Overcoming Agglomeration Challenge
In nutraceutical production, precision isn’t just an advantage—it’s a necessity. Manufacturers work tirelessly to create uniform, high-flowability products that meet industry standards, but complex ingredient blends can present unexpected roadblocks. For one leading manufacturer, the challenge wasn’t just about mixing; it was about controlling agglomeration without compromising quality. Their 20-component blend, designed for encapsulation, was prone to excessive sticking, turning what should have been a smooth process into a frustrating cycle of trial and error. Conventional mixing methods failed, and with kosher and halal compliance in mind, alcohol-based solutions weren’t an option.
The Challenge
Their initial process relied heavily on water, which inadvertently melted the sugar-like material in the blend. This caused excessive sticking within the mixing equipment, particularly on the agitator, resulting in material buildup and inefficiencies. Despite experimenting with standard equipment—including a planetary mixer, vacuum oven, and a Fitchpatrick hammermill—they couldn’t replicate the mustard seed-like consistency they envisioned.
Beyond the physical challenges, compliance requirements posed another obstacle. To meet kosher and halal market standards, the manufacturer needed a solution that ensured their product remained alcohol-free—without compromising the integrity of their blend.
The Solution
Advanced Powder Solutions (APS) stepped in with a precision-driven approach, leveraging GEMCO’s Formulator, a versatile machine capable of blending, sifting, drying, and pulverizing. APS recognized that the improper ratio of water and alcohol was the root cause of the agglomeration issue.
Through careful experimentation, APS identified the optimal balance that allowed bead formation while ensuring a controlled drying process. More importantly, APS refined the method to eliminate alcohol content, making the final product compliant with kosher and halal standards.
The Result
The manufacturer was highly satisfied with APS’s expertise and problem-solving approach. Their new process successfully produced agglomerated beads with the desired flowability and uniformity, improving consistency and efficiency in production.
Beyond delivering technical solutions, APS strengthened their collaboration with the manufacturer’s chief engineer, reinforcing the importance of precision and thorough investigation when facing complex agglomeration challenges.
APS continues to be a trusted partner in innovative powder processing, providing tailored solutions to meet the evolving demands of the nutraceutical and food industries.