Process technologies for tomorrow.


Turning dead marine algae into a powdered animal feed product is an excellent example of full-circle sustainability. Grinding, mixing and drying of these algae results in a completely natural calcinated seaweed, containing lots of different minerals. This calcinated seaweed is enriched with magnesium oxide and suitable as an organic livestock feed in powder form. The resulting product works as an acid buffer, regulating the acid in a cow's stomach to aid digestion and – in addition to its health benefits – it also reduces the production of methane.

An important requirement for the mixing process of calcinated seaweed and magnesium oxide is to minimize the amount of dust produced by the powdered end product, because this will cause problems for farmers, resulting in unnecessary product loss of the feed during the dosing process in silos, and also for the cattle because the fine powder can cause irritation in the nose/lungs.

Optimal solution with scale-up potential

Hosokawa's proven Flexomix technology forms the basis of the custom-designed process. The Flexomix continuous mixer/agglomerator is placed above a fluid bed dryer. It is provided with two powder feeders – one for the calcinated seaweed and one for the magnesium oxide – and then also a liquid feed for the spray-on binder. To reduce stuffing, a larger particle size is created – going from 5 microns to 200 microns. This improves the flow properties so that the powder doesn't produce too much dust. These larger particles then pass into the dryer where the excess water is dried off in a continuous process.

The overall agglomeration, mixing and drying process should be optimized to avoid underload or overload of the continuous system. The control system enables the operators to adjust the recipe for the ratio of magnesium oxide or liquid as necessary. Potential future scale-up is easy because another dryer can be added to the agglomeration machine without a problem. Safety considerations, including hazard analysis, anticipate them in the design process such as by using regulators or sensors.

Need help setting up your process?

Test Centre in Doetinchem, the Netherlands

Take advice from Hosokawa Micron, experts in processing technologies for the production of powdered animal feed from algae. Our development and engineering team is always on hand to help you explore new and innovative processes and applications. Testing is the foundation for a successful product or process.

Our test facilities in the Netherlands offer outstanding opportunities to test ingredients, machinery, parameters and process flows, whether in the laboratory, as a pilot set-up or on an industrial scale, to ensure you achieve the necessary product quality and operating efficiency to generate the maximum return on investment for your business.

Common algae processing challenges

If you're interested to discuss your interest in or production challenges in algae processing, get in touch with Hosokawa Micron. We can help you with a range of questions about this fast-growing sector, including:

  • How to achieve the highest quality powders, for optimal absorption and digestion;
  • The best mixing, drying and agglomeration techniques for algae processing;
  • The advantages of Hosokawa technologies over traditional processing methods;
  • How to plan, test and improve your algae processing line.


To learn more about our equipment and systems for processing animal feed from marine algae, contact us:



Hosokawa Micron B.V. is certified according to ISO 14001. Our certification covers all environmental themes of ISO 14001: air, soil, energy, waste, water, noise and hazardous substances. In addition, Hosawa Micron was awarded an EcoVadis Silver Medal for its sustainability achievements. EcoVadis determined that the company was among the top 15% of companies rated by EcoVadis in the special machinery industry.

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