Why Industries Need of Powder Flow Testing & Measurement Equipment

There is a dire need for testing the powder flow properties in industries and to meet this objective, tap testing tools are employed in the labs. These toolsets are widely employed for the testing and measurement of pharmaceutical powders. These toolsets are used for figuring out the properties of powder flow. The equipment to use to achieve this goal is called tap density meter. The apparatus used for the measuring and testing of powder flow is employed in the research and the development of entire establishments. This is the reason which places this in the list of the most efficient tools for testing powder compressibility.

This tool is used to measure the powder bulk density and volume of a pharmaceutical powder. A very specific purpose is solved by this tool which is finding the difference between the powder property to flow and the powder’s compressibility property. There once was a time in history when powder testing was performed. There used to be very high chances of the test failing. Scientists introduced the powder rheometer in order to reduce the possibility of certain erroneous results. Powder rheometer is put to use in different types of measurements with no failure at a very different range and level. A person can find the tap density measurements and also use the tap density measurement tool in a lot of different ways.

There are some instruments that are put to work in order to categorize the powder without much difficulty. Along with this, there is a possibility that they will find the tap density with no error. It was never this easy to capture tap density measurements. Powder rheometer is used to perform the powder compressibility test. Powder rheometer is an instrument that assists in observing the powder’s rheology more intensely. The Powder rheometer functions as a powder flow tester. There have been occurrences when the density or volume has been mistaken, which has led the result of the whole measurement falling apart. Hence, it is very important to make sure that everything is accurate.

There is another apparatus that can be used to measure and observe the powder’s bulk density and it is called auto tap tool. The auto tap tool is very compact in size. The body of the auto tap tool contains two cylinders which rotate on their axis. The cylinders find out the powder’s tap density with the help of appropriate taps. The best part is that after a certain time, the process stops.

Granupack is another instrument that helps in finding the used powder’s nature and it also serves the purpose of getting the measurements that are required for a particular case.

Selection Of Industrial Powder Flow Equipment

The powder is used in various industries as a raw material for coating, making tablets or just to be sold in a powdered form. For converting it to any final product, it needs to be traveled through different stages like from storing it in storage vessels till it is processed. For making it pass every stage without any obstruction or hindrances, its flow through channels is pre-examined so that production or manufacturing could run smoothly, without any flow hassle.

The flow of the powder is measured and checked by the flow analysis equipment. The equipment is able to check probably each and every powder flow properties which could create problems while flowing through channels. Things which affect the flow like powder flow angles, powder electrostatic charge or powder compressibility should be pre-examined by a powder flow tester before starting a fully fledged production.

Let’s discuss the properties which affect the powder flow usefulness of powder flow equipment in facilitating easy powder flow.

1. Powder compressibility – Measurement of powder compressibility helps to assess the strength of powder to get compressed at a certain temperature and humidity and every powder has different compression level. If not measured properly or calculated precisely, it could lead to obstruction in flow channels. The powder, having varied granule size, moisture content has a different compressibility ratio which affects the flow and discharge in the channels.

Flow analysis equipment definitely helps to measure the powder compressibility and further helping in a smooth flow.

2. Powder flowing angle – The flow of the powder is also dependent upon the inclination and design of channels. If the channels do not have the proper inclination it would not allow the powder to flow smoothly. Normally the angle of inclination of powder flow varied ranges from 10 degrees to 45 degrees. A powder flow tester analyses the powder properties and wall-powder surface friction strength and could tell at what degree a flow channel could facilitate powder flow.
3. Powder electrostatic charge – The powder granules when flowing struggles to discharge themselves with force and this creates friction between them. The friction between channel walls and powder surface also generates an electrostatic charge which affects the flow. A tester could effectively measure the electrostatic charge between powder particles at the stable condition and suggest the required force, humidity for a smooth flow in channels.

Other measures are also taken into consideration for facilitating smooth powder flow such as-

• The cut and design of the channel outlet should be customized so that the powder could be transported from one manufacturing unit to another unit.
• Powders are compared with one another for a better understanding of features which allows the manufacturer to decide specific conditions for various powders.

Powder flow analysis and selecting appropriate equipment for examining powder properties, definitely, reduces the risk in the production process.

Recognize the Powder Flow with Best Instruments

The ease with which a powder flows under a set of particular conditions such pressure, humidity or the equipment used to make the powder flow is known as powder flowability. This is used to test the behavior of a powder, its character and how its individual particles behave. For a manufacturer who is involved in the manufacture of powders, testing all of the above properties is indispensable. To employ the testing of powder flow properties many powder flow testers have emerged in the market which makes testing very comfortable.

What is Powder Flow Testing?

These are tests involved in measuring and testing the properties of powder flow under different conditions. They measure the behavior of the bulk’s material and how the powder flows. These methods are employed to detect any poor flow that might occur with the materials. These tests are a compulsion when we have to design new material handling equipment such as silos, bins, conveyors etc. These factors hamper the efficiency of machines and hence testing the flow and correcting is a vital process.

What are the different Powder Flow Properties?

These are the various properties that are tested.

1. Powder compressibility: It signifies how much the material consolidates and flows easily through a vessel.
2. Bulk Density: the density of the material which may hamper the flow.
3. The angle of repose: the tilt angle of the machine which enables easy flow.
4. Powder electrostatic charge: how electrostatic charge between particle may hamper flowability.

What are the Best Instruments for Powder Testing?

1. Powder Rheometer: These instruments are capable of measuring the shear, bulk and various dynamic properties of a powder. The powder samples are analyzed for various different conditions like consolidated, conditioned or even in the fluidic state leading to a full exploration of various properties.

2. Bulk Density Tester:These instruments are used to measure the bulk density of the powder sample. The values determined by these tests are used in various applications such as designing a mold tool.

3. Granulate Flow Tester:These test instruments are used widely to measure the flow characteristics of powders. The main aim of these tests is to ensure that the correct dosing of the material is present which does not hamper the flow in any way
4. Laboratory Mixer: These instruments are used to mix a sample of powder solution to further test the different properties associated with it.
5. Pourability Tester:The main aim of these testing instruments is to check and measure pourability of a powder. These are also used to measure the pouring angle which is optimum for efficient operations.

Thus, using the above-mentioned test instruments achieving the optimum and efficient result is guaranteed every time when we need to test the different properties of powder flow.

Important Considerations In Bulk Powder Handling Instruments

Powder Flow Tester : Powder Flow Tester or PFT, is a method which provides rapid and swift analysis of the operation of powder flow in an industrial apparatus or paraphernalia which performs the mechanical or a chemical procedural behavior. It is an exemplary and classic model or complete consummate for people who are engaged in the manufacturing of powders every day and want to minimize the expenses and cut down the downtime during which the hoppers which are tapering containers working in a hopping motion through which bulk materials are discharged, behave in an unpredictable manner which is not even or regular. The attributes and the benefits are as follows:

• Performs tests on powders as a particular expression of an idea or theory.
• Condensed close-packed design.
• Final density of the Bulk Powder.
• Effortlessly uncomplicated to use.
• Completely terminate the unwanted downtime and also extra expense.

Powder Flow Properties: The flow properties of powder or any bulk solid depends on a framework of specifications which include:

• Size distribution of any of the numerous subatomic constituents.
• Shape of the tiny particles.
• Moisture present.
• Chemical configuration or composition.

To presume the flow ability of the powder, the secondary or contingent parameters to be measured are:

• Bulk density
• Rate of flow
• Angle of reposition

Powder Flowing Angle: Powder Flowing Angle or Angle of Repose, is a well-grounded and plausible method of estimating or predicting the gradient of internal abrasion or resistance of the bulk medium if the strong coherence or linkage can be disregarded or overlooked and also if the size of all the tiny particles fall in the same range of extremities. It is the undeviating and unvarying 3-D angle which can be devised or created with the help of any of the following methods:

• The height of the conduit or channel of pipes should be determined and fixed in a relative way considering the base.
• The base upon which the pile gets created might be of a certain diameter, which should be fixated to a particular size.

Powder Electrostatic Charge: Powder Electrostatic Charge is an elaborate phenomenon which might be serpentine in its intricacy because of the bipolar charging of the tiny particles. The charging can be led to the formation of lumps or aggregation of mass, dissociation or insulation and extreme incoherence, that is, adhesion of surface walls. This entire mechanism or stratagem of powder handling can negatively affect the ultimate execution.  All said, it comes with risky consequences to human safety because it can lead to sparks which in turn can lead to an explosion or fire.

Powder Compressibility : Powder Compressibility is enumerated and expounded by the powder handling industry as a means of pressure discrepancy or change or variation.  Testing compressibility is very straightforward and hence is used to establish or ascertain the flow properties which include cohesiveness and an abundance of loads on walls and feeders.

Important Considerations In Bulk Powder Handling

Bulk powder handling or bulk density is nothing but the ration of the mass to the volume of the material. This material can be any random powder sample which is untapped. It is given in grams or milliliter. The density and arrangement of the particles determine how the bulk powder will be handled. The consideration points which are necessary here are that how the powder will be prepared, treated and stored? The methods which help in considering this are as follows:

Angle of Repose: The angle of repose is formed by the cone like structure and then it is measured. The angle is required to be around 25 to 30 degrees, which shows the perfect powder flow. Dynamic angle of repose is angle which is capable of changing frequently and adjusting it to the powder testers. Poor powder flow is determined when the degree go over and above 66 degrees.

Powder compressibility:  Powder compressibility is measured from the Compressibility or the Hausner ratio. This shows the ability of settling and permitting assessment of inter-particulate interactions, which are of relative importance. In bulk density the particles are closer in value and in free flow these are less significant.

Powder Rheometer:  the properties of rheometer are basically governed through the flowable parameter, Shear property and bulk properties.  Many other factors like de-blending, de-aeration and moisture effect are all can be understood with the help of rheometer. The properties of the powder and the experience with the powder will enable much more clear understanding of the bulk powder testing.

Powder Cohesion: Powder cohesion is a sort of test which is done by putting the powder in the graduated cylinder. The powder involves a downward movement of 20 mm and upward movement is taken to be around 75mm. Cohesivity index value is then calculated by putting the force in numerator and distance in denominator.

As the inflation is on the go upwards the companies wants to learn bulk handling of things in order to minimize the involvement of the employees much. In such a cost effective situation, effective methods will be needed to ensure that the output is maximum in minimum input employed. Bulk powder handling concept calls for efficiency, reducing labor content and eliminating manual handling much. The above points highlight the important considerations to be made before selecting a powder tester machine. The factors discussed above are the important considerations which will help an industry related person to understand what is best for the company and where the resources available to the company should be employed. Before making a choice there are certain considerations listed above which should be understood to handle the Bulk Powder or bulk density.

The Benefits of Powder Flow & Measurement Tools

The benefit of testing the flow of the powder in industries is very high. For testing the flow of the powders, many different tools are used. One of the tools that are used for testing the flow and compressibility of the powders is the tap test tool. Tap test tools are basically used for measuring the powders. They help in determining the flow properties of the powder. Powder additive manufacturing demands the metal powder’s formation and its growth is increasing at a phenomenal level and so is the growth of the suppliers of the powders. So, the question arises is “what are its benefits?”.

A component is fabricated by putting it on a bed of finely-spread layer of powders. This is what happens in most of the cases. It is properly observed that the powder is uniformly spread as this distribution of powder will have a great impact on our final outcome which will benefit us in the measurement. So, this can depend upon the powder’s properties. Powder flow properties can be altered once you gain access to the quality of the raw powder. Additive manufacturing requires all this effort which finally pays during the outcomes.

The tap density apparatus involves objects like cylinders which rotate in order to test the properties of the granular material. The sale of powder bed equipment has increased over time. This is the result of the adoption of the automobiles and aerospace, etc. The benefits of manufacturing metallic compounds and using manufactured additives in order to perform powder measurement have also increased. Moreover, powder electrostatic and powder fluidization is also gaining more and more recognition resulting in the manufacture of powder metal bed. Now, instruments to measure the fluidization of the powder and studying the electrostatic motion of the powder are in great demand which has benefited the science in a great way. This will gradually result in the increase of metal powder’s cost. The feedstock’s characters of starting the powder are exactly what the base of the component of AM is dependent upon and also its quality and consistency depend on it. There are always some exceptions. The suppliers of additive manufacturing of the equipment are selling a powder that is validated. The validated powders are used only and only for additive manufacturing. There are thoughts about the validated powders like the validated powders can actually lower the risk of powder getting procured for the additive manufacturing. But it also limits the usage of the powder. The limit of powder mainly surrounds a single supplier of the prior source. Also, it contributes to the prevention of any kind of future expertise. The perfect example of these validated powder is the EOS.

All about Measurement of the Tap Density of Metal Powders

Used for testing pharmaceutical powders, Tap test tools are widely used in labs. Tap test tools are also known as tap density meter. The tap density tool is the tool that is used for development and research of totally different establishments, that’s why it is one of the most useful and efficient compressibility tools. It also helps in measuring the volume and density of the powder.  The purpose of this tool is to differentiate between the compressibility property and ability to flow of powders. In past, when the test was done, there were chances of failure due to possibilities of errors. So powder rheometer was introduced.  Powder rheometer had the ability to perform different measurements with whole different range.

To use a tap test tool and find the tap density measurements, there are a lot of methods.

Given below is the list of tap density apparatus that is needed for initiating the measurements.

• A measuring cylinder of 250 ml
• A measuring cylinder of 100 ml
• A cylinder holder of 250 ml
• A cylinder holder of 100 ml
• And an acoustic cabinet

These are the instruments that help in categorizing the powders very easily. The will also help in finding the exact tapped density.  The powder rheometer is the device which will help in studying the powder’s rheology easily. Once the powder starts to flow, it will become more vivid to do the characterization.

Tap density can be called the outcome or remainder of the volume and the density. This has to be very specific, as a single mistake can ruin the measurement. Now, this tap density will be used to do the derivation of the powder’s packaging dimensions. Also, it will result in the harmony of packaging.

Now the procedure of measurement of powder density starts when the cylinder is tapped mechanically until the observation of volume change. The cylinder must contain the sample. So by using the mass and volume of the sample, we can calculate the tap density.

Auto tap is the instrument used to analyze the outcome or the tap density. The analyzer is very small and consists of 2 rotating cylinders. The cylinders with the appropriate taps, find out the tap density of our sample powder. After a certain number of taps, the process stops on its own.

Using a Granupack, an instrument that is used for the determination of the evolution of compactibility of the powder through time, this way we can easily identify the strong relationship between the particle size, hausner ratio and the index of flowability. It is like a tap density meter that helps in figuring out the nature of powder and help in making the measurements.

All about Measuring and Understanding Powder Flow

The study of powder flow has a lot of implications in industry and powder behavior is non-conformist as far as flow properties are concerned! The reasons are manifold. For one, with the extremely small powder particles, gravitational flow is much less easy to predict. Then there is the loss of energy they undergo due to friction with other particles and the sides of the container. Powder flow is a vast field of study with many scientists having painstakingly decoded the behavior to the best of their ability providing us with information on how powders behave under different conditions.

What are powder flow properties?

In practical applications and difficulties like segregation, pneumatic conveying or caking, certain properties of powder flow are studied to understand the behavior of powders. These are:

• Cohesive strength
• Wall friction
• Internal friction
• Powder Compressibility
• Permeability
• Angle of repose
• Chute angles for powders.

In all these tests, actual plant or process conditions are simulated.

What is a powder rheometer?

A powder rheometer characterizes the flow properties or rheology of the powder. This is its primary function. But rheometers have been continuously refined so that they have become versatile powder flow tester with different accessories to measure wall friction and bulk properties like density, permeability, and compressibility etc.

Powder flow measurement.

The classic tests and associated measurements with a wide range of applications have been

1. Flow through an orifice – measuring the rate at which powder flows through an orifice of tightly defined dimensions directly gives a value to the flowability of the powder.
2. Angle of Repose – when powder is poured from a vessel, it forms a conical pile. The angle of the cone to the horizontal is directly indicative of the nature of the interaction between the particles and hence a measure of flowability.
3. Tapped density tests. – A powder when tapped causes the particles to realign with each other which depends on the cohesivity of the particles, which also affects the flowability. These test values are expressed in ratios of the tapped density to the untapped density like the Hausner Ratio and the Carr’s Compressibility Index.

All the above tests provide parameters according to which the flowability of the powder can be classified.

These are simple tests and are manually done using simple and inexpensive equipment. They are the choice of most manufacturers in the powder industry.

The disadvantages of these simple tests are that, because of the element of manual implementation, they do not achieve consistence in repeatability. There is also little scope of the testing environment to reflect the actual manufacturing environment.

Why Measuring Powder Flow Properties is Important for Many Industries

Powders exhibit properties of both solids and fluids, but not quite all of them!  Consequently, they were studied separately and certain behaviors exhibited are documented.

What are the common powder flow properties that are measured and what are their implications?

Cohesive strength of the particles

Internal friction between the particles

Wall friction

• Compressibility – bulk density values resulting from consolidating pressure
• Angle of repose – of material pile at rest
• Loose/tap density – bulk density values before and after vibration
• Chute – angles to maintain the flow after impact
• Permeability – interaction of different materials with each other which influence the discharge rate from hoppers

Why is measuring these properties important for many industries today?

Today’s major industries and stock market Supremes are picked from the pharma industry, the cement industry, and the food processing industry. Powder flow properties are key to these and their understanding will result in smooth manufacturing processes and timely delivery and distribution of the finished products to domestic and global markets.

The flow properties of powders are not inherent properties, but depend also on the powder handling equipment. Instruments to measure the powder flow as a net result of the processes and the nature of the powder are called powder rheometer widely available to observe and measure any or all the above listed powder flow properties under different conditions of pressure, temperature, and moisture.

For example, in the preparation of xanthan gum, which is used as a thickening agent, in food, pharmaceutical, cosmetic, and other industries., the fine powder is dispersed into the liquid with the help of mixers with high seas, which will rapidly disperse it without forming any lumps. Using this type of mixer is better than using just an agitator as the mixing times to achieve full hydration of the powder are long and costly. Even then, the mixing is not uniform and hydration may continue even during further processing or storage, which can alter the final product. The properties of the xanthium gum powder were first studied before concluding that this sort of mixer would be required for it.This is just one instance. There are many such implications and concerns across various industries.

Rheometers use fluidization or fluidization bed measurements to characterize powders in their fluid state, almost like the way liquids are done. This is to remove the ambiguity that is an inherent part of the nature of powders. This is also termed as erasing the ‘powder memory’! During this process, the behavior of the powder is measured under various conditions with highly sophisticated motors that can resolve changes in torque as small as 1nNm.

The Features of Powder Flow Instrument

Powders are fine, dry particles that are created by grinding, crushing or the disintegration of a solid substance. These particles can flow freely when they’re shaken or their container is tilted. There are two types: Granular and Fine. Granular materials are more particulate and individual grains are larger in size than fine powders. Finer grain sizes tend to clump or form lumps while flowing.

Properties of Powders

Examples of manufactured powders include flours, cosmetics, talcum powder, sugar, powdered coffee, gunpowder, photocopying machine toner. Volcanic ash, dust, sand, dry snow etc is all natural powders.

Common properties of powders include:

• Ability to be compacted or loosened
• Light and fluffy when sprinkled
• Dense and static when vibrated or compressed
• Ability for segregation, jamming, unjamming, loss of kinetic energy, frictional shearing, compaction etc.
• Supports shear stress unlike liquids

Powders: Uses and Issues

Powders are used extensively in the pharmaceutical, cosmetic and food industries, apart from many others. This has resulted in the need for precise measurement and ensuring the smooth, uninterrupted and controllable flow of powders. As a result, flow instruments, flow measurement devices and powder flow tester have become a necessary part of any industry that used powder handling equipment.

The main issue with powders is that they don’t flow reliably and consistently from bins, containers, hoppers, feeding machines, packaging machines, dosers, silos etc. This causes production issues, uneven quality etc and can even cause plant shutdown, leading to loss of revenue. Variations in mixtures, packaging and quality can result in the company’s losing clients.

Powder flow instruments

Flowability testers generally fall into two categories: Dynamic and Static Assessment equipments. Dynamic testers measure the powder as it flows or is about to flow , while static testers measure the flowability at rest or if the powder has been compressed. Both types of testers are required to give a comprehensive picture of powder behavior.

These instruments measure flow function, wall friction, bulk density, etc.

There are different options available, based on the brand, function and company that manufactures them. Optional accessories include temperature probes, humidity sensors, sieve kits, real time clock display, choice of flow function tests, data output options etc.

Powder handling equipments include powder rheometer and sensor systems that provide different types of data based on your needs. Texture analyzers are used for batch and source variation, addition of lubricants, processing conditions etc. Sophisticated computer controlled equipments include acoustic envelope detectors, dough inflation units etc. Such instruments help to present consistent samples under identical, controlled conditions.

All these equipments ensure that flowability problems are detected/analyzed/corrected well ahead before they cause production breakdowns.

Read Also About angle of repose apparatus.