process technologies for tomorrow - Hosokawa Micron Powder ...

technologiesMixing, drying, agglomeration… name any process technology connected topowder in any way, and we have the expertise. Our extensive R&D into andbroad view on the subject matter explains why we have come up with a largenumber of well-known and universally recognized developments in powdertechnology. And why we are still doing just that. It also explainsour wide product range and our established reputation in many industries.That reputation is being worked on continuously and keeps growing.Is this all too arrogant? No, the truth of our technological superiority maybe told, especially when that truth springs from an organization which -bothnationally and internationally- considers engineering, testing and service tobe of paramount importance.MiXingDryingAgglomeration4 5

Max. Mixing intensity [W/kg]1000100IntensivemixersConvectivemixersVitomixCT MixerVrieco-Nauta MixerPaticle designmixersIntensomixCyclomixmixingThe ideal knowledge mix of markets, productsand processing. In other words, theability to view any mixing problem fromevery angle. What really counts is that thesefactors together determine which mixer andwhich technology offer the best solutions.On that basis, we developed a broad rangeof mixers and mixing technologies. OurRIBBON SCREW MIXERThe Vitomix is a mid shear mixer. Capable of ultra quick cycle times, with up to 8 timesmore transport volume than conventional screw cone mixers, it uses tip speed from0,4 m/s till 6,0 m/s.Key features:• Fast gentle mixing of powders, pastes and slurries• Lump free moistening of powders, even without lumpbreakers• Good temperature control• Available from 500 to 10.000 litersexperts are much more than just technicians,100,1 1 10 100Tip speed [m/s]Batch Mixingwith all due respect. We focus our engineeringactivities on product developments thatmake a difference. Hence our efforts tofacilitate extensive testing, in our ownlaboratories and in close cooperation withour clients wherever possible. Hence ourabsolute conviction that with us, you canalways count on the mixer that is tailor-madefor your markets, products and processes.RIBBON PADDLE MIXERThe Intensomix is a ribbon paddle mixer designed for an intensive powdertransport. It performs well when high shear leads to product deformationand low shear results in inadequate mixing.Key features:• Compact design• Intensive mid shear mixing• Unique rotor design for maximizing powder transport• Available from 500 to 25.000 litersConical screw mixerThe Vrieco-Nauta conical mixer is a lowintensity mixer specially designed for segregative,free flowing and pasty products. Alsoapplicable for cohesive products when usingthe intensifier.Key features:• High mixing accuracy with a fillingratio from 10 -100%• Full discharge without segregationand distortion• Heating, cooling, drying, mixingand moistening• Available from 5 to 100.000 litersVertical ribbon mixerThe Hosokawa CT-mixer is a conical, verticalribbon blender especially designed forhandling free flowing and cohesive powders.Key features:• Quick mixing with a high mixing accuracyand full discharge• Sanitary design, compatible for CIP andSIP processes• Perfect heat transfer for heating andcooling processes• Available from 5 to 6.000 litersHigh shear/Impact mixerThe Cyclomix is a high shear intensivemixer specially designed for fine cohesivepowders, slurry and liquid.Key features:• Excellent temperature control• Intensive mixing, multiple processinglike coating, heating and bonding• Unique intensive mixing capabilities• Available from 1 to 2.000 liters6 7

mixingStrongHigh speed paddle mixerHigh shear mixerMaterialstrengthWeakRibbon mixerHigh impact mixerSegregate Free flowing Cohesive Pastesflow characteristiccontinuous mixingHigh impact mixerThe Schugi Flexomix is a high intensitycontinuous mixer, developed to achieve aperfect mixing of free flowing and cohesivepowders with liquids.Key features:• High mixing accuracy• Compact and self cleaning design• Famous for powder-liquid mixing andagglomeration• Capacities from 50 kg/hr to 40 t/hrHigh shear mixerThe Extrud-O-Mix is a low to mediumpressure kneader that generates uniformpastes or extrudates. It will accept plasticmasses or generate its own.Key features:• Intensive mixing of viscousmaterials or solids with liquids• Compact design with easy access• Mixing and kneading in one step• Capacities from 100 l/hr to 10 m 3 /hrHigh speed paddle mixerThe Turbulizer is a high speed continuouspaddle mixer developed for fine and cohesiveRibbon mixerThe Hosokawa Continuous Ribbon MixerHMC series is developed for gentle continuousmixing of segregative and freeflowing powders.Key features:• Compact design with easy access• Flexible operation with adjustablepowder applications.Key features:• Flexible operation with mixing energyadjustment• Perfect temperature control during mixing• Excellent for coating, heating upand moistening• Capacities from 100 kg/hr to 100 t/hrMODULAR MIXERThe Modulomix is a continuous Modularmixer based on the proven Cyclomix batchmixing technology. It can be used for low,Key features:• Excellent for mixing active ingredientswith carriers and add flow agents (e.g.before pharmaceutical tablet presses)residence time• Process flexibility including, heating,cooling and moistening• Capacities from 0,1 m 3 /hr to 100 m 3 /hrmedium or high shear applications and it • Sequential mixing with several modules incan be integrated in a PAT environment. series possible• Low residual material and quick responsetime• Capacity from 20kg/hr to 200kg/hr8 9

DRYING500Product temperature: ϒc400Fluid Bed Dryer300200Conical Dryer100Vertical Ribbon Dryer0 10 100 1.000 kg/hrFreeze Dryer-100maximum product temperature and the required evaporation capacityEver more energy efficient, ever highercapacities and ever lower maintenance. Thatis the road we are travelling in drying technology.On what exactly is this vision based?On over 50 years of experience and theresulting wealth of market knowledge. Onthe fact that we cradled many innovations indrying technology, and on market referencesfrom over a thousand active units.The basis is process thinking. Just like dryingis always part of something larger, our star-Vertical ribbon dryerThe Central shaft dryer is specially designed for efficientdrying free flowing powders and filter cakes under vacuumconditions.Key features:• Excellent for sterilizing in place(SIP) processes• Simple mechanical construction outside the vessel• Optimal heat transfer for freeflowing products• Available from 5 to 6.000 litersBATCH DRYINGting point is always the client’s product andprocess, however specific.Fluid bed dryerThe Agglomaster is a batch fluidi-An important, if not deciding factor in ourzed bed dryer with additional fea-success and innovative leadership is ourown in-house pilot plant, in which we testall possible drying techniques for and withtures for a high versatility and flexibilityfor drying free flowingpowders and cakes.Key features:clients. Not only in laboratory conditions,but also on a pilot and plant scale.ACTIVE FREEZE DRYer• Unique bottom design to fluidizeultra fine particles• Particle size control with pulse jettechnology to produce ultra finesThe active freeze drying system is a newlygranulated materialsdeveloped dynamic process. Fantastic• Available for powder drying andalternative to tray freeze dryers for bulkspray dryingpowder production. It produces a fine• From 1 to 1.000 liters batch sizenon-lumpy and uniform powder, which isdirectly available from the product collector.Key features:• Short cycle times and high qualityend-product• Fine powder in one step without extramanual handling or de-lumping stepsConical screw dryer• Suitable to dry Nano materialsThe Vrieco-Nauta dryer is a well proven design for drying• Available from 5 to 1.000 literspowder, filter cakes, paste and viscous slurries, both underatmospheric or vacuum conditions.Key features:Material to be driedFreezing medium• Multipurpose dryer to handlevarious products• Excellent mixing pro perties and suitablefor highly sensitive products• Excellent for secondary drying upDryerChamberDryerChamberProductCollectorSolventCondenserVacuumto ppm level• Available from 5 to 20.000 litersDried Product10 11

DRYING500Product temperature: ϒc400300200100PaddleDryerDrumDryerFlash DryerMill DryerFluidBed DryerDiscDryer0 10 100 1.000 10.000 100.000 kg/hrFlash dryerThe Micron Dryer, Drymeister and Long Gap mill are flash dryers,capable for drying (or high speed milling & drying) of wet powders,filter cakes, pastes, sticky materials and slurries.Key features Micron Dryer and Drymeister:• Produces a uniform and fine product with defined particle size• High energy efficiency with less than1 kW/kg of liquid evaporated• Compact design with space savings up to 50% compared toconventional flash dryers• Evaporation rates from 20 up to 4.500 kg/hr-100maximum product temperature and the required evaporation capacityCONTINIOUS DRYINGKey features Long Gap mill:• Up to 750 kW for milling• Ultra fine grades up 99% < 10 µ• Suitable for close-loop operation(e.g. solvent-recovery)• Evaporation rates from 20 to4.500 kg/hrDISC DRYERThe Torusdisc is a low speed horizontal indirectdryer/cooler, suitable for heating andcooling various types of products like filtercakes, powders and granules.Key features:• Compact design with a high heat transfersurface up to 400 m 2• Adjustable residence time (15-60 min.)• Suitable for close-loop operation(e.g. solvent-recovery)• Evaporation rates up to 35 t/hrPaddle dryerThe Solidaire is a high speed horizontalin direct dryer/cooler. Suitable to heat and dryslurry, filter cakes, paste, powder and granules.Key features:• High heat transfer due to highpaddle speed• Nearly plug flow process• Suitable for close-loop operation(e.g. solvent-recovery)• Evaporation rates from a few kg/hrup to 10.000 kg/hr12 13

AgglomerationHighHigh shear granulationIn order to de-dust, to improve flow qualities,to counter segregation, to give powdersinstant qualities, to optimize productpre scription. There are countless possibili-HighDry granulationDensitySpray granulationFluid bed granulationties when it comes to applying agglomeration,or the production of granules frompowders.It is therefore only logical that agglo-DensityMixing &fluidbedgranulationExtrud-O-MixLow pressureextrusionGear extrusionLow0,1 1 size in mm10meration technology is widely used in manypowder processing industries. The fact thatthis technology keeps finding new applicati-LowFluid bed granulation0,1 1 size in mm 10 70Batch Agglomerationons in a growing number of markets has alot to do with our broad experience andexpertise. Not only in the field of agglomeration,but also in other well-known powdertechnologies. It is this diversity that allowsus to view agglomeration in a wider contextand access the whole process.Continuous AgglomerationHigh shear granulationFluid bed / Spray granulationMixing & Fluid bed granulationThe Cyclomix combines a high shear inten-The Agglomaster is a multi purpose batchThe combination of the Schugi Flexomixsive mixing process and a well-controlledfluidized bed processor with additionalagglomerator and the Schugi Fluidized Bedagglomeration mechanism using both meltfeatures facilitating high versatility andDryer is a perfect concept for agglomerationand liquid binders. Granules of dense structurefrom 100 µm up to 2 mm can be produ-flexibility. Granules with a porous structureup to 1.2 mm can be produced withpurposes. Granules with a porous structurefrom 0.1 to 1.2 mm and with a D50 betweenMedium pressure extrusionced with medium to high density.low to medium density.300 and 700 µm can be produced with a lowThe Extrud-O-Mix is a horizontal mixer/Key features:Key features:to medium density.kneader, suitable to achieve a highly homo-• Accurate size control of agglomerates• Unique bottom design to fluidizeKey features:geneous powder-liquid mixture in a conti-• Short processing times and excellentultra fine particles• Vertical mixer / agglomerator with selfnuous process. Extrudates from 1 to 10 mmtemperature control• Particle size control with pulse jetcleaning mixing chambercan be produced with high density.• Possibility for well defined coatingtechnology to produce ultra fine• Multiple simultaneous liquid additionKey features:and bonding processesgranulated materialspossible• Mixing and extrusion in one machine• Available sizes ranging from 1 to• Available for powder granulation and• Separate operating units for• Compact design including heating/2.000 litersspray granulationagglomeration and drying/coolingcooling jacket• From 1 to 1.000 liters batch size• High throughput for the size from• Excellent mixing performance50 kg/hr to 40.000 kg/hr• Capacity from 50 kg/hr up to 2.000 kg/hr1415

LaboratoryequipmentFrom pilot plant to industrial scale, we coverthe whole range. We love to show what weare capable of in the field of testing andtrying on a small scale. And like no other,we can apply the results to the bigger pictureand the real thing. Consider our laboratorywork as an extra certainty: for ourselves,but naturally for our customers as well.Because in this world too, seeing is believing.Moreover, we also sell laboratory equipment,in order to enable our customers to achievethe best possible characterization of theirpowders. That way there won’t be anysurprises in subsequent processing stages.AncillariesWhen, like us, you are at the pinnacle of powdertechnology, offering complete solutions,you also have to offer a wide range ofan cillaries. Ancillaries of our own manufacturethat is, and therefore of superior quality,tailor-made to our customers’ requirements.Ancillaries may be called by-products, butthat doesn’t do justice to their properties.Piece for piece, our ancillaries are feats oftechnical skill, enabling our customers tofully profit from our main products.5l conical screw vacuum dryerball segment valvesflash dryer mdv-o1l high shear-impact mixerPowder Characteristics testerdensification rotary valveCrusherCyberjetSample taker16 17

servicesThe 24/7 economy, ever shorter delivery times, ever more expensive high-techand therefore larger investments, cutthroat competition… in all these hecticmarkets, ‘downtime’ is absolutely unacceptable.That is why the market demands more security and peace of mind whenengineeringafter salestesting & tollingit comes to machines, but also when it comes to engineering, research& development, testing and service.It is good to know therefore that we are frontrunners in all these areas.We can pride ourselves on an elaborate range of machines and a wealthof technology and process knowledge. Add to this our highly competent, veryexperienced engineering department, our truly unique in-house pilot plantand our responsive and smoothly operating service department, and youknow your trust is in the best hands.18 19

engineeringReverse thinking is really what engineeringis all about. From the machine back to theprocess, from the process back to the product,all this is carried out in close cooperationwith the client. For if daily practice hasproven anything, it is that joining forces (theclient knows his product, we have a wealthof knowledge of machines and processes)leads to the best solutions. These in turnlead to the best and most cost-effectiveproduction methods.About best production methods… our abilityto research any production process fromstart to finish in our own in-house facilitiesis naturally an important advantage to ourclients. Our broad technical expertise inmixing, drying, agglomeration and containmentis an added bonus, to say the least.Key services:• Assistance in feasibility studies to helpthe customer finding optimum process• Evaluation & confirmation of processeswith testing in house or on site• Basic & detailed engineering forequipment or systems• Theoretical & practical process know-how• Industry & product knowledge• Project management including validationservices, commissioning and start up• Know-how & experience to comply withall international standards & guidelineslike ATEX• Quality control20 21

after salesserviceQuality, reliability and predictability. Completelyeliminating the risk of breakdowns,or at least keeping them to an absoluteminimum. Clients want more, demand morethan ‘just’ a top quality product. This is whatthey get from us, in the shape of a smoothlyoperating after sales service, which meetstheir growing expectations in every regard.Long-term contracts in cast-iron agreementsare the norm, rather than the exception.These contracts and agreements are oftenvery specific and tailor-made for any client,whether it is about 24 hour on site-serviceor the complete outsourcing of the entirestock control.Speaking of tailor-made… apart fromcontracts and agreements, it goes withoutsaying that you can rely on our servicemechanics always being well trained andup-to-date in every discipline, whether it beTesting & TollingfacilitiesIf the behaviour of powders could besummarised in a set of rules and laws, inother words if it could be predicted, thentesting would be unnecessary. Successwould be guaranteed, with any treatmentor processing of any product whatsoever.Of course reality is somewhat different, if onlybecause developments in nanotechnologyare continuously leading to new high-techpowder technologies.This explains why testing is our natural resortand why we have our own well-equippedand ultramodern testing facilities. Here wecan test and develop both existing and newmachines. We often work on technology inpartnership with clients, as customer feedbackis critical. We also act as contractors inproducing smaller batches for clients, toensure maximum quality and repeatabilityfor them.mechanical and electrical, or process andcontrol technology.On site servicesTestingRental Equipment• Preventive maintenanceWe offer a unique infrastructure for testing Although all equipment is installed in• Inspection and trouble shootingpowder processes like:our test station, for customer convenience,• Repair & service• Batch mixing: from 1 up to 3.500 litersrental units of some technologies• Process support and optimization• Continuous mixing: from 10 kg/hr up are also available for installation at the• Modifications and upgrading to theto 1.000 kg/hrcustomers site.latest technology• Batch drying: from 2 up to 3.500 liters• Internal transport, re-location• Continuous drying: from 20 kg/hr up Toll processingand erectionto 80 kg/hrSince a couple of years, in Doetinchem,• Operator training either on site or• Batch agglomeration: from 1 up to 250 we installed contract processing facilitiesin Doetinchemlitersto help customers to go from• Commissioning• Continuous agglomeration: from 50 kg/hr research phase to production phase. Contract• Certification and validationup to 500 kg/hrprocessing is mainly offered to cli-• Reconditioning of used machines• Crushing, sieving and densificationents for:• Dry and wet Cleaning In Place• Processing materials before customersrun on their own installation• Market test• Customer process development22 23

industriesOur very diverse approach to processing technology, our many years of multidisciplined experience, our place in a well established global organization, andof course our focus on solutions in customer service: all this has contributed toour sound reputation across a wide industry base.Foodpharmaceuticalchemicalminerals & metalsEspecially in the food industry, the pharmaceutical industry, the chemicalindustry and the minerals & metals industry, we are held in high regardas a team which knows the ropes in each and every one of these sectors.A team moreover, which can pride itself on expertise in a wide variety ofprocesses and applications.24 25

FoodindustryPharmaceuticalindustryApplications & Processes• Batch and continuous mixing of multiple ingredients likedairy products, bakery products, sweeteners, thickeningagents• Batch pasteurization• Taste masking of food supplements• Continuous flash mill drying of thickeners• Steamsterilisation and intensive mixing of spices,herbs and seeds• Heat treatment or modification of flours and starches• Continuous agglomeration of instant products• Batch agglomeration and spray granulation of flavoursand sweeteners• Production of tabletting mass• Drying of food production residues• Surface modification of sugar based product• Alkalisation of cacao nibs• Drying and sterilizing of fish mealSome typical products handled• Potato starch, wheat starch and tapioca starch, flours,alginates, CMC, bakery mix and cereals• Gelatines, carrageenan, agar agar, pectin, gum and xanthane• Lactose, egg powder, milk powder and lactitol• Flavours, fragrances, spices and herbs• Silk sugar, sorbitol, dextrine, cocoa mixtures and nougat• Food preservatives• Vitamins and mineral premixes for animal food andmilk replacer• Carrot, fish, soya, okaraOur specific services• Application and process advice• Engineering, designing and manufacturing ofturn-key installations• To meet today’s hygiene and sanitary standards, all ourequipment manufactured in full compliance with internationalstandards and guidelines like FDA, EHEDG, 3A.• Contract production services on mixing, drying, coatingand agglomeration in house or with third parties• Carrying out trials, production of samples of a few kgto a few tonnes for market and client surveysApplications & processes• Mixing, homogenisation and coating of active ingredientsbefore tablet press of powders, and granulated products• Coating of ultra fine bulk carrier with liquids and/ornano-active ingredients• Dispersion of solids into liquids and emulsion• Vacuum drying of active pharmaceutical ingredients andcarriers coming from centrifuges or spray drying• Wet granulation with fluid bed and high shear technologies• Containment solutions up to less than 1 µg/m 3• Continuous agglomeration systems for veterinarypharmaceutical products• Mixing/dispersion line for cosmetics like eye linersand facial products• Pharmaceutical valves for vacuum & pressure operationSome typical product handled• Bulk pharmaceutical products, granules, tablets suspensions,inhaling and injection drugs• Active of highly active pharmaceutical ingredients• Carriers like lactose, starch, CMC• Sterile and non sterile products• Primary and secondary pharmaceutical products• Raw materials to make veterinary products• Vitamins and tooth paste• enzymesSpecific pharmaceutical services• Experience & expertise in making and executing validationdocumentation and protocols: DQ (QPP, FS, FAT,.),IQ (e.g. stationary SAT), OQ (e.g. dynamic SAT) andassistance for PQ• Compliance with the latest standards like GAMP4and 21 CFR 11• Dedicated project management• Process development with our unique test stationfrom laboratory scale to industrial scale• Supply of CIP or SIP solutions; Cleaning In Placetesting facilities• Supply of single units to turnkey systems for mixing,drying, and agglomeration technologies26 27

ChemicalindustryMinerals & MetalsindustryApplications & Processes• Mixing and addition of additives before and after grinding• High shear mixing / coating of powders• High intensity mixing of slurry• Continuous drying of organic, inorganic pigments• Mixing and homogenisation of bulk materials in volumesup to 100 m 3• Life hoppers for products with poor flow products• Mixer / Hopper (Master batch) in front of extruder• Batch drying of performance plastics, pigments• Flash drying and milling of cellulose and zinc phosphate• Solid phase polymerisation of polyester pellets• Mill- drying of wet grinded slurry down to 1 µm• Production of wet dispersible granular pesticides• Drying and mixing for chemically produced toner• Specialty valves for vacuum & pressure operationApplications & Processes• Mixing of metal or oxide powders and pastes for productslike iron, aluminium and bronze• High accuracy mixing of minerals and metals withadditives, pigments or flow agents before sintering,calcinations or compaction• Coating of minerals and metals with waxes or melt bindersto manipulate typical product characteristics• Wet agglomeration by fluid bed and high sheartech nologies of iron oxide, and raw materials forrechargeable batteries• Direct and indirect drying of cakes and slurries like rareearths• Flash drying, milling and classifying of wet grindedproducts down to few µm• Vacuum drying of nuclear wasteSome typical products handled• Pigment powders and slurries, like titanium dioxide,zinc phosphate• Plastics (PE / PP / PVS / ABS / HOPE / PET)and plastics additives• Fungicides, insecticides, herbicides• Super absorbent polymers• Technical starch derivatives• Phosphates• Catalysts• Raw materials of rechargeable batteries• Detergents for powder or tablet form• Glues, wall plasters, CMC• Inorganic salts like aluminium hydroxide• Basic chemicals compoundsOur specific services• Application and process advice• Carrying out trials, production of samples of a few kgto a few tonnes for market and client surveys• Contract production services on mixing, drying, coatingand agglomeration in house or with third parties• Engineering, designing and manufacturing ofturn-key installationsSome typical products handled• Minerals, limestone, dolomite, talcum, perlite, silica,graphite, gypsum, cement, sand, phosphate, marble.• Kaolin, bentonite, carbonates• Ceramics, quartz, copper oxide, aluminium oxide, magnesium• Abrasives, SiC, SiO, boron carbide, diamonds, tungsten carbide• Metals, iron powders, tungsten, cobalt, nickel, lead,aluminium, bronze, molybdenum, copper, chromium, alloys• Nuclear fuels, uranium oxide / di-oxide, plutoniumOur specific services• Application and process advice• Process simulation to prove product quality andprocess functionality.• Contract production services on mixing, drying, coatingand agglomeration in house or with third parties• Developing, design, engineering, manufacture, installationand service from single unit to turn key system.28 29

Hosokawa Micron group worldwideHosokawa is the world’s largest provider of processing systems for the field ofpowder and particle processing. Renowned names such as Alpine, Bepex, Micron,Mikro, Stott, Vitalair and Vrieco-Nauta are all included in the Group’s range.Regardless of the size, i.e. production-scale systems, pilot systems or laboratoryequipment, Hosokawa’s products and technologies are used in numerousprocess stages, for example during mixing, drying, agglomeration, containment,filling, metering, size reduction and classification.contactThe NetherlandsHosokawa Micron BVGildenstraat 26PO Box 987000 AB Doetinchem, NLPhone: +31 (0)314 37 33 33Fax: +31 (0)314 37 34 56E-mail: info@hmbv.hosokawa.comInternet: www.hosokawamicron.nlTeam food/pharmaPhone: +31 (0)314 37 34 62Fax: +31 (0)314 37 34 91E-mail: fp@hmbv.hosokawa.comTeam chemicals/minerals/metalsPhone: +31 (0)314 37 34 60Fax: +31 (0)314 37 35 22E-mail: cmm@hmbv.hosokawa.comTeam servicePhone: +31 (0)314 37 33 74+31 (0)314 37 33 75Fax: +31 (0)314 37 34 31E-mail: service@hmbv.hosokawa.comService Help DeskAfter office hours30 Phone: +31 (0)314 37 35 0531