We not only provide powder processing trials for spray drying, spray cooling, and freeze granulation, but also services that include pre- and post-powder processing, such as wet pulverizing, mixing, molding, sintering and freeze-drying. We operate a total of three locations: two Powder Technical Centers in Japan and ASEAN Powder Technical Center in Thailand under the partnership with T.S.K. Engineering Co., Ltd.. Our brand new Powder Technical Center 2 (PTC2), which was newly established in 2023, has one of the largest collections of analytical measurement equipment in Japan. We provide one-stop support for powder processing and analytical measurements.
特徴
- Consistent support from R&D to mass production
- One-stop service from powder processing to analytical measurements
- The latest facilities are available without initial investment and maintenance costs
- Time saving by outsourcing operations and analysis
- Obtain new awareness and insights through collaboration with specialized engineers
Services
Usage example of analytical measurements
The followings are usage examples of analytical measurements for powder characterization obtained by spray drying, spray cooling, and freeze granulation.
The particle size and shape of granules are analyzed using multiple image analyzers and a laser diffraction analyzer. The image analyzers can perform shape analysis such as particle size distribution and circularity, as well as brightness analysis of each individual particle. An online real-time laser diffraction PSD analyzer is also available to perform continuous particle size distribution analysis. SEM analysis is also conducted to observe the surface of particles.
Powder characteristics analyzer and powder rheometer are used to analyze powder fluidity and flowability. In addition to the traditional methods of evaluating fluidity, such as angle of repose, bulk density and Carr’s fluidity index, dynamic analysis is also available to measure the actual behavior of powders in a dynamic environment. Dynamic rheometer can also analyze the disintegration properties due to frictions among flowing particles, making it possible to evaluate filling and handling properties of powders.
Analysis of specific surface area and density of particles is also important. We measure a specific surface area and pore distribution by constant volume method using gas adsorption. We also analyze true density and particle density by gas displacement method. Micro-particle crushing force measurement is also available to evaluate a particle strength by physically crushing a single particle.
The physical properties of a liquid material are also evaluated for parameters that affect the latter process: powder processing. In the case of slurries or suspensions, the particle size distribution is measured using laser diffraction analysis. By circulating a liquid material and continuously measuring the particle size distribution, it is also possible to evaluate changes in cohesion, disintegration and re-dispersibility. We also perform rheology analysis using a wet rheometer for dynamic flow behavior such as viscoelasticity, shear stress, cohesive/dispersion stability, thixotropy and dilatancy properties, and yield point.
Facilities
Spray dryers
Spray dryer
SB39: 4 units
Chamber diameter: φ387mm
Atomization system: Two-fluid nozzles
Water evaporation vol.: Up to 3kg/h
Note: Closed-cycle system available
TR160: 1 unit
Chamber diameter: φ1600mm
Atomization system: All systems available
Water evaporation vol.: Up to 15kg/h
Note: Closed-cycle system available
P260: 2 units
Chamber diameter: φ2600mm
Atomization system: All systems available
Water evaporation vol.: Up to 30kg/h
D350: 1 unit
Chamber diameter: φ3500mm
Atomization system: All systems available
Water evaporation vol.: Up to 50kg/h
SB39: 1 unit
Chamber diameter: φ387mm
Atomization system: Two-fluid nozzles
Water evaporation vol.: Up to 3kg/h
Note: PTC ASEAN (Thailand)
TR80: 1 unit
Chamber diameter: φ800mm
Atomization system: Rotary atomizers, Two-fluid nozzles
Water evaporation vol.: Up to 3kg/h
Note: PTC ASEAN (Thailand)
Spray coolers
Spray cooling processing is available using the above spray dryers.
Freeze granulators
LS-6: 1 unit
Container diameter: φ120mm
Atomization system: Two-fluid nozzles
Material feed capacity: Up to 6kg/h
Cooling temperature: −196℃
Cooling system: Wet cooling system
CS-30: 1 unit
Chamber diameter: φ300mm
Atomization system: Two-fluid nozzles
Material feed capacity: Up to 15kg/h
Cooling temperature: −10 ～ −120℃
Cooling system: Dry cooling system
CS-220: 1 unit
Chamber diameter: φ2200mm
Atomization system: All systems available
Material feed capacity: Up to 320kg/h
Cooling temperature: −10 ～ −50℃
Cooling system: Dry cooling system
Freeze dryers
FDU-2110: 1 unit
Tray volume: 700ml × 6 stages
Cold trap capacity: 3kg
Cold trap temperature: −80℃
FD-551: 1 unit
Tray volume: 8000ml × 3 stages
Cold trap capacity: 10kg
Cold trap temperature: −45℃
TFD-10: 1 unit
Chamber volume: 85L
Cold trap capacity: 10kg
Cold trap temperature: −40℃
RHEOFREED: 1 unit
Chamber volume: 160L
Cold trap capacity: 30kg
Cold trap temperature: −45℃
Liquid processing & Wet grinding
POT MILL: 4 units
Note: Various capacities available
BALL MILL (50L): 2 units
Container capacity: 50L
Material contact part: Nylon
Ball: Zirconia φ10mm
BALL MILL (100L): 2 units
Container capacity: 100L
Material contact part: Nylon
Ball: Zirconia φ10mm
BEAD MILL: 1 unit
Model: RMH-08
Vessel capacity: 0.95L
Material contact part: Zirconia
Beads: Zirconia φ0.5mm or 1.0mm
Molding & Sintering
UNIAXIAL MOLDING MACHINE: 1 unit
Model: SMT-200AF
Pressure capacity: max. 200kN
Note: CIP container available
MUFFLE FURNACE: 1 unit
Model: FP103
Temperature range: 100 – 1150℃
Inner dimensions: 100 x 150 x 100mm
Note: Nitrogen available
HORIZONTAL TUBULAR FURNACE: 1 unit
Model: HF1800
Temperature range: 300 to 1800℃ (normal use 1700℃)
Chamber: Al2O3 tube φ60mm
Note: Vacuum and nitrogen available
Analytical measurements
PSD ANALYZER: 1 unit
Model: Morphologi G3
Measurement items: Particle size, shape, PSD, etc.
Note: Image-based analysis
PSD ANALYZER: 1 unit
Model: Morphologi 4
Measurement items: Particle size, shape, PSD, etc.
Note: Image-based analysis
PSD ANALYZER: 1 unit
Model: Mastersizer 3000
Measurement items: Particle size, PSD
Note: Laser diffraction
REAL-TIME PSD ANALYZER: 1 unit
Model: Insitec
Measurement items: Particle size, PSD
Note: Laser diffraction
SEM: 1 unit
Model: JCM-6000Plus
Measurement items: Shape, structure, surface, etc.
CHARACTERISTICS TESTER: 1 unit
Model: PT-X
Measurement items: Angle, compaction, bulk density, etc.
POWDER RHEOMETER: 1 unit
Model: FT4
Measurement items: Stability, compressibility, bulk density, etc.
SURFACE AREA ANALYZER: 1 unit
Model: TriStar II Plus3030
Measurement items: Specific surface area, pore distribution
DENSITY ANALYZER: 1 unit
Model: Accupic II
Measurement item: Density
Note: Gas replacement method
CRUSHING FORCE ANALYZER: 1 unit
Model: NS-A200
Measurement item: Particle crushing force
WET RHEOMETER: 1 unit
Model: MCR302e
Measurement items: Dynamic flow properties
VISCOMETER: 1 unit
Model: DVE
Measurement item: Viscosity
MOISTURE ANALYZER: 1 unit
Model: MKV-710S
Measurement item: Moisture content
UNIVERSAL TESTER: 1 unit
Model: AGS-10kN
Measurement items: Tension, compression
How to apply
1. Contact
Please contact us via the contact form or by phone.
2. Initial Q&A session
We will discuss the outline of your plan by phone, email, face-to-face, online, etc. We will also provide information about our Powder Technical Center and inform you possible facilities to be selected and time slots available. Depending on the facility selected, reservations may be booked for several months, so we ask you to schedule your appointment early.
3. Submission of Trial/Contract Processing/Analytical Measurement Confirmation Sheet
Please fill out and submit the Trial/Contract Processing/Analytical Measurement Confirmation Sheet. You can skip items that are unclear or non-disclosure information. *We ask for detailed disclosure regarding the safety and environmental information.
4. Submit a quotation
We will submit you a quotation based on the Trial/Contract Processing/Analytical Measurement Confirmation Sheet.
5. Schedule adjustment
The trial date will be fixed after we receive your formal request.
6. Shipping your material
Ship your material by the day before the trial date. If you visit our PTC and observe your trial on the day, you may bring your material with you.
7. Conducting your trial
If you observe your trial on the day, we will conduct the trial while discussing operating conditions with you. Even if you are not present, we can adjust the conditions while reporting the progress over the phone.
8. Submission of Trial/Contract Processing/Analytical Measurement Report
A report will be submitted within one week from the trial date.
FAQ
Q. Is it possible to test a small amount?
A. By using a small facility, it is possible to test from approx. 1L at a time.
Q. What kinds of materials do you accept for trials?
A. We generally handle a wide variety of applications. However, we may not be able to accept some materials due to safety and/or environmental aspects.
Q. Is it possible to request a trial without disclosing the material information?
A. Regarding safety and environmental aspects, we must ask you to present the detail information including SDS, etc. and we will evaluate whether or not we are able to conduct the trial. We may also enter into a confidentiality agreement with you.
Q. Is it possible to witness a trial?
A. Yes, we always welcome you at our PTC.
Q. Is it possible to request only powder analysis/measurements?
A. Yes, we are pleased to support for your analytical measurements.
Q. How are costs estimated?
A. Powder processing trial costs are estimated on a daily basis, including the cleaning process of the facility. It is also possible to conduct the trial on multiple consecutive days. Analytical measurements are estimated based on a sample quantity basis. A liquid material preparation, wet pulverizing, freeze drying, molding and sintering are estimated in working-hour basis.
Q. Can you inform about the reservation status?
A. We can notify you of the latest reservation status by phone or email. We usually take reservations 1 to 3 months in advance. You can also make a reservation on the waiting list.
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