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Maker - Product Challenge

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Changemakers

Crystallization Technologies

Continuous

Industrial

In the sugar industry, achieving finely milled, storage-stable icing sugar without additives is a challenge. Conventional sugar milling systems often require extensive additional equipment that increases the investment and operational costs.
<h2>Achieve shelf-stable icing sugar in one compact system.</h2>
The Sugarplex SX Flow by Hosokawa Alpine is an advanced fine impact mill specifically tailored for the sugar industry. Designed as an all-in-one solution, it integrates grinding and recrystallization processes inside a pressure-shock resistant stainless steel vessel. What sets the Sugarplex SX Flow apart is its ability to recrystallize amorphous icing sugar within the mill, ensuring shelf-stability without the need for additives. The compact design eliminates the need for additional filters, fans, or cooling equipment, reducing space requirements and maintenance costs. The system can achieve throughputs of up to 3 t/h at a fineness of 99% < 450 µm or 1.5 t/h at a fineness of 99% < 150 µm. Powered by an 18.5 kW three-phase motor and regulated by a frequency converter, the mill allows for precise control of fineness. The grinding chamber includes two integrated pin discs, easily accessible for cleaning through the wide mill door. This system's design ensures lower energy consumption, making it a cost-effective solution for producing high-quality icing sugar.

Sugar grinding and recrystallization system

Crystallization

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

solid

In the production of sugar cones for ice cream, ensuring a hardened fat glaze quickly and reliably is essential. Without proper crystallization, the cones can lose their crispness and fail to provide an adequate barrier between the ice cream and the cone, leading to decreased product shelf life.
<h2>Speed up fat glaze hardening</h2>
The Dohmeyer Fat Glaze Crystallization Unit is specifically designed to address the need for rapid and reliable hardening of fat glaze in sugar cones. This unit is installed on new or existing cone filling lines and is a result of co-engineering efforts with major ice cream filling units. The fast crystallization process creates a solid barrier in just 10 seconds after the fat glaze is applied, preventing moisture transfer between the ice cream and the cone. This ensures the product retains its crispness and increases the shelf life of the cones up to 7 months. The unit reduces the quantity of fat glaze needed, making the process more efficient while maintaining product quality and consistency. Major cone producers globally have achieved the crispiest cones using this unit.

Fat glaze crystallization for sugar cones

In the production of chewy candies, achieving precise crystallization is essential for obtaining the correct texture and sweetness. This requires a system that can control and enhance the crystallization process efficiently, ensuring consistent product quality.
<h2>Enhances crystallization using advanced shearing techniques.</h2>
The CHEWMASTER® from CHOCOTECH is a specialized crystallization system designed for chewy candy production. The system continuously pumps the cooked sugar solution to a tempering screw, where the mass is supersaturated, initiating the crystallization process. It then enters a specially designed maturing tank for additional crystallization over a set residence time. The mass is subsequently pumped through the TORNADO®, which uses intense shearing via stator and rotor pins to further enhance crystallization without additional air for non-aerated products. For aerated chewy candies, controlled air is introduced during the shearing process. The CHEWMASTER® ensures efficient and uniform crystallization, maintaining the desired texture and quality of the candy.

Crystallization process for chewy candy production

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

Feeding

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

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

Tempering

In industries like pharmaceuticals and chemicals, efficient crystallization processes are essential to produce high-purity compounds. Managing temperature control and creating optimal crystallization conditions are common challenges that require advanced solutions.
<h2>Optimize crystallization with precise temperature control</h2>
The Crystallization Package - 100L 316L SST Dual-Jacketed Reactor with Pump by Across International is designed for effective crystallization processes. This reactor features a dual-jacketed design with sealed outer insulation, providing exceptional temperature control inside the chamber. It includes a 100L main vessel made from pharmaceutical-grade 316L stainless steel, ensuring high durability and resistance to corrosive materials. The reactor's internal chamber is electro-polished, significantly reducing surface roughness and improving vacuum pressures and out-gassing rates. It has a detachable condenser and dual collection tanks for efficient draining without breaking vacuum. With multiple port configurations and integrated components, this reactor simplifies cleaning and maintenance tasks, making it suitable for food and pharmaceutical applications. The electrical motor and controller are certified to UL and CSA standards, while the pneumatic motor model is approved for use with various solvents like Acetone and Ethanol.

Stainless steel crystallization reactor 100l

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

Measurement &amp; Control

Batch

Manual

In chemical laboratories, achieving precise control over temperature and vacuum conditions is crucial for effective synthesis and crystallization processes. Researchers and engineers face challenges related to material handling, consistency, and reproducibility.
<h2>Ensure controlled synthesis and recovery</h2>
The Ai 20L Glass Reactor with MPC301 by Across International is designed for the synthetic reaction of different materials. It offers a controlled environment featuring adjustable stirring speeds and a constant pressure feeding funnel for uniform material addition. The built-in condenser enables the recovery of materials at a controlled rate. The reactor uses high borosilicate glass that is heat, cold, and corrosion-resistant, allowing operations within a wide temperature range of -110F to 400F. Dual jacketed models provide enhanced temperature control and vacuum protection. This system includes solvent-resistant PTFE components for durability, digital speed, and temperature displays, and a heavy-duty stainless steel framework with lockable casters for stability and ease of mobility.

20l glass reactor for crystallization and isolation processes

Synthesis

liquid

Entry level

In the development of high-quality single crystals, precision control over temperature gradients and environmental conditions is crucial. Achieving these exacting standards requires a specialized furnace capable of maintaining stable high temperatures and allowing flexible access to the growing crystals.
<h2>Facilitates stable high-temperature crystal growth</h2>
The Bridgman Crystal Growth Tube Furnace by Across International is designed to support advanced crystallization processes at temperatures up to 1700°C. This furnace features a swing-open chamber for easy access to the growing crystals, and uses Kanthal spiral wire coils embedded in high-quality Mitsubishi alumina fiber insulation. It includes a high-precision Eurotherm 3504 PID controller with 50-segment program capability, allowing for precise temperature regulation and stable thermal conditions. The system also integrates a computer interface for remote monitoring and control. Key safety features such as overheat protection and an automatic hoisting limit switch ensure safe operation. Ideal for laboratories and industrial applications requiring high purity crystal growth.

Bridgman crystal growth furnace for advanced crystallization processes

In the production of chocolate and confections, achieving a homogeneous and nearly solid mass for fat-based centers without pre-cooling can significantly streamline the workflow. Traditional systems often leave room for inefficiencies that lead to increased waste and longer production times.
<h2>Achieve precise aeration and crystallization</h2>
The SuperNova Orbit from Aasted is tailored for the crystallization and aeration of fat-based masses, such as crème fillings. Capable of crystallizing the mass to an almost solid state, it enables transfer to open hopper wire cutters and extruders without the need for pre-cooling on conveyor belts. The unique constant velocity scrapers ensure uniform handling, making the mass pumpable and homogeneous. Air can be injected mid-crystallization, dispersing naturally due to shear adding, eliminating the need for traditional mixing heads. This dual-purpose flexibility minimizes waste and reduces production time, providing consistent results for both aerated and non-aerated applications. Suitable for various dessert chocolates and bar fillings, the SuperNova Orbit supports a wide range of densities and ingredient compositions.

Crystallization and aeration unit for fat-based center masses

Aerators are devices used for mixing air (oxygen transfer) with a liquid such as water or oil to form a homogeneous product. Selecting an industrial aeration system involves choosing a suitable mixing head and considering the desired input and output flows, temperature, level of aeration, properties of the liquid phase, and the degree of automation and pressure control. Aerators are used in the food industry for the production of fat-based center masses and crèmes and in the chemical industry for wastewater treatment. When it comes to water treatment, surface aerators are most commonly used.

Aeration

In many industry applications, traditional drying methods pose challenges when dealing with heat-sensitive, heavy, or sticky materials. Efficiently drying powders, bulk solids, pastes, and slurries without compromising their properties requires advanced vacuum drying technology.
<h2>Efficiently dry powders and bulk solids</h2>
The vacuum dryers from Hosokawa Micron are designed to handle various materials, including powders, filter cakes, pastes, and viscous slurries, even those that are heat-sensitive or contain solvents. The Nauta vacuum dryer and Conical Paddle Dryer (CPD) are equipped with unique features for rapid and efficient drying. The Nauta vacuum dryer, originally developed to replace the vacuum tray dryer, offers energy savings and uniform drying. The CPD, with its vertical, centrally driven design, combines fast drying rates with a compact footprint. These dryers are suitable for a wide range of materials in industries such as chemicals, metals, and pharmaceuticals. Each system can be customized for specific applications, ensuring optimal functionality and efficiency. Furthermore, Hosokawa Micron provides solutions for additional processes like reaction, crystallization, and sterilization.

Vacuum dryers for powders and bulk solids

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Industrial sterilization processes are employed in different industries to completely eliminate all living microorganisms from the final product. For instance, in food processing, sterilization equipment is used to produce a stable product with a long shelf-life by eradicating harmful bio-contaminants. Instead, in the medical field, sterilization technologies aim to prevent the transmission of microbes to patients by sterilizing all the tools and medical devices that come in contact with the patient. Most sterilization equipment, such as autoclaves, employs high-temperature pressurized steam to destroy bacteria and disinfect surfaces from spores. Other methods include radiation sterilization or using chemicals such as hydrogen peroxide for disinfection.

Sterilization

Powder

In industries like chemicals, food, and pharmaceuticals, achieving homogeneous mixtures of fine and cohesive powders in short timeframes is essential. Traditional batch mixing systems often struggle with residue and temperature increases, leading to inefficiencies in production lines.
<h2>Efficient and adaptable powder mixing</h2>
The Modulomix is a continuous mixer from Hosokawa Micron designed for processing fine and cohesive powders. It operates with high tip speeds, which makes it effective at dispersing materials quickly and precisely. Whether for low, medium, or high shear applications, the Modulomix offers a compact solution that minimizes residue and ensures rapid start-up and shutdown. The system's modularity allows for cascading multiple mixing units to adapt to complex mixing regimes. Key features include limited temperature increase, excellent heat transfer efficiency, and adjustable rotor speed to accommodate varying mixing conditions. The system is suitable for a range of applications including dry powder mixing, hydrating difficult powders, coating, sterilization, crystallization, and more.

Continuous mixing for fine and cohesive powders

Blending

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

Coating

In industrial processes, achieving consistent, high-quality mixing of high-viscosity materials presents multiple challenges, such as ensuring optimal homogenization and viscosity control throughout various stages.
<h2>Ensure homogeneous mixing and viscosity control</h2>
The Ultimate Continuous Processor (UCP) by HASLER Group is specially designed for high-viscosity applications and incorporates multiple processing stages into one streamlined operation. This industrial continuous kneader offers thousands of combinations for process design. Key features include two co-rotating axes for slow automated homogenization, which promote mixing without forcing the material. The UCP's flexible paddle arrangement and double jacket allow for precise temperature regulation from -20°C to +300°C. This system supports diverse operations such as kneading, shearing, degassing, and crystallization. Its robust design and abrasion resistance ensure long-term durability with minimal maintenance, making it suitable for industries like chemicals, pharmaceuticals, food, and plastics. The UCP's integrated SCMIII control system with recipe software provides batch traceability and precise production monitoring.

Continuous kneader for viscous applications

Degassing

Kneading

Shearing

When producing fondant masses for various confectionery items, precise control over crystallization and mass distribution is essential. Without this control, the final product may have an undesirable texture and consistency, impacting both consumer satisfaction and production efficiency.
<h2>Produce fine fondant with controlled crystallization</h2>
The MICRON® by CHOCOTECH is a continuous system designed for the efficient production of fondant masses. This two-step system begins by tempering the mass in a specialized cooling screw to the point of supersaturation. The initially tempered mass then transfers to a specially designed beating screw, which induces immediate recrystallization through high shear blending. The design of the beating screw ensures fine and smooth fondant with a defined particle size and distribution. Operating parameters can be adjusted to achieve different crystal sizes and mass distributions, offering a flexible solution for various recipes and applications. The unit supports capacities ranging from 300 to 1500 kg/h, depending on the recipe, making it suitable for a wide range of production needs.

Fondant mass production system

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Pilot

In the food industry, producing and crystallizing margarines and shortenings requires precise temperature control and consistent agitation to ensure product quality and stability. Handling large-scale production up to 20,000 kg/hour demands highly efficient and robust thermal management solutions.
<h2>Provides precise temperature control for crystallization</h2>
The Chemetator from CHEMTECH is a scraped surface heat exchanger designed for the production and crystallization of margarines and shortenings. This system can handle production scales from pilot plant up to 20,000 kg/hour with a product pressure rating of up to 150 bar. The Chemetator's fully enclosed design ensures it operates quietly and maintains a high level of hygiene, while being easy to maintain. It supports multiple direct expansion refrigerants like Ammonia, Freon, and Carbon Dioxide, making it versatile for different cooling requirements. The system's modern design and efficient thermal management make it an excellent choice for the food industry.

Scraped surface heat exchanger for oils and fats

Handling

In various industrial sectors, including pharmaceuticals and chemicals, there is a need for efficient and reliable evaporation processes for solvent recovery, sample concentration, and distillation. These processes must be carried out under controlled conditions to ensure safety, product integrity, and energy efficiency.
<h2>Perform automatic distillation with remote monitoring</h2>
The Rotavapor® R-220 Pro by Buchi is an industrial rotary evaporator designed to handle large batch sizes up to 10 liters. What makes this evaporator stand out is its user-friendly design combined with advanced automation features. It supports continuous operations with a distillation rate of up to 12 liters per hour for ethanol. The heating bath can reach temperatures of up to 180 °C, and the system includes a vacuum controller to manage vapor pressure. The Rotavapor® R-220 Pro is made from corrosion-free stainless steel and FDA-compliant materials to ensure durability and safety, even in harsh production environments. With programmable methods, automatic foam detection, and remote monitoring via mobile phone notifications, it offers precision and convenience. It is suitable for various industries such as chemical, pharmaceutical, and academia, facilitating processes like concentration, drying, solvent recycling, and recrystallization.

Industrial rotary evaporator for distillation

Industrial distillation equipment is used in the process of separating different constituents of a liquid mixture. Considerations for choosing suitable distillation systems include the boiling points of the components, heat sensitivity of the product of interest, pressure requirements during the process, and the scale of production. Distillation is used for concentrating extracts such as herbal extracts, flavors, and aromas in the food industry. In the pharmaceutical industry, distillation is used in the production of active ingredients and in the chemical industry for the purification of chemical products.

Distillation

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

Evaporation

In applications where medium to high-viscosity fluids or particle-containing fluids need efficient and homogeneous heat treatment, conventional heat exchangers often face challenges such as fouling and uneven heating.
<h2>Reduces fouling and pressure losses</h2>
The scraped-surface rotative heat exchanger (RM series) from Aurum is designed to optimize heating processes in industrial applications. It consists of a tube bundle welded to a heating jacket, with a rotating bar equipped with scrapping elements inside the inner tubes. This design ensures that the inner surface of the tube remains free of fouling by continuously scraping it, while simultaneously stirring and mixing the product to create turbulence, which enhances efficiency. The system includes bellows or an expansion joint to balance differential expansion between the inner tube bundle and the heating jacket, thus increasing the lifespan of the heat exchanger. Suitable for both food and industrial applications, it is recommended for products like hummus, industrial fruit and vegetable processing, sauces, and infant food. Special applications include evaporation, crystallization, and aseptic processes, with notable advantages such as reduced processing times and improved end-product quality. The exchanger ensures homogeneous heat treatment, very low fouling levels, and reduced pressure losses, thereby decreasing the space needed and increasing production cycles.

Scraped-surface heat exchanger for industrial fruit processing

<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

Processing

In the production of chocolate and bakery products, achieving optimal crystallization and cooling is crucial. Traditional cooling methods often fall short in providing the consistent quality and efficient processing required in industrial settings.
<h2>Ensures perfect crystallization and cooling</h2>
The Nielsen Cooling Tunnel by Aasted is designed to provide precise cooling and crystallization for chocolate, confectionery, and bakery products. With a flexible range from 420 to 1800 mm, this system offers both direct and indirect cooling depending on product requirements. It features easy-to-open individual hatches for straightforward cleaning and maintenance. The cooling tunnel ensures even airflow distribution using re-circulation fans and evaporators to maintain low humidity and transform moisture into dry air, ensuring perfect crystallization. Available in aluminum, stainless steel, or a hybrid construction, the system accommodates the diverse needs of the industry. Its design prioritizes ease of maintenance, maximizing uptime.

Cooling tunnel for chocolate and bakery products

In chemical processing, you often need to separate crystalline solids from liquid solutions. This is essential when dealing with precipitation, purification, or reducing waste volume in operations like pharmaceuticals or pollution control.
<h2>Produce and purify crystalline solids efficiently</h2>
The Dedert evaporative crystallizer is designed to produce solids from a wide range of process and waste solutions. It handles products with high boiling point elevations, making it versatile for various industries including chemical, pharmaceutical, and food. This system works by continuously mixing feed with a circulating slurry of precipitated solids. The slurry flows through heat-exchange tubes where condensation provides the necessary heat for evaporation. Commonly used energy sources for evaporators are also applicable to these crystallizers. Dedert offers both Forced Circulation Crystallizers and skid-mounted solutions which come pre-assembled with heat exchangers, structural steel, pumps, motors, instrumentation, control valves, and piping. Each unit can be customized with 3-D modeling and optional code stamps for pressure vessels.

Evaporative crystallizers for chemical processing

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

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