contract powder blending services
We offer processing standards of medical, food,
personal care and industrial quality.
FOOD ADDITIVES
Hundreds of tonnes of multiple component powder formulations have been accurately batch blended and packed to lined big bags, sacks or lined boxes.
Thousands of tonnes of food additives have been continuously blended to high accuracy using loss in weight systems.
Often blending is incorporated into other value added processes such as milling and compaction.
Stringent independent check procedures ensure the blend quality for every batch.
Validated cleaning procedures ensure products are contamination free.
ANIMAL health
We have 20 years of experience in accurate blending to GMP standards as a first stage in the production of products containing pharmaceutical actives.
Thousands of tonnes have been processed within segregated Units licenced by the Veterinary Medicines Directorate.
Unique batch record sheets accompany every batch through the process with independent checks at all critical stages.
Validated cleaning procedures ensure changeover between different blends with no cross contamination.
SPECIALITY POWDERS
35 years of experience in developing the unique solutions required for blending numerous speciality chemicals.
We offer process standards from medical quality to personal care and even industrial grade powders.
Accurate dispersion of liquid into powder batches with the capability of operating under inert atmosphere.
Dispersion of oils and waxes often requiring heat input in order to achieve the right blend quality.
BULK POWDERS
Thousands of tonnes of detergent components processed to high accuracy and high throughput.
Hundreds of tonnes of plastic additive formulations have been blended often requiring special process conditions to accommodate a variety of physical characteristics.
Raw materials can be supplied in sacks, big bags or even road tanker. Product is packed to big bags or sacks.
Blending can be large scale batch or continuous process with accurate metering of materials by loss in weight systems.
CUSTOM POWDERS contract BLENDING services
The following processes are available in many of the 16 self-contained process units in our Crewe (UK) and Helmond (NL) factories.
3 Low shear batch blending units.
4 High shear batch blending units.
3 Continuous blending systems.
2 Fluidised bed systems.
All equipment is fully stripped and cleaned after use and is then visually inspected. Start-up of the next grade involves purging with customer approved material, then the purge is checked to verify that there is no cross contamination.
LOW SHEAR BATCH BLENDING
Based on ribbon and U Trough blending equipment these blenders achieve a gentle folding action with blend times typically 20 to 60 minutes.
Feed to the blenders can be from big bags, sacks, drums or boxes. Feed material can be check screened prior to charging into the blender.
Product is typically discharged to big bags but can also be packed to sacks or boxes incorporating check screens.
With careful operation these blenders can disperse oils and waxes onto powder or granules in order to reduce the dustiness of the final product.
HIGH SHEAR BATCH BLENDING
Ploughshare mixers are available with capacities ranging from 2000 to 4200 litres. They are capable of the accurate dispersion of low levels of chemicals in short blend times.
Chopper units (running between the ploughs) permit dispersion of liquids into the blend and also serve to control oversize generation should this be an issue.
Feed to the blenders is typically from sacks or big bags, with batches to be blended either pre-prepared and independently checked or automatically dosed through computerised batch systems.
On a smaller scale, vertical high shear mixers can accurately disperse even high viscosity liquids and waxes into powders. These mixers can impart high levels of energy into the product to aid dispersion or to generate the heat necessary to disperse some components. These smaller mixers can be operated under inert atmosphere.
Batches are normally transferred from the vertical high shear mixer to intermediate big bags prior to packing.
CONTINUOUS BLENDING SYSTEMS
Based on in-house developed loss in weight technology, accurate continuous blending of up to 5 components can be achieved. Incorporation of liquid is also possible. The accuracy of the mix is continuously data logged.
Three types of mixer are available from high shear vertical mixer (Schugi Flexomix), to higher shear horizontal pin or ring mixer (Loedige CB30) or a low shear drum mixer.
In the Schugi Flexomix, powder falls past high speed rotating blades on a vertical shaft. Adjustment of blade angles and rotation speed can change the mixing profile. Liquid can be dispersed into the powder mix via internal air atomised nozzles.
Residence time within the Schugi is short, typically less than 2 seconds, thus there is little time for liquid to absorb into a powder. Higher levels of liquid addition can cause agglomeration which depending on the end product requirement can be either a benefit or a problem. Drying is possible post mixer in a continuous fluid bed dryer.
The Loedige CB30 mixes horizontally with powder mechanically transported through the mixer by the mixing pins. Energy input can be higher than the Schugi, thus it is possible to increase powder density through the addition of low levels of liquid.
FLUIDISED BED SYSTEMS
Two batch fluid bed systems are based at the UK site. Both systems are capable of blending powders with a degree of similarity in density and particle size between the components of a batch.
Fluidised bed systems would not normally be selected unless dispersion of liquid into the powder without causing agglomeration is a prime requirement.
Liquid can be sprayed and thus dispersed into the fluidised powder. With simultaneous drying it is possible to continue spraying for longer than is usual. Thus dispersion of a liquid component can range from low levels to a total coating of each particle.
FOOD SAFETY SYSTEM
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
- Carcinogens
- 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 processes 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.
ISO 14001 CERTIFIED SINCE 1997
FSSC 22000 CERTIFIED SINCE 2012
VETERINARY MEDICINES DIRECTORATE INCORPORATING GMP COMPLIANT SINCE 2002
