Manual powder handling processes, such as scooping, pouring, and weighing, have been integral to the food and beverage industry for decades. Efficient powder processing ensures product quality, safety, and profitability. However, many manufacturers face various challenges when handling powders and bulk solids. This guide by Hosokawa will explore the food and beverage industry’s top five powder processing challenges and potential solutions.
Challenge 1: Flow Issues and Material Buildup
Among the most persistent challenges in powder processing is inconsistent material flow. Almond flour, pancake mix and brown sugar are products notorious for clinging onto surfaces, which can cause many problems like:
- Reduced efficiency as material gets stuck in equipment
- Increased cleaning and maintenance time
- Potential for product waste and loss of valuable ingredients
Potential Solution for Flow Issues and Material Buildup
Advanced mixing technologies can help manage sticky and difficult-to-flow materials. For instance, rotor-stator mixers create intense shear to disperse or emulsify ingredients, and inline high-shear mixers are a mixing system for fast emulsification and homogenisation. These mixers’ designs ensure uniform blending and prevent material buildup.
Challenge 2: Dust Control and Workplace Safety
Dust control is crucial for health and safety, product quality, hygiene standards, and compliance with strict regulations (like HACCP, FDA, or BRCGS). Dust can cause a plethora of potential risks for the product and workers’ health, such as:
- Respiratory hazards for workers exposed to airborne particles
- Risk of dust explosions in specific environments
- Cross-contamination between different products
- Difficulty in maintaining a clean processing environment
Potential Solutions for Dust Control and Workplace Safety
Dust control systems can minimise these risks to the product and workers’ health. Examples include Dust Extraction (LEV) Systems that capture dust (silos, mixers and conveyors) at the source, Baghouse Filters that use food-grade fabric filters to trap dry ingredients and fogging systems that reduce fine mist airborne dust. These systems mean that manufacturers can create a clean processing environment and improve workplace safety.
Challenge 3: Achieving Consistent Particle Size
Many food products like flour, sugar, cocoa, coffee grounds, milk powders and ice cream mixes require a specific particle size to ensure the perfect taste and texture. Achieving this consistency can be difficult because of:
- Variations in raw material properties
- Wear and tear on milling equipment
- Changes in environmental conditions
- Complications related to controlling the milling process
Potential Solutions for Achieving Consistent Particle Size
Different size reduction technologies can mitigate these issues in food and beverage manufacturing. Examples include hammer mills, which use high-speed rotating hammers to break materials into smaller pieces; pin mills, which use rotating pins to grind particles through impact; jet mills, which use high-speed air to break down particles without heat; and cryogenic milling, which freezes materials with liquid nitrogen before grinding to prevent heat damage.
Challenge 4: Handling Heat-Sensitive Materials
Many food ingredients like spices and herbs, tea and coffee, dairy and plant-based powders and sweeteners are heat-sensitive, which means they degrade and lose flavour. Traditional processing methods can lead to:
- Nutrient loss, reducing the nutritional value of the final product
- Altered flavor profiles, affecting taste and consumer acceptance
- Changes in color or appearance
- Degradation of functional properties (e.g., solubility, emulsification)
Potential Solutions For Handling Heat-Sensitive Materials
Advanced drying technologies can help manufacturers preserve heat-sensitive materials. Examples include isolator glove boxes, enclosed units with glove ports for the safe handling of powders; flexible film isolators, transparent plastic enclosures for small-scale batch processing; and transfer bags, used to transfer powders between equipment without exposure safely. These methods allow for rapid drying at lower temperatures, minimising heat exposure and maintaining the quality of sensitive ingredients.
Challenge 5: Cross-Contamination and Allergens
Undeclared allergens have been identified as the leading cause of food recalls. A study analysing FDA data from 2004 to 2013 found that 27% of food recalls were due to undeclared allergens (source: Charts of Note “Pathogen contamination and undeclared allergens are leading reasons for food recalls“). Preventing cross-contamination and managing allergens is essential for maintaining safety in food processing. Challenges include:
- Risk of allergen cross contamination
- Difficulty in thoroughly cleaning equipment between batches
- Requirement for separate processing areas for allergen-free products
- Ensuring accurate labeling and traceability
Potential Solutions For Cross-Contamination and Allergens
Containment and isolation systems, including gloveboxes and hygienic filling systems, can provide a controlled environment for processing allergen-free or specialty products.
Final Thoughts: Food and Beverage Powder Processing Challenges
As the food and beverage manufacturing industry evolves, discover how Hosokawa’s cutting-edge powder processing technologies can help you overcome your food processing challenges. Get in touch with our experts today to discuss your unique production needs.
