High Shear Mixer Granulator For Seasoning Powder: The Complete Buying Guide In 2025

1.What is high shear mixer granulator for seasoning powder?

AIPAK high shear mixer granulator

A high shear mixer granulator is an equipment used in industries for homogenous mixing powder and then converts them into medium to high density granules by using mechanical shear. It is perfect for free-flow, clean and hygienic seasoning powders or granulated seasoning products. It ensures the evenly mixing, controlled granulation and enhanced flow-rate because this machine has a mixing bowl, chopper and the high speed impeller.

2.What are the benefits of using high shear mixer granulator for seasoning powder?

Have you ever wondered, what’s the secret behind staying of seasoning powder smooth and perfect texture, full of flavor and clump-free? The secret lies in a game-changing machine known as high shear mixer granulator, the seasoning perfection. Let’s dive into the benefits you get by using high shear mixer granulator for seasoning powder.

A fast and uniform powder and granulation process

Uniform powder

Everyone wants a flavorful, hygienic and free of clump seasoning powder. The high shear mixer granulator mixes all the ingredients very uniformly.

In a very short time, it forms a medium to high dense granules which have excellent properties like compressibility and flowability and have amazing performance in terms of taste, texture and stability.

Improved powder flowability

Flowability

Are you tired of annoying sticky fine power? Well, the high shear mixer granulator transform the light and sticky seasoning powder into uniform granules which may be of medium or of high density. Now the denser seasoning granules can easily be handled.

You now must be thinking about the packaging of seasoning powder. The granulated powder has now high flowability which makes them easy handle, transfer and package.

Precise and accurate granule production

Precise and accurate granule production – Picture courtesy: minimalistbaker.com

The high shear mixer granulator mixes all the ingredients very well. This device also has a controlled size regulator and also has a shape control. Due to this, every granule hold same flavor, same size and same shape.

Consistent granule size improves the packaging mechanism and also appealing to both manufacturer and consumer.

Dust-free granule formation

Dust-free granules

The high shear mixer granulator mixes all fine seasoning powder into compact granules that when exposed to air, reduces the interaction of airborne dust. In this way, this equipment ensures the safety of product as well as of consumer, and high efficiency of production.

Enhanced product stability

Enhanced product stability

Some of the seasoning powder have volatile components which may affect the flavor of seasoning powder. When granules are formed, the sensitive and volatile ingredients are embedded with them. The granulation reduced the interaction of these ingredients with air resulting in the safer mode of ingredients and improved shelf-life.

Requires a small quantity of binder solution

Requires a small quantity oil as a binder solution

As this machine has high ability of mixing. By using small quantity of binder solution, it uniformly and consistently distribute it throughout the seasoning powder.

By using small quantity of binder solution, you can get original taste and color of seasoning ingredients.

Short powder drying time

Powder drying time

Due to less binder solution usage during high shear mixer granulation process, the resulting granules have less moisture content. This results into the quick drying process. After a drying, the manufacturer can proceed the process. In this way, in a short time, you can get high production.

Scalability

Scalability

The high shear mixer granulator is suitable for both small-batch product production and for large-scale industrial production. The different parameters like controlled particle size, quantity of binder solution etc. can be replicated in different sized batches, which ensures you in the uniform quality production.

3.What are the types of high shear mixer granulator for seasoning powder?

High shear mixer granulator is used for uniform mixing of seasoning powder such as chili powder blends, garlic-onion mixes and other spice blends. Sometimes, coating is also required for flavor consistency, increase flowability and compressibility, reduce dust exposure and smooth texture.

The following are commonly used types of high shear mixer granulator used in market:

Based on the position of bowl

Based on the position of bowl, they are divided into two types:

Vertical high shear mixer granulator

Vertical high shear mixer granulator-Picture courtesy: freund.com 

Vertical high shear mixer granulator structure consists of vertical cylindrical bowl having bottom-mounted the impellers that rotate in vertical position and on side, high-chopped chopper is mounted.

The purpose of these parts is to hold and mix powders, chop agglomeration and evenly distribute binder such as oil or liquid flavoring.

It ensures that your putted powders are mixed uniformly and allow controlled granule size and density.

It is suitable for batch-sized production in mid-sized facilities.

Horizontal high shear mixer granulator

AIPAK Horizontal high shear mixer granulator

The horizontal high shear mixer granulator consists of horizontal oriented bowl having both impeller and chopper mounted on side. Due to this property, mixing and blending occur at high speed.

You can get benefit from this machine if you have sticky or large batches because they need more shear force. If the seasoning powder has a high fat-content, then you can also get benefit from this.  This machine process at high speed that’s why you can get high stock in less time.

Based on the position of impeller and chopper

Based on the position of impeller and chopper, they are divided into two categories. Both types produce high quality granules but they have specific benefits. Let’s discuss the types.

Top-driven high shear mixer granulator

Top-driven high shear mixer granulator

In top-driven high shear mixer granulator, the impeller and chopper are fixed from the top of machine. The mixing bowl remains at the bottom.

It is suitable option for producing low to high density granules. You must have to implant it in clean and wide room where the operators have top access.

As the impeller, chopper and the bowl can easily be separated so, you can easily clean it. It provides hygienic mixing of seasoning powders and you can easily discharge the finished seasoning powder from the bottom which is implanted at the bottom of the machine.

Bottom-driven high shear mixer granulator

Bottom-driven high shear mixer granulator

In bottom-driven high shear mixer granulator, the impeller is attached to the bottom of the bowl and chopper may either fixed to the side or bottom depends upon the model. In this machine, you will observe that the mixing will start at the bottom in the impeller and then seasoning powder will circulate to upward side.

The cleaning of parts of this machine is a bit challenging and it has a moderate hygiene environment. It is a suitable option for dense seasoning powders like cheese and masala blends.

4.What are the main components of high shear mixer granulator for seasoning powder?

The number of components of machine and designs may vary for various types of machine but the main components of high shear mixer granulator are listed below:

1.Bowl lid

2.Liquid inlet

3.Chopper

4.Impeller

5.Mixing bowl

6.Granule outlet

7.Motor and gearbox

8.Control panel

Components of high shear mixer granulator for seasoning powder

Component of machine	Function
Bowl lid	You will noticed the bowl lid in every machine. The purpose of this lid is to seal the mixing chamber. During operating the machine, due to high-speed operation, the powder may have chances to escape but this lid prevent the seasoning powder to escape. It also provide safety to seasoning powder against contamination and dust particles. It also has viewing windows through which you can see and inspect the process.
Liquid inlet	It is also called binder spray nozzle. During wet granulation, through this inlet, binder solution which may be water, starch or oil solution is sprayed into the seasoning powder. Due to spraying of binder solution, you can get controlled and even granulation.
Chopper	Chopper is high-speed and sharp blades that is located inside the mixing bowl. The function of chopper is to chop the large sized or lump of powder into small sized particles to increase the surface area for interaction with other seasoning powder. If you want to spray the binder solution into seasoning powder, then chopper evenly dispersed the binder throughout seasoning agents. It also plays a vital role in controlling the granule sized that you desire.
Impeller	In impeller, seasoning ingredients are properly mixed and push the materials towards the chopper to produce controlled granule size. It also start the granulation procedure through mechanical force. It add salt, pepper and flavor to the seasoning powder.
Mixing bowl Mixing bowl-Picture courtesy: gangsons.com	The mixing bowl is usually stainless steel bowl where impeller and chopper reside in or on the side of bowl. Here, you pour seasoning ingredient for mixing and granulation procedure. It provide safe and contaminated free environment to the seasoning powder.
Granule outlet	It is also called as discharge valve. After the completion of mixing and granulation, this outlet can open for discharging of finished seasoning powder. It is designed in unique way to prevent clogging formation and you may get hygienic and clean finished product. Then, they wet granules are set for drying and you will get seasoning powder for storage.
Motor and gearbox Gearbox	Usually two motor are used. One to rotate the impeller while the other to rotate the chopper for speed control and torque adjustment. The gearbox ensures that torque transmission occurs.
Control panel	The control panel is used for the adjustment of various parameters used for proper granule and finished seasoning powder obtaining. The parameters include size of granule, time, density of granules and rotating speed of impeller and chopper etc.

5.What are the working steps of a high shear mixer granulator for seasoning powder?

There are too many high shear mixer granulators for seasoning powder are available in the market. You may be thinking about the working steps of these different machines. The working steps is almost same for each machine. Let’s discuss the steps involved in high shear mixer granulator for processing seasoning powder.

Loading of dry ingredients into the mixing bowl

Loading of dry ingredients

In pre-processing step, you can use sieve to remove any lump or foreign agent in the powder. This will ensure you to uniformly mix the seasoning powder. Then, you have to precisely measure and weigh the seasoning powder.

The weighted ingredients of seasoning powder is then loaded into the mixing bowl where all seasoning powder mixes well. These seasoning powder are typically spices, ginger powder, salt, sugar, flavor enhancers and anti-caking agents.

Dry-mixing of ingredients

Dry mixing of ingredients-Picture courtesy: AIPAK

In the second step, you will see that all the dry ingredients are mixed well before the binder liquid is inserted.

The impeller operates at a moderate speed and it ensures the mixing of ingredients and also the radial and lateral flow of materials. The materials are then pushed to the chopper which operates at higher speed. Here, all the agglomeration in seasoning powder is broken down into fine pieces.

In the dry-ingredient mixing step, it ensures that all the seasoning powder is mixed well and homogeneously.

Addition of binder

Addition of binder-Picture courtesy: ivenpharmatech

If you are using ingredients having volatile components or you want to add flavor in to the seasoning powder then you have to add binder solution. Binder solution typically are starch, water or oil.

Through nozzle system, a binder solutions are sprayed into the seasoning powder at controlled rate. Don’t over-wet the powder.

Granulation

This step is an important milestone where the binder solution mixes well into the seasoning powder by the combined action of the impeller and the chopper. The impeller compacts the wet mass by mechanical force while the chopper cuts and shears the particles.

You may check the granule size and consistency of seasoning powder.

Detection of end-point

Detection of end-point (formation of granules)

How will you know when to stop the machine? The end-point detection is done either by operator or machine itself. An operator may stop the machine and check the desired granule size and density. Some machines also have sensors that detect the selected size and density of seasoning powder and then stop.

You will get fine and free of lump seasoning powder which adds a delicious taste to your food.

Discharge of finished seasoning powder

Discharging of seasoning powder

Once you get your desired seasoning powder, the discharge valve at the bottom of the machine opens. Through this valve, you can collect the finalized seasoning powder either manually or some machines also have air jets which propel the seasoning powder outside into the tray. This powder can now be set for the drying.

6.What is the application of high shear mixer granulator in seasoning powder industry?

In the heart of every pinch of seasoning powder lies a fascinating story. This pinch tells us the tireless effort of high shear mixer granulator in food industry to provide us consistent, dust-free and hygienic blend. Some of the applications of high shear mixer granulator in seasoning powder industry are as follows:

Spice and seasoning blend manufacturing

Spice and seasoning blend

High shear mixer granulator is widely used for spice-manufacturing. It allows the mixing of dry ingredients like chili, salt, garlic, turmeric and onion powders and for flavor, starch etc. This machine allows the homogenously mixing of these ingredients and you’ll get ready-to-cook seasoning powder.

Instant seasoning powders for packaged food

Seasoning powder sachets for packaged food

This machine is also used in industries that manufacture seasoning sachets for noodles, Maggi, snacks, pasta and frozen food. The HSMG ensures the immediate dissolution of seasoning by putting it into hot water. This allows greater flowability and is ready to package in packets.

Seasoning cubes ( wet granulation)

Seasoning cubes

The industries that make seasoning cubes like Knorr cubes or chicken cubes also use high shear mixer granulator. As HSMG allows the spraying of liquid binder into the dry powder for enhancing flavor and shelf-life. So, for this purpose, the wetting of seasoning powder is then compressed into balls which then changed into cubes.

Fortified seasoning powder

Fortified seasoning powder-picture courtesy: Etsy.com

Some industries add micronutrients like zinc, vitamins, herbs etc. to seasoning powder to produce healthy seasoning powder. The impeller and chopper mixes these micronutrients into the seasoning powder, without compromising the flavor. This ensures that every pinch of seasoning powder has an equal amount of micronutrients. This seasoning powder not only add flavor to your food but also you get health benefits by using it.

Flavored granules ( chips, popcorns )

Flavored granules- picture courtesy: sugarhero.com

Some industries prepare flavored granules like chips and popcorns etc. They add flavor or oil to coating these granules which allows stability and shelf-life. The high shear mixer granulator allow the mixing and coating of oil and flavor. The coated granules have a better aroma and longer shelf-life.

7.What are the critical process parameters for high shear mixer granulator for seasoning powder?

Quality-controlled parameters

Have you ever wondered why every pinch of seasoning powder have same taste, color and free of clump? High shear mixer granulator have some of the controlled parameters which allows the seasoning powder has the same taste, flavor and flowability. Some of the parameters are listed below:

Parameters	Function
Impeller speed	You must adjust the desired speed of the impeller because the function of the impeller is to mixing and shearing of ingredients. If its speed is too low, the ingredients may not mix well and if too high, then the ingredients will over-shear and resulting in the degradation of ingredients. This may also cause heating which can cause damage.
Chopper speed	Chopper speed should also be carefully handled. A chopper can form granules by breaking down the lumps. If the speed of the chopper is too slow, it will not form granules. If the speed is too high, maximum fine particles will be generated and can also cause overheating.
Binder quantity	Binder solution is used for wet granulation. You have to put moderate amount of binder solution into the seasoning powder. If the quantity is too-little, the formed granule will be rough and dusty while by adding too much binder solution, it will create sticky cubes having less flowability.
Mixing time	Mixing time directly impacts the aroma and consistency of the batch. It is the time when dry mixing and wet granulation occur. If it is too short, then you will get unblended flavor while if it is too long, it will over processed and can affect the flavor.
Temperature	You must have a controlled temperature environment especially if you have volatile and heat-sensitive components in your ingredients. Because it may affect the aroma, color and flowability of your desired seasoning powder.
Humidity control	You must have a humidity control system typically maintained between 30%-50%.  In seasoning powder, mostly hygroscopic ingredients like sugar, salt and spice extracts are present. They absorb moisture and lead to loss of aroma, clumping and non-uniform granulation production. By disrupting these qualities, you may get unwanted seasoning powder.

8.What safety factors to be considered while operating high shear mixer granulator for seasoning powder?

Safety is not an optional in the world of flavor in fact, it is essential. When you are handling the food equipment like high shear mixer granulator for seasoning food, you must have to consider some safety measures. Here are some of them are listed below:

Machine interlock

Machine interlocks

In high shear mixer granulator, lids and ports are there. The lid is used to cover the mixing bowl and from it, you can also inspect inside process of the machine. Before operating the machine, you must make sure to lock the lids and ports in order to avoid any accidents.

By ensuring the locking of these parts, you may never meet any mishap.

Overload protection

Overloading protection

While operating the machine, make sure to adjust the system. This will protect you from any unfavorable result.

Also make sure to avoid overloading. If overloading occur, then motor or other equipment may have chance of damage.

Easily accessibility to emergency button

Emergency button-Picture courtesy: alternative-doctor.com

In case of any emergency, make sure that emergency button is accessible to you. If any misfortune occur then you will have to shut down the system.

Dust- controlled system

Dust-controlled system-Picture courtesy: allprep.com

In the food industry, a hygienic environment is the first priority. You may have a dust extraction system or operate the machine in a closed system. This will prevent any cross-contamination into your seasoning powder.

Training and SOPs

Operator and SOPs

Operators must be trained in handling and cleaning and have problem solving abilities. It is also important for operators to wear a gloves, a face mask, a hairnet and a protective clothing. This will create hygienic and clean environment for seasoning powder.

9.What safety factors are to be considered while operating high shear mixer granulator for seasoning powder?

While operating high shear mixer granulator for seasoning powder, don’t compromise on hygiene because it is essential. Here are some of the hygienic measures that you must to be consider while manufacturing seasoning powder.

Features	Detail
Material of construction	The parts of the machine must be of stainless steel which may have a chances of corrosion and is good for carrying food ingredients.
Easy-to-clean design	The machine parts may also be able to disassemble. Due to this feature, you can easily clean the machine and may have no chance of the residue retention and microbial growth.
CIP system for cleaning	The machine must have clean_in_place and steam-in-place system. This will allow to clean the residue in your machine without requiring disassembly of machine parts.
Routine sanitation Sourced:wrappedinrust.com	You must have clean and sanitize the machine parts in order to prevent any microbial growth or cross-contamination.
Proper sealing	You must have to seal the machine to prevent any entry of foreign agent or contamination. Otherwise, this will enter into the seasoning powder as well and that is risky.

Conclusion

In conclusion, the high shear mixer granulator is used in the food industry for seasoning powder. It converts raw materials into powder and then into flavored granules. The granules have excellent flowability and compressibility. There are different types of high shear mixer granulators are present in the market. The working principle is almost the same for every high shear mixer granulator but every machine has its own advantages. It is also used in different industries for making seasoning powder. While operating the machine, you must have to consider some safety and hygiene factors to ensure clean seasoning powder production. If you still have any queries, feel free to reach AIPAK!