high volume production of larger presses. This line of presses uses the proven technology of Amandus Kahl’s larger sized presses in a scale more appropriate to the smaller production volumes. The presses use pan grinder rollers to compact the input material and force it through a flat pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimized generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for your particular needs.

The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses. Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. Amandus Kahl variable speed proportioning screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Small scale pelleting press

Production of certain pelletized products requires working with output products of a pasty consistency. These products include pigments, clay, detergent additives, vitamin products, and many other products where problems of adhesion of fresh pellets are often encountered. Processing of these types of products requires a pelletizing press that allows the fresh pellets to be directly deposited on a gently transporter such as a conveyor.


<h2>A pelletizing press for depositing pellets directly onto your conveyor</h2>
Amandus Kahl produces pelletizing presses with overhead drives that allow pellets to be deposited directly onto a conveyor from above-eliminating the adhesion issues of fresh pellets often encountered with pasty products. This line of presses uses the proven technology of Amandus Kahl’s other pelletizing presses but the drive unit is above the pelletizing die rather than below it allowing gentle direct deposition of the fresh pellets onto a conveyor. The presses use pan grinder rollers to compact the input material and force it through a pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimizing generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs.

Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. A Kahl variable speed proportion screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Pelleting press with overhead drive

Quality of gypsum and stucco products are highly influenced by the quality of the calcining process employed in production. Consistent grinding, purification, and drying of raw mineral inputs prior to their being entrained in the hot gas flow of the calcining equipment ensures efficient calcining and a resultant high-quality final product.


<h2>Grinding, purifying, drying, and calcining from a single piece of equipment</h2>
Claudius Peters’ EM Mill is a calcining system for gypsum and stucco with an integrated grinding mill. The mill uses free moving steel balls rather than stationary rollers which ensures uniform fine grinding while avoiding the need for any bearings inside the mill. The grinding system employed requires very little maintenance and has been known to achieve a service life of over 40,000 hours. At the base of the grinding system, a scraper acts on the ball track conveying foreign material out of the mill into the reject box.

The efficiency of the grinding system allows low material time inside the mill enhancing the controllability of the process and ensuring uniform product quality. After sufficient grinding material is entrained in a calcining gas flow of unusually high temperature which yields lower gas volumes and optimal energy consumption. The constant randomized motion of the ball grinding system ensures even and constant distribution of raw gypsum for exposure to the calcining flow.

Mill for calcining gypsum

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

Biomass fuels come in many forms and often include impurities that can damage equipment and cause process disruptions.  Successful biomass energy conversion operations invest in equipment that reliably removes impurities and processes raw fuel material into more consistent forms suitable for use in modern boilers.


<h2>Robust and easy to maintain screening and pre-processing equipment for biomass energy conversion</h2>
Raumaster has been working in the wood processing and energy industries in Finland for over 30 years.  The company is a world renowned expert in biomass material handling solutions and offers a line of screens and crushers that prepare your raw biomass fuel before it reaches your boiler.  All raw biomass fuels inevitably contain some impurities such as stones, metal, and oversized particles.  These are removed from your fuel stream by disc screens, gyratory screens, vibratory screens, and air classifiers before they can damage equipment or interrupt the process.  Magnets, metal detectors, and eddy current separators are also used when a high degree of metal contamination is present.  Crushers are available with slowly turning shredding heads or cutting drums with higher rotation speeds depending on the nature of the raw biomass input and the desired particle size for subsequent processing.  The screens, separators, and crushers are combined and implemented in your plant as a complete optimized solution tailored specifically to your raw materials and process.  All equipment is designed for reliable operation with low maintenance costs.  Effort has been made in all equipment designs to give reliable operation and very easy maintenance.

Solid biomass screening and crushing equipment

When you want flexibility to grin beans for filter coffee to Turkish coffee at particle sizes ranging from 50 to 125 µm,  a professional roll mill may be just what you need.


<h2>Ultimate control over the particle size of your powdered coffee</h2>
The new IBO-600 Roll Mill from Toper R&amp;D is  a Roll mill for coffee beans. It offers the perfect solution for uniform particle size and high-precision ultra-fine grinding. With extra high-quality mechanical components and perfect heat control, it provides 24 hours non-stop operation with the same grinding quality. The water-cooled grinding rolls ensure coffee beans’ grinding temperature to remain below 40°C at all times.

Roll mill for coffee beans

Traditional milling of coffee beans or seeds, with a stationary bedstone and a turning runner stone which actually does the grinding. It has a superior grinding capacity due to its especially engineered grinding stone mechanism.


<h2>Tradional milling of coffee beans or seeds</h2>
The stone mill for coffee beans developed by Toper R&amp;D builds on ancient technology to provide a state-of-the art coffee grinding solution. Coffee beans, rice flour, cracked wheat, cracked corn, animal feed, spices and every kind of chemicals, are among the products this stone mill is able to grind to the highest standards.

Stone mill for coffee beans

Being able to obtain an on-point grinding is easily achievable with these hammer mills, from coffee to multiple seeds can be crushed and filtered on a fast pace due to its capacity.


<h2>Hammer mill optimized for grinding coffee beans</h2>
The Toper TRY Series is a famous hammer mill for coffee beans that provides an accurate grinding. Primarily aimed for coffee beans, the TRY Series is also known for its utilization in the crushing and grinding of cereals, legumes, dried plants, animal feeds, minerals, flowers, spices, dried food and non-food materials. The TRY series hammer mills have a crushing rate of 290 kg to 2.5 tons per hour, depending on the model, whether it be the TRY-20, the TRY-26 or the TRY-38.

Hammer mill for coffee beans

Equipment operating under the rotor/stator principal is often employed when more traditional methods of stirring cannot achieve desired results. High performance continuous dispersing equipment is needed to achieve desirable results for almost any mixing process in circumstances where other machines fail.
<h2>Rotor/stator mixing in a robust and simple package that is easy to clean</h2>
The IKA ULTRA-TURRAX UTL 2000 is inline high-performance single-stage dispersing machine used for the production of emulsions and suspensions. The UTL 2000 uses the rotor/stator principle and is best suited for continuous applications that cannot be accomplished using conventional stirring methods.

During the full continuous process the components to be mixed are fed into the machine at an appropriate rate through various inlet connections. These components are then thoroughly mixed, dispersed or homogenized within the machine and discharged from the machine through the outlet. Thus, all particles or droplets are treated producing a narrow particle or droplet size distribution with minimal concentration/quality variations. Additionally, the UTL 2000 creates a pumping action which can be used for transfer purposes at low to moderate viscosities with a maximum of about 20 m (ca. 2 bar).

The machines are designed for easy and reliable scale-up and sizes are available with throughput from 50 to 125.000 liters per hour.

Dispersing machine for emulsions and suspensions

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

Dispersing

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

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

For products of medium viscosity and relatively consistent particle size such as honey, cremes, and some plastics, a simple, low cost mixing machine is useful to ensure even dispersion.  The most efficient production plants take advantage of such equipment in continuous production processes to minimize required floor space and serve double-duty as mixing and pumping/transfer equipment.
<h2>A basic effective mixing machine with transport pump capabilities and low cost</h2>
The lower-priced ULTRA-TURRAX UTL 1000 machines from IKA are particularly multifunctional and are used for the mixing, dispersing (emulsifying/suspending) and homogenizing of solid and liquid substances up to viscosities of several thousand mPa·s, such as honey, plastic masses and crèmes. The mixing components are fed into the machine at the inlet connection. The materials are mixed, homogenized and then discharged from the machine via the outlet connection. The economic dispersing machine does not have automatic suction, but does have a conveyor height of up to 20 meters.  Units are available with flow rates from 4.800 to 125.000 liters per hour.

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Economic dispersing machine for emulsions and suspensions

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

Emulsifying

For creating extremely fine emulsions and high quality dispersions a high pressure homogenizer is often chosen.  These machines use pressure shock to create very even distributions of extremely small particles.  They are; however, limited in their available flow rates and their ability to handle tough agglomerations of solids.  For these applications where a high pressure homogenizer cannot handle the raw materials or provide enough throughput, a colloid mill is often the better choice.
<h2>Extremely high quality dispersions of consistently sized particles with a very high throughput</h2>
The IKA MK 2000 is a high-performance inline colloid mill capable of performing wet and fine milling of tough and grainy raw materials. The MK 2000 is especially suitable for the production of colloidal solutions or extremely fine emulsions and suspensions. Excellent dispersing performance allows the IKA Colloid Mill MK 2000 to be used for continuous processes, providing a narrow distribution range of ground particles in a single pass. For challenging milling tasks the colloid mill can be installed into a recirculation loop with a working vessel by means of tube connections.

The conical geometry of the milling tools enables an axial displacement of the stator for an infinite adjustment of the milling gap. This allows influencing the dispersing effect, particularly regarding tasks with variable raw materials.

As neither the rotor nor the stator is slotted throughout, the probability of particles passing through the generator untreated is negligibly small. These collective features enable the IKA Colloid Mill MK to achieve the finest particle size reduction, thereby contending with a high pressure homogenizer by attaining similar dispersing results at higher flow rates.

The machines are designed for easy and reliable scalability and sizes are available with flow rates from 200 to 80,000 liters per hour.

Colloid mill

When your raw materials include agglomorated suspensions of grainy or crystalline solids and your process needs a steady, consistent flow of smaller particle sizes you need a high performance mill that is both powerful and flexible.  Furthermore, to ensure an efficient facility and maximum machine up time, the equipment should have a minimal footprint and be easy to clean.
<h2>Powerful and consistent milling of tough particles and viscous mixtures</h2>
IKA's MKO 2000 is a high-performance inline cone mill capable of performing wet and fine milling of tough and grainy or crystalline raw materials. The MKO 2000 is especially suitable for the de-agglomeration of suspensions. Excellent dispersing performance allows the IKA Cone Mill MKO 2000 to be used for continuous processes, providing a narrow distribution range of ground particles in a single pass.

For challenging milling tasks the cone mill can be installed into a recirculation loop with a working vessel by means of tube connections.  The gap between the conical shaped rotor and stator is infinitely adjustable allowing for excellent control of particle and droplet size.  Rotation speed and the resultant dispersion effect are also adjustable.  the unique conical milling head geometry also allows excellent grinding performance while the rotor and stator tools are never in contact with one another.  This, together with the extremely tough and high quality surface finishes on the tools, prolongs life and reduces contamination of the product due to machine wear.  The units are designed for easy and reliable scalability and sizes are available with flow rates from 150 to 6000 liter per hour.

Cone mill machine

Silos, hoppers, bins, and other containers can build up a layer of powdered product on the internal walls. A mechanical shock is required to dislodge this layer for processing. Difficult to discharge materials may also need a shock to improve the flow.


<h2>Remove material build-up on sidewalls with air shocks</h2>
Air Shocking Hammer (ASH) from GVF Impianti helps remove layering of powdered material on the internal walls of silos, bins, and hoppers. It delivers an impact comparable to that of a hammer to remove the layered material. The ASH System is preferred to the normal vibration equipment because it does not unnecessarily stress the welded joints of the bin. It has very low air consumption and is virtually maintenance-free. ASH systems are used to improve the flow of difficult-to-discharge materials. They are suitable for silos, hoppers, and bins containing powders. They are also used to completely remove the product from the vessel when switching products.

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Airshocking hammer

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

<span style="font-weight: 400;">Biotech and pharmaceutical development programs often require a mixing method that achieves both particle size reduction and complete cell lysis. When piloting production systems, it’s vital that you have complete control over the pressure to accommodate all cell types, and that the results of testing are completely scalable to full production.</span>
<h2>High-pressure homogenizer offering all configurations</h2>
<span style="font-weight: 400;">The DeBEE 2000 from BEE International is a complete pilot solution for high pressure homogenization in a highly compact format. Offering user-adjustable pressure control from 5,000 to 45,000 psi, the unit is suitable for a wide range of pharmaceutical and biotechnology applications and its modular design means lower costs of maintenance and repair.</span>

<span style="font-weight: 400;">This pilot unit also offers a wide range of options to suit all process and budget requirements, including Dual Feed, Dual Jet, control of cavitation, shear and impact and secondary additive feed for particle synthesis.</span>

<span style="font-weight: 400;">PLC control and HMI touch screen provide simple monitoring, and the unit is designed to be easily cleaned (Clean in Place) and portable.</span>

High pressure pilot homogenizer

Biotech equipment is used for cellular and biomolecular processing to develop products that improve our lives and the planet. With the help of specialized lab equipment, the active substance is manufactured or extracted from biological origin materials and typically produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Cell isolation, cultivation, cell banking, and culture expansion are called upstream processes. After harvest, the production process moves into a downstream process to meet purity and quality requirements which is divided into cell disruption, purification, and polishing. Biotechnology equipment makes use of various laboratory machinery such as bioreactors, centrifuges and incubators.

Biotech

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

Formulation

<span style="font-weight: 400;">For any industrial pharmaceutical process that relies on high pressure homogenization it’s vital that the equipment used is robust enough to cope with the demands of continuous operation. More than this, modern production demands high levels of process control and automation, as well as seamless integration with plant controls and providing results that satisfy the highest regulatory demands.</span>
<h2>Homogenizer offering the highest level of automation, compliance and capacity</h2>
<span style="font-weight: 400;">The DeBEE 4000 series from BEE International is the company’s top-of-line homogenizing solution for high performance situations. Designed from the ground up to achieve the best results as efficiently as possible, the DeBEE 4000 uses DeBEE’s proprietary homogenization technology for unequalled results, coupled with a hydraulically driven vertical intensifier pumps with a slow stroke rate to provide higher pressure and higher process intensity, all with lower maintenance costs.</span>

<span style="font-weight: 400;">Featuring a PLC with bespoke HMI software and full-colour touch screen, the DeBEE 4000 offers easy access to several features including security modes and authorisations, integrations with plant controls using network data gathering, and dynamic visual schematics for at-a-glance system status and component parameters.</span>

<span style="font-weight: 400;">The DeBEE 4000 features a fully sanitary design making it ideal for pharmaceutical and biotech production, as well as use in the chemical industries.</span>

High pressure industrial homogenizer

<span style="font-weight: 400;">It’s vital that small units for experimentation can scale up with 100% accuracy. Ease of use, reliability and simple maintenance means increased work efficiency, and rapid cleaning and suitability for sanitary uses increase flexibility and improve return on investment.</span>
<h2>Cost-effective benchtop homogenizer with reliable and consistent process for R&amp;D</h2>
<span style="font-weight: 400;">The Nano DeBEE from BEE International is a market-leader in laboratory-scale homogenizers. Designed for maximum flexibility, the Nano DeBEE can be used for a range of procedures including cell disruption, particle size reduction, nano/micro emulsions and nano/micro dispersions. Despite the minimum sample size of only 5ml, the results obtained from the DeBEE are guaranteed 100% scalable to production processes.</span>

<span style="font-weight: 400;">Offering excellent value for money, the Nano DeBEE can operate at up to 45,000 PSI of pressure and yet it is simple to clean and maintain and it’s suitable for sanitary applications where required. A further major benefit is that DeBEE will provide new staff training for the lifetime of the product.</span>

High pressure electric laboratory homogenizer

<span style="font-weight: 400;">Offering lab-scale to small pharmaceutical production scale output for in one unit means maximum cost-benefit when acquiring a homogenizer. Capable of achieving a range of processes including cell disruption, particle size reduction, creating stable nano/micro emulsions and working with polymers and liposomes, this benchtop scale unit can operate at up to 15 litres per hour capacity, yet still offer lab quality results.</span>
<h2>Air-operated, compact, bench-top homogenizer suitable for a broad range of applications</h2>
<span style="font-weight: 400;">The Micro DeBEE from BEE International is a compact, laboratory-scale homogenizer that can also be used for small-scale production. This is an air-powered unit that can process as little as a single 5ml sample, up to as much as 15L per hour, offering exceptional flexibility.</span>

<span style="font-weight: 400;">Features that make it an excellent R&amp;D machine include maximum pressure of 45,000 PSI/3100 bar (at 150 PSI, 55 CFM). In addition, the back pressure can reach 5,000 PSI/350 bar, but this is adjustable to your specific process.</span>

Micro DeBEE is simple in operating, and exceptionally easy to maintain and clean (with no disassembly required), adding further to the value proposition.

High pressure air powered laboratory homogenizer

<span style="font-weight: 400;">For maximum value, a high-pressure homogenizer that’s suitable for both laboratory and pilot/small scale pharmaceutical production is the ideal choice. Full control over all process elements and 100% scalability coupled with cost-effective electric operation offers substantial cost-savings over alternative options.</span>
<h2>Cost-effective unit suited for both laboratory and pilot use</h2>
<span style="font-weight: 400;">The Mini DeBEE from BEE International is hydraulically driven homogenizer that is suitable for both laboratory use and in pilot plants or in small-scale production. Offering the highest process intensity available in its class, it will disrupt the toughest cells with the highest yield, or obtain the smallest particle size.  </span>

<span style="font-weight: 400;">With proprietary modular homogenising cell, the Mini DeBEE offers completely independent control of pressure, flow, cavitation, impact, shear and process duration. The minimal sample size of only 10ml makes it an excellent choice for R&amp;D and lab work. Because it guarantees 100% scalability, it can easily be transferred to pilot operations, or the machine itself can also be used for small-scale and batch production, offering continuous flow of up to 15 litres per hour.</span>

<span style="font-weight: 400;">PLC control with digital interface means simple operation and monitoring, with user-adjustable operating pressure from 2,000 to 45,000 PSI. Coupled with a wide range of options, this makes the Mini DeBEE suitable for application in the pharmaceutical, biotech, chemicals, cosmetics and food industries.</span>

Pilot high pressure homogenizer

<span style="font-weight: 400;">By shredding cooked cereals, innovative breakfast and snack products can be created, including single-ingredient items with healthy benefits. To achieve the highest quality and most consistent shredded products, specialist shredders with high specification are needed.</span>


<h2>High quality cereal shredder that can produce a range of shredded products</h2>
<span style="font-weight: 400;">The Baker Perkins ShredMaster Systems deliver high quality shredded cereal and snack products using best-in-class equipment.</span>

<span style="font-weight: 400;">The ShredMaster can produce a large variety of product, including multi-layered shredded wheats, 2, 3 or 4 layer corn, rice or wheat squares, and even shaped and filled products.</span>

<span style="font-weight: 400;">ShredMaster system uses pairs of contra-rotating shredding rollers. Several pairs can be used in series to lay webs of shredded grains on top of each other, forming a multi-layered sheet.</span>

<span style="font-weight: 400;">The versatility of the ShredMaster means it can produce products with up to 20 layers. It can also add fillings between the layers. Thus a variety of crunchy textures is possible, as well as enhancing health benefits with the addition of fruit or other natural fillings.</span>

<span style="font-weight: 400;">A large variety of finishing options is available, meaning that the finished shred sheets can be shaped, cut or slit into finished products ranging from bite-size pieces to larger bars.</span>

Cooked cereals shredder

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

Many confectionery and bakery processes rely on the uniform grinding of raw ingredients such as nuts, nougat, cookie, chocolate and other small-size hard items. A modern grinder produces repeatable, consistent grinds for a wide range of raw ingredients without affecting flavour or quality.


<h2>Accurate and durable grinders for small particle down to powder grinding of hard products</h2>
The Crick-Crock Grinder from MIA Food Tech has been specifically designed for the efficient grinding of toasted nuts (including almonds, peanuts, walnuts, hazelnuts, and more), as well as other hard ingredients such as chocolate, nougat, cookies, crunchy, and other similar ingredients.

Engineered with small scale production in mind, the Crick-Crock Grinder is available in a range of sizes and capacities to suit all grinding requirements, from grain to powder.

Features of the Crick-Crock include rotary blade modules for rapid interchange and cleaning; all stainless-steel construction for longevity and ease of sanitising; product throughput of between 70 and 110kg per hour, depending on grind grain size.

Rotary blades provide an exceptionally uniform grain size while introducing minimum heat to the raw ingredients, ensuring maximum taste and flavour is carried through the grinding process.

Operator safety is ensured through the use of non-removable guards over the product entry hopper and exit chutes, and grind adjustment can be easily carried out in operation by use of the external grind adjustment knobs without the need to stop the machine or for the operator to come in to contact with moving parts.

Small scale nut grinder

Sugar powder is a key ingredient in a wide range of bakery, confectionery, and patisserie products. For small-scale producers buying ready-milled Powdered sugar adds additional expense and storage requirements to your production line. A dedicated in-house small-scale sugar mill for grinding your own icing sugar can reduce ingredients costs and increase efficiency, allowing you to produce only the quantity you need.


<h2>Robust and high-quality sugar mill designed specifically for small-batch production environments</h2>
The MIA Food Tech Sugar Mill has been designed specifically for small-scale producers to make their own icing sugar from granulated sugar. The Sugar Mill offers high-quality milling and top-end components with a size of only  1000mm x 450mm x 1200mm.

As well as all sugar-contacting parts being made of stainless steel for sanitary purposes, the entire assembly is also manufactured from stainless steel. As well as making cleaning of the external parts easier, this ensures maximum robustness of construction and a long lifespan.

Simple to operate with only On and Off controls, the Sugar Mill is designed to work either in a stop/start fashion or to be operated for longer periods. When operating continuously, the Sugar Mill can process up to 35kg of granulated sugar per hour.

Granulated sugar is introduced manually into the upper hopper, which is highly polished to reduce friction to a minimum and ensure all the sugar passes smoothly to the milling blades. The output bin has an easy-open stainless steel lid, ensuring sugar dust is kept contained within the bin to improve the working environments around the machine.

Weighing only 150kg and fitted with high-quality wheels, the machine can be moved easily, allowing it to be stored away from the production area when not in use. The height of the input funnel has been specifically designed to make hand-loading comfortable for operators, and the wide opening reduces the risk of spillage and wastage.

Small sugar mill for entry level production

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

Cooking

Decoration equipment adds the finishing touch to your industrially-prepared foods by depositing ingredients in a specified pattern on the surface of the products. Your items pass individually under a system of nozzles that lay the decorating formula precisely and uniformly. Popular in confectionery, decoration is used to differentiate products in the market.

Decorating

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

Heating

When designing a new chocolate line or experimenting with new ingredients for existing processes, the ability to have a scalable roasting solution is particularly advantageous. Precise and repeatable temperature and grinding settings are necessary, and the ability to have a portable unit makes for efficient use of space a distinct advantage.


<h2>Portable roaster and grinder for lab-scale cocoa bean and nuts production</h2>
The IDB25 from DSC is a dedicated lab-line roasting and grinding solution for cocoa and nuts, with a design capacity of 15kg to 25kg per hour, depending on product and process.

This unit consists of an infrared toasting unit, a cooler/peeler unit, a grinding unit, and a sieving unit.

As well as cooling for cocoa beans, almonds and pistachios, the combined cooler/peeler can also clean toasted hazelnuts and peanuts.

The patented grinding system allows granulation without pressure or heat, retaining product quality, oils, and flavor compounds. It’s adjustable to provide grains above 4mm, 2 to 4mm, or flours of less than 2mm. In addition, it comes in all-stainless steel construction for strength and ease of cleaning.

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R&D roaster for cocoa beans

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

Roasting involves extended exposure to heat in an oven or over a fire. Depending on your end product, roasting equipment makes sure that the raw materials you put in undergo even roast intensity before they are transferred for further processing. Some roasting technologies may also be used for other cooking requirements, including toasting and drying. When thinking about roasting, the idea of roasted coffee comes to mind. However, there are a wide array of food products that go through a roasting process. For example, nuts such as almonds and cashews go through a roasting machine

Roasting

Many confectionery and bakery products use nuts as a key ingredient or decoration. The ability to accurately chop nuts into the desired size for a wide range of purposes is vital in many recipes. Traditional small-scale machinery tends to crush the ingredients, affecting quality and taste. A chopping solution provides flexibility as well as excellent product quality.


<h2>Accurate and adjustable chopper for chopping and granulating nuts</h2>
The TR100 from DSC is a versatile chopping and granulating machine for small scale production. Portable and robust, the TR100 is the ideal solution not only for nuts but also for other hard ingredients, including chocolate and biscuit.

Made from stainless steel and featuring removable feed hopper, the TR100 is easy to clean inside and out.

The machine features two pairs of individually adjustable chopping rollers, and a final pair of granite finishing rollers, again adjustable to allow a uniform final size of the product grains. Chop size can be adjusted from coarse grains down to a powder in increments of 0.1mm.

The unit has a simple control panel where the speed of the chopping rollers and finishing rollers can be individually controlled. The TR100 can utilise only one set of chop rollers if the production requires this.

Small scale nut chopping machine

For the highest quality chocolate production, complete control of the entire process is desirable. For small scale, artisanal producers this often means sourcing raw cocoa nibs from specialist producers. By investing in a dedicated, small form factor cocoa bean processing line, small scale producers can now take complete control of the chocolate production process by ensuring the cocoa beans you select are handled to your exact requirements and recipe.


<h2>Compact, space-saving machine to process raw cocoa beans for small-scale producers</h2>
The Multiprocess R from Tecno 3 is purpose-designed for the small-scale production of cocoa nibs as the first part of a “bean to bar” production process. This machine has been designed to be compact and portable, and yet it is able to dry, roast, sterilise, crush and winnow cocoa beans - all in one unit. The drying and roasting unit uses a partial air removal system to control moisture, and the roast is achieved via internal hot air circulation. Temperatures and times can be fully customised for drying and roasting times, allowing complete control of the process.

Three UV units ensure that the roasted beans are fully debacterialised. A screw feed and three belt system ensure that the beans are separated and exposed to UV on all sides, ensuring quality. After sterilization, the beans can either be removed from the process whole, or sent to the crusher and winnower, where the nibs are sieved into four sizes ready for chocolate production. Adding to the Multiprocess R’s flexibility, the machine can also be used to roast, peel, sanitise and crush various nuts, such as almonds, hazelnuts, and pistachios.

The entire system is constructed of AISI 304 stainless steel for strength and hygiene and is mounted on wheels for easy movement if required. Designed for single-operator use, the Multiprocess R features an easy-to-use Siemens touch screen and the entire process is visible to the operator thanks to transparent Lexan guards. It also makes an attractive sight if placed in an area where customers can see it operating.

Small scale cocoa beans processing machine

The production of high-quality chocolate from the bean can often be out of the reach of small producers, who often have had to rely on using chocolate produced by others to create their own confections. An affordable, small scale bean to bar machine can allow small-scale producers to create handcrafted chocolates to their own recipe, adding significant value to their product by selecting specific beans, including single-origin.


<h2>Compact machine to produce high-quality chocolate directly from cocoa nibs</h2>
The Multiprocess C from Tecno 3 is the first small-scale machine to produce chocolate directly from nibs. The unit combines all the processes for chocolate production in one easy-to-operate unit. Process steps include nib grinding, ingredient mixing, ball milling, conching, tempering, and refrigeration. Ease of use and maintenance is ensured by the lack of any pumps or connection pipes, making cleaning straightforward. The entire machine is constructed of AISI 304 stainless steel for strength, longevity and hygiene.

The bean to bar machine is available with 3 mixer sizes allowing the production of batches of 5kg, 25kg or 50kg of chocolate. As well as high-quality bars of dark, milk or white chocolate, the Multiprocess C can also produce Gianduja chocolate, chocolate spreads, nut pastes, and creamy chocolate fillings, providing even more flexibility to small-scale confectionery producers. Designed to be easy to use by a single operator, the Multiprocess C is fitted with a Siemens touch screen HMI to adjust recipe parameters and to monitor the chocolate production process.

Entry level bean-to-bar machine

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.

Continuous milling solutions

Which continuous milling solutions equipment do you need?