Industrial Mixers
PerMix Applications
Application: Algae Processing — From Biomass to High-Value Powders
Algae is more than a green revolution—it’s a biochemical powerhouse shaping the future of food, nutraceuticals, cosmetics, pharmaceuticals, and renewable energy. But producing high-quality algae products isn’t simple. It requires precision control through every phase of processing, from cultivation and dewatering to drying, blending, and final formulation. PerMix provides the engineering backbone of this transformation—helping turn harvested biomass into premium, ready-to-use ingredients with unmatched efficiency and quality.
Processing algae biomass is a multi-stage operation designed to retain as much of the biological value as possible while achieving stability and uniformity. Let’s break it down:
Microalgae species such as Chlorella, Nannochloropsis, Spirulina, and Haematococcus pluvialis are grown in open raceway ponds or closed photobioreactors under controlled nutrient and light conditions. Once mature, the culture is harvested using centrifugation, membrane filtration, or flocculation. At this point, the biomass is typically 90–95% water.
The harvested slurry undergoes dewatering via belt filters, decanters, or screw presses, concentrating the biomass to about 15–25% solids content. Efficient dewatering reduces downstream drying costs, as water removal is the most energy-intensive step in algae processing.
Drying is a critical step, as algae cells contain heat-sensitive compounds like chlorophyll, carotenoids, and polyunsaturated fatty acids (PUFAs). High heat can cause oxidation, color degradation, and nutrient loss.
This is where PerMix Vacuum Mixers & Dryers shine. Operating under vacuum lowers the boiling point of water, allowing moisture to evaporate at gentle temperatures—often between 40°C and 80°C—preserving color, aroma, and bioactivity. The built-in mixing ensures uniform heat distribution, preventing clumping and hot spots.
Vacuum drying is particularly advantageous for algae powders that need to maintain fine particle size and high bioavailability for applications in supplements or cosmetics.
After drying, the algae cake may be milled to achieve the desired particle size distribution. PerMix’s partner brand, DP Pulverizers, offers pin mills, turbo mills, and jet mills ideal for micronizing algae powder while minimizing heat buildup. These mills create uniform fine powders ready for blending or encapsulation.
The dried and milled algae powder is often blended with carriers, stabilizers, excipients, or other functional ingredients to achieve specific end-use characteristics. For instance:
PerMix Ribbon Mixers, Paddle Mixers, and Plow Mixers ensure that all powders are homogeneously blended without damaging delicate particles. Their dual or triple motion mixing design achieves complete uniformity even with powders of varying densities and flow properties.
For large-scale production, these mixers create a fluidized zone that allows fast, three-dimensional mixing—reducing cycle times to as little as 30–60 seconds for uniform blends. Perfect for integrating high-protein algae powders with other micronutrients or binders.
A typical algae powder production line utilizing PerMix and DP Pulverizers may include:
This integrated approach provides unparalleled control over the final particle size, color, moisture, and homogeneity, ensuring a consistent, premium-grade powder ready for food, nutraceutical, or feed use.
At PerMix, we believe sustainability and precision can coexist. Our Vacuum Mixers & Dryers, combined with our powder blending technology, give algae manufacturers the tools to efficiently produce stable, nutrient-rich powders that help feed, fuel, and heal the world.
From pilot development to full-scale algae processing, PerMix engineers solutions that protect product integrity, enhance yield, and drive performance.
PerMix – Engineering the Future of Algae Processing.
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