Milling, Mixing and Granulating: Building a Pilot Line

Many powder processes chain together milling, mixing, granulation and drying. Building that line at pilot scale exposes problems early.

What each step does

1. Milling: reduces material to the target particle size, which then affects mixing and granulation.
2. Mixing: makes several powders uniform so each portion has the same composition.
3. Granulation: improves flow and reduces dust and segregation for packing or tableting.
4. Drying: removes water after wet granulation and sets the final moisture.

Linking the steps

• Particle size: milled size must suit mixing and granulation; too fine can cause clumping.
• Mixing time and order: whether the main ingredient or the excipient goes in first affects uniformity.
• Moisture: after wet granulation, dry under suitable conditions to avoid over- or under-drying.
• Segregation: materials of different density and size can separate during transfer after mixing.

How to choose equipment

Goal	Pilot equipment to consider
Milling to a fine powder	Pilot hammer mill
Uniform mixing	2D, 3D, V and double-cone mixers
Granulation	Fluid bed, high-shear, roller compaction, rotary basket

Running the full sequence with your material shows how the steps affect each other. Book a trial.