09.2025 | Specialist article
Modular thinking, flexible production
More product variants, new raw materials, stricter regulations - production processes need to be increasingly flexible. Thanks to a consistently modular system and machine design, systems can be easily adapted and expanded to meet changing process requirements.
Processes, raw materials and end products are changing - and ever faster. This means that product ranges are being expanded or new powdered components are being used that require completely different processing steps. For example, modern cold-swelling thickeners make energy-intensive and failure-prone cooking processes superfluous. At the same time, these new substances pose challenges for production: They are more prone to clumping and require much more complex dispersion - especially low-cost alternatives.
Raw materials with extended functionalities are increasingly being used, such as emulsifying starches, cationizing stabilizers, modified proteins or new types of fillers with active properties. Their processing is complex. Simply stirring them in is not enough. Rather, they must be treated differently in the various phases of production. They often require high shear forces at the beginning, but react sensitively to mechanical stress after hydration.
Coarsely crystalline, soluble powders, for example, must first be stirred up intensively in the lower part of the container - otherwise local over-concentrations prevent complete dissolution. Once this step has been completed, a gentle mixing movement is sufficient. The situation is different with highly viscous media: if mixing is too vigorous during feeding, trapped air cannot escape as it is always drawn back into the liquid by the movement. To avoid such effects, process parameters must be variably controllable and adaptable to the respective process phase.
Flexibility as the key to future-proofing
Procuring separate machines or converting systems for each new task is neither economical nor practical. Conversions mean project planning costs and production downtime. This is why forward-looking planning, simple retrofitting, adaptability and future-proofing are crucial for sound investment decisions.
Controlled process conditions
Ystral meets these requirements both in the machine and system design and in the controls. Systems, devices and control units have a modular design and can be used flexibly. The Conti-TDS systems have been developed to aspirate powders dust-free and disperse them directly into liquids - with a completely different approach to conventional processes. The machine generates a strong vacuum in the dispersing zone, through which the powder is introduced directly into this area. Over 60 tool variants are available to meet the wide range of requirements. The dispersion chamber has a modular design, all components such as tools and inlets are compatible with each other and can be exchanged quickly. This means that the system can also be quickly adapted for future process requirements.
Targeted control of dispersion processes
The powder feed is automatically adjusted to the flow rate of the liquid. For example, viscosity changes in thickeners, temperature increases in exothermic reactions or concentration fluctuations can be controlled in a targeted manner. The shear intensity is regulated via the speed. The process combines high dispersion performance with short process times and maximum utilization of the powder materials used. It is used in food production, the production of pharmaceuticals, cosmetics, paints, varnishes and chemical products.
The main area of application of the Conti-TDS is the dust-free suction and dispersion of powders. In addition, liquids that are difficult to mix and have different physical properties - such as polarity, viscosity, density or surface tension - as well as gases can also be introduced into liquids. This significantly expands the range of applications. Special tools are available for processes in which neither powder nor other media are added and the entire output is used exclusively for dispersion. This allows the machine to be converted into a high-performance dispersion system with shear gradients of over 100,000 s-¹ in just a few simple steps.
Standardized production worldwide
Globally active companies must deliver consistent product quality - even if batch sizes, standards and local specifications vary greatly. This requires globally standardized machines and processes that can still be adapted to new tasks with minimal effort. Ystral has developed a basic machine concept that enables use on all power grids and under different regional standards. The equipment is designed for a wide range of products. With interchangeable tool kits, the machines can be quickly converted to achieve identical results worldwide. This modular system has proven itself many times over.
Many systems for the production of cleaning, care and food products rely on this principle: a basic machine supplemented by interchangeable tool kits - economical and versatile. Complete systems also benefit from maximum adaptability. In a plant for the production of wood varnishes, for example, over 400 recipes are produced in variable quantities - previously with 20 dissolvers in different sizes. Today, only one system consisting of two Conti-TDS twin-tank systems takes care of this. The special feature: The two process tanks are different sizes. This allows batches of 100 to 3,000 liters to be produced. The systems cover the entire spectrum of formulations and volumes - transparent and colored. None of the previous dissolvers are needed any more.
Magazine: P&A
Author: Dr. Hans-Joachim Jacob
Publication date: 09/2025
About ystral
With our vast knowledge and many years of experience in Process- and Application Engineering we offer targeted, customer-oriented solutions across industries - from lab equipment to production machines or plants.
Together with you, we develop concepts and implementations for your individual applications, which mean mmediately realisable and quantifiable added value for you.
