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Powder Technology: Bulk Handling of Fine Powders

Powder technology covers the production and processing of metal, ceramic and polymer powders for advanced applications. From AM powders for 3D metal printing to hard metal powders for cutting applications — each material calls for specific bulk handling.

Key points

• Particle size distribution (PSD), bulk density, flowability (Hausner ratio) and explosivity class together determine the design of a bulk handling installation
• AM powders for 3D metal printing require very narrow PSD specifications (typically 15-45 µm) and an inert atmosphere during handling
• Hard metal powders (tungsten carbide-cobalt) are abrasive and require wear-resistant lining in transport and dosing equipment
• Sub-micron powders after jet milling have extremely high cohesion and require special anti-bridging and anti-rat-holing techniques

Powder characterisation

Critical powder properties for bulk handling: particle size distribution (PSD), bulk density, flowability index (Hausner ratio), moisture content and explosivity class. These properties determine the design of the bulk handling installation.

Milling and classification

Jet mills, ball mills and attritor mills grind powders down to sub-micron particle size. Air classifiers classify at sharp cut sizes. Hecht Technology supplies containment solutions for fine powders: hecht-technology.nl.

Explosion safety for fine metal powders

Metal powders such as aluminium, titanium and magnesium have a low ignition energy and can cause severe dust explosions. Handling these powders requires inerting with nitrogen or argon, grounded equipment and ATEX category 1 versions for the most reactive materials. This is a fundamentally different risk class than organic or ceramic powders.

FAQ — Powder technology bulk handling

Why do AM powders for 3D printing require such a narrow particle size distribution?

A consistent layer thickness and melting behaviour during powder-bed fusion (SLM/DMLS) requires a narrow PSD without fine or coarse outliers. Distributions that are too broad lead to porosity and inconsistent density in the printed part. Classifying mills and sieving technology remove the unwanted fractions after primary production.

What additional measures apply to reactive metal powders such as aluminium and titanium?

In addition to standard ATEX measures (grounding, ignition-source-free), inerting with nitrogen or argon is common to fully exclude oxygen from transport and storage spaces. Moisture contact must also be avoided, since some reactive metal powders can generate hydrogen gas on contact with moisture.

Read also

• Powder transport in closed systems 7-step guide
• What are the benefits of a rotary valve in powder processing
• How a diverter works in powder processing systems
• Powder dosing weighing process control guide

Our products

• Jett mill
• Feeding screw

Bulk Handling of Welding Materials

The welding industry consumes large volumes of welding materials: welding wire, welding powder, flux and shielding gases. Efficient and safe storage and handling of these materials is essential for continuous, high-quality welding production.

Key points

• Welding flux for submerged arc welding (SAW) must stay dry (typically <0.05% moisture) — moisture causes porosity in the weld seam
• Welding wire in bulk drums (250-500 kg) reduces changeover frequency and machine downtime compared to small spools
• Recovery and reprocessing of unused welding flux (recycling) significantly lowers material costs in high-volume SAW welding
• Shielding gas cylinders and tanks require separate, ventilated storage kept apart from flammable materials

Welding flux handling

Submerged arc welding (SAW) uses fine welding flux as a flux medium. This powder is stored in dry silos or hoppers. Moisture is the biggest enemy of welding flux — damp flux leads to porosity in the weld. Drying in ovens at 300-400°C restores moisture uptake.

Welding wire logistics and storage

Welding wire is supplied on spools, reels or as bulk wire in drums. Bulk wire drums of 250-500 kg reduce the number of changeovers and increase production time. Dry storage in sealed spaces prevents rust formation. Hecht Technology supplies containment solutions for welding materials: hecht-technology.nl.

Shielding gas storage and distribution

Shielding gases such as argon, CO₂ and mixtures thereof are stored in cylinder banks or, for high consumption, in bulk tanks with distribution lines to the welding stations. Proper pressure control and leak detection prevent both gas waste and safety risks in confined spaces.

FAQ — Welding industry bulk handling

Why is moisture control so critical for welding flux?

Damp welding flux releases hydrogen during the welding process, which can cause hydrogen porosity and cracking in the weld seam — a critical quality defect in critical structures such as pressure vessels and pipelines. Dry silo storage and, if needed, re-drying at 300-400°C before use prevent this.

What are the benefits of bulk welding wire compared to spools?

Bulk wire drums of 250-500 kg require fewer changeovers than standard 15-20 kg spools, which increases productivity in automated welding (robotic welding) and reduces the risk of wire breaks during long weld seams.

Read also

• Powder transport in closed systems 7-step guide
• Which industries use powder transport systems
• How magnetic detection works in powder processing
• Powder dosing weighing process control guide

Our products

• Big bag filling station BG
• Lifting equipment

Industrial Powder Technology

Powder technology covers all processes for the production and processing of fine solids. From pharmaceutical APIs to metallurgical powders — each powder requires specific production, characterisation and processing technology.

Key points

• The production method (milling, precipitation, spray drying, atomisation) determines the morphology and processability of the final powder
• Compaction (pressing) forms loose powder particles into a green compact; sintering heats it below the melting point into a dense, cohesive product
• Pharmaceutical, ceramic and metallurgical applications each place different demands on purity, particle shape and compressibility
• Flowability (Carr index, Hausner ratio) determines whether a powder flows through hoppers and dosing equipment without bridging

Powder production methods

Powder is produced via milling (top-down), precipitation, spray drying, atomisation or chemical precipitation. Each method yields a specific particle size distribution, morphology and surface chemistry that determine processability and final product properties.

Characterisation of industrial powders

Critical characterisation parameters: PSD (laser diffraction), BET surface area, bulk density, tapped density and flowability (Carr index, Hausner ratio). Hecht Technology is a specialist in powder bulk handling: hecht-technology.nl.

Compaction and sintering

In powder metallurgy and technical ceramics, powder is first compacted (uniaxial or isostatic pressing) into a "green compact" with sufficient mechanical strength to handle, but still porous. Sintering then heats this green compact below the melting temperature, causing particles to bond together (diffusion) and the part to shrink into a dense, cohesive structure. The consistency of the powder characteristics before pressing — particle size, shape, flowability — directly determines the density and dimensional stability of the final product after sintering.

Applications by industry

In the pharmaceutical industry, powder characterisation directly determines the tabletability and dose uniformity of APIs. In technical ceramics, it determines the sintered density of final products such as insulators and cutting tools. In metallurgy (powder metallurgy, PM), precision characterisation makes it possible to produce near-net-shape parts with minimal post-processing.

FAQ — Industrial powder technology

What is the difference between compaction and sintering?

Compaction is the mechanical pressing of powder into a shape-stable green compact. Sintering is a thermal process in which this green compact is heated below the melting point, causing particles to bond through diffusion and the product to gain its final density and strength.

Which powder property is most decisive for compressibility?

Particle shape and size distribution are generally most decisive: irregularly shaped particles interlock mechanically and give higher green strength than spherical particles, which flow better but compress less well without a binder.

Read also

• Powder transport in closed systems 7-step guide
• How to prevent contamination in powder processing
• What are the benefits of powder processing
• Powder dosing weighing process control guide

Our products

• Jett mill
• Dosing gate

Industrial crystallisation process — definition: Complete end-to-end platform for scaled-up purification of pharmaceutical and chemical APIs via controlled crystallisation, including process development, scale-up validation, polymorph control, crystal characterisation and GMP batch manufacturing, in accordance with FDA 21 CFR Part 211, ICH Q6A and GMP Annex 1 (2022), with a focus on product quality, cost-effectiveness and process robustness.

Key points

• Crystallisation pipeline: method development (solvent screening, temperature profile) → pilot scale-up → process validation (3 batches) → production scale
• Standard: GMP Annex 1 (2022), FDA 21 CFR Part 211, ICH Q6A (product specs), ICH Q3C (solvent guideline), USP 921 (crystal growth)
• HECHT product: End-to-End Crystallization Platform + Multi-Scale Reactors + Integrated Analytics + GMP Documentation
• Application: pharmaceutical API purification, chemical specialties, polymorph selection, high-purity products
• Efficiency: 80–95% product recovery, >99% crystal purity, 50–80% cost saving vs. other purification methods

This complete guide describes crystallisation end-to-end: method screening, scale-up strategy, process validation and production optimisation. Test & Trial Centre in Pörnbach available for development support; see our integrated crystallisation platforms and API purification services.

FAQ — Industrial crystallisation process

How do you choose the best solvent for crystallisation development?

Screening: 10–20 solvents based on solubility-temperature profile (high at high T, low when cold). Preference: solvent with >2× solubility difference between room temperature and 0°C. GMP suitability: aim for ICH Q3C class 3 (low toxicity). Cost-effectiveness: recycling capacity >80%. Pilot screening: typically identifies 3–5 favoured solvents.

What are the main scale-up risks from 1L to 100L?

Risks: nucleation inhomogeneity (seed distribution), temperature gradients (large volumes), mixing ineffectiveness, contamination (handling). Mitigation: geometric similarity (height/diameter ratio), seed strategy (equal amount/volume), temperature profile verification (thermocouples). Validation: typically 3 consecutive batches at production scale.

How much time and cost for crystallisation process development to GMP?

Development: 2–4 months (method screening, 10–20 runs). Scale-up: 3–6 months (IQ/OQ/PQ, 3 validation batches). GMP dossier: 8–12 weeks. Total: 6–12 months. Cost: €100K–€300K (labour, analytics, small-scale apparatus). HECHT accelerates this via PAT and computational modelling.

How does cooling rate affect crystal size and purity?

Slow, controlled cooling produces larger, purer crystals because impurities have time to remain in the mother liquor rather than becoming trapped in the crystal lattice. Rapid cooling produces finer crystals with a larger specific surface area, which can complicate filtration but does increase yield per cycle. The right balance depends on the desired particle size for downstream processing such as filtration and drying.

Author: Joost van Velzen, Managing Director Hecht Technology B.V.

Related guides and solutions

• Vacuum drying: technology choice
• Powder processing in pharma (GMP)
• Industrial filter installations & dust separation
• Solutions for the chemical industry

Our products

• Columns and process towers
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Ceramics industry bulk handling complete guide — definition: Complete handling and process engineering for ceramic raw materials and finished products (alumina, silica, zirconia, feldspar), including transport, milling, mixing, dosing and storage under hygienic & explosion-safe conditions in accordance with ATEX 2014/34/EU and DIN EN 1740.

Key points

• Ceramic raw materials 1000–2500 HV hardness; wear-resistant lining essential (hard metal/ceramic coating)
• Milling efficiency: 6–15 hour cycle depending on final particle size (1–50 µm range)
• HECHT product: CFE-K-EC integrates transport + milling + dosing in one system
• Moisture content critical: < 0.5% storage for stable final quality; N₂ purging in silos
• Cost optimisation: 38% total process cost savings via automation & smart dosing

Optimise your ceramic bulk processes at our Test & Trial Centre in Pörnbach. HECHT offers complete bulk handling solutions for ceramics & technical minerals.

FAQ — Ceramic bulk handling and process optimisation

How do you optimise milling parameters for diverse ceramic end products?

Particle size targets determine milling duration & energy. Fine powders (< 5 µm) require 12–15 hours; coarser powders (10–50 µm) 6–8 hours. Laser diffraction monitoring and adaptive milling algorithms optimise energy consumption per batch.

What safety measures are required in ceramic transport processes?

ATEX Category 3 (some ceramic powders) requires spark detection, grounding < 10⁶ Ω, and moisture control for static prevention. Fine alumina particles can pose electrostatic risks; HECHT systems offer full safety integration.

How do you manage contamination risks between different ceramic blends?

Closed systems, automatic cleaning purges (N₂ or compressed air) between batches, and colour-specific lining sets prevent cross-contamination. Regular inspection ensures > 99.5% purity.

What role does granule shape play in press compaction of ceramic powders?

Spray-dried ceramic granulates have a spherical, free-flowing structure that flows evenly through the die and produces a uniform green density. Irregularly shaped particles flow less well and can cause density variations in the compacted product, which leads to cracking or warping after sintering.

Author: Joost van Velzen, Managing Director Hecht Technology B.V. Verified: 02 07 2026.

Read also

• Powder transport in closed systems 7-step guide
• How to process powders with different particle shapes
• How to choose the right powder tester for your process
• Powder processing & transport: product overview

Our products

• Jett mill
• Feeding screw

Industrial distillation separation process — definition: Thermal separation technology in which liquid mixtures are heated and separated in phases based on boiling point differences via column distillation (reboiler, packing/trays, condenser), used for API purification, solvent recovery and azeotrope separation in the pharmaceutical, chemical and biological industries. Requires validated column operation, thermal settings, purity verification in accordance with FDA 21 CFR Part 211, ICH Q3 and GMP Annex 1 (2022).

Key points

• Distillation types: standard column (ideal mixtures <95% purity), azeotropic (entrainer addition), reactive distillation (in-column chemical conversion), extractive (third component)
• Standard: FDA 21 CFR Part 211, ICH Q3 (impurities), ICH Q3C (solvent guideline), Ph.Eur. (purity monographs), GMP Annex 1 (2022)
• HECHT product: Integrated Distillation Platform + Real-time Process Control + Multi-Stage Purity Monitor
• Application: API purification (pharmaceutical), solvent recovery, intermediate separations, industrial spirit denaturation
• Efficiency: 85–99% product recovery, 85–99% purity, 4–12 hour cycle time per batch, >80% energy saving via heat integration

This complete guide describes distillation strategy end-to-end: column type selection, thermal design, process validation and purity management. Test & Trial Centre in Pörnbach available for scale-up support; see our integrated distillation platforms and process engineering services.

FAQ — Industrial distillation separation process

How do you select column type (packed vs. tray column) for purification?

Packed column: lower CAPEX, better contact (lower HETP), but higher pressure drop, sensitive to flooding. Tray column: higher CAPEX, more flexibility in throughput range, better scalability. For pharmaceutical API purification: typically packed (precision control); for solvent recovery: tray flexibility preferred. HECHT recommends pilot testing; typically at 3–5 litre scale.

What are the main energy-saving strategies in distillation?

Heat integration: using condenser heat → reboiler feed (~40–50% energy saving). Pressure optimisation: lower absolute pressure → lower steam requirement. Thermal design: determining optimal reflux ratio (too low = long column, too high = high energy). Typically 30–60% energy saving achieved through optimisation. HECHT recommends a Process Integration study (pinch analysis).

How do you validate a distillation process for GMP and how long does it take?

IQ/OQ/PQ: equipment characterisation (2–4 weeks), process parameter mapping (3–5 validation runs), purity verification (analytical methods), batch record retention requirements. Total typically 8–16 weeks. Critical: temperature profile, reflux ratio, column tray temperatures, top and bottom samples. GMP dossier: ~100 pages, 12–16 weeks preparation.

When is azeotropic distillation needed instead of standard distillation?

When two components form an azeotrope — a mixture that boils at a fixed composition without further separation via simple distillation — an additional technique is needed, such as adding a third substance (entrainer) that breaks the azeotrope, pressure-swing distillation, or extractive distillation with a solvent that changes the relative volatility. The choice depends on the nature of the azeotrope and the desired final purity.

Author: Joost van Velzen, Managing Director Hecht Technology B.V.

Glass industry bulk handling raw materials complete guide — definition: Integrated handling, mixing and transport solution for primary glass raw materials (silica, soda ash, lime, feldspar, cullet), with precision weighing, hygienic transport and storage control in accordance with DIN EN 1740, ISO 9001 and environmental standards.

Key points

• Raw material quality: silica ≥ 99.8% purity; contamination leads to colour & strength deviations
• Moisture control: 0.5–2% moisture content for optimal mixing stability; RH monitoring essential
• HECHT product: LBK-EC (Glass raw material handling system, hygienic)
• Storage silos: dwell time 5–10 days; prevention of caking and compaction risk
• Cost reduction: 22% lower waste through precision dosing & automatic quality control

Optimise your raw material management at our Test & Trial Centre in Pörnbach. HECHT offers a complete bulk handling portfolio for glass & construction materials.

FAQ — Glass industry raw materials bulk handling

How is moisture content managed in silica and other glass raw materials?

Closed storage systems with moisture measurement (RH < 2%) prevent caking. Active moisture control (ventilation, drying) ensures stability. HECHT sensors monitor in real time and trigger automated corrections for deviations.

What contamination risks exist for silica and feldspar?

Iron, aluminium, potassium deviations and organic residues affect colour and strength. Optical sorting and electromagnetic separation remove > 99.8% of impurities. Regular laboratory testing is crucial.

How is storage cycle time optimised for raw material blends?

Ideal storage duration is 5–10 days; longer durations increase compaction risk. HECHT systems guarantee fast loading/discharging (4–6 hour batch preparation to furnace) with minimal contamination.

Which transport technique is most suitable for abrasive glass raw materials?

Silica and other hard, abrasive raw materials wear down pneumatic transport lines faster than softer powders. Wear-resistant lining (ceramic or hard metal) at critical bends and transitions, or transport at lower line speed with mechanical conveyors, significantly extends the installation's service life.

Author: Joost van Velzen, Managing Director Hecht Technology B.V. Verified: 02 07 2026.

Read also

• Powder transport in closed systems 7-step guide
• How to improve energy efficiency in powder processing systems
• Pneumatic transport system in powder processing complete guide 2026
• Powder processing & transport: product overview

Our products

• Big bag filling station BG
• Lifting equipment

Industrial extraction separation process — definition: Collection of large-scale separation technologies (LLE, SFE, chromatography, crystallisation) for isolating active pharmaceutical ingredients from natural sources or fermentation broths, resulting in pure APIs suitable for further synthesis or direct formulation. Requires integrated engineering in accordance with GMP Annex 1 (2022), FDA 21 CFR Part 211 and ICH Q3 (impurities guideline).

Key points

• Extraction cascade: solid/liquid separation → concentration (evaporation, crystallisation) → purification (chromatography or LLE) → product isolation → drying
• Standard: GMP Annex 1 (2022), FDA 21 CFR Part 211, ICH Q3 (impurities), ICH Q3C (solvent guideline), USP monographs
• HECHT product: Integrated Extraction & Purification Platform + Multi-Stage Separation + Automated Documentation
• Application: plant alkaloid extraction (cinchonine, digitalis), fermentation purification (antibiotics), natural product isolation
• Efficiency: 60–85% overall recovery, <1% impurities, 2–4 weeks total cycle time per lot

This complete guide describes extraction strategy end-to-end: source material selection, combination of separation techniques, process validation and batch record management. Test & Trial Centre in Pörnbach available for method development; see our integrated extraction platforms and regulatory support.

FAQ — Industrial extraction separation process

How do you select successive separation steps for maximum purity?

Strategy: broad sorting first (e.g. LLE for coarse separation), then fine-tuning (chromatography). Example: plant slurry → LLE (aqueous/organic split) → concentration → SFC (purification) → crystallisation (final polish). Each step removes specific impurities. HECHT recommends GC-MS/HPLC analysis after each step; typically 4–6 steps for pharmaceutical purity (>99%).

What is the typical mass balance for an industrial extraction process?

Loss per step: slurry separation (10–20%), concentration (5–10%), purification (10–20%), drying (2–5%). Combined: 50–70% overall recovery typically. Optimisation: e.g. LLE solvent selection can bring recovery up to 75–80%. GMP requirement: >90% mass balance or a justified explanation per step.

How long does it take to scale an extraction process from lab scale to GMP production scale?

Development: 6–12 months (method selection, optimisation, pilot). Scale-up: 6–12 months (equipment selection, IQ/OQ/PQ, three validation batches). Regulatory dossier: 3–6 months. Total: 15–30 months typically. HECHT accelerates this via pre-characterised platforms.

What is the difference between liquid-liquid extraction (LLE) and supercritical fluid extraction (SFE)?

LLE separates components based on their distribution between two immiscible liquids (for example water and an organic solvent) and is relatively straightforward to scale up. SFE uses supercritical CO₂ as the extraction medium — it leaves no solvent residue and is therefore attractive for natural products and food applications, but requires high-pressure equipment and a higher capital investment.

Author: Joost van Velzen, Managing Director Hecht Technology B.V.

Our products

• Columns and process towers

Beverage production bulk handling — definition: Specialised process technology for safe transport, storage and dosing of bulk liquids in the food and pharmaceutical industry, in accordance with GMP Annex 1, ATEX 2014/34/EU and USP standards. Includes containment measurement, hygiene management and flow optimisation.

Key points

• Containment measurement required up to OEB 3–5 level for liquid ingredients (max 10⁻⁶ absence of leakage)
• GMP Annex 1 (2022) compliance for pharma and food-quality applications
• HECHT product: LAS-EC (Liquid transfer system ATEX-certified containment)
• EHEDG & FDA requirements for food: 316L stainless steel, 3A dairy-grade tubing
• ROI: 40% reduction in waste, 25% faster cycle time through precision control

At our Test & Trial Centre in Pörnbach, liquid formulations can be tested under full GMP control. For more information about our liquid handling portfolio or food and beverage sector solutions.

FAQ — Beverage production and bulk handling

Which containment class is required for beverage production in pharmaceutical applications?

For pharma and food, containment classes OEB 3–4 are recommended, depending on the potency and toxicity of the ingredients used. HECHT supplies containment systems that comply with ATEX 2014/34/EU and GMP Annex 1 (2022), with leakage standards up to 10⁻⁶ absence of leakage.

How is leakage in liquid transfer measured and validated?

Leakage measurements are performed via isokinetic sampling, mass balance tests and visual inspection. USP chapter 1225 describes validation methods. HECHT offers integration with online sensors and real-time leakage monitoring via IoT systems.

What are the ATEX requirements for beverage production in countries with explosion risk?

ATEX 2014/34/EU requires grounding, spark-free materials and safe transfer speeds (<2 m/s for most gases) for alcoholic and carbonated beverages. HECHT systems are certified for ATEX categories 2–3.

How is hygiene ensured when switching between different beverage products on the same line?

Validated CIP (Cleaning-in-Place) cycles with documented time, temperature and concentration parameters per product changeover, supplemented with periodic microbiological verification (swab tests), ensure that no residual product or micro-organisms from the previous batch remain.

Author: Joost van Velzen, Managing Director Hecht Technology B.V. Verified: 02 07 2026.

Read also

• Powder transport in closed systems 7-step guide
• How to choose the right powder tester for your process
• How a diverter is used in powder processing systems
• Powder dosing weighing process control guide

Our products

• Big bag filling station BG
• Feeding screw

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

• Powder processing
• Pharma powder processing
• Industrial filtration

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.

Our products

• Jett mill

See also: cleaning and maintaining homogenisers

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

• ATEX & explosion safety
• OEB bands
• Industrial vacuum cleaners
• Containment systems
• Powder processing

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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Lifting systems determine whether your operators work safely and ergonomically with drums, big bags and containers, or whether you risk back and shoulder injuries, product loss and downtime. In pharmaceutical, chemical, food and battery production, staff lift loads every day that far exceed the ergonomic limit without assistance. This pillar shows how HECHT lifters automate powder and drum handling, which safety standards apply and how to combine ergonomics with containment.

Why lifting systems are indispensable

A drum of powder easily weighs 50 to 200 kg, a big bag 500 to 1000 kg. Tilting, lifting or emptying by hand is physically demanding and error-prone. Lifting systems take over that load, position the product accurately above a discharge point and prevent spillage. The result: less absenteeism, higher throughput and a reproducible process that does not depend on the physical strength of the operator.

Types of lifters for powder and drum handling

The right lifter depends on your load type, height and process step.

• Drum lifters: lift, tilt and empty drums in a controlled way above a mixer or hopper.
• Big bag lifters: hoist and position big bags for dust-free emptying, often with a discharge station.
• Container and IBC lifters: dock to IBCs for charging process installations at height.
• Mobile lift tables and column lifters: bring products to working height and bridge level differences in the line.
• Vacuum lifters: lift sacks and packages without mechanical clamping force, ideal for varying formats.

Ergonomics as a design principle

Ergonomics is not a side issue but a design requirement. Good lifting systems bring the discharge point to the correct working height, eliminate reaching and bending and let the operator steer with minimal force. Match the operating height, tilt angle and speed to the task. A lifter that follows ergonomic guidelines measurably lowers the risk of musculoskeletal complaints and keeps your people deployable longer.

Integration with containment and dust-free working

Lifting and containment belong together. For active or hazardous powders you couple the lifter to a dust-free discharge, for example via a liner, a docking station or a split butterfly valve. This prevents the lifting moment itself from causing dust emission. Combine the lifter with a closed transfer to secure operator protection and ergonomics in a single action.

Safety, ATEX and standards

Lifting systems fall under strict safety rules. In zones with explosive dust the lifter must be ATEX-compliant, with spark-free design and correct grounding. The Machinery Directive and requirements for safe loading, emergency stop and fall protection also apply.

• ATEX: spark-free, certified design for dust explosion hazard zones.
• Machinery Directive: CE conformity, risk assessment and safe operation.
• Load safety: validated maximum working load, overload protection and stable pick-up.
• GMP/EHEDG: hygienic design and cleanable surfaces for pharma and food.

Material and hygienic design

In pharma and food the hygienic design determines suitability. Choose stainless steel 316L, crevice-free welds and surfaces that comply with EHEDG and GMP. This prevents product build-up, eases cleaning and keeps cross-contamination out. For corrosive chemicals you select materials resistant to the specific medium.

Return on investment and total cost of ownership

For procurement, more counts than the purchase price. Factor in the saving on absenteeism, the higher throughput and the lower product loss from spillage. A lifting system that speeds up changeover and eliminates manual steps often pays for itself within a few years. Moreover, automating handling lowers the risk of costly process errors and recalls.

Frequently asked questions about lifting systems

What load can a drum lifter handle?

That depends on the configuration, but standard drum lifters handle drums up to around 200 kg; heavier configurations are available to specification.

Are lifting systems suitable for ATEX zones?

Yes, provided you choose an ATEX-certified, spark-free design with correct grounding for zones with explosive dust.

How do I combine lifting with dust-free working?

By coupling the lifter to a closed discharge via a liner, docking station or split butterfly valve, so the lifting moment causes no dust emission.

Do lifters comply with GMP and EHEDG?

HECHT lifters are available in stainless steel 316L with crevice-free, hygienic design that meets GMP and EHEDG for pharma and food.

What does a lifting system deliver?

Less absenteeism through ergonomics, higher throughput, less product loss and a reproducible process, lowering total cost of ownership.

Related guides

• Big bag handling
• Drum & barrel discharge
• Bulk material handling

Tailored advice from HECHT

Want to know which lifting system fits your load type, working height and containment requirements? HECHT engineers lifters that combine ergonomics, safety and dust-free working. Request a no-obligation consultation and receive a proposal tailored to your line.

Our products

• Lifting equipment
• Barrel lifting aid