In the food industry—particularly for high-end chocolates, confectionery coatings, and specialized baking—the particle size of sugar powder directly determines the sensory mouthfeel and flowability of the final product. Recently, Epic Powder successfully implemented a customized Air Classifier Mill (ACM) system for a major food ingredient manufacturer in South Africa. The project achieved a breakthrough D90 target of 6.3–6.7 μm, representing a major advancement in sugar ultra-fine grinding technology.
Project Background & Core Challenges
The South African client aimed to supply ultra-fine sugar powder that meets the highest international standards. Conventional industrial sugar powder typically maintains a D90 between 20 μm and 40 μm. However, pushing the particle size limit to below 7 μm introduced several significant technical challenges.
- Thermal Sensitivity & Caking: Sugar is highly susceptible to melting or sticking due to mechanical heat generated during high-speed grinding, which often leads to screen blinding or off-spec particle sizes.
- Ultra-Narrow Particle Size Distribution (PSD): Maintaining a D90 within the strict range of 6.3-6.7 μm requires extreme precision. Any presence of “over-sized” particles would compromise the quality.
- Hygroscopicity Management: At such a fine scale, the massive specific surface area makes the sugar powder extremely prone to moisture absorption and subsequent clumping.
Technical Solution: Эпический порошок Воздушный сепаратор (ACM) System
To address these challenges, the project utilized the Epic Powder ACM Series. This flagship system integrates grinding and classification within a single unit. It is widely recognized as an efficient solution for sugar ultra-fine grinding, especially when processing heat-sensitive materials with medium-to-low hardness.
1. Equipment Specifications & Performance
- Core Equipment: Epic Powder Air Classifier Mill (ACM System)
- Finished Particle Size: D90 = 6.3 – 6.7μm (Significantly exceeding industry standards)
- Rated Capacity: 100kg/h (Maintaining high throughput at ultra-fine specs)
- Raw Material: Refined White Granulated Sugar (Sucrose)
2. Process Highlights: Achieving Precision at Scale
Integrated High-Efficiency Classifier:
The mill features an internal, independently driven high-speed classifying wheel. Ground material rises with the airflow; only particles reaching the sub-6.7μm threshold pass through, while coarser particles are rejected back to the grinding zone. By finely tuning the wheel speed and air volume, the D90 is locked precisely within the client’s requested window.
Temperature Control & Cold Air Injection:
Sugar has a relatively low melting point. Without proper cooling, heat generated by high-speed grinding can cause softening and agglomeration. To prevent this issue, the ACM system is equipped with a chilled air injection compensation system.
The cooling airflow rapidly dissipates heat generated by the grinding disc and rotor. This keeps the grinding chamber temperature well below the softening point of sugar. As a result, the equipment can operate continuously and stably while maintaining the ultra-fine particle size requirement.
Negative Pressure & Explosion-Proof Design:
The entire system operates under negative pressure, ensuring zero dust leakage. Given the high explosion risk of ultra-fine organic dust, the equipment integrates explosion-venting devices and anti-static filter media, complying with international food safety and ATEX standards.
Client Benefits & Feedback
The South African client reported that the commissioning of this equipment has provided a significant competitive edge:
- Quality Transformation: This ultra-fine sugar powder integrates more seamlessly with cocoa butter in premium chocolate coatings, providing a superior, grit-free experience.
- Process Streamlining: The extremely fine D90 reduces the time required for subsequent refining/conching stages, boosting overall factory efficiency.
- Batch Consistency: With the D90 fluctuation held within a 0.4μm margin, the client ensures total consistency across all production batches.