Powder and Bulk Mixing Processes and Equipment

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Course Overview

In this course, you will examine the influence of particle and powder properties on blending results, learn how to measure the performance of blending equipment, and explore available options to improve blending performance and uniformity, and reduce operating and energy costs.

Who Should Attend?

Engineers, scientists, and production personnel who are responsible for the design, operation, selection, or specification of powder and dry-solids blending equipment in food, chemical, and pharmaceutical operations and applications. 

Course Outline

Difficulties in Powder Blending

  • What makes powder blending and mixing unique?
  • Why do so many problems develop?

Tumble Blending and Mixing Equipment and Mechanisms

  • V-blenders
  • Double-cone blenders
  • Blending and mixing by sliding flow and bulk motion
  • Limitations to fill levels
  • Methods for liquid addition and intensification

Rotating Element Blending and Mixing Equipment and Mechanisms

  • Ribbon blenders
  • Paddle blenders
  • Plow blenders
  • Bulk motion and dispersion mechanisms
  • Effective ranges for fill levels
  • Liquid addition and other processing
  • Batch and continuous operation

Other Types of Blenders and Mixers

  • Turbine blenders
  • Mullers

Auxiliary Equipment for Blenders

Sampling Methods

Particle Size and Bulk Density Effects on Mixing

  • Particle size and size distribution
  • Particle shape
  • Diffraction methods
  • Optical measurements and observations

Blender and Mixer Selection

  • Selection criteria and flow chart

Agglomeration and Deagglomeration

  • Liquid addition
  • Tableting and briquetting
  • Impact agglomeration and particle size control

Blender Mechanical Components

  • Drive components
  • Electric motors and explosion proof categories
  • Shaft seals

Safe Handling of Powders

  • Protection and safety in mixer installations
  • Protection against the occurrence of explosions
  • Protection against the effects of explosions
  • Combined protective measures


"A very good course. Well-planned and executed. It provided information I can use every day."


David Dickey

David S. Dickey, Ph.D., is an independent consultant with MixTech, Inc., in Coppell, Texas. His experience is unique in the field of mixing and scale-up since he has had exposure to both the theoretical and practical aspects of real problems, having learned about successes and failures. During more than 23 years with process equipment manufacturers, he has engineered liquid mixing equipment, powder blending equipment, viscous mixing equipment, static mixers, and other industrial process equipment. He has published numerous technical articles and book chapters and was one of the contributing editors of the handbook, Advances in Industrial Mixing (Wiley, 2015).

His diverse equipment background developed out of a technical background with a bachelor’s degree in chemical engineering from the University of Illinois, followed by master’s and PhD degrees in chemical engineering from Purdue University. In 2005, Dickey received the North American Mixing Forum Award for Excellence and Sustained Contributions to Mixing Research and Practice.


Elaine Andrysick

Elaine M. Andrysick, joined Engineering Professional Development, University of Wisconsin-Madison, as a continuing engineering education specialist in 1988.  She is responsible for the development and delivery of high-value continuing engineering education short courses for practicing professionals in the areas of chemical and process engineering and laser material processing.  Also, she manages the University’s Laser Welding Certificate program.

Upcoming dates (1)

Apr. 20-22, 2021

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Program Director

Elaine Andrysick

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