Industrial Mixers UK
PerMix Applications
Application: Biomass & Microalgae Vacuum Mixing & Drying
Across the biotechnology, food ingredient, and nutraceutical industries, the processing of high-moisture biological materials such as microalgae, biomass extracts, and fermentation-derived compounds presents a unique engineering challenge.
These materials often begin with very high moisture levels — frequently above 90% water content — and must be converted into a stable dry solid while maintaining product quality, biological activity, and uniform composition.
This requires a carefully controlled process combining:
For manufacturers producing microalgae-based ingredients such as SupaBlu™ and other natural colourants, proteins, and bioactive compounds, achieving a homogeneous temperature profile and efficient moisture removal is critical to maintaining product performance and yield.
PerMix vacuum mixing and drying technology is designed specifically to address these challenges.
High-moisture biological materials behave very differently from conventional powders.
At the start of the process, these materials often resemble a wet paste or slurry, containing 92–95% moisture. As drying progresses, the material gradually transforms into a loose powder or granulated solid.
During this transformation several process issues occur:
• Agglomeration or lump formation
• Uneven heat distribution
• Product build-up on equipment surfaces
• Local overheating or degradation
• Inconsistent drying across the batch
Without proper agitation and heat transfer, the product may dry unevenly, leading to reduced yields and inconsistent quality.
This is why simultaneous mixing and vacuum drying is essential.
Drying under vacuum significantly improves both efficiency and product protection.
Under vacuum conditions, the boiling point of water decreases dramatically. Instead of requiring temperatures well above 100°C, water can evaporate at much lower temperatures.
This offers several advantages:
Lower thermal stress
Sensitive biological compounds are protected from degradation.
Faster moisture removal
Vacuum accelerates evaporation rates.
Improved product quality
Uniform drying prevents hotspots and product damage.
Energy efficiency
Less heat input is required compared with atmospheric drying.
When combined with continuous mixing, vacuum drying becomes an extremely efficient method for processing high-moisture biomaterials.
During drying, the material transitions from:
Wet paste → sticky solids → free-flowing powder
Without agitation, the product may form crusts or large agglomerates that trap moisture internally.
Continuous mixing solves this problem by:
• Constantly renewing the product surface area
• Breaking apart agglomerates during drying
• Maintaining uniform temperature distribution
• Preventing product build-up inside the vessel
This ensures that moisture removal occurs evenly throughout the batch.
For this type of process, PerMix typically recommends the PerMix PTPD Vacuum Paddle Mixer / Dryer.
This machine is specifically engineered for mixing, reacting, and drying high-moisture solids under vacuum.
Inside the vessel, specially designed paddle agitators gently but thoroughly move the product while maintaining excellent heat transfer from the jacketed vessel walls.
Key advantages include:
Exceptional Heat Transfer
The paddles continuously move product across the heated surfaces, dramatically improving thermal efficiency.
Uniform Temperature Profile
Continuous agitation ensures the entire batch maintains a homogeneous temperature.
Efficient Moisture Removal
The vacuum system rapidly removes water vapour generated during drying.
Gentle Handling
Biological materials such as microalgae and fermentation biomass remain intact and undamaged.
Minimal Product Build-Up
The paddle design prevents sticking and promotes self-cleaning of internal surfaces.
Although each application is engineered individually, typical operating conditions for biomass drying include:
Initial moisture
92–95%
Final solids content
Up to 95–96%
Drying temperature
85–105°C
Operating pressure
Vacuum between -850 and -250 mbar
During operation, the product is continuously mixed while heat is applied through the jacketed vessel. Moisture evaporates under vacuum and is removed through a condenser system.
The result is a uniformly dried, free-flowing powder with consistent composition.
PerMix vacuum mixing and drying systems are widely used for processing:
Microalgae ingredients
Natural blue and green pigments
Fermentation biomass
Plant-derived proteins
Bioactive compounds
Nutraceutical powders
Specialty food ingredients
As demand continues to grow for natural colourants, functional proteins, and sustainable food sources, manufacturers increasingly require processing equipment capable of handling complex biological materials efficiently and reliably.
When designing vacuum mixing and drying systems for biomass applications, PerMix engineers evaluate several critical factors:
• Moisture content and evaporation rate
• Particle size and density
• Adhesion and agglomeration behaviour
• Heat transfer requirements
• Vacuum level and vapour handling
• ATEX or explosion protection requirements
By tailoring equipment design to the specific process conditions, PerMix ensures optimal performance and long-term reliability.
PerMix vacuum mixing and drying systems are trusted by manufacturers worldwide because they deliver:
• Superior engineering
• Reliable vacuum drying performance
• Excellent heat transfer efficiency
• Consistent batch-to-batch quality
• Robust construction for demanding industrial processes
With decades of experience in powder processing and vacuum drying technology, PerMix continues to support biotechnology, pharmaceutical, and food manufacturers developing the next generation of natural and sustainable ingredients.
If your process involves high-moisture biomass, microalgae, fermentation solids, or other biological materials requiring controlled vacuum drying, our engineering team can help design the ideal mixing and drying system for your application.
Contact PerMix today to discuss your process requirements and discover how our vacuum mixing technology can improve product quality, efficiency, and reliability.
Stay Connected