Process Systems for Detergent Powders
Produce high-performance detergent powders with maximum efficiency, flexibility and quality. Hosokawa Micron’s advanced powder processing equipment supports every stage of detergent production—from agglomerating complex, multi-ingredient compounds to post-blending and final formulation. Our systems handle surfactants, bleaches, softeners, enzymes and fragrances with precision, ensuring optimal flowability, bulk density and dosing accuracy.
With growing demand for customised detergent formulations, manufacturers need cost-efficient, flexible systems to stay competitive. The energy-efficient Flexomix continuous agglomeration system delivers porous, free-flowing, dust-free granules with consistent quality—while using over 35% less energy than spray towers. Tested and proven in >100 plants worldwide, our solutions help detergent producers improve sustainability and scale performance.
Continuous Agglomeration Process
Detergents have to fulfil one main requirement: they have to clean things in water. To do this in a powder form, they need to undergo some form of drying. One of the most common methods of producing detergents is spray drying. In a spray drying process, the mixtures start out as liquids, before a drying process takes place.
With the Flexomix continuous agglomeration process, the initial mixing starts with dry media, saving energy and costs. Next, aqueous and fatty solutions can be added to the premix. A small dose of water/binder solutions is used to form wet agglomerates which are then collected in a fluid bed dryer.
This over-wet mixture is dried off, resulting in free-flowing, dust-free agglomerates. These agglomerates can be compounds needed for the complete detergent formulation or the final product. If it is a compound, the remainder of the detergent formulation can be mixed afterwards.
Flexomix Compared to Spray Towers
By mixing in the powdery phase, the Flexomix has to dry off less water, thus requiring considerably less energy. In an independent study by the Ontario Ministry of Energy, a 4 t/hr detergent Schugi® Flexomix manufacturing line was compared to a spray drying process with the same capacity. It showed an energy saving by the Flexomix of 42.5%. The purchasing investment for the Flexomix was also approximately 20% less than traditional spray dryers, making it a more cost-effective and environmentally-friendlier solution.
Key Benefits
Over the years, Flexomix technology has proven itself for the production of detergent powders. The large number of Flexomix detergent powder production plants around the world speaks for itself. The advantages of the Flexomix technology include:
✅ 100% Non-Tower Detergent (NTD)
✅ Produces porous, dust-free agglomerates
✅ Bulk density 300-1000 g/l
✅ Cost-effective (both CAPEX and OPEX)
✅ Suitable for a wide range of formulations / ingredients
✅ Uses over 35% less energy, compared to spray tower
✅ Proven in 100+ plants worldwide
Test Before You Invest
Run trials with your own materials on production-scale equipment at our 2,000 m² Test & Process Development Centre in the Netherlands. Our experienced process specialists work with you to determine the optimal process, equipment or plant setup. We offer lab and production-scale trials, each supported by a detailed technical report covering setup, process parameters and performance insights—helping you choose the best solution with confidence.
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Talk to our experts
Find out how Flexomix can support your detergent production. Boost efficiency, reduce energy use and create consistent, dust-free powders with proven non-tower technology.
Sustainable process technologies
Hosokawa Micron B.V. is committed to sustainable and responsible process technology. Our ISO 14001 certification covers key environmental aspects such as air, soil, energy, waste, water, noise and hazardous substances. With an EcoVadis Silver Medal, we rank among the top 3% of EcoVadis-rated companies in the special machinery industry.
