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Powder Processing
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Milling with Exwold for Maximum Performance
Powder Processing Services
Exwold has built its expertise in powder processing over many years.
Over the years our range of specialist equipment and facilities has been developed extensively. The result is that we have now built up an enviable reputation for quality and a collaborative approach to our clients. With a portfolio of multinational clients, we’re always looking to develop innovative solutions for your projects.
Blending
At Exwold, we are able to blend multi-component powder products to your specific requirements.
Sieving
We have a number of different types of sieving equipment available to separate or screen materials.
Compaction
Using roll compaction technology, we provide specialised contract services to transform powders into granules.
Classifying
Beyond conventional sieving, precise particle separation often requires advanced technology like a classifier.
Power Blending
We are equipped to precisely blend multi-component powder products according to your specific requirements. We utilize a range of specialized blending machines to achieve this uniformity, including Ribbon, Double Ribbon, Tumble, and In-line blenders, as well as Plough Shear units fitted with refiner blades. Furthermore, the majority of our blending machines are fitted with pre-screening or sifting equipment, which ensures the final product is uniform and completely free from oversized particles. We possess a wide range of blending capability, handling batch sizes from 25kg up to 2000kg.
Additionally, our capabilities extend beyond dry blending. We can integrate the process of spraying liquids onto powders, which is used to produce a highly free-flowing and agglomerate-free product. For more comprehensive information detailing our mixing and blending expertise, please download the PDF provided below.
Roll Compaction
We specialise in contract compaction, utilising advanced roll compaction technology to efficiently produce high-quality granules directly from your fine powder materials. As a superior dry granulation technique, this process delivers immediate operational and material advantages.
Core Benefits and Applications
Choosing our powder compacting service ensures a product that is dust-free and free-flowing, significantly improving handling efficiency and safety in your operations. Crucially, roll compaction requires no liquid additions or binders, making it the ideal choice for moisture-sensitive products or materials where solvent residue is a concern. We are committed to delivering competitively priced granules with superior quality.
This versatile technology is perfectly suited for a wide array of demanding speciality chemical applications, including:
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Flame Retardants
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De-icing Products
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Water Treatment Products
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Plastic Additives
For a technical deep-dive into the mechanics of our process, please download the comprehensive Powder Compaction Document (126.1KB).
Sieving
We provide expert services using various sieving equipment to achieve precise particle size separation. Through this process, we are able to separate both large and fine particles efficiently. A key capability is the use of two decks simultaneously, which allows for the efficient removal of any oversized material as well as fine (undersized) particles in a single operation. This processing technique is also commonly referred to as screening.
We use a comprehensive range of equipment types to suit different material characteristics and throughput requirements:
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Circular Sieves: We employ equipment such as those made by Algaier and Russell Finex.
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Rectangular Sieves: This includes machines manufactured by Locker.
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Sifters: We also utilize specialized sifters from providers like Powtek.
Classifying
As an effective complement to sieving (screening), materials can be separated using an advanced classifier. This technology achieves separation not by passing material through a physical screen, but by utilizing centrifugal forces to accurately differentiate and separate particles based on size.
Our Air Classifier Mill (ACM) employs this classification method. The ACM is designed to keep larger, unreduced particles inside the milling chamber for further processing. This action effectively classifies the material, ensuring the desired particle size distribution is met.
Our Resources Section
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Case Studies
Surface Coating Blending
A multinational company required a cost-effective 2mm granule of a waxy product used as surface coating additive .
The product had not been previously extruded. The material was supplied as a waxy solid block with a melting point below 100 ºC.
The material also required careful handling as it was corrosive and a significant aim was to reduce contact hazards.
Surface Coating Additive Milling
Exwold was approached by a leading chemical company to process a range of automotive surface coating additives.
The surface coating additive is produced as a molten solid in drums. Once cooled it forms a waxy, solid mass. The material has a low melting point <50ºC. The client required this in physical form to charge into coating with a specific particle size distribution to ensure dispersion.
Coating Processing
A powder coating manufacturer contacted us to establish whether a process could be established to recycle fines (the fine powder generated and removed during powder coating manufacture).
The company was sending around 10-25mt of fines to landfill each year and wanted to reduce the environmental and financial impact. The fines ranged in PSD but were typically 150 microns.
Downloads
Supplier Code of Conduct
Exwold is committed to doing business responsibly, ethically and sustainably at all times.
The company adheres to the highest code of conduct and expects its suppliers to do the same. Exwold will only deal with suppliers, consultants and distributors who conduct business in an ethical and responsible manner. Our supplier code of conduct ensures we work together.
Booking In Form
Our booking-in form ensures every collection and delivery to site is managed safely, efficiently, and with transparency.
By confirming arrival times and key details in advance, we can prepare the right resources, minimise delays, and maintain a secure working environment. It also provides a clear audit trail for all shipments, helping us protect product integrity and meet regulatory and safety requirements.
Reports
ESG Report 2025
Our ESG Report embodies our commitment to sustainability, ethical business practices, and transparency. Through this report, we detail how we measure and manage our environmental impact, uphold human rights and employee well-being, and enforce high standards of corporate governance. By doing so, we build trust with stakeholders and demonstrate accountability, showing that profitability and responsibility can go hand in hand.
Particle Size Distribution
Particle Size Distribution (PSD) is a key factor that determines how powders and granular materials behave during processing and final use. Even with identical chemistry, variations can affect flow, stability, reactivity, and product appearance.
This guide outlines what PSD is, why it matters, and how effective measurement and control lead to greater efficiencies and quality.