News overview and blog about products

Stay up to date with the latest developments within Hecht Technology and the industry. In this overview, we share practical insights, technical innovations, market trends, and company news. From containment solutions and process optimization to project updates and events – here you will find relevant knowledge and current affairs for professionals in high-containment and powder handling.

Filling systems for powders

Filling is the final, critical step in powder processing: this is where the product is transferred into bags, drums, big bags or containers at the right weight and without dust. A good filling system combines accuracy, speed, hygiene and operator protection. For engineers, buyers and QA in pharma, chemical, food and the battery industry, the filling strategy determines product quality, throughput and the safety of the working environment. HECHT designs filling systems tuned to your product, packaging format and containment requirements.

What a filling system must deliver

A reliable filling system doses the correct weight, fills dust-free, protects the operator and keeps pace with production. These requirements often conflict: fast filling generates dust, accurate filling costs time. A good design balances them by aligning dosing, deaeration and containment.

The choice of system follows from the product, the packaging format and the required accuracy and capacity.

Filling formats and packaging

Each packaging format calls for its own approach.

  • Bag filling — open or valve bags, manual or (semi-)automatic, for 5–50 kg
  • Big bag (FIBC) filling — bulk packaging up to 1,000 kg and beyond, with deaeration and compaction
  • Drum filling — for powders and granules in steel or plastic drums
  • Container filling — IBCs and process containers for closed transfer
  • Bottles and small packs — accurate dosing of small quantities in pharma

Accurate dosing during filling

Fill accuracy determines whether you deliver under- or overweight — both cost money. Gravimetric filling with integrated load cells corrects during filling and holds the weight within tight tolerances. A coarse/fine dose (fast fill, then top-up) combines speed with precision. HECHT couples the dosing screw or valve to the weighing system for reproducible fill weights.

Dust-free filling and deaeration

During filling, powder displaces air, which wants to escape carrying dust. Dust-free filling requires closed fill heads, extraction at the fill point and deaeration of the pack. A vacuum deaerator before the fill head supplies compact, deaerated powder, so the pack settles less and dusts less. The result is a clean working environment and a consistent fill weight.

Containment and operator protection

For highly active powders, filling is the moment of highest exposure risk. Containment filling systems use split-butterfly valves, continuous liners or isolator technology to minimise operator exposure.

  • OEB 1–2 — local extraction and closed fill heads often suffice
  • OEB 3–4 — split-butterfly valves and continuous liner for closed transfer
  • OEB 5 — isolator or glovebox with validated, SMEPAC-verified containment

Hygienic design and ATEX

In pharma and food, fill heads and product-contact parts are fully CIP/WIP-cleanable, in 316L with smooth surfaces and no dead zones to GMP and EHEDG. For combustible powders, the filling system is earthed and built ATEX-compliant; for battery powders, filling can take place under nitrogen.

Frequently asked questions about filling systems

What fill accuracy is achievable?

With gravimetric filling and coarse/fine dosing, accuracies within a few tenths of a percent are achievable, depending on product and packaging.

How do I fill dust-free?

With closed fill heads, extraction at the fill point, pack deaeration and a vacuum deaerator that compacts the powder beforehand.

Which filling system suits highly active substances?

Depending on the OEB band: split-butterfly valves, continuous liner or isolator technology with SMEPAC verification.

Can one line handle multiple packaging formats?

Yes, with interchangeable fill heads and stations a line can handle bags, drums and big bags, depending on the design.

How fast can I fill?

Capacity depends on packaging format, dosing principle and accuracy requirement; HECHT dimensions to your required throughput.

Related guides

Tailored advice from HECHT

Looking for a filling system that fills your product accurately, dust-free and safely into your packaging? HECHT's specialists analyse your powder, packaging format and OEB band and design a filling line that combines quality, throughput and operator protection. Contact us for a filling analysis and a tailored proposal.

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Powder processing: the complete guide to processes and safety

Powder processing is a discipline of its own. Powders behave unpredictably: they dust, segregate, cake and form explosive mixtures. For pharma, chemical, food and the battery industry, controlling those properties determines whether a process runs safely, reproducibly and profitably. This pillar gives technical decision-makers an overview of the complete powder processing chain, from receipt to packaging, with an emphasis on safety, containment and GMP.

What makes powder processing so challenging

Unlike liquids, powders follow no fixed flow laws. Their behaviour depends on particle size, shape, moisture content, density and charge. The same powder can flow freely today and bridge tomorrow. That variability makes powder processing complex and explains why standard solutions often fail. Those who understand powder properties design a process that performs consistently.

The process steps in the chain

Powder processing is a sequence of operations that each carry their own risk.

  • Receipt and discharge: dumping sacks, big bags and drums, the dustiest part of the process.
  • Transport: moving pneumatically or mechanically between process steps.
  • Mixing and dosing: homogenizing and weighing accurately for reproducible quality.
  • Sieving and milling: adjusting particle size for flow and quality.
  • Sampling: sampling representatively for QA without opening the chain.
  • Packaging and discharge: controlled filling into final packaging or IBC.

Containment as the common thread

Throughout the chain runs one question: how do I keep powder in and the operator out? Containment means a closed process in which dust never leaves the product. You achieve this with liners, docking stations, split butterfly valves, closed transport and isolated sampling. Containment is not a separate component but a design philosophy that protects every transfer in the chain.

OEB classes and operator protection

The required containment depends on the toxicity of the product, expressed in OEB classes.

  • OEB 1-2: low activity, simple extraction and good ventilation often suffice.
  • OEB 3-4: moderately active, requires liners, closed transfer and well-engineered docking.
  • OEB 5 and higher: high-potent, requires isolators, endless liners or gloveboxes with validated disconnection.
  • Validation: confirm each containment step with SMEPAC measurements to demonstrate exposure.

ATEX and dust explosion safety

Almost every organic or metal powder can cause a dust explosion. Fine dust in the air plus an ignition source is enough. ATEX-compliant design controls this risk via zone classification, grounding of all conductive parts and, where needed, explosion protection or inertization with nitrogen. For battery powders and reactive chemicals this is an absolute design requirement, not an option.

GMP, hygiene and cleanability

In pharma and food the hygienic design determines whether an installation is usable. Choose stainless steel 316L, crevice-free welds and surfaces that comply with GMP and EHEDG. This prevents product build-up, eases CIP and rules out cross-contamination. Single-use components eliminate cleaning between batches and speed up changeover, a direct advantage with frequent product changes.

From components to an integrated system

The greatest value arises not in individual machines but in an integrated chain. When discharge, transport, mixing, sampling and packaging connect via a consistent containment and interface philosophy, the dust leaks at the transition points disappear. HECHT engineers that complete chain, so every transfer stays closed and the entire process runs reproducibly, safely and efficiently.

Frequently asked questions about powder processing

Why is powder processing more complex than liquid processing?

Because powders follow no fixed flow laws; their behaviour varies with particle size, moisture, density and charge, which often makes standard solutions fail.

What does containment mean in powder processing?

A closed process in which dust never leaves the product, achieved with liners, docking, split butterfly valves and closed transport and sampling.

How do I determine which OEB class I need?

Based on the toxicity and exposure limit of the product; the lower the permitted exposure, the higher the OEB class and the required containment.

Is ATEX necessary in powder processing?

For almost all organic and metal powders, yes, because fine dust forms an explosive mixture. Zone classification, grounding and explosion protection are then required.

How do I keep an installation GMP-compliant?

With stainless steel 316L, crevice-free hygienic design, cleanable surfaces per EHEDG and validated cleaning or single-use components.

Related guides

Tailored advice from HECHT

Want to make your powder processing safer, closed and reproducible? HECHT engineers the complete chain, from discharge to packaging, tailored to your OEB target, ATEX zone and GMP requirements. Request a no-obligation process consultation and receive a concrete proposal.

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Industrial vacuum cleaners

Industrial vacuum cleaners keep production areas dust-free, prevent cross-contamination and control the risk of combustible dust. Unlike an ordinary vacuum cleaner, they are built for continuous heavy use, fine and hazardous powders and strict hygiene and explosion requirements. For engineers, buyers and QA in pharma, chemical, food and the battery industry, the right industrial vacuum cleaner is an indispensable part of a safe and GMP-compliant process. HECHT supplies vacuum cleaners tuned to your dust, environment and classification.

Why an industrial vacuum cleaner

Dust that accumulates on floors, equipment and ledges causes three problems: it contaminates other products, it exposes operators and it can form an explosive dust-air mixture. An industrial vacuum cleaner removes that dust at source, with filtration and construction designed for fine and hazardous powders. It is therefore not a cleaning aid but a safety and quality instrument.

Selection criteria: what to look for

You choose the right cleaner based on the dust and the environment.

  • Type of dust — particle size, density, toxicity and combustibility
  • Filtration class — from standard to HEPA H14, depending on the OEB band
  • Drive — electric or compressed-air (venturi); in ATEX zones often compressed air
  • Collection volume — matched to the amount of dust and the desired emptying frequency
  • Cleanability — CIP/WIP and smooth 316L surfaces for pharma and food
  • Mobility — mobile for local use or fixed for central extraction

Filtration and the OEB band

Filtration determines whether the cleaner is suitable for hazardous substances. For highly active powders, HEPA final filtration (H13/H14) is necessary, often with a validated bag-in-bag-out (BIBO) discharge of the collected dust, so the operator is not exposed when emptying.

  • OEB 1–2 — standard to fine filtration suffices
  • OEB 3–4 — HEPA filtration with safe, closed dust discharge
  • OEB 5 — dual HEPA and validated BIBO, SMEPAC-verified

ATEX: vacuuming in explosion-prone zones

In zones with combustible dust or vapour, the vacuum cleaner must be ATEX-compliant. That means an earthed, antistatic design, spark-free components and often a compressed-air (venturi) drive without an electrical ignition source. The correct zone classification (for example zone 22 for dust) determines the required design. HECHT supplies ATEX vacuum cleaners with the accompanying documentation and zoning.

Hygienic cleaning in pharma and food

In GMP environments, the vacuum cleaner itself is a potential contamination source. That is why product-contact parts are made in 316L with smooth, seamless surfaces and no dead zones to EHEDG, and are CIP/WIP-cleanable. Per product or batch, the filter unit can be swapped to prevent cross-contamination.

Mobile or central system

For incidental cleaning or several workstations, a mobile unit suffices. For large areas, continuous dust generation or multiple extraction points, a central vacuum system is more efficient: one powerful vacuum source serves multiple connection points through a fixed pipe network. HECHT advises based on your layout, dust load and frequency of use.

Frequently asked questions about industrial vacuum cleaners

What distinguishes an industrial vacuum cleaner from an ordinary one?

Continuous heavy use, high-grade filtration up to HEPA, robust construction and suitability for fine, hazardous and combustible powders.

Which filtration do I need for pharmaceutical dust?

HEPA H13/H14 with a validated, closed dust discharge (BIBO), matched to the product's OEB band.

When do I need an ATEX vacuum cleaner?

As soon as you work in a zone with combustible dust or vapour; a compressed-air-driven, earthed design avoids electrical ignition sources.

Can I use the same cleaner for several products?

Yes, provided you swap the filter unit per product and apply CIP/WIP cleaning to prevent cross-contamination.

Mobile or central: which is better?

Mobile for incidental and local use; central for large areas, continuous dust generation or multiple extraction points.

Related guides

Tailored advice from HECHT

Looking for a vacuum cleaner that suits your dust, OEB band and environment? HECHT's specialists analyse your dust load, classification and layout and advise a mobile or central solution with the right filtration and ATEX design. Contact us for a cleaning analysis and a tailored proposal.

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ATEX and explosion safety in powder processing

Dust explosions are an underestimated risk in the powder processing industry. A cloud of fine organic or metallic dust combined with an ignition source can trigger a devastating explosion within milliseconds. For engineers, buyers and QA managers in pharma, chemicals, food and the battery industry, ATEX-compliant process equipment is therefore not an option but a legal and operational necessity. HECHT supplies powder handling systems that build explosion safety into every design.

What ATEX means for your process

ATEX refers to two European directives: 2014/34/EU for equipment in explosive atmospheres and 1999/92/EC for the protection of workers. For powder processing companies this means all equipment in contact with combustible dust must be certified for the correct zone and explosion group. Non-compliant equipment leads to audit failures, insurance complications and, in the worst case, personal injury.

The core of ATEX compliance is breaking the explosion triangle: combustible dust, oxygen and an ignition source must never be present simultaneously in dangerous proportions.

Dust explosions: the mechanism

A dust explosion requires five elements, captured in the explosion pentagon:

  • Combustible dust — organic substances (sugar, starch, milk powder), metals (aluminium, lithium) or pharmaceutical APIs
  • Sufficiently fine particles — typically below 500 microns, with explosivity rising as particle size falls
  • Suspended dust cloud — a dispersion at a concentration above the lower explosion limit
  • Oxygen — from the ambient air
  • Ignition source — sparks, hot surfaces, static electricity or mechanical friction

Dust explosion characteristics are expressed in Kst value and Pmax. These determine the explosion class (St 1, St 2, St 3) and thereby the construction requirements.

Zoning: classifying ATEX zones

Zoning divides your installation according to the likelihood of an explosive dust atmosphere forming. Correct zone classification is the basis of the explosion protection document (EPD).

  • Zone 20 — dust cloud present continuously or for long periods, for example inside a mixer or silo
  • Zone 21 — present occasionally in normal operation, such as at filling and discharge points
  • Zone 22 — present rarely and briefly, typically in the immediate vicinity of equipment

HECHT equipment is available in category 1D, 2D and 3D versions, matched to the zone in which the equipment is installed.

Earthed design and static electricity

Static charging is one of the most common ignition sources in powder transport. Friction between powder and hose walls, or between powder and equipment surfaces, builds up charges that discharge as a spark. An earthed design prevents this.

HECHT consistently applies:

  • Continuous earthing — all conductive parts electrically bonded to an earth potential below 10⁶ ohm
  • Conductive or antistatic hoses and seals — to prevent charge build-up in flexible sections
  • Earthing control — monitoring systems that verify earthing continuity before a process starts

Explosion protection: preventing and controlling

ATEX recognises two strategies that HECHT combines: explosion prevention (avoiding ignition) and explosion protection (controlling the consequences). Where prevention cannot be fully guaranteed, constructive measures are applied.

  • Pressure-shock-resistant design — equipment built to withstand the full explosion pressure without failing
  • Explosion pressure relief — bursting discs that vent pressure in a controlled way to a safe area
  • Explosion suppression — fast-acting suppressant injection that smothers the explosion at its source
  • Decoupling — fast-closing valves that prevent an explosion propagating through pipework

Integration in dust-free and closed systems

Explosion safety and operator protection reinforce each other. A closed, dust-free process design not only limits operator exposure to powder but also reduces the chance of an explosive atmosphere outside the equipment. HECHT integrates ATEX compliance into vacuum transport, containment filling heads and dosing systems, so a single installation meets both safety and GMP requirements.

Inerting with nitrogen is a complementary measure: by bringing the oxygen content below the limit value, explosion becomes impossible regardless of dust concentration or ignition source.

Frequently asked questions about ATEX

When is ATEX equipment mandatory?

As soon as a combustible dust atmosphere can form in your process, ATEX applies. The zone classification determines the equipment category you need.

What is the difference between Kst and Pmax?

Kst indicates the rate of pressure rise and determines the explosion class; Pmax is the maximum explosion pressure. Both are needed to size protective measures.

Is earthing sufficient as protection?

Earthing prevents static ignition but does not cover all ignition sources. A complete ATEX concept combines prevention with constructive protection.

What is inerting?

Replacing oxygen with an inert gas such as nitrogen, making combustion impossible. This is especially relevant for lithium and reactive APIs.

How is zoning determined?

Based on the likelihood and duration of an explosive atmosphere, recorded in the explosion protection document. HECHT advises on this together with your safety officer.

Related guides

Tailored advice from HECHT

Explosion safety starts with the process design, not with a bursting disc added afterwards. HECHT analyses your powder properties, zone classification and handling process and delivers an ATEX-compliant system that aligns with your GMP and operator protection requirements. Contact our engineers for a no-obligation risk analysis and a concept tailored to your installation.

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Sieving technology for powders

Screening technology separates powders and granules by particle size and removes unwanted foreign matter, lumps and oversize. It is an indispensable step for product quality: a screened powder flows better, doses more accurately and meets specification. For engineers, buyers and QA in pharma, chemical, food and the battery industry, the screening strategy determines purity, particle distribution and process reliability. HECHT supplies screening solutions tuned to your product, capacity and hygiene requirements.

What screening technology does

A screen passes powder over a tensioned mesh with a defined aperture. Particles smaller than the aperture fall through (the good fraction); larger particles, lumps and foreign matter are retained (the oversize). Through vibration, rotation or ultrasonic activation, the mesh stays open and throughput high. In this way, screening ensures a consistent particle distribution and a product free of contamination.

Main screen types

The choice depends on the separation goal, the capacity and the fineness.

  • Vibratory screen — circular vibration for general separation and control screening
  • Tumbler screen — gentle, horizontal motion for high precision and multiple fractions
  • Centrifugal screen — rotating rotor that pushes powder through a cylindrical mesh, high throughput
  • Control screen (safety screening) — fine screen that catches foreign matter just before packaging
  • Ultrasonic screen — ultrasonically activated mesh for very fine and sticky powders

Separating, control screening or de-lumping

Screening technology fulfils several roles, depending on where in the process the screen sits.

  • Classifying — splitting into multiple particle fractions to specification
  • Safety screening — final check for foreign matter before packaging
  • De-lumping — breaking up agglomerates and lumps into a free-flowing product
  • Separating — removing oversize, fibres or packaging residues

Capacity and fineness

A screen's throughput depends on the aperture, the screening area and the product properties. Fine apertures and sticky or moist powders lower capacity; ultrasonic activation then keeps the mesh open and restores throughput. HECHT dimensions the screen based on the required fineness, capacity and product properties, so you achieve both separation and throughput.

Dust-free screening and containment

Screening is an open process that releases a lot of dust without control. A closed screen design with sealed inlets and outlets, integrated into vacuum or screw conveying, keeps the dust inside. For highly active powders, the screen is built containment-compliant with split-butterfly valves and, depending on the OEB band, SMEPAC-verified enclosure to minimise operator exposure.

Hygienic design and ATEX

In pharma and food, screen and mesh are fully CIP/WIP-cleanable, in 316L with smooth surfaces and no dead zones to GMP and EHEDG. Quick-change screen decks speed up product changeovers and prevent cross-contamination. For combustible powders, the screen is earthed and built ATEX-compliant; for oxygen-sensitive battery powders, screening can take place under nitrogen.

Frequently asked questions about screening technology

What is the difference between classifying and safety screening?

Classifying splits a product into multiple particle fractions; safety screening is a final fine check that only catches foreign matter and oversize before packaging.

Which screen suits fine, sticky powders?

An ultrasonic screen keeps the fine mesh open and restores throughput with sticky or moist products.

How do I achieve high throughput in fine screening?

By combining sufficient screening area, the right motion (tumbler or centrifugal) and, where needed, ultrasonic activation.

Can I screen dust-free with highly active substances?

Yes, with a closed screen design, split-butterfly valves and SMEPAC-verified containment matched to the OEB band.

How fast can I change between products?

With quick-change screen decks and CIP/WIP cleaning, product changeovers are short and free of cross-contamination.

Related guides

Tailored advice from HECHT

Looking for a screening solution that separates, controls or de-lumps for your product and capacity? HECHT's specialists analyse your powder, fineness requirement and OEB band and design a screen that combines quality, throughput and dust-free operation. Contact us for a screening analysis and a tailored proposal.

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Containment filling heads: function, OEB classes and choice

Filling bags, drums, IBCs or reactors with powder is one of the most dust-sensitive steps in any production process. Every discharge releases fine dust that exposes operators, causes product loss and risks cross-contamination. Containment filling heads solve this at the source. For engineers, buyers and QA in pharma, chemicals, food and the battery industry, filling heads are the key to dust-free, controlled and GMP-compliant filling. HECHT designs filling heads that integrate seamlessly into your existing process.

What is a containment filling head?

A filling head is the connection between your dosing or transport system and the container being filled. A containment filling head adds enclosed dust control: the product flows within a sealed space from the outlet into the container without dust escaping to the surroundings. The difference from an open discharge point is fundamental: an open point accepts dust emission, a filling head eliminates it.

Filling heads are used in both small-scale manual filling and fully automated lines, and scale to OEB class and throughput.

How dust-free filling works technically

Dust-free filling relies on controlling displaced air. When powder flows into a container, an equal volume of air must flow out. That air carries dust with it. The filling head captures this air and filters the dust back into the process.

  • Sealed coupling — an inflatable or mechanical seal connects the container airtight
  • Return venting — displaced, dust-laden air is extracted and filtered
  • Negative pressure control — a slight vacuum in the fill zone keeps dust inside the system
  • Product guidance — a central fill pipe guides the powder gently into the container to limit turbulence

Containment levels and OEB classes

Not every product requires the same protection level. The Occupational Exposure Band (OEB) determines how strict the containment must be. HECHT supplies filling heads across the full spectrum.

  • OEB 1–2 — standard low-dust filling heads with return venting, suitable for food and non-critical chemicals
  • OEB 3–4 — enhanced containment with double sealing and integrated filtration
  • OEB 5 — high containment with split butterfly valves and wash-in-place, for HPAPI and highly active substances

Containment performance is verified to SMEPAC, giving you objectively measured exposure values for your QA file.

Applications by industry

Filling heads are used in virtually every powder processing sector, each with different priorities.

  • Pharma — high-containment filling of APIs and formulations under GMP, with demonstrable operator protection
  • Chemicals — dust-free filling of pigments, additives and reactive powders, often in an ATEX zone
  • Food — hygienic filling to EHEDG standards, with cleanable surfaces and avoidance of product residue
  • Battery — controlled filling of cathode and anode materials under inert atmosphere

Cleaning, GMP and EHEDG

For validated production, cleanability is as important as containment. A filling head that cannot be thoroughly cleaned poses a cross-contamination risk during product changeovers. HECHT designs filling heads with polished, crevice-free surfaces that meet GMP and EHEDG guidelines.

Depending on the application, the filling head is available with wash-in-place (WIP) or clean-in-place (CIP), so cleaning takes place without disassembly and with reproducible results. This shortens downtime between batches and supports your validation.

Integration into the process chain

A filling head never functions in isolation. Its performance depends on how it works with the dosing system, vacuum transport and downstream containers. HECHT supplies filling heads as part of an integrated handling concept in which dosing accuracy, transport capacity and containment are matched to each other.

This prevents bottlenecks: a filling head is only as good as the feed supplying it and the seal the container provides.

Frequently asked questions about filling heads

What is the difference between a filling head and an ordinary discharge point?

A discharge point is open and lets dust escape; a containment filling head seals the fill zone and filters displaced air, so no dust is released.

Up to which OEB class can HECHT fill?

Up to and including OEB 5, with split butterfly valves and WIP for highly active substances such as HPAPIs.

How is containment performance demonstrated?

Through SMEPAC tests that measure actual exposure concentration, usable as objective evidence in your QA file.

Are filling heads available ATEX-compliant?

Yes, in earthed and zone-certified versions for combustible powders and inert processes.

Can a filling head be fitted into an existing line?

Yes, HECHT designs the connection to your existing dosing and transport systems and to your container formats.

Related guides

Tailored advice from HECHT

The right filling head depends on your product, OEB class, container format and cleaning requirements. HECHT brings these factors together in a single validated design that protects operators, eliminates product loss and passes your audits. Contact us for an analysis of your filling process and a tailored filling head concept.

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See also: complete guide to containment OEB 1 to 6

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Rotary valves for powder processing: operation, types and applications 2026

Anyone transporting powders, granulates or pellets via pneumatic systems will sooner or later encounter the dosing gate — also known as a rotary valve, rotary airlock or rotating valve. This compact device plays a crucial role in every powder processing installation: it provides controlled transfer of bulk goods between spaces of different pressure, without losing the airflow.

For process engineers and production managers in pharma, fine chemicals, food and battery production, choosing the right dosing gate directly affects process stability, production loss and installation safety.

How does a dosing gate work?

A dosing gate consists of a rotor with cells (vanes) that rotates within a cylindrical housing. The principle is simple but effective:

  1. Filling — material drops through the inlet into the rotor's cells
  2. Transport — the rotor turns and carries the material to the outlet
  3. Discharge — the material drops or is blown into the receiving system

Rotation speed determines dosing accuracy: slower = less material per unit of time. This makes the dosing gate suitable for both continuous processes and precise batch dosing.

Because the rotor seals off the space between the high- and low-pressure sides, the pressure difference remains intact. This is essential in pneumatic transport, where the transport air would otherwise escape via the material stream.

Types of dosing gates

Not every dosing gate is suitable for every application. The main variants:

Standard dosing gate (open rotor)

For dry, free-flowing materials without high hygiene requirements. Suitable for granulates, pellets and non-sticky powders in the chemical industry.

GMP dosing gate (hygienic design)

Fully cleanable (CIP/SIP), polished surfaces, no dead zones. Required for pharma, food and nutraceuticals. Complies with FDA and EHEDG standards.

ATEX dosing gate

For explosion-sensitive powders (St1–St3) in zones 20, 21 or 22. Fitted with an explosion-proof motor, grounding and spark-free materials. Mandatory for flammable powders such as fine metal dust, pigments or certain food products.

Containment dosing gate (closed system)

For products with a low exposure limit (OEL < 1 µg/m³). Equipped with a mechanical seal to fully prevent dust emission. Applicable to APIs, cytostatics and hormones.

High-temperature dosing gate

For hot gases, drying processes or high-temperature pneumatic transport. Housing and rotor are made of heat-resistant steel.

Applications by sector

Pharma and API production: Dosing gates are used for transferring active substances between dryer, mill and packaging. Containment versions with SMEPAC validation are standard for OEB 3–5 products.

Fine chemicals and ATEX environments: Pigments, catalysts and fine chemicals require ATEX compliance. The dosing gate acts as a pressure-resistant transition in the pneumatic transport system.

Food and nutraceuticals: Sugars, proteins, herbs and vitamins are hygienically transferred via GMP dosing gates with CIP capability. The installation complies with EHEDG and FDA standards.

Battery production: Lithium salts (LiPF6) and cathode material (NMC, LFP) are moisture- and oxygen-sensitive. The dosing gate is fitted with an inert gas seal and ATEX Zone 21 certification.

Plastics and polymer processing: Granulates and pellets are precisely dosed into extruders and mixing installations via dosing gates, with minimal particle damage.

What to consider when choosing a dosing gate?

Several parameters play a role in selecting a dosing gate: bulk density and flow properties of the material, desired throughput capacity (kg/h or m³/h), pressure difference across the gate (bar), ATEX requirement (zone and dust class), hygienic design (CIP/SIP), wear resistance for abrasive material and the required containment level (OEL class).

An incorrectly chosen dosing gate leads to wear, leakage, product loss or — in the worst case — a safety incident. Hecht Technology always advises based on product analysis and process parameters.

Hecht Technology: integrated dosing gate solutions

Hecht Technology supplies and integrates dosing gates as part of a complete powder handling system. From pneumatic transport to containment filtration: the dosing gate is matched to the product, the pressure difference and the safety requirements of your installation.

More information about dosing gates and rotary valves is available at hecht-technology.nl and hecht.eu.

Conclusion

A dosing gate is an indispensable link in every powder processing installation with pneumatic transport. The right version — GMP, ATEX or containment — determines the safety, accuracy and cleanability of your process. Choose based on product characteristics and process parameters, not on price alone.

Want to know more? Visit hecht-technology.nl or get in touch directly.

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Vacuum technology in the process industry

Moving powders through a plant looks simple, but in practice it is a source of dust, product loss, segregation and physical strain. Vacuum transport solves these problems by moving powder in a closed, dust-free way using negative pressure. For engineers, buyers and QA in pharma, chemicals, food and the battery industry, vacuum technology offers a hygienic, safe and flexible way to move bulk materials through the process. HECHT designs vacuum transport systems matched to your product and layout.

How vacuum transport works

Vacuum transport moves powder through a closed pipeline using a vacuum pump that creates negative pressure at the end. The powder is drawn in at the pick-up point, carried in the air stream and separated from the air in a receiver. The air is filtered and discharged; the powder drops through a valve into the next process step.

Because the system operates under negative pressure, no dust escapes in the event of a leak — air is drawn inward instead. This makes vacuum transport inherently safer than transport under positive pressure.

The core components of a vacuum system

A reliable vacuum transport system consists of matched components.

  • Pick-up point — lance, hopper or suction nozzle that takes the powder from a bag, big bag or container
  • Transport line — smooth, earthed pipe or hose that guides the powder without loss
  • Receiver — vacuum separator in which powder and air are separated
  • Filter unit — cartridge or bag filter that removes fine dust from the exhaust air
  • Vacuum generator — pump or venturi that delivers the required negative pressure
  • Outlet valve — valve that passes the powder in metered fashion to the next step

Advantages over mechanical transport

Mechanical transport systems such as screws and conveyor belts have moving parts in contact with the product, bringing wear, cleaning and contamination issues. Vacuum transport offers structural advantages.

  • Dust-free — fully closed transport protects operators and the environment
  • Hygienic — smooth, cleanable pipes without dead spots, suitable for GMP and EHEDG
  • Flexible — pipes follow any route through the plant, including vertical runs
  • Product-friendly — controlled velocity limits particle breakage and segregation

Applications in the process industry

Vacuum transport suits a wide range of powders and processes.

  • Pharma — transport of APIs and excipients under containment, with validation to GMP
  • Chemicals — moving pigments, catalysts and additives, often in ATEX environments
  • Food — hygienic transport of milk powder, cocoa, flour and spices
  • Battery — transfer of cathode and anode powders under inert, moisture-free conditions

Containment and operator protection

For highly active substances, vacuum transport is a natural containment strategy. Because the powder is never exposed to open air, operator exposure is minimal. Combined with split butterfly valves at pick-up and discharge points, a vacuum system can meet high OEB classes.

Containment performance is verified to SMEPAC, giving you objective exposure figures. For combustible powders the system is earthed and built ATEX-compliant, optionally with nitrogen inerting.

Design factors that determine performance

The performance of a vacuum system depends on correct sizing. An undersized system clogs; an oversized system wastes energy and can damage powder.

  • Product properties — density, particle size, flowability and moisture sensitivity
  • Transport distance and height — determine the required negative pressure and air flow
  • Throughput — required capacity in kilograms per hour
  • Cycle time — continuous or batch, depending on the downstream process

HECHT determines these parameters through product analysis and, where needed, transport trials in its own test centre.

Frequently asked questions about vacuum transport

Why is vacuum transport safer than pressure transport?

Under negative pressure, air is drawn inward, not blown outward. In a leak, no dust is released, protecting operators and the environment.

What distances can vacuum transport cover?

Depending on product and system, distances of several tens of metres horizontally and vertically are achievable.

Does vacuum transport damage the product?

With correct sizing and velocity control, particle breakage is minimal; HECHT matches air velocity to breakage sensitivity.

Is vacuum transport suitable for highly active substances?

Yes, combined with split butterfly valves and SMEPAC-verified containment it suits high OEB classes.

How is the system cleaned?

Via WIP or CIP, depending on the version, so cleaning takes place without disassembly and reproducibly.

How do I choose a vacuum transport system for pharmaceutical powders?

Match the system to the OEB classification of your substance: standard vacuum conveying suits low-potency excipients (OEB 1 to 3), while high-potency APIs (OEB 4 to 6) require containment-integrated vacuum transport with split-valve or isolator connections and SMEPAC-validated performance.

Related guides

Tailored advice from HECHT

A vacuum system that fits your product starts with a thorough analysis of your powder, distance and throughput. HECHT sizes, tests and supplies vacuum transport that is dust-free, hygienic and safe, and that integrates seamlessly with your dosing and filling systems. Contact us for a transport analysis and a tailored system proposal.

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Handling bulk materials: systems and best practices

Bulk material handling determines the efficiency of virtually every powder processing operation. From unloading big bags to feeding reactors, every transfer is an opportunity for dust, product loss, segregation or downtime. A well-designed handling system is the difference between a smooth, safe production line and a chain full of bottlenecks. For engineers, buyers and QA in pharma, chemicals, food and the battery industry, HECHT delivers integrated bulk material handling that is dust-free, hygienic and reliable.

What does bulk material handling cover?

Bulk material handling is the entirety of systems that receive, store, transport, dose and discharge powders and granulates within a production process. It goes beyond individual machines: it is a chain in which every link must connect to the next.

A typical chain begins with the receipt of raw materials in bags, big bags or bulk trucks, and ends with feeding a mixer, reactor or packaging line. The challenge lies in the transfer points, where most problems arise.

The links in the handling chain

Each link has its own function and its own risks.

  • Receipt and unloading — big bag discharge stations, sack tipping stations and discharge chutes with dust extraction
  • Storage — silos, hoppers and IBCs with level monitoring and discharge promotion
  • Transport — vacuum or mechanical transport between process steps
  • Dosing — gravimetric or volumetric metering into the process
  • Discharge and filling — containment filling heads into containers or packaging

Dust-free and closed design

Open transfer points are the largest source of dust and product loss in a handling chain. A closed design addresses this at every link, not just the most visible one.

  • Closed discharge stations — big bags are emptied dust-free with sealed connections
  • Extracted discharge points — displaced air is captured and filtered
  • Closed transport — vacuum transport avoids exposure between process steps
  • Containment discharge — filling heads close the chain dust-free

This protects operators, prevents cross-contamination and reduces raw material loss that hits margins directly.

Flow and preventing blockages

A handling system is only as reliable as its worst flow point. Powders with poor flow properties form bridges and ratholes in hoppers, leading to downtime. HECHT designs for guaranteed flow.

  • Mass-flow hoppers — geometry that guarantees first-in-first-out flow
  • Discharge promotion — vibrating bottoms, aeration or mechanical aids against bridging
  • Segregation prevention — controlled discharge and transport to avoid separation of fractions

Hygiene, GMP and EHEDG

In pharma and food, hygiene is as critical as flow. Product residue in dead spots poses a contamination risk during product changeovers and complicates validation. HECHT supplies handling components with polished, crevice-free surfaces to GMP and EHEDG standards.

Cleaning via WIP or CIP enables thorough cleaning without disassembly, shortening downtime between batches and delivering reproducible results. This is essential for validated production.

Safety: ATEX and operator protection

Many bulk materials are combustible or highly active, so safety must be embedded in the design. For combustible powders the entire chain is earthed and built ATEX-compliant, with explosion protection where needed. For highly active substances, containment by OEB class provides operator protection, verified via SMEPAC.

An integrated approach prevents safety from becoming a patchwork of separate solutions: one system, one safety concept.

Frequently asked questions about bulk material handling

Where do most problems in a handling chain arise?

At the transfer points between links, where dust, segregation and blockages converge. An integrated design targets these points specifically.

How is bridging in hoppers prevented?

With mass-flow geometry and discharge promotion such as vibrating bottoms or aeration, matched to the flow properties of the product.

Is bulk material handling suitable for highly active substances?

Yes, with containment by OEB class and SMEPAC verification, the chain provides operator protection to high levels.

Can HECHT upgrade an existing line?

Yes, HECHT analyses your existing chain and replaces or integrates links to reduce dust, loss and downtime.

What does a closed handling chain deliver financially?

Lower raw material loss, less downtime, faster product changeovers and lower safety costs, reducing total cost of ownership.

Related guides

Tailored advice from HECHT

Bulk material handling is not a sum of separate machines but a chain that must work as a whole. HECHT analyses your full process, identifies the bottlenecks and delivers an integrated system that is dust-free, hygienic and safe. Contact us for a process analysis and a handling concept tailored to your production.

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Pressure vessels in powder processing

Pressure vessels are an indispensable part of many powder processing operations, particularly in pneumatic transport under positive pressure. A pressure vessel stores powder and then pushes it with compressed air through a pipeline to its destination. For engineers, buyers and QA in pharma, chemicals, food and the battery industry, pressure vessels are a reliable way to move powders over greater distances. At the same time, strict requirements apply to design, safety and certification. HECHT supplies pressure vessels that meet these requirements and integrate with your process.

What is a pressure vessel and how does it work?

A pressure vessel, also called a sender vessel or transmitter, is a closed reservoir that receives powder and discharges it under positive pressure. The operating principle is cyclical: the vessel is filled, sealed, pressurised with compressed air, and emptied as the powder is pushed through the transport line.

Unlike vacuum transport, which operates under negative pressure, a pressure vessel uses positive pressure. This makes it particularly suitable for long transport distances and high throughputs, because the available pressure is greater than under vacuum.

Applications of pressure vessels

Pressure vessels are used where distance, capacity or product properties call for positive-pressure transport.

  • Long distances — transport over tens to hundreds of metres, where vacuum falls short
  • High throughput — large quantities of powder per cycle, suitable for continuous production
  • Dense phase transport — slow, product-friendly transport with minimal particle breakage
  • Abrasive powders — controlled velocity limits pipe wear

In the battery industry and chemicals, pressure vessels are often used to move large volumes under inert conditions.

Dense phase versus dilute phase transport

A pressure vessel can convey powder through the line in two ways, with major consequences for product integrity and wear.

  • Dilute phase — high air velocity, powder suspended in the air stream, suitable for free-flowing, non-friable products
  • Dense phase — low air velocity, powder moves in plugs, product-friendly with minimal breakage, ideal for friable or abrasive powders

The choice determines the sizing of vessel, pipeline and compressed air supply. HECHT advises based on your product properties.

Safety and certification

A pressure vessel falls under the European Pressure Equipment Directive (PED, 2014/68/EU). This sets requirements for design, material selection, manufacture and inspection. An uncertified pressure vessel is a safety risk and not permitted in a professional installation.

  • PED compliance — design and manufacture to the pressure equipment directive
  • Overpressure protection — safety valves that prevent inadmissible pressure
  • Material certification — traceable materials with certificates for process suitability
  • Periodic inspection — re-inspection in accordance with applicable regulations

HECHT supplies pressure vessels with the required certification and documentation for your safety file.

Containment, hygiene and ATEX

Pressure vessels in pharma and food must meet hygiene and containment requirements alongside pressure ones. HECHT designs pressure vessels with polished, cleanable surfaces to GMP and EHEDG, with WIP or CIP where validated cleaning is required.

For combustible powders the pressure vessel is earthed and built ATEX-compliant. With reactive substances, as in the battery industry, nitrogen inerting can be applied to prevent explosion and unwanted reactions.

Sizing and process integration

The performance of a pressure vessel depends on correct matching of vessel volume, cycle time, pipe diameter and compressed air supply. An undersized system fails to achieve throughput; an oversized system wastes compressed air.

HECHT determines these parameters through product analysis and transport trials, and integrates the pressure vessel into the broader handling chain with dosing, filling and storage systems. The vessel thus functions not as a standalone component but as part of a coherent whole.

More about pressure vessels: in-depth articles

Want to read more about a specific topic? Below you will find all our articles on pressure vessels.

Frequently asked questions about pressure vessels

What is the difference between a pressure vessel and vacuum transport?

A pressure vessel operates under positive pressure and suits long distances and high throughput; vacuum transport operates under negative pressure and is inherently dust-safer in a leak.

When do I choose dense phase transport?

For friable or abrasive powders, where low velocity minimises particle breakage and pipe wear.

Must a pressure vessel be certified?

Yes, a pressure vessel falls under the PED directive and requires compliant design, manufacture and inspection.

Are pressure vessels suitable for pharma?

Yes, in GMP- and EHEDG-compliant versions with cleanable surfaces and optional WIP or CIP.

Can a pressure vessel operate under inert atmosphere?

Yes, with nitrogen inerting for reactive or combustible powders, relevant in chemicals and battery.

Related guides

Tailored advice from HECHT

A pressure vessel that fits your process requires correct sizing, the right transport phase and complete certification. HECHT analyses your distance, throughput and product properties and delivers a PED-compliant pressure vessel that is safe, hygienic and integrated into your handling chain. Contact us for a transport analysis and a tailored pressure vessel concept.

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Homogenizers for powders

A homogeneous end product is, in many industries, not a luxury but a requirement. Whether it concerns a pharmaceutical formulation, a food product, a coating or a battery slurry, the consistency of the mix composition determines the quality. Homogenisers ensure that components are evenly distributed down to micro or nano scale. For engineers, buyers and QA in pharma, chemicals, food and the battery industry, HECHT delivers homogenisation solutions that are reproducible, hygienic and safe.

What does a homogeniser do?

A homogeniser reduces and distributes particles or droplets in a medium so that a uniform, stable composition results. The device applies intensive mechanical forces — shear, pressure, impact and cavitation — to break agglomerates and mix phases evenly.

The aim is a product in which no measurable differences in composition exist between different samples. This is essential for both product quality and process reproducibility.

Operating principles of homogenisation

Homogenisers work according to various physical principles, each suited to different applications.

  • Shear — high velocity differences between rotor and stator break particles and droplets apart
  • High pressure — the medium is forced through a narrow gap, where pressure and cavitation reduce particle size
  • Impact — particles collide with surfaces or each other, breaking up agglomerates
  • Cavitation — imploding vapour bubbles deliver locally intense energy for particle reduction

The combination of these forces determines the fineness and uniformity of the end result.

Types of homogenisers

Various constructions exist, matched to product and desired result.

  • Rotor-stator homogenisers — a fast-rotating rotor in a fixed stator, versatile for mixing and dispersing
  • High-pressure homogenisers — for very fine emulsions and suspensions down to nano scale
  • Inline homogenisers — integrated into a continuous process flow, suitable for high throughput
  • Batch homogenisers — for processing metered quantities in a vessel

HECHT advises the type that fits your viscosity, particle-size requirement and production format.

Applications by industry

Homogenisation is broadly applicable, each time with different goals.

  • Pharma — uniform distribution of APIs in suspensions and emulsions, critical for dosing and efficacy
  • Food — stable emulsions and consistent texture in sauces, dairy and beverages
  • Chemicals — dispersion of pigments and additives into stable coatings and pastes
  • Battery — homogeneous electrode slurries, decisive for cell performance and lifetime

In the battery industry, homogenisation of slurries is a direct quality factor: inhomogeneity leads to local capacity differences and shorter lifetime.

Hygiene, GMP and cleanability

In pharma and food, a homogeniser must deliver hygiene alongside performance. Product residue in dead spots poses a contamination risk and complicates validation. HECHT supplies homogenisers with polished, crevice-free surfaces to GMP and EHEDG.

Cleaning via WIP or CIP enables validated cleaning without disassembly, shortening downtime between batches and delivering reproducible results. For validated production this is a hard requirement.

Safety: ATEX and containment

Many homogenisation processes handle combustible solvents or powders, or highly active substances. Safety must therefore be embedded in the design. For combustible media the homogeniser is earthed and built ATEX-compliant, with inerting where needed.

For highly active substances, homogenisation is integrated into a closed, containment-compliant system, verified to SMEPAC. Operator protection thus remains assured, even under intensive mechanical processing of the medium.

Frequently asked questions about homogenisers

What is the difference between mixing and homogenising?

Mixing distributes components coarsely; homogenising reduces particles and droplets to a uniform, stable composition at micro or nano scale.

Which type of homogeniser fits my product?

That depends on viscosity, desired particle size and whether you produce in batch or continuously; HECHT advises based on your product properties.

Is homogenisation suitable for battery slurries?

Yes, homogeneous electrode slurries are crucial for cell performance; HECHT delivers solutions tailored to this application.

Can a homogeniser be cleaned in a validated way?

Yes, with GMP- and EHEDG-compliant construction and WIP or CIP for cleaning without disassembly.

Are homogenisers available ATEX-compliant?

Yes, in earthed, zone-certified versions with optional inerting for combustible media.

Related guides

Tailored advice from HECHT

The right homogeniser depends on your product, particle-size requirement, production format and safety and hygiene requirements. HECHT analyses your process and delivers a homogenisation solution that is reproducible, hygienic and safe, integrated into your handling chain. Contact us for a process analysis and a tailored homogeniser concept.

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Industrial filtration

Industrial filtration separates solid particles from gas or air streams and is indispensable in every form of powder processing. For manufacturers in pharma, chemical, food and the battery industry, the filtration strategy determines whether a process runs dust-free, safe and GMP-compliant. HECHT designs filtration solutions that combine operator protection, product retention and process efficiency. This page explains the available techniques, how to select a filter, and what to consider regarding OEB bands, ATEX and hygienic design.

Why filtration is critical in powder processing

Every transfer, conveying step or dosing operation releases fine dust. That dust poses three risks at once: operator exposure, cross-contamination of product and explosion hazard with combustible powders. Effective filtration captures particles before they spread, keeps the working environment clean and protects downstream equipment from wear.

Correct filtration also lowers your OPEX. Less dust loss means higher yield, less cleaning and longer service life for pumps and fans.

Key filtration techniques

The choice depends on particle size, flow rate, dust load and the required separation efficiency.

  • Cartridge filters — compact, high filter area per volume, ideal for fine dust and continuous operation
  • Bag filters — robust at high dust loads and coarser particles, easy to maintain
  • HEPA/ULPA filters — for critical separation up to 99.995%, essential in pharma and cleanrooms
  • Cyclones — pre-separation of the coarse fraction, reducing the load on the main filter
  • Sintered lamellas and metal filters — for high temperatures, aggressive media and cleanable applications

Cleaning: jet-pulse and mechanical

A filter inevitably becomes saturated. Cleaning during operation determines continuity. Jet-pulse cleaning uses a short blast of compressed air to release the filter cake from the medium, so the process need not stop. For containment applications, bag-in-bag-out (BIBO) designs let you replace the filter without exposure. Differential pressure monitoring tracks saturation and signals the right moment to clean or replace.

Filtration and OEB bands

For active pharmaceutical ingredients (APIs), the OEB band is decisive. The higher the OEB band, the lower the permitted exposure and the stricter the requirements for filtration and containment.

  • OEB 1–2 — standard dust extraction with cartridge or bag filter often suffices
  • OEB 3–4 — closed systems with HEPA final filtration and safe filter replacement
  • OEB 5 — isolator technology, dual HEPA filtration and validated BIBO procedures

ATEX and explosion safety

Many powders are combustible. As soon as a dust-air mixture is ignitable, the installation falls under the ATEX directive. Filtration systems must then be designed with explosion-pressure-resistant housings, pressure relief, spark detection or an ignition-source-free design. HECHT supplies ATEX-compliant filter units with the correct zoning and documentation.

Hygienic design: GMP and EHEDG

In pharma and food, cleanability matters as much as separation. Filtration components built to GMP and EHEDG guidelines have smooth surfaces, no dead zones and are CIP/WIP-cleanable. Stainless steel 316L, FDA-compliant seals and validated cleaning procedures prevent cross-contamination between batches.

Filter selection in practice

Good selection starts with process data: which powder, which particle size distribution, which flow rate and which separation efficiency. From there you define the filter class, the cleaning principle and the containment requirements. HECHT calculates the filter area based on the permitted filtration velocity, so you neither over- nor under-dimension.

Frequently asked questions about industrial filtration

Which filter class do I need for pharmaceutical powder?

For APIs with a high OEB band, HEPA H13/H14 is the starting point, often combined with a pre-filter and validated BIBO replacement.

What is the difference between a cartridge and a bag filter?

Cartridge filters offer more area in less space and perform better with fine dust. Bag filters are more robust at high dust loads and coarser particles.

How often must I replace filters?

That depends on dust load and cleaning principle. With jet-pulse cleaning filters last longer; differential pressure measurement indicates the right replacement moment.

Is my process subject to ATEX?

As soon as a combustible dust-air mixture can form, ATEX applies. A dust explosion analysis determines the zoning and the required protection.

Can I combine filtration with existing equipment?

Yes. HECHT integrates filtration into existing conveying, dosing and filling lines, including the correct containment connections.

Related guides

Tailored advice from HECHT

Want to know which filtration solution suits your powder, OEB band and process? HECHT's specialists analyse your situation and design a system that protects operators, retains product and complies with GMP and ATEX. Contact us for a no-obligation consultation.

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