It only takes an instant Schugi Mixing and Agglomeration Process Mattijs Raadsen Hosokawa Group Area Manager NL, for Food & Pharma Tel +31 (0)314 373415 / (0)6 51277153 m.raadsen@hmbv.hosokawa.com
HOSOKAWA MICRON Corporation Established in 1916 Production facilities in 5 countries 10 R&D and test centres world-wide 1600 Employees HOSOKAWA MICRON Corporation, Osaka, Japan
HOSOKAWA business worldwide Powder Processing Technologies: Blowing Film Technologies:
HOSOKAWA Powder Processing Technologies Milling Classifying Mixing Drying Particle size enlargement Compaction Agglomeration Containment Nano technology
HOSOKAWA Powder Processing Technologies Knowledge about relation - Process - Composition - Properties Test equipment Support in starting up
Definition of Instant agglomeration Instant characteristics Fast solubility (no dispersion) => define fast
Summary of objectives Flow Properties Particle size / shape Instant characteristics Wettability / Dispersability Prevent segregation Uniform particle size & bulk density De-dusting Increase particle size > 100 µm (roughly)
Comparison table product characteristics: Product form and Properties Onion shape Agglomerate Extrudate Extrudate Hollow cone Flow properties ++ ++ + + -. Bulk Density ++ +/0 + ++ - Instant Char. - ++ +/- - + Particle size 3-10 mm 0.2-1.2 mm 0.3-5 mm <.2 mm Technology Disc-Granulation Schugi Agglomeration Low pressure extrusion Granulation Compaction: Spraydryer:
Flexomix: Continuous Mixing / Agglomeration Mixing and Agglomeration For Raspberry particle structure Particle size 0,2-1,2 mm Capacity 0,05-100 m³/h Instant Food Processing The Schugi Principle
Flexomix: System configuration Flexomix Air filtration Powder dosing Liquid dosing Classification Fluid bed dryer / cooler Process air Controls
Hosokawa Flexomix:
Flexible wall Self cleaning mixing chamber Flex-wall materials adapted to different applications Adjustable cleaning intensity
Typical design features Multiple liquids and powders in one operation Product residence time 0.2 1.0 seconds Less than 10% product in mixer chamber Aerated mixing chamber Controlled energy input product Adjustable mixing elements Self cleaning mixing chamber Easy accessible Throughput (range) 50 25000 kg/hr depending on product / application
Flexomix: A wet agglomeration process Spraying Wetting Solidifying Final Agglomerate Binder Droplets & Powder Liquid Bridges Solid Bridges Raspberry Structure
Particle size Agglomeration: The Influence of moisture content Mixing Agglomeration % Liquid
Flexomix: A wet agglomeration process Are the dry components dissolvable?. Yes => Flexomix No => Is a binder allowed? No => Different technology Typical binders: CMC PVA Maltodextrine Molasses Sugar Starch
Static Fluidbed Dryer: Dry Product Static Fluidbed High air velocity Compact design Fixed mounting
Typical Drying Curve: Moisture Content % Hot Air Temperature Product Moisture Product Temperature Temop [ C] Drying Time
Typical Flow diagram: - Powder dosing Cyclone / filter Liquid dosing Flexomix Classifica tion Aspiration Fluid bed dryer Controls Air heating
Wet Agglomeration Process: Tuning Interacting Parameters Capacity Powder Binder Rotor speed Knife Angle Powder / Liquid Ratio Drying Temperature Cooling Temperature Air Capacity Product level Fluidbed Residence Time Process Yield Particle Size Particle Size Distribution Characteristics
Example - Impression:
Typical Flexomix process development steps: Conduct lab scale / bench test (1 kg.) feasibility: binder and product Pilot trial at Hosokawa test center (500 kg) feasibility: on FX-160 in batch mode Confirmation trial at Hosokawa test center confirmation: in continuous mode
Hosokawa Agglomeration Test Center: Powder dosing Flexomix Liquid dosing Fluid bed dryer / cooler Controls
Typical Applications Flexomix: Cacao Bakery products Soups & Sauces Seasonings Milk powder Sugar Spices Lactose Energy Drinks Instant drinks Phosphates Gelatin Gums Starch Food Processing
Typical Applications Flexomix: Chemicals Detergents CMC MC (absorbers) Pesticides Phosphates Starch
New brochure Release Autumn 2016
Case Study Instant Cacao
Case study: instant cocoa drink Home Use: Vending: Typical Formulation Milk based drinks Water based drinks Sugar Cocoa powder Skin milk powder Flavouring Binder Emulsifier Vitamins 78% 19% 0% 3% 39% 28% 31% 2%
Case study: instant cocoa drink Typical Characteristics: Home Use: Vending: Solubility good good Visual Dark brown Homogeneous composition Bulk Density ( +/- 500 gr/l ) ( > 650 g/l ) Binder Steam Water Particle Size 200 700 Micron 200 700 Micron
Case Study: Instant Cacao P&ID with Pre- Mixing and Packing system:
Technology Comparison: Product / Proces: Batch FB: Conti- FB: Spraydryer: Flexomix: Instant characteristics ++ + ++ ++ Homogeneous compos. +- +- ++ + Liquid % (evaporation) + + -- ++ Steam addition + +- - ++ Receipt complexity ++ +/- ++ ++ Flexibility in particle size ++ + + ++ Particle size distribution + +- ++ + Coating / emulsifying ++ + -- +
Technology Comparison: System: Batch FB: Conti- FB: Spraydryer: Flexomix: Capacity Kg/hr. - + ++ ++ Energy ballance +- + -- + System complexity + +- -- +- CIP +- +- +- +- Building footprint ++ * + +- + Building height ++ * + -- + Automation level ++ ++ ++ ++ Investment ++ * + +- + * (1.000 kg/hr. max.)