FAQs About Powder Processing & Bulk Solids Handling

At Powder Process Group, we specialize in solving complex challenges in bulk material handling, powder processing, and heat transfer systems. Below are answers to some of the most common questions about bulk solids processing, thermal systems, and industrial equipment selection to help you optimize performance, reduce costs, and improve product quality.

How much product can I fit into a 1000 literI BC? A. A 1000 liter

A 1000 liter (1 cubic meter, 35.3 cubic feet) IBC refers to the total volume inside the IBC. The usable volume and product weigh that the IBC can hold is dependent on the product’s bulk density and angle of repose. A good rule of thumb is to assume that 80% of the total volume can be considered usable volume. To determine the weight an IBC can hold you can multiply the usable volume by the product density. Example: A 1000 liter IBC will hold 847.2 lbs of product that has a density of 30 lb/ft3.  

What is the difference between a feeder and a conveyor?

Very simply put, a conveyor is pre-fed at the inlet and a feeder is flood fed at the inlet.

What is the difference between mixing and blending?

 Mixing is the process of combining wet and dry materials; blending is the term used to describe the process of combining only dry ingredients.

What is the best technology to blend my dry ingredients?

There are several blending technologies for both continuous and batch process systems.The right choice depends on production rate, particle shapes and size distribution, density, temperatures, moisture, blend uniformity, and a myriad of other factors. You should document as much as you know about the ingredients,the process, and the available space and consult with a Powder Process Engineer

Is a tumble blender a good choice for my ingredients and process?

There are A quick and easy indication of blend performance is to portion out the ingredients so the accumulated amount will fill a sealable jar or bucket 2/3 full. Rotate the container several times or a few minutes then measure the uniformity of a few samples. Note that .  

How do I decide between a vibratory sieve and a centrifugal sifter for my application?

The decision comes down to your material's physical properties and your throughput requirements. Vibratory sieves are the more versatile option and handle a wide range of dry powders and granules effectively. Centrifugal sifters are better suited to sticky, fatty, or high-throughput applications where the material needs to be actively disaggregated as well as screened.

The trade-off with centrifugal force is that it can break down some fragile oversize particles, which may not be acceptable in all applications. If you are unsure which motion type suits your material, a product trial at our facility will confirm performance before commitment.

How do I specify the right mesh size for my material and separation requirements?

Mesh size, measured in microns or millimetres, should be chosen based on the particle size you want to retain and the size of contaminants or oversize you want to remove. As a starting point, your mesh aperture should be slightly larger than the maximum acceptable particle size for your product.

For check sieving, a single mesh is typically sufficient. For grading, you will need multiple decks with progressively finer apertures. For very fine separations below 100 microns, ultrasonic deblinding is usually necessary to maintain consistent throughput. Our engineering team can advise on the right specification for your material, and a product trial often helps confirm the optimum aperture before ordering.

How does powder flowability affect sieve selection?

Powder flowability is one of the most important factors in sieve selection because it directly affects how consistently your material moves across the mesh and separates.

Free-flowing powders with low cohesion and good particle shape tend to perform predictably on standard vibratory sieves.

Cohesive, moisture-sensitive or electrostatically charged powders resist flowing freely and are prone to bridging, clumping and mesh blinding, requiring adjustments to sieve type, mesh aperture or motor settings, or the addition of ultrasonic deblinding and additional oversize outlet control options. If your powder behaves inconsistently on your current sieve, flowability is usually the starting point for diagnosing the problem.