The Bextruder produces cylindrical granules with diameters typically ranging from 0.3 to 3 mm, depending on the chosen die and process settings.
Menu
AGGLOMERATION
Process technologies for tomorrow.
Bextruder
Extruder & Granulator
The Hosokawa Bextruder is a low-pressure basket extruder and granulator, designed to produce cylindrical pellets with a porous structure, large surface area and excellent dispersibility. It applies gentle compaction that preserves the product’s integrity while ensuring free-flowing behaviour, rapid dissolution and reliable handling. This makes the Bextruder ideal for producing powdered beverages, soups and sauces, crop protection agents and detergents.
Key Benefits
- Gentle product densification
- Produces porous, free-flowing and uniform cylindrical granules with diameters from 0.3 to 3 mm
- Gentle shaping with minimal heat and pressure — ideal for sensitive products
- Low energy consumption: typically 2–5 kWh/ton
- Flexible configuration and compact footprint
- Quick cleaning, rotor exchange and screen replacement
- Compatible with the Hosokawa Flexomix for extrusion-agglomeration
- Designed for hygienic processing and easy automation
Principle of Operation
The Bextruder combines a conical feed section with a cylindrical processing chamber. Inside, two counter-rotating rotors handle both mixing and extrusion. The upper rotor, equipped with inclined paddles, homogenises the feed and conveys it evenly downwards. The lower extrusion rotor, fitted with curved arms, gradually compresses the product and presses it outward against the cylindrical screen basket, which is a perforated die.
As the product moves outward, the available volume between rotor and die decreases, causing gentle densification. Final shaping occurs as the material is extruded through precision-drilled press channels in the die, producing uniform cylindrical pellets with controlled deformation, high porosity and excellent dispersibility in water.
This approach emphasises shaping rather than strong compaction, which keeps granules porous and dispersible. As a result, the Bextruder is particularly suitable for heat- or shear-sensitive formulations where solubility, flowability and reconstitution are critical.
Process Flexibility
The Bextruder offers exceptional versatility:
- Independent rotor speed control for precise process tuning
- Flexible drive configuration — mounted above or below the chamber
- Multiple discharge options including direct fall-through, vibrating chute or rotating disc
- Easy access to contact parts for fast cleaning, rotor exchange, and die replacement
This makes the system equally suitable for short runs, frequent product changes or large-scale continuous operation.
Models & Capacities
| Model | [–] | ABX 150 | ABX 300 | ABX 450 | ABX 600 |
|---|---|---|---|---|---|
| Drive | [kW] | 3 | 8 | 11 | 17 |
| Throughput | [kg/h] | 1 – 300 | 200 – 800 | 400 – 1,600 | 800 – 3,200 |
Available accessories include different rotors, screen baskets with various hole diameters and wall thicknesses, outside rotating cutting knives, vibration discharge chutes, rotation discs for product discharge and blow-off rings for cooling and separation.
Integration with Flexomix
For enhanced performance, the Bextruder can be combined with the Hosokawa Flexomix, a high-intensity continuous mixer. The Flexomix introduces liquid binder into a powder stream, producing a homogeneously wetted, aerated material that extrudes easily. This setup reduces energy use by up to 50% compared to spray drying, increases extrusion throughput by up to 35% and significantly improves granule dispersibility.
The Bextruder can also be integrated downstream with fluid bed drying, cooling or coating systems.
More about the Flexomix
Test Before You Invest
Before investing in new equipment, test your materials under real process conditions at our Test & Process Development Centre in the Netherlands. Our experienced specialists help you determine the most efficient mixing, agglomeration or drying process, from laboratory trials to full-scale production testing.
Whether you want to evaluate a single machine or a complete processing line, we provide tailored testing and process optimisation to ensure reliable scale-up and proven performance.
Learn more
Talk to our experts
Looking for a reliable solution for powder agglomeration and extrusion? Speak to our specialists and explore how the Hosokawa Bextruder can optimise your process — from pilot testing to full-scale production.
Applications
The Bextruder Extruder & Granulator is ideal for a wide range of products. Here are a few examples:
FAQ – Hosokawa Bextruder
What granule sizes can be produced with the Bextruder?
Can the Bextruder handle heat-sensitive or sticky powders?
Yes. Its low-pressure, low-heat extrusion makes it suitable for shear- and temperature-sensitive materials. Even sticky powders can be processed, often with a small addition of water or binder.
What scale-up options are available?
The Bextruder is available in different sizes, from pilot plant units for R&D to full-scale industrial systems. This ensures a smooth transition from development to production.
How quickly can the Bextruder be cleaned or changed over between products?
Rotors and screen baskets are designed for quick release and easy access. Cleaning and product changeover can be completed in a short time, reducing downtime in multi-product plants.
What impact does the Bextruder have on operational efficiency?
With its low energy demand (2–5 kWh/ton), fast cleaning and reliable granule quality, the Bextruder helps reduce production costs and increase throughput consistency.
Can the Bextruder be integrated into a complete processing line?
Yes. It can be configured as a stand-alone granulator or as part of an extrusion-agglomeration line with upstream mixing (Flexomix) and downstream drying, cooling, or packaging systems.
How does the Bextruder compare to spray drying for water-dispersible granules (WDG)?
Spray drying requires creating a slurry, while the Bextruder (with Flexomix) processes powders directly with less liquid. This reduces energy use by up to 50% and produces stronger, yet easily dispersible granules.
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.
