Get a Grip on Granulation Processes
Wet or dry input. Large or small output. Rough targets or tight specs. Bepex handles it all. Transform powders, dust, or other fine feeds into granules of consistent size, shape, density, strength, and solubility.
Why choose Bepex?
From instant dispersion drink mixes to slow dispersing granules, we can produce the exact product you need. Bepex offers options for both wet and dry granulation and a broad line of equipment for both up- and downstream additional processing. Plus our Process Development Center works with you to build, test, and scale your total granulation system.
Our high pressure Roll Compactor dry presses powders, dust, or low density, highly-aerated fines into granules – either as a final product or to simplify transport, storage, or disposal. Starting with larger dry solids? Our Granulator hammer mill grinds dry solids to a consistent particle size, producing on-spec granules at high speeds.
In wet granulation, liquid binders are added to grow particles during mechanical agitation. Our Turbolizer provides nearly instantaneous agglomeration to produce fine, dust-free granules. The TurboFlex and FlexTurbolizer product line addresses a wide range of wet granulation needs and includes a self-cleaning feature to prevent material build-up. The Extrud-O-Mix extrudes powders into pastes, then cuts them to produce granules to exact size specifications.
Expert Engineering Advice
Granulation is a complex process, often requiring upstream grinding or downstream sizing, drying, curing, or coating equipment to complete production. With Bepex’s broad line of material transformation equipment, we can simulate the end-to-end granulation production process in our Process Development Center. We’ll work with you to design, test, quantify, and scale a complete granulation system to commercial production.
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Selecting the Right Thermal Processing Equipment
Most materials can be successfully treated using one or more of the thermal technologies commercially available today, such as direct, indirect, flash, and radiant drying.
Wet or Dry. Granulation Equipment, Experience, and Expertise.
Select a product to learn more
The Granulator is designed for precise granulation of dry solids, producing exact-sized, to-spec particles ranging in size from 4-100 mesh at high speeds. Its drop-through design requires little floor space and provides high-capacity milling capabilities in a small footprint.
The Extrud-O-Mix bridges the gap between mixing/blending and particle enlargement equipment. It uniformly mixes powders and liquids, producing pastes or consistent, free-flowing pellets or granules. The Extrud-O-Mix combines the mixer, kneader, and extruder into a single unit, simplifying process flow.
The FlexTurbulizer is specifically designed to handle cohesive, sticky materials that traditional mixers can’t. Its flexible, self-cleaning mixing chamber eliminates solids buildup that fouls traditional mixers. The result: less downtime, more consistently rounded particles, and superior granule quality.
The Roll Compactor dry presses fine powders or dust into larger granules, briquettes, pellets, or other specialized shapes. The Roll Compactor forms shapes without adding a liquid binder, eliminating the cost and complexity of additional downstream drying processes.
The TurboFlex is purpose-built for instant mixing. The self-cleaning, flexible mixing chamber prevents material build-up, making the TurboFlex ideal for hydrating difficult-to-wet powders; coating or surface-treating solids; or producing particles with rapid dispersion requirements.
The Turbulizer is built for near-instantaneous mixing or agglomeration of liquids and solids. Its high-speed rotor with adjustable paddles creates intense turbulence with short residence times to produce dust-free particles ranging in size from fine powders up to 2-3 mm.
All new inquiries begin with a feasibility study. These studies aim to provide preliminary insights into the viability of a commercial process. Using as little as 100 grams of material, we can begin early process design, develop plans for pilot-testing and/or confirmation, and begin providing early economic estimates. Our experience across our wide range of technologies gives us a unique ability to provide quick feedback on the feasibility of your process.
From our learnings, we’ll begin the process development work. The primary work in this phase takes place in the form of pilot-scale testing in our Process Development Center. Our pilot tests look a bit different than what you may have experienced in the past. Each test is designed to measure the system performance and feasibility rather than that of any single machine.
Each system is custom assembled for each test. Our goal is to provide as much of a pilot-scale simulation as possible while gathering scale-up data to deliver on commercial capacities. When a certain technology proves ineffective, we’ll draw from our range of options to determine if there is a better fit. The Process Development Center is our sandbox to build, test, and revise to ensure we get every detail right.
With a successful pilot simulation completed, we now have everything we need to scale up and provide proposals for capital equipment with included performance guarantees.
System Design And Build
After receipt of the purchase order, we begin with both equipment and system engineering. Each proprietary technology we sell is custom-designed and built per application. We do not have any off-the-shelf units. At this stage, your exact system begins to take shape, including auxiliary equipment, process flow diagrams, process and instrumentation diagrams, safety provisions, and more.
After delivery and installation of your new system, Bepex will provide a mechanical check to ensure everything is placed according to plan. This is followed shortly thereafter by system commissioning. This is where our pilot-scale simulations become invaluable, as our team of application engineers, controls technicians, and sales engineers begin working with your team to successfully bring your system online.
At this point, you’re up and running at rate, producing a quality product, but our work doesn’t stop there.
Following commissioning, Bepex remains a reliable partner, providing quality OEM parts, immediate field service, process optimization, training, system troubleshooting, and more. We have consistently had high customer retention rates, and we believe it is due in large part to our comprehensive approach to serving our customers long after the original sale.
Meeting Your Granulation Needs (Not Ours…)
Our broad portfolio of granulation technologies and supporting up- and downstream equipment means we can design a total system to exactly fit your needs. So you won’t be forced to fit your needs into a narrow product line due to lack of options. You deserve a total systems approach. Contact a Bepex processing expert to learn more.