Nutraceutical Processing

Q: How do you support frequent flavor or formula changeovers?

PK systems are designed with sanitary finishes and easy-access configurations to reduce cleaning time and support efficient changeovers.

Our equipment helps manufacturers turn nature’s raw potential into powerful, high-quality products. Powders are refined to the perfect size and transformed through liquid granulation with oils or fats, creating strong, effective agglomerates. Fragile plants and flowers are treated with care, using precise recipe controls for temperature, humidity, and airflow to preserve their natural strength and beauty. Our advanced blending techniques ensure every mixture is uniform, while flavors, oils, and lubricants are seamlessly coated with powders to boost tableting performance. Nothing goes to waste—unwanted solvents are recovered and recycled for greater efficiency and sustainability. With specialized inoculation and sterilization, we amplify the natural vitality of plants while protecting them from bacteria, mold, and fungus. Finally, our controlled drying process delivers flowers, plants, and seeds at their perfect moisture level—ensuring purity, potency, and consistency in every batch.

Product Solutions

Multi-Vessel-Processor-Slant-Cone-Blender

Multi-Vessel Processors (MVP)

Single drive station accommodates multiple vessel sizes and geometries for a variety of process operations.

Double Cone Shell Dryer

Low-profile, efficient design with intensified or non-intensified blending.

Slant Cone Shell Blender

High-efficiency design with intensified or non-intensified nutraceutical blending operations.

Solids Processor

Reduce particles to a desired powder size and add liquid granulation to create powerful agglomerates.

Continuous Tubular Dryer

Continuous, quick, and uniform drying of temperature-sensitive nutraceutical products – ideal for multi-vitamin drying.

Blend Master

Small-scale lab blender configured for tumble blending, intensifier blending, and liquid addition functions.

Engineered for the Quality & Consistency Demands of Nutraceutical Manufacturing

Nutraceutical production requires consistent blend uniformity, ingredient integrity, and efficient scale-up while maintaining strict quality standards. Patterson Kelley delivers precision blending, drying, and powder processing solutions engineered to support supplement manufacturers with repeatability, cleanliness, and confidence at every stage of production.

PK Blenders are purpose-built for botanical powders, vitamins, minerals, protein blends, probiotics, functional ingredients, and sensitive formulations where consistency, safety, and traceability matter. From R&D formulation through full-scale manufacturing, our equipment supports nutraceutical processors with proven performance and scalable design.

Nutraceutical Pain Points We Solve

Blend inconsistency in multi-ingredient formulations

Segregation of vitamins, minerals, and fine powders

Dust control and cross-contact concerns

Moisture sensitivity in botanical and probiotic materials

Scale-up challenges from pilot to production

Long cleaning cycles between flavor or formula changeovers

Inconsistent flowability during downstream packaging

Optimize Your Nutraceutical Processing Line

We help supplement manufacturers achieve consistent powder processing while improving efficiency and protecting ingredient integrity.

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

Material density differences and particle size variability

Sensitive ingredients such as probiotics or botanicals

Throughput and packaging targets

Scale-up between lab, pilot, and full production

Sanitation and allergen control requirements

Moisture and temperature constraints

Engineered for Nutraceutical
Powder Processing

Integrated Drying & Conditioning

PK drying technologies, including the Solids Processor (SP) and Tubular Vacuum Dryers, provide gentle, controlled drying to reduce moisture and condition heat-sensitive nutraceutical ingredients.

Scalable Systems

From lab-scale testing with the Blend Master and bench-top units to full production systems with sanitary finishes and integrated process controls, PK supports every stage of product development and commercialization.

High Uniformity Powder Blending

PK blending technologies, including Twin Shell, Double Cone, Cross-Flow®, Slant Cone®, and Zig-Zag® Continuous Blenders, are engineered to deliver exceptional homogeneity across complex multi-ingredient supplement formulations.

Why Choose Patterson Kelley

Nutraceutical Manufacturers Need:

Consistent blend uniformity for multi-component formulations

Sanitary, easy-to-clean equipment for frequent product changeovers

Controlled drying for moisture-sensitive ingredients

Scalable systems that support growth

Reduced segregation during blending and discharge

Flexible batch sizes from pilot to production

Reliable processing of fragile or fine powders

PK Benefits

Uniform blends across diverse ingredient types

Faster batch cycles with repeatable results

Sanitary designs that support food-grade standards

Energy-efficient drying and blending options

Reduced cleaning and downtime

Proven performance with vitamins, botanicals, and protein blends

Long equipment life with dependable reliability

Technical Advantages

Sanitary welds and food-grade finishes

Precision speed and fill-level control

Vacuum drying for heat-sensitive ingredients

Dust-tight containment options

CIP-ready configurations

Food-safe materials of construction

Batch data capture and process monitoring

Custom-engineered systems for allergen or specialty ingredient control

Scalable Systems From R&D to Production

Supplement manufacturers benefit from PK’s ability to support every phase of product development. From lab-scale testing with Blend Master and bench-top units to pilot-scale validation of blend uniformity and moisture control, and full-scale production systems with integrated sanitary features, PK ensures performance at every step. Our lab testing services allow you to bring your material to PK and validate blending or drying performance before investing in equipment.

Nutraceutical Manufacturing Applications

PK supports a broad range of nutraceutical powder processing applications:

Vitamin and mineral blending
Botanical powder blending
Protein and meal replacement formulations
Probiotic and enzyme blends
Functional ingredient mixing
Powder conditioning for improved flowability
Moisture reduction and stabilization
Batch blending for capsules, tablets, and stick packs

System Integration Capabilities

PK equipment integrates seamlessly into nutraceutical production environments, including:

Material transfer systems
Bin and IBC handling
Milling, sifting, and particle sizing
Vacuum transfer and dust containment
Flavor addition systems
PLC-based batch tracking and recipe management
Packaging and filling integration

FAQs for Nutraceutical Processing Equipment

How do you prevent ingredient segregation in supplement blends?

PK blending systems are engineered to promote uniform material movement and controlled discharge, reducing segregation of fine, dense, or fragile ingredients.

Can PK equipment handle probiotics and heat-sensitive ingredients?

Yes. Vacuum drying systems and gentle tumble blending designs help protect sensitive ingredients from excessive heat and mechanical stress.

Is lab testing available before purchasing equipment?

Absolutely. PK offers lab and pilot testing services so manufacturers can validate blend uniformity, moisture control, and scalability before committing to full production systems.

How do you support frequent flavor or formula changeovers?

cleaning time and support efficient changeovers.

Can systems scale as our supplement line grows?

Yes. PK offers scalable solutions from R&D units to full production systems, designed to support increasing throughput as your business expands.

We Have The Solution For Your Process.

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