High-speed and high-precision micro-milling (micronisation) play a crucial role in various industries, including pharmaceuticals, food production and the development of critical raw materials for battery production. Reducing the particle size of substances to enhance their properties and functionalities is often a vital step in making powdered products more effective, whether as ingredients for the latest oncology drugs or diverse, essential materials for making electric vehicle (EV) batteries.
By achieving particle sizes ranging from single digit µm, and up toto 100 µm through micro-milling, and 50 nm to 500 nm through nano-milling, the surface area of particles is significantly increased. This enhancement is particularly beneficial in pharmaceutical applications, where it improves properties such as solubility and bioavailability.
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Latest equipment on show at POWTECH
This September, Frewitt will be demonstrating the latest innovations in fine micronisation equipment from 23-25 September at the POWTECH show in Nuremberg, Germany. Highlights include the launch of Frewitt’s newest FlexMills – the PMC-260 and PMC-260 Cryo. Here we have an exclusive first look:
FlexMill PMC-260
The PMC-260 is a premium-quality, high-speed pin mill ideal for production applications requiring a high output of homogeneous, micronised granular products down to a fineness of 5 µm. FlexMill integrates two milling processes into a single platform, making the PMC-260 the best solution for combining micronisation and cost saving.
The continuous pin-mill is designed to process batches from 100g to 150 kg/h, while maintaining a compact and modular design so that it is easy to place in Laminar Air Flow (LAF) or to fully integrate into nearly any process flow. Frewitt’s famous modularity also ensures all PMC-160 and PMC-260 processing heads provide the operator with easy handling and cleaning.
Constructed to ensure optimal, reliable production in Good Manufacturing Practice (GMP) and high containment for a broad range of products, the PMC-260 has been designed to ensure that identical results are guaranteed in the scale-up from lab to pilot to full-scale industrial production scale levels.
Process characteristics:
- Size reduction range 2 mm – 5 µm
- Productivity 2 l/h – 150 l/h
- Temp. range of product -20°C to +60°C
- Product density up to 2kg / dm³
Suitable for pharmaceutical, battery, chemical and food processing, the PMC-260 includes as standard an integrated dosing system, integrated cooling system and mobile cart with lifting device; while options include WIP cleaning, controlled milling under inverted atmosphere, specific custom tooling, and pressure and temperature sensors, among many other additional features.
FlexMill PMC-260 Cryo
The PMC-260 Cryo features the same premium-quality, high-speed mill but for production applications requiring a high output of homogeneous, micronised granular products down to a fineness of 5 µm. The PMC-260 Cryo also features two milling heads in one system, as well as many of the same standard features, plus integration of the Cryogenic Feeder CF-25 and options which utilise liquid nitrogen to freeze materials to their point of brittleness, facilitating powder size reduction.
Due to its versatility and high performance, the mill can be used in many demanding milling processes: achieving optimum particle size distribution; milling temperature-sensitive products; or even potentially explosive substances.
Process characteristics:
- Size reduction range 2 mm – 5 µm
- Productivity 2 l/h – 150 l/h
- Temp. range of product -196°C to +60°C
- Product density up to 2kg / dm³
Featuring easy top-down cleaning, reduced product contact surface areas and reduced energy consumption, the PMC-260 cryo allows users to reduce polymer type products to powder and limits the phenomenon of degradation, hence preserving the quality of the milled product.
How fine micronisation and nano-milling are transforming industry
Pharmaceuticals
Active Pharmaceutical Ingredients (APIs) are a crucial part of many modern drugs and nano milling is a vital technique for improving the bioavailability of water-soluble APIs by reducing the API in size to the nanometre range, typically below 200nm, and then stabilising it with biocompatible surfactants. Increasing the surface area directly correlates to an increase in the dissolution rate of the final product and allows for highly concentrated solutions.
Such processes often require a completely sterile environment, and this is when having a specialised solution provider on board is key. Frewitt has been a key player in the pharmaceutical, battery, food and fine chemical industries for over 75 years and its nano-milling range contains specialist features to ensure the sterility of pharma products as well as automatic Wash-in-Place and Clean-in-Place (WIP & CIP) systems[i].
Batteries
Homogenous particle size distributions of both anode and cathode materials are critical in the battery market, as particle size distribution (PSD) homogeneity is required to ensure consistent conductivity from battery to battery. Stable temperatures are also required to ensure the preservation of the active properties and the end-users’ ability to work with the materials in subsequent down-stream processes.
Food products
Probiotics are gaining popularity for their perceived health benefits, so the ability to process dried, concentrated cultures into powders with predetermined particle sizes and density is essential. Shelf-life viability is key for producing probiotics in adequate quantities, and to maintain this, they must be manufactured in a robust, stable, and temperature controlled manner. Additionally, dried, concentrated probiotic cultures are the most convenient for incorporating into functional foods.
According to a recent report, functional foods global sales are expected to reach US$91.7 billion by 2030, so the capacity to mill such food products is essential[ii]. Frewitt has been developing dry and wet milling processes for the pharmaceutical, fine chemical and food sectors since 1946 and offers cutting-edge milling, sieving, homogenising, deagglomerating, conveying, dosing and filling systems for powders, granulates and suspensions[iii].
To learn more about the latest FlexMill innovations and see the FlexMill PMC-260 and FlexMill PMC-260 Cryo in person, join Frewitt live at the POWTECH Show Stand 12-566 on September 23-25, 2025 at Messe Nürnberg , Nuremberg, Germany.
[i] https://www.pharmaceutical-technology.com/sponsored/small-matter-big-challenges-nano-milling-in-a-sterilised-environment/
[ii] StrategyR, Probiotics World Market Report. https://www.strategyr.com/market-report-probiotics-forecasts-global-industry-analysts-inc.asp
[iii] https://www.just-food.com/sponsored/functional-foods-milling-dried-probiotics-material-and-cell-culture-media/
