Processing Systems for Instant Foods
Manufacturers of instant food products – such as instant soups, sauces, gravies, cocoa, beverage mixes and meal replacements – face specific challenges in powder processing. These products require powders that dissolve instantly without clumping, flow easily through processing and packaging lines, and deliver consistent quality in every batch. Hosokawa Micron offers integrated solutions that meet these demands with efficiency, hygiene and precision.
At the heart of our offering is the Flexomix continuous agglomeration system, which transforms fine powders into granules with excellent solubility, flowability and bulk density. This innovative solution reduces dust, enhances product performance and improves process stability. Combined with complementary equipment such as a fluid bed dryer, sieves and dedusting systems, the Flexomix forms the core of a complete, compact agglomeration line for instant food powders.
Instant Benefits Through Agglomeration
Agglomeration is the process of binding fine particles into larger, uniformly shaped granules. For instant food powders, this transformation offers key advantages: granules disperse instantly in liquids without clumping and generate significantly less dust during handling. These improvements lead to faster, cleaner processing with fewer interruptions and greater operator safety. The resulting powders have stable bulk density, supporting reliable dosing in vending machines, sachets or jars, and maintaining consistent quality throughout the production chain.
By producing a homogeneous product, agglomeration also prevents ingredient segregation after mixing, ensuring every portion contains the correct ratio of nutrients or flavour components. Whether used in instant soups, gravies or nutritional drinks, agglomerated powders fill packaging units with accurate, repeatable volumes—optimizing shelf appeal and product performance.
Introducing the Hosokawa Flexomix
The Flexomix is a continuous vertical mixer and agglomerator, designed to produce free-flowing, raspberry-shaped granules with excellent instant properties. Powders and liquids are fed with precision dosing, then intensely mixed in a chamber with flexible walls that prevent build-up and ensure consistent, hygienic operation. The entire mixing cycle takes less than one second, enabling high-speed processing with low energy use.
Available in capacities from 50 to over 25,000 kg/h, the Flexomix is typically combined with a Schugi® fluid bed dryer for drying and cooling, followed by sieving, dedusting and product recovery. The modular setup enables fast recipe changes, quick cleaning and optional CIP, with smooth, easy-to-clean surfaces throughout.
Agglomerated gravy powder, produced with the Hosokawa Flexomix
Driving Innovation in Instant Food Processing
Through innovative technologies like the Flexomix agglomeration system, Hosokawa Micron enables manufacturers to meet growing consumer demand for instant products with high solubility, low dust and consistent bulk density. Our commitment to performance, hygiene and efficiency helps optimise your production while delivering high-quality, value-added powders. Discover the possibilities of customised powder processing with Hosokawa Micron.
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
Ready to take your instant food powders to the next level? Contact Hosokawa Micron to discover how our agglomeration technology can improve product quality, process stability and operational efficiency.
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.
