A high-impact mixer uses high-speed rotors to generate intense turbulence, instantly combining powders and liquids into homogeneous mixtures or granules within fractions of a second.
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CONTINUOUS MIXERS
for Powders & Bulk Solids
Flexomix
High-Impact Mixer
The Schugi® Flexomix is a unique vertical, high-impact continuous mixer–agglomerator that produces highly homogeneous powder–liquid blends in a single compact unit. Combining precise powder and liquid dosing with ultra-short residence times, it delivers consistent, dust-free granules with controlled porosity and excellent wettability—across a wide range of formulations, including sticky or cohesive materials.
Key Benefits
- Continuous, high-throughput operation (100–40,000 kg/h)
- Instantaneous, homogeneous mixing (< 1 s residence time)
- Handles powders, liquids and viscous media; multiple liquid nozzles
- Self-cleaning chamber with external roller cage; low maintenance
- Compact vertical footprint with minimal product loss
- Flexible for trials and predictable scale-up
Principle of Operation
The Flexomix high-impact mixer delivers highly homogeneous mixing of powders and liquids. With its vertical cylindrical chamber and rotating shaft, it is unlike any other continuous mixer. Its high rotational speed and turbulent mixing keep the chamber clean, while precise dosing of both liquids and solids ensures accuracy—even with the stickiest of media.
The Flexomix operates under tightly controlled conditions to maximise product quality and efficiency. Multiple pitch-adjustable knives on the high-speed vertical shaft generate an intense turbulent airflow inside the mixing chamber.
Powders and liquids can be fed into the unit via top inlet(s), where agitation creates a spiral flow with frequent particle collisions. Liquids of varying viscosities and steam can be added using atomising nozzles positioned above the upper mixing blades.
This combination makes the Flexomix high-impact mixer ideal for mixing powders with powders, liquids with powders, as well as wet agglomeration to form porous granules.
Process Flexibility
The Flexomix is widely used in food, chemicals, minerals and feed for solids mixing, agglomeration, hydration and instantising, including:
- Production of detergent powders
- Hydration of phosphates
- Adding cross-linkers to SAPs
- Instantising of drinking chocolate
- Modification of starch
- Agglomeration of veterinary antibiotics and pesticide formulations
- Agglomeration of fine powders for compaction
- Finishing of filter cakes
- Humidifying products (e.g., before extrusion)
Models & Capacities
Indicative values; performance depends on product properties and process parameters. Detailed information is available on request.
| Model | [-] | FXD-100 | FXD-160 | FXD-220 | FXD-250 | FXD-335 | FXD-400 |
|---|---|---|---|---|---|---|---|
| Length | [mm] | 520 | 702 | 976 | 976 | 1,270 | 1,270 |
| Width | [mm] | 650 | 620 | 880 | 880 | 1,100 | 1,100 |
| Height incl. motor | [mm] | 1,265 | 1,500 | 1,967 | 1,967 | 2,270 | 2,910 |
| Capacity (bulk density 0.5 kg/l) |
[kg/h] | 100 – 400 |
250 – 1,000 |
800 – 2,500 |
2,000 – 4,000 |
3,000 – 10,000 |
8,000 – 40,000 |
| Typical motor power | [kW] | 3 | 7.5 | 7.5 – 10 | 11 – 15 | 22 – 45 | 37 – 75 |
System Integration
Integrate the Flexomix into an existing line or have us design a complete, continuous powder agglomeration system—including all required equipment, ancillaries and process controls—tailored to your product and process. With 100+ years of solids-processing expertise, Hosokawa Micron delivers proven, scalable mixing and agglomeration solutions from pilot systems to full-scale production plants.
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Test Before You Invest
Before investing in new equipment, test your materials under real process conditions at our Test & Process Development Centre in the Netherlands. Our experienced specialists help you determine the most efficient mixing, agglomeration or drying process, from laboratory trials to full-scale production testing.
Whether you want to evaluate a single machine or a complete processing line, we provide tailored testing and process optimisation to ensure reliable scale-up and proven performance.
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Talk to Our Experts
Let our experts help you configure the right continuous mixer for your powders and bulk solids — optimised for efficiency and performance.
Applications
The Flexomix high-impact mixer is ideal for a wide range of products. Here are a few examples:
FAQ — Flexomix High-Impact Mixer
What is a high-impact mixer?
How does the Flexomix work?
A vertical rotor fitted with adjustable blades creates a spiral air flow inside a cylindrical chamber, instantly dispersing and agglomerating powders and liquids fed from above.
What materials can the Flexomix process?
It handles fine, cohesive, or sticky powders; liquids of varying viscosities; and mixtures requiring wet agglomeration or hydration.
What are the advantages of the Flexomix?
Continuous operation, ultra-short residence time, self-cleaning chamber, high mixing accuracy, compact footprint and reliable scale-up.
What sizes and capacities are available?
Models span from pilot units to large industrial systems with throughputs from 100 kg/h up to 40 t/h, supporting consistent scale-up and integration.
Sustainable Process Technologies
Hosokawa Micron develops powder processing systems with a focus on energy efficiency, process optimisation and long-term operational performance. As an ISO 14001 certified company with an EcoVadis Silver Medal, we support more sustainable powder and bulk solids processing.
