Shu Powders Africa is pleased to announce the successful completion and commissioning of Pneumatic Powder Conveying Phase 3, a significant milestone in the company’s strategic journey towards full process automation, digitalisation, and enhanced workplace safety. The Pneumatic Powder Conveying programme represents a long-term investment in modern manufacturing infrastructure, designed to strengthen operational efficiency whilst placing employee health and environmental responsibility at the centre of process design.
The completion of Pneumatic Conveying Phase 3 marks the final phase of this transformation. With the entire cobalt powder processing route now automated and fully enclosed, Shu Powders Africa has fundamentally changed how material flows through the plant, delivering measurable improvements in safety, quality, consistency,
and cost competitiveness.
The need for change
Cobalt powder processing presents fundamental operational and occupational challenges, particularly when material handling relies on open systems and manual intervention. Historically, certain stages of the process at Shu Powders Africa required operators to collect and transport powder using trolleys between different processing points. Whilst effective at the time, these practices resulted in potential exposure of employees to cobalt dust, increased dependence on personal protective equipment (PPE), and greater variability in material handling.
In addition to health and safety considerations, manual powder transfer introduced inefficiencies, including higher labour requirements, increased housekeeping demands, and greater potential for material losses, contamination, and scrap. As production demands increased and expectations around safety and sustainability continued to evolve, it became clear that a fundamentally different approach was required.
The Pneumatic Powder Conveying programme was therefore initiated with a clear objective: to eliminate direct operator exposure to cobalt powder by transitioning to a fully enclosed, automated, and digitally controlled process, whilst simultaneously improving productivity, quality, and operational resilience.
The pneumatic powder conveying journey: a phased transformation
Phase 1: Automated Feeding System
The first phase of the programme focused on addressing inefficiencies and ergonomic risks associated with the manual feeding of cobalt powder. Prior to this, the feeding process relied on the manual loading of 25 kg bags, which required general workers to stop frequently to replenish the feed system. Depending on production conditions, operators were required to manually load approximately ten 25 kg bags every 30 minutes to one hour, making the task both labour-intensive and time-consuming.
To address these challenges, Shu Powders introduced an automated feeding system using 600 kg big bags. The system was designed to lift the big bags mechanically and transfer material directly into the feed system, eliminating the need for repetitive manual handling of smaller bags.
As a result of this upgrade, bag changes are now required only once every twelve hours, significantly reducing the physical workload on employees and improving overall process continuity. This automation not only enhanced operational efficiency but also improved ergonomics, reduced manual handling risks, and freed up general workers to focus on higher-value tasks.
Phase 2A: Pneumatic Powder Conveying
The second phase of the Pneumatic Powder Conveying journey focused on removing manual powder transportation from the early stages of processing. As part of the programme, the company adopted pneumatic powder transfer systems designed to move cobalt powder through enclosed pipelines under controlled conditions.
Unlike conventional systems that rely on compressed air, the conveying systems utilise nitrogen (N₂)
as the transport medium.
The use of nitrogen is a deliberate and critical design choice. Compressed air contains oxygen, which can promote oxidation of cobalt powder during transfer. By replacing air with an inert nitrogen atmosphere, the risk of oxidation is significantly reduced, supporting improved product stability and consistency. This approach also contributes to lower oxygen (O₂) content in the final product, which is a keyquality parameter.
Pneumatic Powder Conveying Phase 2A involved the installation of an automated pressure conveying system to transfer cobalt powder directly from the furnace to specialised milling. This intervention eliminated the need for trolley-based movement of powder and significantly reduced the frequency with which general workers came into contact with cobalt material.
Beyond its immediate safety benefits, Pneumatic Powder Conveying 2A improved housekeeping standards and introduced a higher level of process control and consistency. By enclosing this critical transfer step, the company established the foundation for a fully integrated and automated material handling system.
Phase 2B: Pneumatic Powder Conveying
Building on the success of the initial phases, the Pneumatic Powder Conveying 2B programme focused on automating and enclosing the transfer of cobalt powder from specialised milling to the cone blending stage. Phase 2B introduced a pneumatic powder conveying system designed to move milled powder efficiently and safely through enclosed pipelines under controlled conditions.
Pneumatic Powder Conveying 2B therefore represents a major advancement in process control and integration. By combining nitrogen-based pneumatic conveying with controlled routing via holding tanks, vessels, and splitters, the phase delivered measurable improvements in efficiency, product consistency, and occupational safety, whilst preparing the operation for full downstream automation in Pneumatic Powder Conveying Phase 3.
Phase 3: Pneumatic Powder Conveying 3:
Full Process Automation and Digitalisation
Transition from Cone Blending to High-Shear Mixing
As part of the continued drive towards full automation and improved process performance, the traditional cone blending process was replaced with high-shear mixing technology. Whilst cone blenders provided adequate mixing in the past, they were limited in their ability to consistently achieve a fully homogenised powder and wax mixture across increasingly stringent quality requirements.
In addition to quality improvements, the transition to high-shear blending has delivered substantial operational efficiency gains. Blending time has been reduced from approximately 1.5 hours to 15 minutes, representing a step-change in productivity. This reduction has improved plant throughput, reduced cycle times, and contributed to more stable and predictable production scheduling.
The replacement of cone blenders with high-shear blending therefore represents a critical enabler of full process automation, supporting both the quality objectives and efficiency targets of the programme whilst reinforcing Shu Powders Africa’s commitment to modern, best-in-class manufacturing practices.
Automated PEG/Wax Addition
A key feature of Pneumatic Powder Conveying 3 is the automation of PEG and wax binder addition within the designed high-shear blender (Blog/Newsletter, November 2025). This advancement has significantly improved the consistency of binder distribution, ensuring uniform mixing and reducing variability in final product characteristics. By removing manual dosing, the process has become more reliable, efficient, and repeatable, directly supporting improved quality outcomes.
Fully Enclosed Processing Environment
One of the most significant outcomes of Pneumatic Powder Conveying 3 is the creation of a completely enclosed processing environment. Powder is no longer visible at any stage of the operation, effectively eliminating direct exposure of employees to cobalt dust. This has led to a safer, cleaner, and more controlled working environment, with reduced dependence on extensive PPE and improved air quality within the plant.
Automated In-Process Sampling
Pneumatic Powder Conveying 3 has also introduced automated in-process sampling, further reducing manual interaction with powder. This improvement enhances sampling accuracy and consistency whilst lowering the risk of contamination and analytical variability. In addition, automated sampling contributes to reduced laboratory workload and lower analytical costs.
Operational quality and cost benefits
The full implementation of Pneumatic Powder Conveying 3 has delivered wide-ranging benefits across the operation. Automation and digital control have improved process stability and efficiency, whilst reduced manual handling has led to lower scrap and recycle rates. The improved control of binder addition and material flow has enhanced product consistency, with the potential for lower oxygen content and the elimination of potential
powder smouldering.
From a safety perspective, the enclosed system has significantly reduced occupational exposure to cobalt dust, reinforcing Shu Powders Africa’s commitment to employee wellbeing. These improvements, combined with optimised staffing levels and reduced analytical requirements, have contributed to improved cost efficiency and strengthened the company’s competitive position.
Strategic impact and future readiness
Beyond immediate operational improvements, Pneumatic Powder Conveying 3 positions Shu Powders Africa for long-term sustainability and growth. The project aligns with global best practices in advanced manufacturing and reflects the company’s proactive approach to safety, quality, and environmental responsibility.
By investing in automation and digitalisation, Shu Powders Africa has created a robust and scalable production platform capable of meeting future demand whilst maintaining consistent product quality and compliance with increasingly stringent industry standards.
Delivering transformation with Shu Powders
The successful completion of Pneumatic Powder Conveying 3 marks a transformative milestone for Shu Powders Africa. Through a structured, phased approach, the company has implemented a fully enclosed, automated, and digitally controlled cobalt powder processing system that significantly enhances safety, operational efficiency, product quality, and cost performance. The integrated SCADA system continuously captures approximately 1,500 data points per second, enabling tighter process control, improved traceability, and more informed decision-making whilst establishing a foundation for future applications of advanced analytics and artificial intelligence.
Pneumatic Powder Conveying 3 therefore represents more than a completed capital project—it reflects Shu Powders Africa’s commitment to continuous improvement, responsible manufacturing, and data-driven production practices. The programme positions the company strongly for future growth whilst reinforcing its role as a leader in safe, high-quality, and technologically advanced cobalt powder manufacturing.
