- 09/08/2025
- Article
- Preparation & dosing
Mixing technology at POWTECH TECHNOPHARM 2025: More efficient, cleaner, more versatile
Whether in the chemical, pharmaceutical, food or building materials industries, mixing technology is at the heart of many processes. The range of new mixers and complementary components on display at POWTECH TECHNOPHARM 2025 is correspondingly wide. From high-precision powder mixers and continuous inline mixers to clever sealing systems, exhibitors are showcasing solutions that noticeably improve efficiency, product quality and hygiene.
Written by Armin Scheuermann
A closer look at the product announcements from exhibitors at POWTECH TECHNOPHARM 2025 reveals some key trends: many manufacturers are focusing on continuous production to make processes more profitable and consistent. At the same time, hygiene and maintenance-free operation are becoming increasingly important – for example, through maintenance-free shaft seals or easy-to-clean mixing systems. The multifunctionality of systems is also increasing, with mixers taking on additional process steps such as drying or granulation. Last but not least, the focus is on energy efficiency, as mixing is one of the most energy-intensive processes. In the following, we highlight the latest developments and present selected innovations in mixing technology.
Continuous mixing for greater efficiency and quality
Traditionally, powders and granulates are processed in batches in batch mixers. However, continuous mixers offer clear advantages: they enable a constant product flow, reduce batch-to-batch variations and can significantly speed up production processes. The pharmaceutical industry in particular is currently undergoing a radical change – more and more companies are switching to continuous production since the FDA and EMA have been promoting this. One example of this development is the DLM/FS solid-liquid inline mixer from INDAG (Hall 9, Stand 9-624), which continuously homogenises liquid and solid flows within the pipeline. Depending on the mixing tool selected, powders or solid particles up to 20 mm in size are either gently incorporated or dispersed with high shear energy without destroying agglomerated particles or granules. Such inline mixers are ideal for creating a consistent product flow in chemical production or food suspensions, for example, while still being able to react flexibly to different ingredients. Continuous systems such as the INDAG DLM/FS also avoid time-consuming filling and emptying cycles as in batch processes and enable optimum mixing even with low active ingredient content – as required, for example, in pharmaceutical mixtures with very low doses of active ingredients. For manufacturers, this means higher yields and more consistent product quality with potentially lower personnel and energy costs per ton of product.
Another player in the continuous processing trend is YTRON (Hall 9, Stand 9-248) with its ZC powder dissolving system. This system specialises in adding powder directly to liquids and dispersing it. Using negative pressure, powder is drawn from a feed hopper into a rotor-stator mixer, where it dissolves without forming lumps. In a single pass, the YTRON ZC works extremely gently on shear-sensitive products – important for thickeners or proteins, for example. If necessary, the mixture can be further homogenised or emulsified in a cycle to achieve the desired fineness. Thanks to optimised rotor-stator geometries and the avoidance of unnecessary pumping energy, the system achieves high dispersion performance with low energy consumption. In practice, this means shorter mixing times and higher product quality – whether in the manufacture of food additives, paints or cosmetics. Continuous powder-in-liquid mixers such as the YTRON-ZC therefore play a key role in the efficient and quality-preserving production of modern formulations, from protein-rich plant-based drinks to high-tech battery slurry.
Energy efficiency and large batches – new standards in powder mixers
Mixing processes are among the biggest energy guzzlers in process engineering. This makes it all the more important to have machines that can homogenise even large quantities of material with minimal energy consumption. One highlight at the trade fair is the Gyraton silo mixer from amixon (Hall 10.0, Stand 10-414), which impressively demonstrates how engineers are saving energy: Up to 70 m³ of powder mixture can be processed at once in this giant conical mixer – with only 5 to 10% of the energy consumption of conventional precision mixers. This is made possible by a special wobbling motion of the mixing shaft, which ensures that the entire volume is reliably mixed even at low speeds. The uniform mixing at moderate speed not only protects the product, but also reduces wear and noise levels. In addition, the compact, vertical design reduces space requirements and thus conveyor distances in the process, which in turn saves energy. The Gyraton mixer is a prime example of the trend towards "intelligent drive systems and optimised geometries" in industrial mixers. Such developments offer enormous savings potential, especially for bulk materials in the building materials or minerals industry, where huge tonnages are moved. At the trade fair, the Gyraton will be presented as an energy-efficient powerhouse that demonstrates that high throughput and sustainability are not mutually exclusive.
Also on display at the stand: the new KoneSlid mixer KS. The vertical mixing tool with SinConvex® technology ensures dead space-free flow and maximum homogeneity. Emptying is quick and complete – ideal for hygienic processes with frequent product changes.
The portfolio is complemented by amixon's AM and VM mixers: highly flexible batch mixers for sensitive or sticky products – including residual emptying and CIP option.
Gebr. Lödige (Hall 12.0, Stand 12-378) is also presenting a high-performance solution at POWTECH TECHNOPHARM: the FKM ploughshare mixer for batch operation. This classic mixing technology has been continuously developed and is characterised by the high mixing quality it achieves in a short time. The centrifugal and vortex mixing principle with its characteristic ploughshare tools generates an intensive material throw that is nevertheless gentle enough to preserve the particle shape. Even difficult-to-mix formulations can be homogenised in just a few minutes – a decisive advantage in industries such as the building materials industry (e.g. dry mortar), where large volumes must be mixed quickly and reproducibly. Lödige also emphasises the robustness and ease of maintenance of the FKM: all mixing elements are easily accessible and the design is geared towards continuous operation. Manufacturers such as Lödige are thus responding to market demand for reliable, durable mixers that can run 24/7 and deliver consistently high product quality. Overall, it is clear that for large production volumes, the new batch mixers focus on both power and efficiency – and save energy with smart technology without compromising on performance.
Hygiene and maintenance-free operation: focus on clean solutions
In many industries, especially food, pharmaceuticals and fine chemicals, hygienic design and reduced downtime are just as important as mixing performance itself. That is why exhibitors at 2025 are paying special attention to components that improve cleaning, maintenance and operational safety. One example is the new rotary shaft seals from CinchSeal (Hall 12.0, Stand 12-254). Mixers and agitators often have rotating shafts that protrude from the container – a potential weak point for product leakage and germs. This is where CinchSeal comes in with two products: The Seal 2.0 and the 9700 series.
The Seal 2.0 is a shaft seal that is designed to be completely maintenance-free. Inside, two special sealing lips ensure a tight seal; once they are worn out, the operator can simply rotate the entire seal 180° and continue using it – a clever dual-purpose principle. Lubrication or readjustment is no longer necessary, which minimises downtime, especially in sensitive production processes. For the user, this means long-term, leak-free mixers without daily maintenance. The second model, the 9700 sanitary seal, primarily addresses the issue of cleaning: it is designed so that it can be dismantled into two halves. This allows it to be mounted or dismantled on an installed mixer shaft without disconnecting the drive – a huge relief during inspections or replacements. In addition, it is made entirely of stainless steel and meets FDA requirements, making it ideal for hygiene-critical processes. This seal is leak-free and can withstand aggressive cleaning (CIP/SIP) as is common in the pharmaceutical and food industries. Overall, such components help production facilities run longer and reduce the risk of contamination. A clear trend is emerging: suppliers are adding smart accessories to their mixing technology that are revolutionising cleaning and maintenance – from self-aligning seals and low-dead-space valves to CIP-compatible mixer designs.
Multifunctional mixers at POWTECH TECHNOPHARM 2025
Great variety, one goal: modern mixing technology is all about processing precise recipes reproducibly and efficiently – even with widely varying ingredients. At POWTECH TECHNOPHARM 2025, manufacturer PerMix (Hall 10.0, Stand 10-119) will be showcasing two solutions that meet this challenge: a vertical paddle mixer for high mixing homogeneity and a multifunctional system that combines four process steps in a single device.
The PerMix Vertical Paddle Mixer (PAM series) is designed for applications that require high mixing precision and a wide variety of products. With a conical stainless steel container and specially shaped mixing tools, the system achieves homogeneous mixtures even under extreme mixing ratios of up to 1:1,000,000. Typical areas of application include the production of enzymes, cosmetics, pharmaceutical active ingredients and functional foods, where even the smallest components must be completely distributed. Practical: the container can be completely emptied, minimising product loss and reducing cleaning times. For demanding hygiene requirements, a CIP system is available as an option, enabling automated wet cleaning – ideal for frequent product changes.
The PerMix 4-in-1 Hybrid Vacuum Mixer/Dryer goes one step further. This multifunctional system combines mixing, granulating, vacuum drying and cooling – offering four process steps in one closed system. Users benefit from shorter process times, fewer interfaces and greater product safety, especially with shear-sensitive or hygroscopic substances. Depending on the product requirements, the mixing chamber can be equipped with different tool geometries: from ploughshare to ribbon to fluidised bed. The drying process is particularly energy-efficient under vacuum, while final cooling in the same container enables media-free product transfer. For tests under real conditions, the company has its own technical centre in Belgium where customers can validate process parameters in advance – a plus for anyone who wants to consider scaling and process integration from a single source.
The Pegasus mixers from Dinnissen B.V. (Hall 9, Stand 9-238) are also following the trend towards multifunctional machines: depending on customer requirements, various processes can be combined in one device: mixing and cooling, agglomerating and homogenising, vacuum drying or even precise dosing of additives – all in one compact system. The individual configuration of the Pegasus mixer results in tailor-made solutions that fit seamlessly into existing production lines while opening up new efficiency potential.
Conclusion: solutions for efficient and clean mixing
The diverse developments showcase the range of technical solutions for efficient and clean mixing that will be on display at POWTECH TECHNOPHARM in 2025. The trends range from continuous processes and energy-optimised large-scale plants to clever detailed solutions for everyday use. Visitors to Nuremberg who take a look at these mixing technology innovations will gain an insight into how future process plants can operate even faster, more safely and more economically.
Are you interested in this topic? Then come to POWTECH TECHNOPHARM and experience this and many other topics live at the trade fair. Secure your ticket here using the following code: PTTP25Insights
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