What is a powder induction mixer?
A powder induction mixer is an inline rotor-stator mixer built for one job: mixing powder into liquid. It creates a vacuum in the flowing liquid, draws the powder in, mixes it with the liquid and pumps it out, wetting it instantly.
We sell it as the liquid powder mixer (LPM). It is also called a solid liquid induction mixer, a powder liquid mixer, an inline powder liquid mixer or a powder induction system. It is one of the four kinds of inline high shear mixers we make, alongside inline homogenizers, the Super Mill and shear pumps.
What it does:
- Dust-free, loss-free and contamination-free powder dispersing and mixing.
- No lumps or agglomerates. The solids are dosed directly into the stream, mixed thoroughly in the liquid and then pumped into the vessel.
- Up to 80% solids in the final product, re-circulated to get the result you need.
- No foreign air is entrapped in the flowing stream, because the powder stream is much denser and thicker.
- Large volumes or small amounts. It handles large volumes of solids as well as small quantities of critical active ingredients.
How a powder induction mixer works
- Vacuum. The liquid flows through the rotor-stator working head, which is designed to generate a strong vacuum directly in the flowing stream.
- Induction. The vacuum draws the powder into the process line from the feed point: a silo, sack, hopper or barrel. The powder enters below the liquid surface.
- Wetting and dispersion. The powder is wetted and dispersed at once under high shear, so it cannot clump on the surface, and no foreign air is entrained in the stream.
- Discharge. The mixer pumps the slurry out, uniform, lump-free and ready for the next process step.
The LPM works in a continuous line or on a batch with re-circulation. On a batch, the product goes round until it reaches the solids content and result you need.
Powder feeding options
The LPM can take powder from any of four feed points, chosen to suit your plant layout and batch volume:
- Jumbo bag unloading system: high-volume, bulk powder handling
- Silo feed: continuous, large-scale production lines
- Flexible hose connection: routing from remote storage or mobile totes
- Hopper feed: manual or semi-automated small batches
Systems can include automated dosing and mechanical sealing options, for example for long batches or corrosive service.
For a bag tipping station, jumbo bag unloading and a suction wand combined with a high shear mixer, see our bag tipping unit with high shear mixer.
LPM models and powder induction rates
| Model | Motor power | Powder induction rate (kg/min)* |
|---|---|---|
| LPM 10 | 10 HP | 30–75 |
| LPM 20 | 20 HP | 75–125 |
| LPM 30 | 30 HP | 100–175 |
| LPM 50 | 50 HP | 150–275 |
| LPM 75 | 75 HP | 250–375 |
| LPM 100 | 100 HP | 350–475 |
| LPM 150 | 150 HP | 450–575 |
| LPM 200 | 200 HP | 550–675 |
*Rates are based on calcium carbonate (CaCO₃) added through a hopper. The actual rate depends on the powder or solid and on how it is fed (jumbo bag, silo or flexible hose).
Send us your powder and liquid details and we will give you induction-rate data for your product.
What a liquid powder mixer is used for
Any process where large amounts of solids go into a liquid.
- Polymer hydration (CMC, HEC, guar gum, xanthan gum). Each polymer particle is wetted in a controlled shear zone before the viscosity builds, which prevents the fisheyes and incomplete hydration that come from poor wetting. See polymer hydration below.
- Pigment and filler wetting for paints and coatings. Better initial wetting reduces bead mill residence time and power consumption. See pigment and filler wetting below.
- Calcium carbonate slurry. The LPM brings bulk calcium carbonate into water or binder without dust and feeds a ceramic-lined bead mill. See calcium carbonate slurry grinding.
- Latex and emulsion polymer slurry, with controlled powder induction and optimised shear profiles. See latex and emulsion below.
- Food and beverage powder reconstitution. Powders are inducted below the liquid surface for lump-free reconstitution. See food and beverage powder reconstitution below.
- Pharmaceutical API slurry and suspensions, with dust-free induction and hygienic mechanical sealing options. See API slurry preparation below.
- Caustic lye. Sodium hydroxide flakes or pearls are inducted into water; typical solids addition is 2–6 TPH, with final concentrations up to 50%. See caustic lye preparation.
- Mineral and chemical salt dissolution, with high solids loading. See salt dissolution systems below.
- Fumed silica, CMC and Carbopol, bentonite, and battery electrode slurries.
In Wahal plants:
- Paint. Powder induction is the first stage of a paint manufacturing plant: the liquid powder mixer takes pigments and fillers into the liquid, the high-speed disperser handles dispersion and let-down, and a bead mill grinds to the target particle size.
- Ink. In an ink manufacturing plant the LPM's rotor-stator head draws powder into the liquid under vacuum for dust-free, lump-free wetting and dispersion.
- GCC milling. The LPM works with a jumbo bag unloading system to dose ground calcium carbonate powder into water without dust, before wet milling. See GCC milling solutions.
Powder induction mixer applications by industry
What goes wrong when each industry's powder is added conventionally, and what the LPM does about it.
Paints and coatings: pigment and filler wetting
Pigment wetting directly affects colour strength, dispersion efficiency and downstream milling. Poor wetting leads to agglomerates, floating pigments and excessive bead mill energy consumption. The LPM inducts pigments straight into a high-shear liquid zone, where the rotor-stator reduces the interfacial tension between pigment particles and the liquid, so they wet at once and disperse evenly. Better initial wetting reduces bead mill residence time and power consumption and makes batches more consistent.
Latex and emulsion polymer slurry
Latex and emulsion polymer systems are sensitive to shear and temperature, and poor powder incorporation can cause coagulation and instability. The LPM inducts the powder under control with an optimised shear profile, so the slurry comes out uniform without damaging the polymer particles. Automation keeps batch quality repeatable and the process stable.
Adhesives and resins
Resin powders often resist wetting and form persistent agglomerates when added conventionally. The LPM's high torque and optimised rotor-stator geometry wet resin powders rapidly, eliminate unmixed lumps and significantly reduce batch times. Customised mechanical sealing options keep it running reliably with sticky or reactive media.
Polymer hydration (CMC, HEC)
Failed hydration shows up as fisheyes, incomplete hydration and long batch cycles, and it starts with poor initial powder wetting. The LPM inducts polymer powder into a controlled shear zone where each particle is wetted individually before the viscosity builds. This stops a gel skin forming around a dry core, so hydration is uniform. The result is faster hydration, consistent viscosity, shorter batches and better product quality. Systems support automated dosing, several powder suction options and mechanical sealing for long batches.
Detergent and surfactant powders
Dissolving detergent powder often comes with foaming and dusting. The LPM inducts the powder below the liquid surface, which reduces air entrainment and foam. Automated dosing speeds up dissolution and improves operator safety and batch repeatability.
Mineral and chemical salt dissolution
Dense, abrasive salts need a robust powder induction system. The LPM handles high solids loading reliably and dissolves salts quickly, with less manual handling and a more uniform concentration, backed by automation and durable mechanical sealing options.
Battery material slurry
Battery material slurries need uniform wetting for consistent electrochemical performance. The LPM wets the powder evenly, prevents agglomeration, reduces the dispersion energy needed downstream and supports scalable, automated production. See also homogenizers for battery production.
Food and beverage powder reconstitution
Food powders often float, clump or foam when added by hand. The LPM inducts them gently below the liquid surface for lump-free reconstitution, with better hygiene, shorter batch times and safer work for operators.
Pharmaceutical API slurry
API slurry preparation needs precise, hygienic and repeatable powder induction. The LPM gives controlled, dust-free induction and better batch-to-batch consistency, and supports validated, automated operation. Hygienic mechanical sealing options provide containment and reliability.
Powder induction mixer or another mixer?
Start from the job the machine has to do.
| Your job | Machine |
|---|---|
| Large volumes of powder into a liquid, dust-free | Powder induction mixer (this page) |
| Dispersing pigments, additives and powders into a liquid | High-speed disperser |
| Stable, fine emulsions or a smaller particle size | Inline homogenizer or high shear homogenizer |
| Grinding to a fine target particle size | Bead mill |
| Blending dry powders with each other | Ribbon blender |
| Pumping and shearing in one unit | Shear pump |
The machines often work together. In a paint line the LPM comes first, and for powders it feeds the bead mill a consistent slurry.
Test your powder before you buy
There's no better way to test a machine than on your own product. Run a trial in our fully equipped laboratory and see what results you get, and how fast. If you need longer, our rental program lets you keep a machine, pre-configured to your requirements, for as long as you need. See trials and rentals.
Wahal Engineers makes powder induction mixers in India, at our factory in Bhigan (Murthal), Sonipat, Haryana, with ISO and GMP compliant manufacturing. Send us your powder, your liquid and your batch size, and we will recommend a machine.
Frequently asked questions
What is a powder induction mixer?
A rotor-stator mixer that creates a vacuum in a flowing liquid and draws powders into it, from silos, sacks, hoppers or barrels. The powder is wetted and dispersed at once, without dust or lumps, and the mix is pumped out. Our model is the liquid powder mixer (LPM).
Is a liquid powder mixer the same as a powder induction mixer?
Yes. Liquid powder mixer (LPM) is the name of our powder induction mixer series. The solid liquid induction mixer is the same machine.
How much powder can an LPM induct?
From 30–75 kg/min on the LPM 10 to 550–675 kg/min on the LPM 200, for calcium carbonate fed from a hopper. The actual rate depends on your powder and on the feeding method.
What solids content can it reach?
Up to 80% solids in the final product, with the product re-circulated to get the desired result.
Can it run continuously?
Yes. The LPM suits both continuous processes and batch processes with re-circulation.
Why is no air drawn into the product?
The powder enters below the liquid surface, and the powder stream is much denser and thicker, so no foreign air is entrapped in the flowing stream.
Can a powder induction mixer blend dry powders?
No. It mixes powders into a liquid. To blend dry powders and other bulk solids with each other, use a ribbon blender.
