Tom Francis, PTI Vice – President and General Manager has retired effective June 2012. We wish him well and thank him for his many years of service with the company. He remains one of the partners and continues to sit on our Board of Directors.

Jeff Friederichs has been named as Tom’s replacement. Now PTI Vice – President and General Manager, Jeff also sits on our Board of Directors. His fifteen plus years of service and dedication to PTI will continue to serve both the company and our customers.

Jeff Barrows, now PTI Sales and Marketing Manager, has been named Jeff Friederichs’ successor. Jeff started with PTI November 2011, and brings a successful Sales and Marketing background from another industry. We are happy to have him on our team.

Lastly, James Hutchinson has been promoted to Production Supervisor. James has been with PTI for over five years and is responsible for production oversight. We wish him well and continued success in his new role with our company.
Please contact us by phone, email, or use the request quote form found on this website to discover the advantages of PTI.

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Recently we had a customer who’s process was time consuming, and therefore costly. We suggested a new way of doing it as our partnership with our customers is something we take very seriously. It was determined, over time and a lot of conversation, a V-Blender would yield similar or better results while allowing for a much quicker, more cost effective process.

As a result of this PTI has purchased a stainless steel V Blender. We are very excited to have this addition to our capabilities and as of Spring 2012, have made it available for other clients as well.

The capabilities and capacities of this machine are as follows:

• This blender is best for 50 pound to 600 pound batch sizes.
• This blender can produce similar, accurate batches consistently.
• This blender can produce simple or complex formulas.
• This blender can remove agglomerates.

Please contact us by phone, email, or use the request quote form found on this website to discover the advantages of PTI.

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It gives the ability to focus on your company’s core competency.
We are passionate about powder processing and it is our specialty. Manufacturers seldom look for solutions to problems that are not readily apparent. However, inconsistent product or a low yield has costly implications. Many companies are trying to do more with fewer resources and not replacing personnel who have retired or left as a result of layoffs, reducing hours, closing plants, etc. Because of this trend a lot of knowledge is leaving and not coming back. Contracting toll processing allows companies to utilize the expertise of processing professionals with a vast knowledge of the process and can apply it to a variety of different materials. As an added benefit selecting a professional toll processor can make your life easier, reduce risk, and give you a competitive advantage while adding to your bottom line.

There is no capital investment required.
Manufacturing costs are predictable and turnaround is fast. Investing in the variety of equipment needed to properly pulverize, micronize, or process powders is cost prohibitive to many companies. Even with companies that have undertaken this burden, different needs often require different machines. As needs change, purchased equipment can become extinct. Even if needs do not change, technologies change, machines depreciate, and the cost of operation and dedicated floor space is still there. In some cases, reducing costs and cutting budgets have led to equipment being replaced less often and, in many cases, maintenance not being performed on a timely basis. This can have very negative implications on a consistent, quality product. With a toll processor there are no internal maintenance or space parts requirements, no need for in house engineering requirements, no need for dust collection or discharge permits, and no need for additional personnel or space requirements.

Toll processing gives the ability to meet the changing needs of your customers.
Contracting gives you the ability to fluctuate production quantities to meet the specific needs of your company and your customers. Without the fixed cost of machinery it gives the ability to readily change production quantities. From research and development in a lab setting to large scale production runs, PTI allows companies to better meet market and customer requirements. We can also be successful relieving companies who process on their own from an influx from peak seasons, special projects, or plant shutdowns offering additional or supplementary capacity. PTI can help reduce lead times and better respond to your customers.

Please contact us by phone, email, or use the request quote form found on this website to discover the advantages of PTI.

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Companies that process on their own often believe they cannot afford to pay someone else to handle their toll processing and material sizing. Others might assume that inconsistent product or low yield is a direct result of inconsistent feed material, as they cannot quantify a vendor’s quality process or simply do not have the time to do so. Even if a company wants to make a change, the potential amount of time required and assumed risk make it difficult to begin the process.

Economic Implications

In general, most manufacturers are trying to do more with less in this economy by not replacing personnel who have retired or left as a result of layoffs, reducing hours, closing plants, etc. Because of this trend, a lot of knowledge and expertise is leaving and not coming back. On the other end of the spectrum, reducing costs and cutting budgets have led to equipment being replaced less often and, in many cases, maintenance not being performed on a timely basis.

How do you increase profits by contracting your toll processing and material sizing needs? Have you considered outsourcing classification, pulverization, blending, screening, and/or particle modification services? Can you afford not to?

It may make sense to outsource this facet of your business to professionals who have the proper equipment, knowledge and experience working with a variety of materials. They not only can handle your processing needs efficiently and effectively, but can possibly apply knowledge gained from other jobs to help improve yours.

Manufacturers that outsource materials processing are not burdened by additional capital investment or the depreciation of new equipment. They can remain focused on current product lines while developing new products out of existing materials through outsourced toll processing. Using experienced toll processors also eliminates extended lead times for equipment delivery and installation, as well as the need for in-house engineering expertise in handling materials, equipment setup, operation requirements, maintenance or spare parts management, facility floor space, clean air compliance, or processing permits. In addition, the time that strategic planners spend analyzing current resources in remaining stock or waste material can be used differently.

These changes can often yield important return on investment. Manufacturing costs are predictable, and turnaround is fast. The burden of obtaining consistent product is transitioned, and quality processes and procedures can improve as the focus is more narrowly defined with a company specializing in toll processing. As an added benefit, managing production schedules, training, operation cost, safety concerns and potential liabilities are also transferred.

Real-Life Applications

As previously mentioned, one of the potential benefits of contracting toll processing and material sizing needs is access to the expertise and ingenuity of personnel who are focused on toll processing. In one example, PTI received an opportunity to process a high-density crystalline material that several other processors had attempted and failed to process to the correct particle size with an acceptable yield.

The raw material was provided in blocks of approximately 10-15 lbs each. The manufacturer requested a finished product particle size of minus 100 mesh (150 micron) plus 270 mesh (53 micron). The solution required a multistage process approach involving more than one type of mill. First, the large blocks of feedstock were reduced to minus 20 mm using a jaw crusher. The jaw-crushed material was further reduced to minus 3 mm size using a hammer mill fitted with boron hard-faced hammers. The hammer-milled material was subsequently passed through an opposed-jet mill with an integral vane-type classifier, further reducing particle size to approximately 80% minus 100 mesh.

The next stage involved passing the jet-milled material through a vibratory screen, producing three fractions, including undersized fines, product to size, and oversized coarse material. Finally, the oversized coarse fraction was re-milled and screened to produce additional product at the target size.

This multi-step, custom approach in size reduction for a challenging material was developed in various stages. While an initial approach produced quality product within customer size specifications, the processes generated a large amount of unusable fines, resulting in a relatively poor product yield of approximately 40% of the material received.

A second method of sizing involved widening the gap in the jaw crusher, which produced fewer fines at this stage. The optimal gap setting was determined through a series of test runs in order to minimize undersize fines. Milling pressure was also reduced by 45% in the jet mill, lowering the energy level applied to the milling chamber and causing less fine particle fragmentation. This second approach reduced fines formation significantly and improved product yield to 54% of material received.

A third approach involved the replacement of the jet mill secondary or strip air blower in order to boost airflow through the mill classification zone. This improvement increased classification efficiency of high-density materials and ultimately increased product yield to 60% of material received. PTI continues to process this material while making additional process modifications to enhance product yield.

Many materials require a complex sequence of procedures in order to achieve the highest product yields. The approach taken to optimize this particular manufacturer’s product, while being unique to that material, is typical of how a toll processor can use their personnel’s experience and their available equipment to achieve the manufacturer’s desired product at the maximum yield.

Long-Term Success

Many manufacturers have benefitted from successful relationships with toll processors. By accessing a broad spectrum of custom services and a wide array of expertise, outsourcing your toll processing needs can provide multiple advantages for the long-term success of your business.

For more information, contact Powder Technology, Inc. at (952) 894-8737 or visit www.powdertechnologyinc.com.

Jeffrey J. Barrows is a Sales and Marketing Manager at Powder Technology, Inc.

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PTI received an opportunity to process a high-density crystalline material that several other processors had attempted and failed to process to the correct particle size with an acceptable yield. Due to customer proprietary status, we cannot disclose the type of material.

The raw material was provided in blocks of approximately 10-15 lb. each. The customer requested a finished product particle size of minus 100 mesh (150 micron) plus 270 mesh (53 micron).

Solution

PTI’s approach is a multistage process involving more than one type of mill. Step one is to reduce the large blocks of feedstock to minus 20 millimeter size using a jaw crusher. The jaw-crushed material is further reduced to minus 3 millimeter size, using a hammer mill fitted with boron hard faced hammers. The hammer-milled material is subsequently passed through an opposed-jet mill with an integral vane type classifier further reducing particle size to approximately 80% minus 100 mesh. In the next stage, jet milled material is passed through a vibratory screen, producing three fractions including undersized fines, product to size, and oversized coarse material.

Finally, the oversized coarse fraction is re-milled and screened to produce additional product at the target size. This multi-step process is a custom approach in size reduction for a particular customer with a challenging material. Many materials processed by PTI require a complex sequence of procedures in order to achieve the highest product yields.

PTI Resolution and Commitment to Process Analysis

Following is a sequence of solutions used to improve product yield during subsequent processing runs of the above material.

• While the initial approach produced quality product within customer size specifications, the processes generated a large amount of unusable fines resulting in a relatively poor product yield of approximately 40% of the material received.
• A second method of sizing involved widening the gap in the jaw crusher, therefore producing fewer fines at this stage. We determined the optimal gap setting through a series of test runs in order to minimize undersize fines. Milling pressure was also reduced by 45% in the jet mill, lowering the energy level applied to the milling chamber, causing less fragmentation of fine particles. This second approach reduced fines formation significantly and improved product yield to 54% of material received.
• A third approach involved replacement of the jet-mill secondary or strip air blower in order to boost airflow through the mill classification zone. This improvement increased classification efficiency (of high density materials) and ultimately increased product yield to 60% of material received. We continue to process this material, making additional process modifications to enhance product yield.
• The approach we have taken to optimize this customer’s product, while being unique to this material, is how PTI approaches all of our customers’ materials to achieve the desired product at the maximum yield.

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