Custom Powders – Specialist Powder and Granule Processing from Process Trials to Industrial Production

In many industrial plants, powder properties determine the reliability and efficiency of the entire process. Particle size, flowability, density, dustiness, blend uniformity and segregation tendency can all have a direct impact on production performance and final product quality. At the same time, investing in dedicated specialist equipment is not always economically justified.

Custom Powders Ltd offers an alternative through comprehensive contract processing of powders and granules. At its facility in Crewe, UK, the company operates 13 self-contained process units with a broad range of possible process configurations. Individual systems can be adapted to the specific requirements of a material and product, while segregation of process areas and rigorous cleaning procedures help protect product integrity and minimise the risk of cross-contamination.

From Milling and Blending to Finished Granules

Custom Powders offers a wide range of processing capabilities including milling, roll compaction, sieving, drying, agglomeration, blending, formulation and specialist processing of microfine materials.

The company supports customers across sectors including food, chemicals, animal health, specialist powders and general industrial applications.

For powder milling, available technologies include air classifier mills, jet mills, impact mills, hammer mills and Nibbler systems. This enables both general size reduction and the production of very fine powders. Depending on the product, processing can also be carried out with cryogenic cooling, controlled temperature conditions or under an inert nitrogen atmosphere.

Roll compaction can be used to increase powder density and particle size, reduce dust, improve flowability and create stable multi-component granules with a lower tendency to segregate. Custom Powders’ compaction capacities range from approximately 50 kg/hr to more than 1,500 kg/hr, and the process can also incorporate pre-blending, milling, sieving and dedusting.

The company also provides a broad range of batch and continuous blending services. Technologies include ribbon and U-trough blenders for gentle mixing, high-shear ploughshare systems for rapid and accurate dispersion, and continuous blending systems using precise loss-in-weight dosing. Up to five components can be blended continuously, with liquid addition and process data logging also available.

More Than Contract Processing – A Process Solution

Specialist powder processing is not simply about putting material through a machine. The behaviour of powders can vary significantly depending on particle size, shape, density, moisture content, surface characteristics and formulation.

For this reason, successful processing often depends on controlling factors such as flowability, dust generation, caking, segregation, particle size distribution and blend uniformity.

Custom Powders applies its practical process experience to these challenges by selecting and combining technologies according to the characteristics of each product and the customer’s required outcome.

This can include everything from initial trials and process development through to optimisation and larger-scale production campaigns.

For customers, the result is a more flexible route to solving processing problems, developing new products or increasing production capacity without the immediate need to invest in dedicated equipment.

Key Trends Shaping the Future of Powder Processing

The powder processing sector is continuing to evolve, and several trends are likely to become increasingly important over the coming years.

Greater control of functional powder properties will be one of the most significant developments. Manufacturers increasingly need to understand not only particle size, but also how a powder behaves during conveying, dosing, mixing, packing and final use. Flowability, dustiness, caking and segregation are becoming increasingly important product and process parameters.

Integration of multiple processing stages is also likely to grow in importance. Combining milling with classification, blending with liquid addition, compaction with screening, or agglomeration with drying can help simplify production, reduce material handling and improve consistency.

Automation and accurate dosing are another important area of development. Continuous systems with loss-in-weight feeding, process monitoring and data logging can improve formulation accuracy, process repeatability and traceability.

At the same time, manufacturers are under increasing pressure to reduce waste, improve yield and control dust emissions. Technologies that allow fine material to be recovered and returned to the process can help reduce product losses while improving housekeeping and overall process efficiency.

There is also growing demand for more specialised and precisely engineered powders. Emerging applications increasingly require tighter control of particle size, density, purity and product behaviour. This creates a need for flexible processing partners capable of adapting equipment and process conditions to increasingly demanding product specifications.

A Processing Partner for Polish Industry

For Polish manufacturers in the chemical, food, plastics, animal health and wider industrial sectors, outsourcing specialist powder processing can provide a practical route to launching a new product, solving a specific processing problem or increasing capacity without committing immediately to major capital investment.

Custom Powders can support projects ranging from relatively small development work through to full commercial production, with access to a broad range of processing technologies within one organisation.

This flexibility allows customers to explore different process routes and select the most appropriate combination of milling, blending, formulation, compaction, agglomeration, drying, sieving and dedusting for their product.

Author: Pascal van Wegberg, Commercial Director, Custom Powders

Custom Powders will be exhibiting at SYMAS 2026 in Kraków on 14–15 October at EXPO Kraków. Visitors are invited to meet the team at stand C38 to discuss specific materials, process requirements and opportunities for trials, development or contract production.