Simple powder induction for pharmaceutical liquid formulations using the Fristam PE Powder Incorporator

Efficient incorporation of soluble powders into liquid batches for pharmaceutical manufacturing

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Introduction to the application and industry overview

In pharmaceutical manufacturing, many liquid formulations require the controlled incorporation of dry powders into a liquid base. These powders may include excipients, stabilisers, active ingredients, or functional additives used in syrups, suspensions, and other liquid pharmaceutical products.

Achieving rapid powder wetting is critical to maintaining consistent formulation quality and batch reproducibility. When powders are added directly to open tanks, they often float on the liquid surface, form agglomerates, or dissolve slowly, which can extend mixing times and compromise uniformity.

Powder induction systems provide a more reliable solution by introducing powders directly into a moving liquid stream, enabling rapid wetting and controlled dispersion before the mixture returns to the process vessel.

The Fristam PE Powder Incorporator is designed for this purpose, providing a simple and efficient method of inducting soluble powders into liquid formulations used across pharmaceutical, food, beverage, and personal care manufacturing environments.

Customer brief

A pharmaceutical manufacturer producing liquid formulations required a more controlled method for adding powdered ingredients into process tanks during batch preparation.

The existing process relied on manually adding powders into liquid vessels where they were dispersed using standard tank agitation.

While this approach was workable, the manufacturer experienced several operational challenges:

Slow wetting of powdered ingredients
Risk of powder floating and agglomeration
Inconsistent dispersion of ingredients
Increased operator handling during powder addition

Because the powders used in the formulation were readily soluble, the manufacturer did not require an aggressive high-shear powder mixer. Instead, the requirement was a simple and reliable powder intake solution capable of inducting powders into the circulating liquid stream efficiently.

Previously used methods

In the original process configuration, powders were added directly to the top of the process tank. Once added, the ingredients relied on tank agitation to disperse into the liquid base. This traditional method presented several common challenges associated with tank-based powder addition:

Powders often floated on the surface before wetting
Clumps could form before full dispersion
Mixing times increased while operators attempted to fully dissolve the powders
Manual powder handling increased operator workload

Process engineers therefore sought a more efficient powder incorporation approach that could improve wetting while simplifying the production workflow.

Fristam’s solution

To improve the powder addition process, the manufacturer implemented the Fristam PE Powder Incorporator as a dedicated powder intake station.

The PE system uses a self-priming side-channel pump to create suction within the liquid stream, drawing powders directly into the flowing product as they enter the system. Unlike traditional tank addition methods, the powder is immediately wetted as it enters the liquid flow, preventing floating powders and improving dissolution behaviour.

The system is mounted on a compact skid with a waist-height hopper for ergonomic powder handling, allowing operators to safely add ingredients without climbing ladders or lifting bags above tanks. This configuration provides a straightforward powder induction method for pharmaceutical batch preparation.

Trial set-up

1. System integration
The Fristam PE Powder Incorporator was installed alongside the existing mixing vessel and connected to the liquid system so that product could be circulated through the powder induction unit.
Liquid was drawn from the tank and passed through the PE before returning to the vessel.

2. Controlled powder addition
Operators added powdered ingredients through the PE hopper. As the powders entered the system, they were immediately pulled into the liquid stream generated by the side-channel pump.

3. Powder induction into the liquid stream
The suction effect created by the pump ensured the powders entered the flowing liquid stream directly. This forced-flow intake rapidly wets powders, preventing surface floating and reducing the risk of clumping during addition.

4. Continuous blending
The powder-liquid mixture returned to the process tank, where it could continue circulating until the formulation was fully prepared. This approach allowed ingredients to be incorporated efficiently while maintaining the existing batch process.

Following implementation of the Fristam PE Powder Incorporator, the manufacturer achieved a more controlled and efficient powder addition process during liquid formulation preparation. By inducting powders directly into the liquid stream, the system eliminated several issues associated with manual tank addition.

The improved wetting behaviour helped create more uniform mixtures and more predictable batch preparation, while simplifying the overall powder handling stage. As a result, the powder incorporation stage became faster, safer, and easier for operators to manage during production.

Do you have any questions so far?

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Process / Product quality benefits

Rapid wetting of soluble powders during addition
Improved dispersion of powdered ingredients into liquid formulations
Reduced risk of powder floating or agglomeration
More consistent ingredient incorporation during batch preparation
Reliable powder induction into circulating liquid streams

Sustainability benefits

Reduced raw material loss caused by floating powders
Improved ingredient utilisation through rapid wetting
More efficient mixing cycles during batch preparation

Financial benefits

Reduced labour required during powder addition
Simplified mixing process compared with manual tank addition
Improved process efficiency during formulation preparation

Other benefits

Ergonomic waist-height powder hopper improving operator safety
Compact skid-mounted system suitable for integration into existing process lines
Simple and operator-friendly powder induction system
Hygienic stainless-steel construction suitable for pharmaceutical production environments

Similar applications

The Fristam PE Powder Incorporator is ideally suited for:

Pharmaceutical syrups and suspensions
Powder excipient incorporation in liquid formulations
Vitamin and nutraceutical premixes
Protein and functional ingredient dissolution
Personal care and cosmetic liquid formulations
Beverage premixes and flavour bases
Dairy formulations with milk powders or stabilisers
Chemical solutions requiring powder dissolution

Frequently Asked Questions

The most efficient method is powder induction into a moving liquid stream rather than adding powders directly to a mixing tank. Powder induction systems draw powders into the liquid flow using pump-generated suction, ensuring immediate wetting and dispersion.

This approach prevents powders from floating on the surface of the liquid and reduces the risk of clumping. It also improves formulation consistency and reduces mixing time during pharmaceutical batch preparation.

Find the optimal solution for your needs in the pharma industry

In addition to mixing & blending technology – check out Fristam’s full range of pumping technologies suitable for the pharma industry.

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Simple powder induction for pharmaceutical liquid formulations using the Fristam PE Powder Incorporator