chemical-processing-blending-equipment | PK Blenders

Chemicals

PK Blenders serves the basic and specialty chemical and agrochemical industries with specialized blending, agglomeration, and drying solutions tailored to the unique needs of each sector. Our products process a wide range of materials, including fertilizers, pesticides, herbicides, rodenticides, and specialty chemicals. With precise formulation and blending of active and inert ingredients, whether in powder, liquid, or granular form, our products ensure consistent product quality and performance. Example applications include coating, impregnating carriers, and drying filter cakes, all designed to enhance product stability, usability, and effectiveness in the field.

Product Solutions

Solids Processor

Add liquid and dry chemical compounds, dry pigments, powders, silica gels and other materials.

Twin Shell Blender

Agglomerate fertilizers and pesticides, coat alumina prills, dry cell batteries, and blend carbon.

M.V.P. Processors

Quick connect multiple vessels to a stand-alone drive station and blend a wide variety of chemicals.

Zig-Zag Continuous Blender

Expedient blending with the ability to mix a wide range of powders depending on the inlet chute size.

Cross-Flow Blender

This blender can handle extremely delicate to heavy abrasive materials since materials are rotated close to the axis.

Tubular Vacuum Dryer

Large heat transfer surface to dry pigments, powders, agglomerated chemicals, catalysts and more.

Engineered for the Complexity & Performance Demands of Chemical Processing

Chemical manufacturing requires precise control over formulation, blending, and drying to ensure product performance, stability, and consistency. Patterson Kelley delivers advanced blending, agglomeration, and drying solutions engineered for both basic and specialty chemical applications.

PK Blenders are purpose-built to handle a wide range of materials, including powders, granules, liquids, pigments, catalysts, and filter cakes, while maintaining uniformity and process control. From R&D formulation to full-scale production, our systems support chemical processors with reliable, repeatable performance across diverse applications.

Chemical Processing Pain Points We Solve

Blend inconsistency in multi-component formulations

Segregation of powders, liquids, and granules

Moisture variability affecting product stability

Poor dispersion of active ingredients or additives

Dust control and material handling challenges

Scale-up inefficiencies from lab to production

Inconsistent particle size or agglomeration results

Equipment not suited for abrasive or reactive materials

Optimize Your Chemical Processing Line

We help chemical manufacturers improve product consistency, process efficiency, and operational reliability.

PK engineers work directly with R&D and production teams to design systems tailored to:

Material composition (powder, liquid, granular, or slurry)

Active and inert ingredient distribution requirements

Moisture control and drying conditions

Agglomeration, coating, and impregnation needs

Throughput and production targets

Scale-up from lab and pilot to full production

Facility layout and system integration requirements

Engineered for Chemical Powder Processing

Integrated Drying, Agglomeration & Conditioning

PK drying solutions, such as the Solids Processor (SP) and Tubular Vacuum Dryers, support moisture removal, filter cake drying, and controlled agglomeration to improve product stability, usability, and downstream performance.

Scalable Systems

From lab-scale testing with Blend Master units to full-scale production systems, PK supports every stage of chemical processing with flexible, application-driven equipment.

High-Uniformity Blending Across Complex Formulations

PK blending technologies, including Twin Shell, Double Cone, Cross-Flow®, Slant Cone®, and Zig-Zag® Continuous Blenders, are engineered to deliver consistent mixing of powders, liquids, and granules across a wide range of chemical products.

Why Choose Patterson Kelley

Chemical Manufacturers Need:

Consistent dispersion of liquids into powders or granules

Controlled drying for moisture-sensitive materials

Reliable agglomeration and particle size control

Scalable systems for pilot to production

Equipment capable of handling abrasive or reactive materials

Safe, contained processing environments

PK Benefits

Consistent product quality across complex formulations

Improved dispersion of additives and active compounds

Reduced segregation and variability

Energy-efficient drying and processing options

Reduced downtime and maintenance

Long equipment life in demanding environments

Proven performance across specialty and bulk chemicals

Technical Advantages

Optimized vessel geometry for uniform blending

Precision control of speed and fill levels

Vacuum drying for temperature-sensitive chemicals

Dust-tight and enclosed system designs

CIP-ready and easy-to-maintain configurations

Corrosion-resistant material options

Batch data capture and process monitoring

Custom-engineered systems for chemical processing challenges

Scalable Systems From R&D to Production

Chemical manufacturers benefit from PK’s ability to support every stage of product development. From lab-scale testing with Blend Master and bench-top units, to pilot trials validating blend uniformity, agglomeration, and drying performance, to full-scale production systems designed for reliability, PK ensures consistent results at every stage.

Our lab testing services allow you to bring your materials to PK and validate blending, drying, and formulation processes before investing in equipment.

Chemical Manufacturing Applications

PK supports a broad range of chemical processing applications:

Fertilizer blending and agglomeration
Pesticide, herbicide, and rodenticide formulation
Pigment and dye blending
Catalyst and silica gel drying
Filter cake drying and conditioning
Coating and impregnating carriers with active solutions
Carbon, graphite, and battery material blending
Powder and granular chemical mixing

These applications support both basic and specialty chemical production, ensuring consistent performance and product quality.

System Integration Capabilities

PK equipment integrates seamlessly into chemical processing environments, including:

Material transfer and conveying systems
Dust collection and containment systems
Liquid addition and spray systems
Agglomeration and granulation systems
Vacuum transfer and pneumatic conveying
PLC-based batch control and automation
Packaging and downstream processing integration

Chemical Processing FAQs

How do you ensure uniform blending of chemical formulations?

PK blenders use optimized geometry and controlled mixing action to evenly distribute active and inert ingredients across powders, liquids, and granules.

Can PK equipment handle both liquid and dry chemical processing?

Yes. PK systems are designed to blend liquids into powders, coat particles, and process multi-phase formulations in a single system.

How does drying impact chemical product performance?

Proper drying removes excess moisture, stabilizes materials, and improves handling, storage, and downstream processing performance.

Is lab testing available before scaling up?

Yes. PK offers lab and pilot testing to validate blending, agglomeration, and drying processes with your specific materials.

Can PK systems handle abrasive or reactive chemicals?

Absolutely. Systems can be engineered with corrosion-resistant materials, containment options, and robust designs to safely process challenging chemical materials.

We Have The Solution For Your Process.

Regardless of the processing industry, PK has been providing solutions to processors for more than a century.