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Process Systems & Pilot Plants

EPIC Powder Liquid Mixing Systems

The Best Way to Mix Powder and Liquid

Creating a truly blended substance can be difficult without the right process engineering company. Viscosities, production output and many other factors must be considered from the very beginning of your project. EPIC’s engineers will augment your staff by partnering with you to address these factors and make sure that you end up with a homogenous blend that can scale up to your production needs. EPIC takes a turnkey approach to engineering, designing and fabricating powder-liquid mixing systems that incorporate powders and liquids into truly homogeneous mixtures.

An Apeel engineer conducts FAT on new powder liquid blending systems

Our process engineers have 20+ years of experience engineering turnkey powder-liquid mixing systems for products ranging from agrochemicals to powder-based food mix-ins. We serve a wide array of industries including:

  • Specialty Chemicals
  • Consumer Products
  • Food & Beverage
  • Pharmaceuticals
  • And more

Ready to talk to an EPIC engineer about your chemical skid fabrication project? Call 314-714-1580 or submit a form.

Powder Liquid Mixing System Examples

Powder Blending System Brings New Detergent to Market

EPIC designed a skid for a Fortune 500 company that allows a powdered ingredient raw material to be added to the blending system and clearly separate the new detergent process from the liquids mixing operations within the manufacturing plant.

Key Features: Raw materials pre-mix skid, full blending system, and process/packaging integration, Condensed two-month timeline from first purchase order to completed commissioning, Wonderware HMI and ControlLogix PLC integration

Read Case Study

Liquid Blending Systems for Edible Powder Mix

An EPIC craftsman installs an Apeel liquid blending skid at a food production facility.

EPIC designed and fabricated a series of liquid blending systems for a biotechnology company that are used to constitute the proprietary edible powder to be applied to produce.  The product is an organic, edible protective coating that slows the aging process of produce.

Key Features: 50-80 Gallon tank capacity, Dual-tank design, On-Demand Inline water heaters, Intuitive operator interface, Food-grade stainless steel sanitary materials of construction, Compact footprint, highly mobile

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Batch Reactor System Automates Powder Additions

EPIC duplicated and added automation to the polymer making process to make various sized batches of polymers. The system included manual, vacuum assisted powder additions and automated mixing, batch reacting, and manual storage in 55-gallon drums.

Key Feature: Batch polymer reactor system, Dual reactors on a single skid design, Raw materials handling & ingredient additions, Hazardous material handling

Read Case Study

Get Pricing for a Powder Liquid Mixing System

To get pricing information or discuss your powder-liquid mixing needs with an engineer, call 314-714-1580 or fill out the form below.

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Powder Liquid Mixing System Services

EPIC specializes in delivering turnkey liquid-powder mixing systems. Our services include:

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    Concept Development

    You bring the process technology; we help design your system

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    Front End Loading (FEL)

    Get a fixed bid quote and preliminary system design

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    Powder-Liquid Mixing System Design

    Detailed design of your powder liquid mixing system with 3D modeling and simulation

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    Automation & Controls Engineering

    In-house controls developed by EPIC’s automation engineers

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    In-House Fabrication & Assembly

    Production-style fabrication in controlled shop conditions

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    Process System Installation

    Our unique approach helps you avoid production downtime and gets you to startup faster

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    Startup & Commissioning

    We remain onsite during full startup, punch list resolution, and operator training

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    Parts & Customer Service

    Contact EPIC anytime to keep your powder liquid mixing system running smoothly

How to Mix Powder into Liquid

Which type of powder-liquid mixing system is most suitable for your mixing process? At EPIC, we use our in-plant experience to recommend a powder-liquid mixing solution that is right for you based on conversations with you throughout the front end loading process. There are two primary ways to mix powder with liquid.

Continuous Powder Liquid Mixing

Continuous powder-liquid mixing generates a continuous stream your final product. So rather than mixing one batch of liquid with one batch of solid, powder, or liquid, you have a continuous flow of components going into the system and a continuous stream of homogeneous mixture coming out the other end. These mixers may still use different mixing stages to ensure that you get a smooth, incorporated product.

Continuous liquid mixing systems can be helpful in situations where you need a completely identical product every time. The textile industry may use this technology to ensure that dye lots stay the same, and the food processing industry can use it to make sure they have evenly hydrated dough. In addition to improving product consistency, it can also up production since it enables you to produce more from one mixer.

Batch Powder Liquid Mixing

Batch liquid mixing systems, on the other hand, mix only one batch of your product at a time. Think of this like the process you use to make cookies in your home. All of the ingredients are carefully measured out and then they’re added to the mixer at the appropriate times in the process to make one batch of your product.

Batch liquid mixing systems can be very important for industries that are creating multiple different products. The paint and fragrance industries, for example, need to be able to produce different batches of different products. And with proper measuring practices, batch mixing can produce results nearly as uniform as continuous mixing.

Batch VS Continuous Mixing Comparison

There are tradeoffs to both batch and continuous mixing systems. Use the resource below to help inform which system type is right for your process or call 314-714-1580 for guidance from our process engineers.


Batch Mixing

Continuous Mixing

Equipment RequirementsLarger tanks are required for batch, and often finished product storage tanks are required for product variationsBest Choice
SpaceBatching systems tend to have larger equipment (tanks) and can often take up more space than continuous mixing systemsBest Choice
Reaction involvedBest choiceInline blending systems move quickly and do not have time to handle a reaction unless you use a special type of system called a CSTR – Continuous Stirred-Tank Reactor
Insoluble ingredientsBest ChoiceInsolubles need more time to mix than a typical continuous mixing application allows
Flammable ingredientsBest ChoiceHighly flammable or a large number of flammables are *usually* too volatile for an inline mixing system
Large ingredient viscosity rangeBest ChoiceInline blending does not usually allow for enough time for ingredients of very vastly different viscosities to come together
Short blending timesYou should consider continuous mixing applications for this if there are no other major inhibitors like flammables or dry ingredients. Continuous systems might allow greater flexibility for lower costsGood Fit
Dry ingredientsBest ChoiceIn general, dry ingredients are harder to move through the piping and instrumentation that continuous inline systems rely on. Batch systems with solid solid mixing equipment is a better choice
High Mixing Energy RequirementsBest choiceA large amount of mixing energy is expensive or impossible to cram into the short mixing times typical of inline mixing systems
Large number of SKU’sRequires holding tanks to store multiple variations of product instead of allowing for a quick rinse-out and recipe change like continuous mixing systems.Best Choice
Accurate Ingredient AdditionsBatch mix skids are designed to mix for appropriate time intervals that ensure accurate mixing.Most continuous mixing systems can achieve accuracy within 1% deviation of the prescribed formulation. Continuous inline blending systems that are constantly running often achieve deviation rates that are less than a 1% average.
CostTypical batch applications require more material mixing equipment and storage the more recipe variations you want to run, so the costs can increase quickly compared to inline blending systems that offer flexible SKU’s with less capital investment and minimal storage requirements.Best choice

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EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US

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