Hundreds of tonnes of specialist food additive formulations have been successfully compacted to exacting particle size requirements at both the UK and Dutch facilities.
Precise control is frequently required, often for multicomponent formulations. This is in order to achieve the right taste and solubility profile.
Humidity controlled environments permit safe processing of moisture sensitive materials.
Over 20 years of experience in processing 15 different formulations for worldwide markets.
Formulation accuracy is critical when incorporating pharmaceutical actives to GMP standards.
Veterinary Medicines Directorate (VMD) licensed dedicated process suites are used for this production.
Products can be packed to lined big bags or foil laminate sacks and can be loaded to containers for shipping.
Validated cleaning guarantees product integrity particularly when changing between different active ingredients.
Numerous specialist formulations have been blended and compacted for personal care applications.
Precise control on compaction conditions is achieved in order to provide the exact performance requirements for each product.
A wide range of compaction equipment is available in segregated production units. This permits tailoring the process to each customer’s requirement.
Compacted products are dispatched for shipping to all parts of the world.
Thousands of tonnes of chemicals have been formulated, blended and compacted for the detergent industry.
Large compaction units are available with capacity up to 10,000 tonnes per annum.
Continuous recycle of non-product streams give excellent product yields.
Products are made to your precise requirement and are validated through our rigorous quality procedures.
Roll Compaction Granulation processes are available for use in five of the 16 self-contained process suites in our Crewe (UK) and Helmond (NL) factories.
Powder compaction capacity ranges from a nominal 50kg/hr to over 1,500kg/hr and can be offered to any of the standards indicated below.
Custom Powders Ltd powder compaction systems are based around Fitzpatrick roll compactors.
Roll compaction offers a range of key benefits for products including:
- Powder Densification.
- Particle size enlargement to reduce dust, improve flow or to match other formulations.
- Uniform distribution and the combination of multiple components in a non-segregating product.
POWDER COMPACTION EQUIPMENT & TECHNOLOGY
Single component products are routinely compacted. There is frequently a requirement to formulate and blend different materials prior to compaction.
Compaction of a pre-blended product prevents different components from segregating in use and ensures consistent delivery of all components with every dose.
As a result of this requirement many of Custom Powders compaction units have integral blending facilities.
POWDER COMPACTION FORMULATION AND PRE-BLENDING
Whether it is for Food, Animal Health or an Industrial product Custom Powders carry out all formulation and pre-blending to a standard meeting the requirements of GMP.
Raw materials are dispensed, independently checked and signed off on batch cards prior to blending.
Blending can be by low shear ribbon or U-trough blender or higher shear ploughshare mixer depending on the raw material properties. Blended powder is then discharged to suitable intermediate IBCs for transfer to compaction.
ROLL COMPACTION OF POWDER
The powder to be compacted is metered into the compactor ‘vertical screws’ where pre-densification and de-aeration occurs.
The vertical screws force the powder into the compactor rolls. The rolls are pressed together by hydraulic rams, the rolls then extrude the compact as a sheet, or series of ‘pencils’, or even briquettes.
A range of roll profiles are available, with different profiles required for different raw material compaction properties.
Similarly the compactors have a range of different pressure capabilities, this is required both to achieve compaction with the different materials and also in some instances to control dispersion property of the final product.
The compact sheet is then milled and then sieved through a multistage process incorporating a single, double or even triple deck sieve. The aperture of the sieve screens is used to control the final product particle size. The selection of the mill type, size and screen design is critical to achieving an efficient compaction process.
DEDUSTING OF ROLL COMPACTED PRODUCTS
Powder compaction processes generate product via a milling step. As a result some roll compacted products can be dusty unless treated prior to packing.
With more than 25 years of experience in roll compaction production, Custom Powders are experts at eliminating dust from compacted products. Many of our dedusting systems are developed in-house, this proprietary information cannot be revealed on our web site.
However, there are 2 fundamental approaches normally used in dedusting compacted granules, these are:
1 Agitation of the granule to dislodge dust which is then removed.
2 Addition of a liquid (oil or water) to bind loose dust into the granule.
The advantage of the first option for dedusting is that it can normally be carried out continuously, as part of the roll compaction process. The dust extracted can be recycled back to the compactor, thus avoiding loss of yield.
The first option alone is not always the best solution and it is not unusual for example in the Animal Health sector to post blend material adding up to 5% of an oil. The liquid added can have other benefits for the product beyond dedusting.
The disadvantage of dedusting by post blending with a liquid is it adds at least one, sometimes two process steps if post blend sieving is required.
FOOD SAFETY STATEMENT
As a processor of food products and in order to maintain our high standards of hygiene and care, we assess all materials to be brought on site. The following materials are excluded from being brought onto the site:
- Genetically modified materials
- Materials with Hazard Identification of Toxic to Human
- Glass powders
- Products of animal origin
In addition any material recognised as an EU food Allergen is excluded from food processing units.
All food processors are HACCP assessed before production starts, customers are invited to be part of the procedure and can request a copy of the HACCP assessment.
Your requirements for Kosher and Halal certification are possible for any food process offered. Due to the often unique process for each product, this is completed on request, on a Customer by Customer basis.
VETERINARY MEDICINES DIRECTORATE LICENCE
ACCREDITED SINCE 1988
ACCREDITED SINCE 1997
ACCREDITED SINCE 2012
ACCREDITED SINCE 2008
ACCREDITED SINCE 2006
CHEMICAL INDUSTRIES ASSOCIATION
MEMBERS FROM 1994