Agglomerated powder is an important tool for improving performance in powdered beverages, nutritional products, and other dry food systems. Agglomeration is a controlled manufacturing process in which fine particles are assembled into larger, more uniform particles. When done correctly, this change in particle size and structure improves how a powder wets, disperses, flows, and fills packages, which directly affects both product consistency and the consumer’s experience.

Why Agglomeration Matters For Performance

Unagglomerated powders consist of very small, dense particles. These particles have a large surface area relative to their mass, so they tend to float on the surface of a liquid and resist wetting. That behavior can lead to slow dissolution, visible clumps, and inconsistent flavor or nutrient delivery in the finished product.

Agglomeration restructures fine particles into larger, porous granules composed of many smaller spheres bonded together. The larger agglomerates have a lower surface-area-to-mass ratio and a more open structure, which allows them to break the liquid surface more easily, absorb water, and then come apart into fully wetted primary particles. This mechanism is why a properly agglomerated powder disperses quickly in both hot and cold liquids and gives a smoother finished texture.

When particle size and structure are engineered through agglomeration, several functional properties improve at once:

  • Improved solubility and dispersibility: The porous structure created during agglomeration increases void space and capillary pathways within each granule. This structure allows liquid to penetrate the particle rapidly, which initiates controlled breakup into uniformly wetted primary particles.
  • Uniformity and homogeneity: When ingredients are pre-blended and sized before agglomeration, each agglomerated granule contains a consistent ratio of actives, flavors, sweeteners, and other components. This helps prevent segregation during conveying, storage, packaging, and dosing, which is critical for products that must deliver accurate vitamin, mineral, or active doses per serving.
  • Dust reduction: Ultrafine particles are easy to aerosolize and can create inhalation concerns and housekeeping problems. Converting those fines into larger, heavier agglomerates significantly reduces dust formation during production and packaging.
  • Controlled bulk density: Agglomerated powders are less tightly packed than their fine precursors and contain more internal void space. The result is a lighter, airier powder that occupies more volume at the same weight, which can improve filling consistency and support specific packaging targets.

Together, these properties support more consistent batching, more stable finished product quality, and a smoother, more predictable mixing experience for the end user.

Tipton Mills Foods Process for Agglomerated Powder

Tipton Mills Foods operates a Krueger Continuous Agglomerator designed for high-throughput, food-grade agglomeration of dry powders. The process begins with pre-blending in a ribbon blender, followed by milling so that all components enter the agglomerator with a similar initial particle size. This step is important for building agglomerates where each granule contains the same proportion of ingredients.

Inside the agglomeration chamber, powders are suspended in an air stream. Low-pressure culinary steam at approximately 130°F is injected to lightly wet the particles’ surfaces. As these partially wetted particles collide in the fluidized zone, they stick together and build into larger agglomerates. When their mass exceeds what the air stream can support, the agglomerates fall onto a conveyor and move through multiple warm-air drying zones to remove excess moisture. The dried agglomerated powder then passes through sieving and sizing equipment to achieve the specified particle size distribution.

This continuous system allows Tipton Mills Foods to process powders that begin with very different particle sizes and convert them into a tight, repeatable agglomerated size range. The result is a consistent functional profile across every lot, even for complex blends that include proteins, carbohydrates, flavors, vitamins, and other sensitive ingredients.

Partner With Tipton Mills Foods To Strengthen Your Powdered Product Line

Agglomerated powder provides a technical advantage by improving solubility, flow, blend uniformity, and dust control, all of which contribute to more consistent product performance and a better end-user experience. With the Krueger Continuous Agglomeration System, high-capacity throughput, and deep experience in functional powder beverages and foods, Tipton Mills Foods offers a scalable platform for agglomeration and turnkey powdered product manufacturing.

To explore how engineered particle size and agglomeration can enhance an existing formula or support a new product launch, contact Tipton Mills Foods and connect with the technical team.