Continuous Kneading with a More Cleanable Solution: A Step Forward in Powder & Bulk Solids ProcessingContinuous Kneading with a More Cleanable Solution: A Step Forward in Powder & Bulk Solids Processing
The move from batch to continuous kneading is a significant opportunity for manufacturers to enhance efficiency, consistency, and scalability.
January 16, 2025

As demands for efficiency, consistency, and scalability grow, many manufacturers are considering the benefits of continuous processing. Transitioning from batch to continuous kneading, especially upstream of extrusion, offers many benefits that can enhance production lines and product quality when mixing powder and bulk solids to a desired consistency. Historically continuous kneaders have been difficult to clean, limiting their implementation in settings where versatility and cleanability are paramount due to sanitary or cross contamination concerns campaign to campaign. With new advancements, the difficultly to clean out at smaller scales has been reduced, making it more advantageous than ever.
Understanding Batch Kneading
Batch kneading involves processing a set amount of material in individual batches. Ingredients are loaded into a mixer, kneaded until they reach the required homogeneity, and then discharged before the next batch begins. While this method has been the industry standard for years, it presents several limitations:
Batch to Batch Variations: Variations can occur due to differences in mixing time, temperature fluctuations, or human error during ingredient loading. Segregation and moisture variation is more likely due to additional handling required prior to downstream continuous processing, namely extrusion, resulting in inconsistent product.
Process Rate Limitations: Downtime between batches for loading, unloading, and cleaning can reduce overall productivity.
Economy of Scale Issues: Increasing production requires proportionally more equipment and space, leading to higher capital expenditures. Labor and other operational cost are also higher.

The continuous kneader provides a homogeneous mix of liquids and powders.
The Continuous Kneading Advantage
Continuous kneading, on the other hand, processes materials in a nonstop flow. Ingredients are continuously fed into the mixer, kneaded, and then moved along the production line. This method addresses many of the shortcomings of batch processing:
Enhanced Consistency: Continuous kneading ensures uniform mixing conditions, leading to a consistent product quality throughout the production run. Flow directly to downstream continuous process limits potential for segregation and/or moisture content uniformity issues.
Increased Efficiency: By eliminating the downtime associated with batch processing, manufacturers can achieve higher throughput and better utilization of equipment.
Scalability: Adjusting the feed rate allows for easy scaling of production without significant changes to the existing setup.
Reduced Labor and Operational Costs: Automation reduces the need for manual intervention, lowering labor costs and minimizing the risk of errors.
Environmental Benefits: Continuous processes often consume less energy and generate less waste, contributing to sustainable manufacturing practices. A more cleanable continuous kneader also reduces wash water required which is typically a disposal.
What to Look for in Mixing & Kneading Equipment
There are many options for mixing and kneading solutions out there depending on your needs. Here are a few things to keep in mind when selecting a continuous mixing/kneading solution:
Versatility: Look for a mixer that gives you the ability to alter residence time with minimal changes to allow for a wider range of applicability. Could be in the form of adjustable feed ports, screw/paddle/kneading blade configuration, baffles etc. Look for jacketed options as well for temperature control.
Consistent Product Quality: Look for a mixer that gives you uniform processing conditions and maintains steady mixing parameters to give you homogeneous products throughout the production run.
Scalability: Having the ability to adjust feed rates and operating parameters will allow you to scale production volumes without significant equipment changes.
Ease of Integration: Systems designed for seamless incorporation into existing production lines.
Ease of Cleanability: Removable components for ease of cleaning allow for quicker transitions between products with minimal wastewater and lowest chance of residual.

Batch kneader
Making the Transition
Shifting from batch to continuous kneading requires careful planning and consideration of various factors:
Process Evaluation: Assess the suitability of continuous kneading for your specific materials and products.
Equipment Selection: Choose mixers and kneaders that align with your production goals and material characteristics.
Staff Training: Ensure that your team is equipped with the knowledge and skills to operate and maintain new equipment.
Pilot Testing: Implement pilot runs to fine-tune process parameters and address any potential issues before full-scale production.
The move from batch to continuous kneading is a significant opportunity for manufacturers to enhance efficiency, consistency, and scalability. This transition can lead to improved product quality and a stronger competitive edge in the market. Embracing continuous kneading is not just a technological upgrade—it's a strategic decision that positions manufacturers for future growth and success.
Lauren Petraglia is sales manager, granulation, LCI Corp. For more information call 704-931-5034 or visit www.lcicorp.com.
Lauren Petraglia has been involved with low-pressure extrusion and spheronization since joining LCI Corp. in 2011. Her responsibilities include evaluation of potential applications, providing technical training presentations, scale-up from laboratory to production, system commissioning, and technical support. Petraglia holds a B.S. in Biology from the Pennsylvania State University.
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