Accelerating fertiliser slurry preparation and eliminating nozzle blockage with Fristam Powder Mixer

Rapid wet–dry ingredient induction and inline particle size reduction for continuous chemical filling

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Introduction to the application and industry overview

Production of liquid fertilisers, mineral suspensions and agrochemical slurries requires reliable incorporation of dry powders into liquid carriers, followed by controlled particle size reduction and stabilisation to ensure consistent filling and product performance. Common challenges in fertiliser and chemical mixing include extended batch times, incomplete powder wetting, agglomeration, sedimentation and downstream nozzle blockage, all of which reduce plant efficiency and profitability.

Inline powder induction combined with rotor-stator shear dispersion enables rapid solids incorporation, uniform slurry homogeneity and stable particle size control, supporting efficient large-scale fertiliser and chemical manufacturing.

Customer brief

A Brazilian fertiliser processor manufactured a mineral-based fertiliser slurry that incorporated multiple solid ingredients followed by addition of 0.25 % xanthan gum stabiliser to prevent separation. The mixture was prepared in a large agitated batch tank, then transferred to a filling system where product passed through a dispensing nozzle into packaging.

However, the processor faced two critical production issues:

Extremely long batch preparation time of 40 hours per batch
Frequent nozzle blockage caused by oversized lumps

These limitations resulted in production shutdowns, material waste and lost profitability, prompting the search for a more efficient fertiliser mixing technology.

Previously unsuccessful methods

Traditional tank agitation for wet-dry incorporation required up to 40 hours per batch to fully disperse mineral powders.
Even after prolonged mixing, the slurry often contained large agglomerates that:

Could not pass through the dispensing nozzle
Forced line shutdown and manual clearing
Required discarding blocked material
Increased operational cost and production delay

This highlighted the need for controlled powder induction and inline shear dispersion rather than extended batch agitation alone.

Fristam’s solution

A Fristam Powder Mixer – a fully mobile skid featuring an induction pump to draw in liquids, a hopper to pour powders and minerals and a shear blender.

Within this configuration, all fertiliser particles are forced through the shear zone, eliminating clumps and producing a slurry suitable for uninterrupted dispensing and packaging.

This approach delivers rapid wetting, homogeneous mixing and consistent particle size, which are essential in fertiliser, agrochemical and suspension-based chemical production.

Trial set-up

1. The liquid media was drawn into the Fristam Powder Mixer and recirculated in the system.

2. The minerals and stabiliser powders were poured into funnel.

3. The integrated Fristam FZ self priming liquid ring pump drew powders smoothly into the liquid stream, preventing dusting and agglomeration.

4. The mixture passed through the inline rotor-stator blender, where particles were uniformly sheared and reduced.

5. Stabiliser addition supported suspension stability and separation resistance.

6. The finished fertiliser slurry flowed to the dispensing nozzle and packaging line without blockage.

Do you have any questions so far?

Please don’t hesitate to contact our customer support. We would be happy to answer any questions you may have about our case studies or similar challenges, and we will provide effective solutions tailored to your needs.

Process / Product quality benefits

Rapid wet-dry ingredient incorporation and slurry homogenisation
Complete deagglomeration and controlled particle size reduction
Stable suspension quality with xanthan-based separation control
Reliable clog-free dispensing and packaging performance
90% Faster process

Sustainability benefits

Lower energy consumption due to shorter mixing cycles
Reduced raw-material waste from blocked or off-spec batches
Efficient utilisation of existing processing infrastructure

Financial benefits

90 % reduction in batch mixing time
Elimination of downtime from nozzle blockage
Reduced material waste and rejected product
Improved throughput and production profitability

Other benefits

Controlled powder induction with minimal dust generation
Hygienic, enclosed inline mixing suitable for chemical environments
Scalable solution for fertiliser, agrochemical and suspension processing
Strong value for OEM skid builders, EPC contractors and plant engineers

Similar applications

Fristam Powder Mixer technology is widely applicable across liquid fertilisers, micronutrient suspensions, soil conditioners and agrochemical formulations requiring reliable powder wetting and dispersion.
Typical fertiliser powders may include mineral salts, trace elements, buffering agents, stabilisers or functional additives, all of which must be uniformly incorporated without agglomeration.
Comparable mixing challenges also occur in industrial chemicals, pigments, coatings, water-treatment slurries and specialty suspensions, where rapid powder induction, particle size control and clog-free transfer are essential for continuous production.

Frequently Asked Questions

Dry mineral powders tend to agglomerate, float or form lumps when added to liquid carriers, making complete incorporation slow and inconsistent without controlled induction and shear.

Find the optimal solution for your needs in the chemical industry

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

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Accelerating fertiliser slurry preparation and eliminating nozzle blockage with Fristam Powder Mixer