The Flexomix is a continuous, high-shear agglomeration mixer that injects atomised liquid binder into a highly aerated powder stream. Its short residence time and intensive, toroidal mixing create uniform, porous agglomerates with controlled moisture. This yields free-flowing, dust-reduced granules and consistent bulk properties—ideal for downstream fluid bed drying/cooling.
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AGGLOMERATION
System for Powders & Bulk Solids
Flexomix
Powder Agglomeration System
The Flexomix is a compact, continuous high-shear mixer/agglomerator for mixing powders with liquids to form uniform, porous granules. Also known as wet granulation or particle size enlargement, the process boosts solubility, flowability, wettability/dispersibility, bulk density and appearance, converting fine powders into free-flowing, dust-reduced granules with stable handling properties.
The system produces raspberry-shaped, open-pore agglomerates with excellent reconstitution. Used widely in food & beverages, detergents, chemicals, minerals and feed, the Flexomix offers a scalable, low-maintenance route for agglomeration, absorption, instantising and micro-encapsulation.
Key Benefits
- Continuous, high-throughput operation (100–40,000 kg/h)
- Dust-reduced, free-flowing agglomerates; improved wetting, solubility and dispersibility
- Controlled PSD, porosity and bulk density
- Self-cleaning design
- Low manpower requirements
- Maintenance-friendly
- Robust, scalable solution from pilot to full production
- Energy-efficient: typically ~35% less energy than a spray tower
Principle of Operation
The Flexomix agglomeration system is a powerful combination of two proven Hosokawa technologies: the Flexomix continuous mixer / agglomerator and the Schugi fluid bed dryer and cooler. This combined design provides optimal process control and makes it the ultimate powder processing solution.
With this system, porous agglomerates can be made in a range of from 100 to 1,500 microns with a typical D50 value between 200 and 700 microns. This technology is also often referred to as Instant Agglomeration, since the Flexomix is extensively used for the production of instantly soluble agglomerates for food, chemical and pharmaceutical applications.
Base powders can be fed as a mixture or as multiple powders in parallel. An accurate, gravimetrical powder feeding subsystem ensures a constant powder/liquid ratio and a liquid dosing skid ensures accurate flow control and a constant powder/liquid ratio in the agglomerator. The liquid skid can be equipped with a stirrer or a heated tank for example, or in the case of solution binders, a preparation tank.
Flexomix Mixer / Agglomerator
At the heart of the Hosokawa continuous agglomeration technology is the unique Flexomix agglomerator. The Flexomix is widely used for agglomeration processes because of its reliability, simplicity, compact design and maximum process flexibility to produce the agglomerates required.
The Flexomix allows for homogeneous mixing of powders and liquids. To achieve this, the Flexomix has a flexible mixing chamber and a shaft with pitch-adjustable mixing blades that rotate at high speed.
Powders and liquids can be fed into the unit through top inlet(s) using air atomisers which combine with turbulent air flow inside the mixer's vertical chamber, mixes powdery and liquid particles intensively and instantaneously.
Schugi Fluid Bed Dryer
Within less than a second, wet agglomerates are formed, which fall under the influence of gravity into the static fluid bed dryer below. Here, the agglomerates are dried, cooled and conveyed to the product classifying section for preparation of the final product.
After classification the product is split into on-size, over-size and (if needed) fines material. Over-size material can be crushed and fines can be reprocessed if applicable. On-size agglomerates can be stored in big bags or transported to a final packaging line. This whole process takes place in continuous mode.
The performance and functionality of the fluid bed in combination with the air treatment section is an important part of the agglomeration process as this can have a direct impact on the level of agglomeration and product quality.
Models & Capacities
The Flexomix mixer/agglomerator is available in six sizes. Their typical characteristics are described below. Please note that these values are indicative only. Detailed information is available on request.
| Model | [-] | FXD-100 | FXD-160 | FXD-220 | FXD-250 | FXD-335 | FXD-400 |
|---|---|---|---|---|---|---|---|
| Length | [mm] | 520 | 702 | 976 | 976 | 1,270 | 1,270 |
| Width | [mm] | 650 | 620 | 880 | 880 | 1,100 | 1,100 |
| Height incl. motor | [mm] | 1,265 | 1,500 | 1,967 | 1,967 | 2,270 | 2,910 |
| Capacity (bulk density 0.5 kg/l) | [kg/h] | 100 – 400 | 250 – 1,000 | 800 – 2,500 | 2,000 – 4,000 | 3,000 – 10,000 | 8,000 – 40,000 |
| Typical motor power | [kW] | 3 | 7.5 | 7.5 – 10 | 11 – 15 | 22 – 45 | 37 – 75 |
Schugi fluid bed dryers/coolers are available in sizes (air distribution plate area) ranging from 0.25 m² to > 20 m². The required size of the dryer/cooler is generally determined in our Test Centre and depends on product throughput, evaporation capacity, particle size distribution, air temperatures and final product temperature.
Controls & Process Automation
Hosokawa Micron's systems include optimally integrated hardware and software controls to ensure consistently high product quality under varying circumstances. We can provide ergonomic and visual HMI-PLC panels including lot traceability, operator identification, remote service, alerts and customised data reports to give you full insight into your production processes.
By integrating processing machinery with an efficient control system infrastructure, Hosokawa Micron maximises value by reducing downtime and costs through analysis, reporting, and notification mechanisms.
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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 to optimise your powder agglomeration process? Our process specialists are here to help you craft the optimal solution for your materials, processing requirements and performance objectives.
Applications
The Flexomix Powder Agglomeration System is ideal for a wide range of products. Here are a few examples:
FAQ – Flexomix Powder Agglomeration System
What is the Flexomix powder agglomeration system and how does it work?
Which products and industries is the Flexomix suited for?
The Flexomix handles a wide range of powders in food and beverages, detergents, agrochemicals (e.g., WDG), minerals, chemicals, catalysts, ceramics and plastics. Typical outputs include instant drink powders, soup bases, milk derivatives, enzyme blends, bleach granules and fertiliser pre-granulates, delivering better flowability, dispersibility and reconstitution while reducing dust and segregation.
What agglomerate size and properties can the Flexomix achieve?
Depending on binder rate, atomisation, air flow and rotor speed, the Flexomix can target agglomerate sizes from ~100 μm up to several millimetres with narrow particle-size distributions. The process emphasises open porosity and capillarity, improving wetting, sinkability and dispersibility. Bulk density and strength can be tuned for packaging, conveying and downstream finishing.
What binders and moisture ranges are typical in Flexomix agglomeration?
Common binders include water, sugar or polymer solutions, surfactants and melts. Moisture uptake is recipe-dependent, typically adjusted to form plastic, porous agglomerates without over-wetting. Operators control binder flow, temperature, atomising pressure and residence time to meet target PSD, porosity and bulk density, enabling predictable scale-up and repeatability.
How does the Flexomix compare to spray drying?
Unlike spray drying, the Flexomix processes powders directly with less liquid addition, so less water needs evaporating later. This often yields lower energy use, higher solids throughput and strong yet highly dispersible agglomerates. Research has shown that the Flexomix powder agglomeration system uses about 35% less energy, compared with a spray tower!
Can the Flexomix be integrated into existing process lines?
Yes. The Flexomix commonly feeds fluid bed dryers/coolers for moisture removal and thermal conditioning. It also integrates upstream with loss-in-weight feeders and liquid dosing skids, and downstream with screening, conditioning or extrusion (e.g., Bextruder/Extrudomix). Fully automated control ensures stable PSD, bulk density and moisture across long runs.
What about cleaning, hygiene and safety (ATEX)?
Flexomix is available with hygienic designs, easy-access internals and CIP options for rapid changeovers. Product-contact parts are engineered for cleanability and uptime. Systems can be supplied ATEX-compliant, with suitable inerting, earthing and dust control. Application-specific materials and surface finishes support food, detergent and chemical standards.
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.
