FLEXOMIX

• Excellent mixing effect
  Flexomix end products are homogenous from sample to sample. Because all ingredients are mixed instantaneously, de-mixing of powders cannot occur. Each sample has a uniform dispersion of liquid(s) and solids that is beyond the capability of conventional mixers.

• Self-cleaning
  The external roller cage massages the outside of the mixing chamber to prevent build-up of product on the inside.

• Flexible
  As product life cycles shorten, production facilities need to be able to switch easily to the manufacture of other types of products. The Flexomix is designed to handle a wide range of different materials with varying product properties.

• Low manpower requirements
  Thanks to the operation of the Flexomix in continuous processing mode, productivity is high and manpower requirements are low. The process is operator-insensitive.

• Maintenance-friendly construction
  The clever design of the Flexomix, with a single rotating shaft plus blades and the external roller cage, reduces the maintenance effort. It can be disassembled in less than two minutes and the liquid injectors are easy to remove.

The Flexomix powder agglomeration system is suitable for a wide range of process applications, including:

• Modification of starch
• Agglomeration of veterinary antibiotics
• Agglomeration pesticide formulae
• Agglomeration of fine powders for compaction
• Hydration of phosphates
• Production of detergent powders
• Finishing of filter cakes
• Instantizing of cocoa drink powder
• Addition of cross-linking agents to Super Absorbent Polymers (SAP)
• Humidifying products (e.g. pesticides) before extrusion

Schugi fluid bed dryers/coolers are available in sizes (air distribution plate area) ranging from 0.25 m² to > 20 m². The required size of the dryer/cooler is generally determined in our test centre and depends on product throughput, evaporation capacity, particle size distribution, air temperatures and final product temperature.

The Flexomix mixer/agglomerator is available in six sizes. Their typical characteristics are described below. Please note that these values are indicative only. Detailed information is available on request.

• Preparation & Dosing
  Liquid premixes can be prepared in the make-up tank and, if multiple powders need to be premixed, a live hopper or Nauta^® mixer can be integrated. To guarantee a constant and accurate flow of powder and liquid, high-quality powder dosing feeders and liquid dosing systems are an integral part of the system. 

• Drying & Cooling
  In the static fluid bed dryer, the agglomerates are dried and cooled. After cooling, the product is conveyed to the product classifying section for preparation of the final product.

• Classification & Packaging
  After classification, the product is split into on-size, over-size and (if needed) fines material. Over-size material can be crushed and fines can be reprocessed if applicable. On-size agglomerates can be stored in big bags or transported to a final packaging line. This whole process takes place in continuous mode.

• Air Treatment
  The performance and functionality of the fluid bed in combination with the air treatment section is an important part of the agglomeration process as this can have a direct impact on the level of agglomeration and product quality.

• Controls & Process Automation
  Hosokawa Micron's powder agglomeration systems include optimally integrated hardware and software controls to ensure consistently high product quality under varying circumstances. We can provide ergonomic and visual HMI-PLC panels including lot traceability, operator identification, remote service, alerts and customized data reports to give you full insight into your production processes.

The Flexomix continuous powder agglomeration system is a powerful combination of a number of functionalities:

• Powder handling system
• Powder dosing system
• Binder dosing system(s): water, steam, and other liquids
• Schugi Flexomix mixer and agglomerator (FX),
• Schugi Fluid Bed Dryer and Cooler (FBD)
• Air system including blower and heating/cooling equipment
• Air exhaust system including cyclone and filter
• Product classification and size crusher (if necessary)
• State-of-the-art integrated control system

When designing a powder agglomeration system, it is important that agglomeration is not treated as a stand-alone process. That's why our experts work closely with your team to design an integral production concept that meets your broader needs – both today and in the future. Our approach is based around the clear definition and careful consideration of each individual process step, including storage, conveying, charging, mixing, agglomeration, drying, cooling, discharging, sieving, packing and more. This results in a tailor-made agglomeration system solution that is optimally engineered for you.