Engineered Materials – Product Improvement Through Granulation

Engineered materials are a diverse group of substances such as polymers, ceramics, alloys, synthetic compounds or any combination of the aforementioned. Typically, engineered materials are developed to overcome some sort of challenge or to outperform a naturally occurring material. Often, these materials need to be manufactured or processed into a granular or powder form for maximum effect. Some common types of granular engineered materials include oilfield additives for drilling fluids, adsorbents, specialty fertilizers, fire retardants and much more.

The process of granulation, also known as agglomeration, compacts material into particles of a distinct size range and consistency. Granulation provides many benefits to engineered material such as ease of dispersion, particle uniformity, dust reduction, flowability, dissolution, transportation and manufacturing.

Engineered materials are often combined to create new products with enhanced benefits. One example would be to combine a specialty polymer with an engineered ceramic to create a novel fire retardant. Another would be an engineered two component fertilizer designed to provide different nutrients at different points in a plants lifecycle.

Co-granulation is an important technique when manufacturing an engineered material composed of two or more components. When co-granulating, the components are blended together then granulated in a continuous in-line process. This ensures that each particle produced has a uniform composition. If each component was granulated and then blended, the resulting mixture would be prone to particle segregation and other challenges.

At Stellar Manufacturing we have experience granulating engineered materials for a variety of industries. We can granulate both single component materials as well as provide co-granulation for multi-component materials. We have a variety of compaction systems (50, 75, 150, and 300-ton) and can manufacture particles in the 70 mesh to 1/2” range.

Do you have an engineered material that needs to be granulated? If so, please contact us at (618) 337-1700 or info@stellarmfg.com to find out how Stellar can support your manufacturing needs.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials for use in a variety of applications by Fortune 500 and 1000 companies.

The Pluses of Drilling Fluid Additives

Drilling fluid additives are important materials which enhance borehole drilling for oil, gas and fresh water. These additives are often composed of solid granulated particles which are then mixed with water, oil or other synthetic liquid to make drilling muds. Additives are used for a variety of reasons such as controlling the movement of rock cuttings, controlling drilling pressure, lubricating drill components and maintaining borehole structure and integrity. Without effective drilling fluid additives, it would be far more difficult to maintain drilling efficiency and well stability.

Drilling fluid additives can be made from many types of materials. Some are composed from common minerals such as bentonite, barium sulfate and calcium carbonate. Others are derived from engineered materials including polymers, polysaccharides and resins. When these additives are solid material, it is usually necessary to tightly control their particle size. Particle size is important to help ensure proper mixing with liquids and maintain the proper density under high pressures.

Stellar Manufacturing provides contract manufacturing and tolling services for companies developing drilling fluid additives. We have fully integrated 50, 75, 150, and 300-ton compaction systems and can produce particles in the 70 mesh to 1/2” range. Stellar also provides blending, mixing, filling and packaging services.

If your company is developing or manufacturing additives for use in the drilling industry, please contact Stellar Manufacturing to understand how our services can help you achieve your production goals. Our contact information is (618) 337-1700 or info@stellarmfg.com.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials for use in a variety of applications by Fortune 500 and 1000 companies.

Overcoming Particle Segregation with Powder Blending Techniques

One of the biggest challenges working with powder material is particle segregation. There are several powder blending techniques to overcome segregation. Particle segregation is essentially the de-mixing of a blended material. In common parlance we might say a mixture is “settling”. However, this is an oversimplification. Segregation is dependent upon several factors such particle size, density, moisture content and more. There are also many types of segregation including sifting, fluidization and dusting. Essentially, whenever a mixture moves there is a chance that some level of segregation can occur.

In manufacturing processes that involve blending powder, manufacturers take several steps to ensure a high degree of homogeneity is maintained. One of these steps is to constrain particle size variation through a process like compaction granulation. Compaction granulation is a common particle sizing technique frequently used for products made from powder based materials such as minerals, fertilizers and industrial chemicals. By maintaining a small particle size ratio, the rate at which each particle flows or moves should be relatively consistent. Therefore, segregation by sifting is reduced. Furthermore, selecting the correct manufacturing equipment is also important. Different types of delivery or collection systems may be prone to different types of particle segregation. Often modifying or changing a set-up can resolve segregation problems.

At Stellar Manufacturing we provide powder blending services for a variety of industries and products such as industrial chemicals, water treatment products and fertilizers. We have helped many companies incorporate blending as part of manufacturing process and have developed solutions to overcome challenges which include segregation, flowability and dusting. Stellar also provides compaction granulation, briquetting, tableting, filling and packaging services involving blended powder.

Find out how Stellar Manufacturing can assist with blending your powder based products and overcoming segregation challenges, contact us at (618) 337-1700 or info@stellarmfg.com.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials for use in a variety of applications by Fortune 500 and 1000 companies.

Four Reasons Why Agglomeration is Important in Chemical Manufacturing

Agglomeration is the process by which particles adhere to one another to create larger aggregates. These aggregate particles are held together by a variety of relatively weak physical and chemical forces depending on adhesion methodology. Often, uncontrolled agglomeration creates manufacturing problems for powder and particle based products such as consumer or industrial chemicals. To overcome these challenges manufacturers employ various agglomeration techniques. For example, Stellar Manufacturing uses roller compaction granulation. These techniques can help overcome challenges related to density, flowability, dusting and product integrity:

Density – By compacting powdered material to a desired density, manufacturers gain more control over dissolution properties. This can be important for products that need to dissolve at a controlled rate for an extended period of time such as water treatment chemicals.

Flowability – Finely powdered products frequently experience caking or sticking if they sit undisturbed for a period of time. In fact this is actually a form of uncontrolled agglomeration, and it can impact product performance as well as end-user experience. Manufacturers minimize uncontrolled sticking by agglomerating material into discrete particles of a controlled size and shape.

Dusting – Powder based chemicals are highly susceptible to dusting during manufacturing and application activities. This becomes a serious concern for chemicals that cause health problems if inhaled. By agglomerating material into larger, heavier particles manufacturers are reducing health risks.

Product Integrity – Agglomeration is often a critical manufacturing step to ensure product performance. Properly compacted material is essential when making durable tablets and briquettes with specific performance qualities. Therefore, bypassing the agglomeration process may increase product breakage and disrupt performance.

Agglomeration Services at Stellar Manufacturing

At Stellar Manufacturing we support a variety of chemical agglomeration activities. We provide mixing and blending for single or multiple component materials, and our fully integrated 50, 75, 150, and 300-ton roll compaction systems ensure your particulates are agglomerated at the optimum size and density. If you need further processing, Stellar can tablet and briquette your material to precise specifications, and our on-site filling, packaging and warehousing completes our comprehensive “Powder to Product” service offerings. To find out how we can help you manufacture your particle based product contact us at (618) 337-1700 or info@stellarmfg.com.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials for use in a variety of applications by Fortune 500 and 1000 companies.

Improving Water Treatment Chemical Performance with Tableting

Water treatment chemical performance is increasingly important as we maintain public safety and hygiene while also preserving our fresh water resources. These chemicals impact large portions of our daily life and we use them in cooling towers, toilet bowls, dish washers and swimming pools. Fortunately, we have several techniques which can help improve chemical efficiency while maintaining expected levels of health and safety. One of those techniques is chemical tableting.

Tableting provides a variety of benefits to water chemicals including:

• Controlled Release – Properly formulating a water treatment product can allow you to tightly control the rate at which your product dissolves. This means consumers gain greater control over the amount of chemical is released into a system over time.
• Pre-measured Units – Tablets are an ideal format if a product is intended to be used by the average consumer or by a workforce without in-depth technical training. There is less chance for miscalculating or over applying chemicals when the product comes as pre-packaged tablets.
• Easy and Clean Storage – Since tablets can come individually packaged or stacked in containers, there is a reduced chance of excess dusting and spillage which can be of concern with un-tableted material.

At Stellar Manufacturing, we provided a variety of tableting solutions for the water treatment industry. We have over 45 presses (mechanical, hydraulic and rotary) which can process material between 5 and 650 tons of pressure. We also support multiple shapes and sizes that range from 250 mg to 1200 grams. Stellar further supports tableting programs by providing on-site compaction granulation, blending, mixing, packaging and warehouse support services.

To find out how Stellar can support your water treatment tableting activities please contact us at info@stellarmfg.com or (618) 337-1700.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials.

Adding Value – Efficient Raw Material Processing

Adding value is the name of the game in the raw material business. If the process of adding value isn’t consistently efficient, a company risks reduced profitability or losing money. Two factors that significantly impact raw material value are proximity to processing facilities and transportation networks. When determining the feasibility of a new product or market, these factors must be carefully evaluated and balanced against customer pricing expectations.

Stellar Manufacturing helps raw material companies add value to their products through our processing services and ease of access to major transportation nodes. We provide compaction granulation, agglomeration and particle sizing services which helps prepare raw material for the next step in the manufacturing supply chain. In addition, we also help companies prepare products for end users through our mixing, blending, tableting, briquetting and packaging capabilities.

Stellar is centrally located in the U.S. in the St. Louis Metropolitan area. We have convenient access to rail and road transportation nodes as well as both the Mississippi and Missouri Rivers. As a result, Stellar’s combined processing capabilities and access to transportation makes it an ideal solution for companies looking to add value to their raw materials.

Our specialties include raw material such as:

• Solid Materials
• Powder Based Chemicals
• Agricultural Fertilizers
• Specialty Raw Materials
• Mined Materials and Minerals

To find out how Stellar can help add value to your raw material product please contact us at (618) 337-1700 or email us at info@stellarmfg.com.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. We provide services such as compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials for a variety of applications. Due to our technical expertise, experience and quality, our clients can rest assured their product production is in good hands.

When Is Specialty Tableting Right for Chemical Products?

Specialty tableting is the complex method of manufacturing tablets made from a formulation that consist of multiple chemical components, such as active ingredients, binders or other fillers. Often times the blending and mixing portion of the process is a crucial step in ensuring the final product meets performance specifications. For example, in order to ensure final product consistency, two or more ingredients may need to be blended together in-line, and then co-granulated prior to tableting. If not done in-line, then the tablet may not have a good uniform distribution of each chemical component, and could result in inconsistent performance properties. Essentially, specialty tableting is critical any time a product is made from two or more components, and therefore needs to be carefully balanced.

At Stellar Manufacturing we have comprehensive specialty tablet manufacturing capabilities to support a wide variety of chemical products. Furthermore we can support complex chemical formulations requiring specific manufacturing techniques such as blending, compaction granulation, tableting and packaging. Some of our capabilities include:

• Specialty blending and mixing equipment (ribbon, v-style, paddle, dual-cone, continuous)
• 50, 75, 150 & 300 ton Bepex MS Roll Compaction equipment
• Particle size reduction and selection equipment
• 45 mechanical, hydraulic and rotary presses capable of exerting 5 to 650 tons of pressure
• Tablet sizes from 250 mg to 1200 grams
• Controlled environment ensures proper temperature and humidity control
• Custom tablet shapes available

Want to find out how your chemical product can benefit from specialty tableting? Contact us at (618) 337-1700 or email us at info@stellarmfg.com.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is also a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. We provide services such as compaction granulation, briquetting, blending, tableting and packaging of materials for a variety of applications. Due to our technical expertise, experience and quality, our clients can rest assured their product production is in good hands.

Tolling Services for Consumer Products

Are you seeking tolling services to achieve greater efficiency and flexibility in manufacturing your consumer product? At Stellar we help companies like yours achieve their manufacturing goals and get products to consumers more quickly while maintaining the highest level of quality. We provide tolling and contract manufacturing services for powder and particle based products like household cleaning products, detergents and pet care products.

We differentiate ourselves from the competitions with our fully integrated services that can take you “from powder to product”. Stellar can granulate, mix, tablet, package and warehouse your product at its state-of-the-art, centrally located facility. We also specialize in handling chemicals that are highly caustic or may be a combustion hazard.

We invite you to contact us at (618) 337-1700 or info@stellarmfg.com to discover the great ways we can help you achieve your product manufacturing goals.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of materials in a variety of applications.

Manufacturing Water Treatment Chemicals and Safety

Safely manufacturing water treatment chemicals requires detailed forethought and planning. Often these chemicals are halogenated or oxidizing compounds and can be a hazard to both workers and facilities. Water treatment products can also be a combustion risk or may need to be sequestered from other reactive products. The safe manufacturing of water treatment chemicals and products requires special quality systems, safety programs, equipment and experienced staff.

At Stellar Manufacturing we have over 25 years of experience safely manufacturing water treatment chemicals for a variety of applications such as cooling towers, food processing, irrigation, agriculture, industrial effluent, potable water, pools and spas. We work with harsh chemicals like trichloro-s-triazinetrione and calcium hypochlorite as well as materials that are a combustion hazard on a regular basis. We even have equipment and manufacturing suites specifically designed for products that may be combustible. Our rigorous safety training and quality systems were developed with water treatment products in mind, and are applied to our extensive toll manufacturing services including compaction granulation, blending, briquetting, tableting, filling and packaging.

To find out how Stellar can support your water treatment product please contact us at (618) 337-1700 or email us at info@stellarmfg.com.

About Stellar Manufacturing

Stellar is a contract manufacturer with 25 years of experience helping companies manufacture consumer and industrial products. Stellar is a leader in solid particle and bulk material processing for products requiring unique safety and handling procedures. Our services include compaction granulation, briquetting, blending, tableting and packaging of chemicals and materials for use in a variety of applications by Fortune 500 and 1000 companies.