In advanced materials manufacturing, even the smallest detail can make a big difference. At Shu Powders, we believe true innovation happens when established practices are reimagined through technology. That belief guided the transformation of our granulated cobalt powder production process.
This is the story of how we modernised binder addition, and in doing so, built a safer, cleaner, and more efficient process for our products and our partners.
From manual to high-shear precision
For many years, binder blending at Shu Powders relied on well-established manual and semi-automated systems.
These methods produced high-quality material but required long blending times and significant operator input.
As demand and performance expectations increased, we saw an opportunity to evolve, moving toward a fully enclosed,
automated, and dust-free shear blending system that would redefine efficiency.
System-wide modernisation
In 2024/25, Shu Powders launched Phase 3 of its modernisation program: a fully integrated, dust-contained manufacturing flow linking thermal reduction, high-shear blending, granulation, and packaging.
The upgrade introduced:
This was more than an equipment upgrade. It was the foundation for a controlled, efficient, and sustainable production environment capable of supporting the next generation of high-performance materials.
Shear blending efficiency gains
Replacing older blenders with shear technology transformed binder addition into a faster, cleaner, and more controlled operation.
Measured improvements include:
Validated through laboratory testing
A comparative dispersion study of three cobalt powder lots confirmed the new process’s efficiency. Using solvent dissolution and filtration, Shu Powders’ lab found that new-process lots dispersed 20 to 30%, while the previous process achieved approximately 10%.
Digitally controlled and monitored
Each shear blender is fully integrated into Shu Powders’ SCADA system, allowing real-time visibility over mass, speed, torque, and powder temperature.
This digital integration enables:
Real-time process optimisation
Predictive maintenance through torque pattern tracking
Consistent, repeatable blending performance across batches
Together, these capabilities ensure that every batch is blended with precision, traceability, and confidence, setting a new benchmark for quality assurance at Shu Powders.
Sustainability and operator safety
The transition to enclosed high-shear blending not only improved energy efficiency but also reduced manual handling, minimised cobalt dust exposure, and enhanced operator safety.
Lower torque and reduced heating demand contribute directly to energy savings and a smaller environmental footprint, aligning with Shu Powders’ ISO 14001 and EcoVadis sustainability goals.
A smarter, safer, and stronger future
By merging research-driven process development, automation, and intelligent control, Shu Powders has built a production line that is faster, safer, and more consistent than ever.
The shear blending system stands as a key milestone in our ongoing journey toward manufacturing excellence, where better processes deliver better products and better outcomes for everyone.
