BROOKFIELD _ POWDER FLOW TESTER

What is powder analysis?

What are the industrial issues with powders?
The classic problem with powders is their failure to discharge
reliably from bins, hoppers, silos, etc., and poor or unpredictable
flow in feeders, dosing machines, packing machines, etc. This
causes unwanted interruptions in the production process, leading
at times to complete plant shutdown in order to correct the flow
restrictions and stoppages. It also leads to variations in pack
weight, mixture, performance and sensory properties of powder
products.

Particulate materials constitute a large group of solids that can

range in size from sub micron particles to large rocks and minerals.
Brookfields Powder Flow Tester measures the flow behavior of
bulk solid materials that have a top particle size of 2mm. At least
90% of the sample should consist of particles less than 1mm in
diameter. In many instances, powders with larger particles can
still be characterized effectively by sieving the material at 1mm and
testing the fines (the fines control the flow properties of a material
with a wide size range). The generic term used by Brookfield to
name these materials is powder, therefore the name of our
instrument is Powder Flow Tester.
Unlike liquids which, under the influence of gravity, tend to have
a horizontal surface, powders exhibit a structure, due to internal
friction and cohesion, which allows them to form piles with angles
relative to the surface on which they are placed. At ambient
conditions, powders do not change flow behavior when subjected to
variable shear rates, whereas most liquids do. However, pressure
controls the strength of a powder (i.e., increases the resistance to
flow) whereas a liquid will show limited change in rheology under
pressure. In other words, the consequence of subjecting a powder
to a compressive force is that the powder will flow less easily; the
relationship between the compressive stress applied to consolidate
the powder and the strength it obtains is the measurement of the
powder flowability, or its Flow Function.

Quality Control Departments are constantly dealing with raw

materials in powder form, which come from multiple suppliers.
The variability in particle size and distribution, moisture content,
and basic ingredients requires a battery of incoming inspection
tests, none of which assure that proper flow will take place when
loaded into the plant equipment. The Brookfield Powder Flow
Tester is a single-solution instrument which can resolve this
uncertainty.
R&D Departments are constantly adjusting formulations of powder
products to satisfy customer demand for improved properties:
better coating action for paints, enhanced taste for spices, rapid
dissolving of chemicals when put into solution. New formulations
do not necessarily have the same flow properties, thereby leading
to production problems when the process is scaled up to high
volume. The Brookfield Powder Flow Tester can predict those
problems so they can be prevented.

How can flow problems

with powders be eliminated?
There is a proven scientific method, called the Flow Function
test, which can analyze powders for flow behavior. ASTM D6128
describes this procedure for compressing and shearing powder
samples in a defined annular shear cell, using a well-defined
methodology established years ago.

There is a need throughout industry to characterize powder flow

properties and flow behavior. The Brookfield Model PFT Powder
Flow Tester is a precision instrument of robust design that satisfies
this need and more.

68

TEL 800-628-8139 or 508-946-6200

FAX 508-946-6262

www.brookeldengineering.com

Test algorithm for powder flow

analysis requires compression
of the sample contained in
an annular cell to a defined
axial load followed by torsional
shearing. Raw data output shows
torsional load values in red.
Compression of sample is shown
as axial load values in green.

The resulting data produces a Flow Function, much like what is obtained
for liquids when testing with a viscometer to create a flow curve.
Flow Function for
powder sample shows
non-flowing to very
cohesive behavior
at low consolidation
stresses and cohesive
behavior at higher
consolidation stresses.
Analysis of the Flow Function leads to calculation of the critical
outlet dimensions of feeders, hoppers, etc., through which the
powder will flow. Comparing the Flow Function, or these critical
dimensions, allows powders to be benchmarked, ranked and
compared against one another for flowability. The dimensions can
also be used to determine whether a particular powder will flow
through an existing plant or process, or to determine what the
geometry should be if purchasing new solids handling equipment.
Data output from Flow
Function test provides
Arching Dimension and
Rathole diameter. Data
output from additional
Wall Friction test provides
Hopper Half Angle.

Why Choose Brookfield?

Brookfield has over 75 years experience in providing reliable, low
cost viscosity and texture measurement instruments while offering
high quality product support. We are now using this recipe for
success to expand our line of physical testing products to include
the Powder Flow Tester.
THE NEW BROOKFIELD POWDER FLOW TESTER IS THE SIMPLE
ANSWER TO INDUSTRY NEEDS:

The purchase price is a small fraction of current devices on the

market.
A competent lab technician can run tests and collect data within
minutes, eliminating the need for a powder specialist.
The automated analysis provided by the Powder Flow Pro software
calculates various properties of the powder, including the critical
dimensions for reliable powder flow out of the hoppers, feeders,
bins and silos.
The Wolfson Center for Bulk Solids Handling Technology at
the University of Greenwich, England, has worked closely with
Brookfield to design the Powder Flow Tester, thereby, ensuring its
suitability for practical industrial use.

Applications
R&D, Incoming Materials Inspection, New Product Formulation,
Quality Control, Process Plant Design
Adhesives
Cosmetics
Chemicals

Although ASTM D6128 has existed for many years, the

instrumentation used to accomplish the test has been expensive
to purchase, requires an experienced operator, and may need a
technical expert to interpret the results.

Construction:
Cement
Fly Ash
Gypsum
Hydrated Lime
Detergents
Equipment
Manufacturing:
Silos
Bins
Feeders
Hoppers

Energy:
Biomass
Coal

Gunpowder/
Ammunition

Fluxes
Food:
Beverages
Biscuits
Cereal
Chocolate
Cocoa/Milk Powder
Cookies
Crackers
Flavorings
Flour
Seasonings
Spices

Healthcare
Products:
Tablets
Minerals
Personal Care
Products:
Talcom Powder
Pharmaceuticals
Starch

Properties Measured
Flow function

relation between consolidation stress

and powder strength

The Brookfield Powder Testing Lab

Angle of internal friction

Angle of wall friction
Cohesive strength

Bulk density
Arching dimension
Rat-hole diameter
Normalized flow function
69

BROOKFIELD _ POWDER FLOW TESTER

PFT Powder Flow Tester

...affordable testing for powder characterization

The PFT Powder Flow Tester

brings quick and easy analysis of
powder flow behavior in industrial
processing equipment. Evaluate
powder discharge from storage
containers. Use as QC check
for incoming materials. Rapidly
characterize new formulations for
flowability and adjust composition
to match flow behavior of
established products.

Whats Included?
Instrument
Powder Flow Pro Software
with USB Cable

Choose one or both:

- Standard Volume Accessory Kit
230cc Trough & 33cc Vane Lid

- Small Volume Accessory Kit

38cc Trough & 5cc Vane Lid

Wall Friction Lid

Choice of Test Options:

- Flow Function
- Time Consolidated Test
with Flow Function
- Wall Friction
- Bulk Density

304 s/s simulated 2B finish

Outer Catch Tray

Inner Catch Tray
with Scraper Tool

Powder Scoop
Cleaning Brush

Choice of Flow Function Tests:

- Demo (8 minutes)
- Standard (38 minutes)
- Time Consolidation
(user-defined)

Optional Accessories
Wall Friction Lids
in Mild Steel 22-28RA, Tivar 88
or special order

Real Time Clock Displays:

- Test Step
- Remaining Time to Completion

Temperature Probe
Humidity Sensor

Shearing Algorithm Captures:

- Peak Stress Value
- Subsequent Stable Stress Value
- Recognizes Slip Stick Materials

Sieve Kit
Standard or Small Volume

Carrying Case for easy transport

Sand Castle Demonstration Kit

Data Output:
- Flow Index for Powder Flowability
- Arching Dimension (Index)
- Rat-hole Diameter
- Hopper Half Angle
- Gravity Chute Angle
(Wall Friction Angle)
- Bulk Density Curve

Powder Flow Demonstration Kit

Compact design with small footprint

Tester fits conveniently on workbench
Depth: 15inches / 38cm
Width: 14inches / 36cm
Height: 27inches / 69cm

Developed in association with

The Wolfson Centre
for Bulk Solids Handling Technology
at the University of Greenwich, England.
Small Volume Vane Lid
.795-13.252 kPa
Standard Volume Vane Lid
.289-4.819 kPa

70

TEL 800-628-8139 or 508-946-6200

FAX 508-946-6262

www.brookeldengineering.com

Powder Flow Pro Software

Included

Operation and control of the Powder Flow Tester is accomplished

with Powder Flow Pro Software.
Main screen provides
choice of basic tests:
- Flow Function
- Wall Friction
- Time Consolidated Flow Function
- Bulk Density

Close-up View of Vane Lid

used for Flow Function Test.

Close-up View of Wall Friction Lid

for wall friction test and density test

Stress data output screen captures

normal stress and shear stress
values and plots data in graphical
format (calculates Mohr Circle
Failure Loci).

Flow Function test produces graphs of

powder flow behavior which show:
Unconfined Failure Strength vs. Major Principal Consolidating
Stress
Arching Dimension vs. Principal Consolidation Stress
Rat-hole Diameter vs. Powder Fill Level

PFT POWDER FLOW TESTER SPECIFICATIONS

Load for Vertical Axis Compression: 7 kg Accuracy 0.6% FSR
Axial Speeds:
0.1mm/second up to 5mm/second
Distance:
Accuracy 0.3mm
Torque:
7.0 Nm Accuracy 1.2% FSR
Trough Rotational Speeds: 1 revolution/hour (RPH) up to 5 RPH
Temperature Sensing:
-20C to 120C*
Humidity Sensing:
10% to 95% RH 5%
Dimensions (wxdxh):
(cm) 36.2 x 39.7 x 67.6
(in) 141/4 x 155/8 x 265/8
Weight:
34 kg (75 lb)
* Requires Part No. DVP-94Y

Reversible
Scraper
Tool
Inner
Catch
Tray
Outer
Catch Tray
Trough
Outer and Inner Catch Trays with Scraper
Tool for Sample Preparation in Trough

Requires Part No. PFT-607Y

MINIMUM COMPUTER SPECIFICATIONS FOR POWDER FLOW PRO SOFTWARE

2GHz processor with 1 GB of RAM and 30 MB hard drive space available
1024x768 video resolution with 128 MB of graphics memory
Windows XP, Vista or Windows 7 (32 and 64 bit) with one USB or RS-232 port

71

BROOKFIELD _ POWDER FLOW TESTER

Testing Service
for powder applications

To assist you in the evaluation of your powder for flow behavior,

Brookfield offers a testing service prior to purchase. Provide
Brookfield with samples of your product to obtain a complete test
report. Data is presented in both graphical and tabular format for
easy analysis and interpretation. The following example shows the
report format and type of information that is presented. In the
concluding section, calculations for critical arching dimension,
rat-hole diameter and hopper half angle assess the potential for
stoppages due to the powder flow behavior or equipment limitations.

Customer Test Report

DATA COLLECTED BY: BROOKFIELD POWDER FLOW TESTER

Bulk Density Graph (230cc Trough)

STANDARD TESTS
This report follows four samples sent to our lab for evaluation. The
specific graph for each sample is color coded for easy identification.
Up to eight data sets can be shown on the same graph.

This bulk density graph illustrates the density of the samples over
different consolidating stresses. Samples #1 and #4 have almost
identical loose fill densities of 900 kg/m. At 9 kPa of consolidating
stress, the density of Sample #1 rises to 1150 kg/m and
Sample #4 rises to 1200 kg/m. Samples #2 and #3 have similar
loose fill densities ranging from 450-500 kg/m. At 9 kPa of
consolidating stress, the density of Sample #2 rises to 770 kg/
m and Sample #3 rises to 590 kg/m at 12 kPa of consolidating
stress. In general a free flowing powder shows a relatively small
change in density with more consolidating stress, while a cohesive
powder shows a large change in density.

Flow Function Graph (230cc Trough)

This flow function graph illustrates the flowability of the samples
over different consolidating stresses. The x-axis parameter is
the consolidating stress used to compress the sample; the y-axis
parameter is the strength of the powder. Sample (Data Set) #2 is
the most cohesive material of all, falling into the very cohesive range
throughout all consolidating stresses. Sample (Data Set) #3 powder
also falls into this category. Sample (Data Set) #4 is very cohesive
at low consolidating stresses (below 1.5 kPa), cohesive at medium
stresses (1.5 - 4.5 kPa), and easy flowing at high consolidating
stresses (above 4.5 kPa). Sample (Data Set) #1 material is cohesive
at consolidating stresses from 0 4.0 kPa, and easy flowing at
consolidating stresses above 4 kPa. Sample 2 clearly exhibits the
greatest difficulty for reliable flow behavior.

72

TEL 800-628-8139 or 508-946-6200

FAX 508-946-6262

Wall Friction Angle Graph (230cc Trough)

This graph illustrates the angles of wall friction for each powder over
different consolidating stresses. At low normal stress (0.5 kPa) all
materials had extremely high wall friction angles ranging from 40
to 65. At a higher normal stress (4.75 kPa), the wall friction angles
dropped to a range of 20 to 35. Wall friction angles above 30 are
considered very high and below 10 are very minimal. This indicates
that Sample #2, and perhaps Sample #1, will have difficulty with
reliable flow on the hopper wall surface.

www.brookeldengineering.com

Summary
CRITICAL ARCHING DIMENSIONS
SAMPLE (DATA SET) #1
SAMPLE (DATA SET) #2
SAMPLE (DATA SET) #3
SAMPLE (DATA SET) #4

Internal Friction Angle Graph (230cc Trough)

This graph illustrates the angles of internal friction at different levels
of normal stress. The angle of internal friction is a measure of the
friction between the powder particles as they slide against each
other. Sample #1 and Sample #4 have the lowest angles of internal
friction and will therefore flow more readily than the other two
powders. The angle of internal friction for Sample #2 and
Sample #3 is approximately 50 which is relatively high and
indicative of potential flow problems.

Types of Flow Patterns

Core-Flow

Flowing
Core

21 mm (0.85 in)
480 mm (19 in)
80 mm (3.1 in)
100 mm (3.9 in)

The critical arching dimension is a conservative calculation of the

powders potential in mass flow behavior to build a stable bridge
over the hopper outlet, thereby restricting flow. The arching values
above indicate that the hopper opening must be greater than 480
mm (18.9 in) to ensure reliable discharge of all powders. The
critical arching dimension for Sample #2 is much greater than the
other three powders due to its very cohesive and sticky nature,
thereby having a much greater tendency to form a stable arch. This
calculation also applies to the design of any conveyance device
directly downstream of the hopper, such as the spacing between
flutes on a screw feeder.
The Powder Flow Tester can also be used to calculate the critical
rat-hole dimension which relates to a behavioral problem that may
occur under core flow conditions. This calculation requires user
input on bin shape, cross section dimension(s), and hopper type
(wedge, conical). When this information is provided, the Powder
Flow Pro software is able to automatically calculate the rat-hole
diameter, as well as the hopper half angle.

Types of Flow Obstructions

Static
Material

RAT-HOLE

ARCHING DIMENSIONS
B.g.Vol

Critical Rat-Hole
Diameter

DRH

Mass-Flow

TIME CONSOLIDATION TEST

Additional testing on these samples would investigate the effect of
time consolidation, which addresses how powders increase their
internal strength when left in bins/hoppers for longer than planned.
Test duration could be as short as 30 minutes or as long as several
days. The former represents a\ temporary work stoppage, the latter
an extended plant shutdown. Long term time consolidation tests
also predict strength buildup in powders stacked on pallets in
storage or in transport over long distance.

1 = c

Dc

G() x crit
DRH = __________
xg
B
(where G() = 0.7771 x e

3 = 0

1 = c

2 x c x 1000
Conical Hopper: Dc = _____________
xg
B
0.0381

Plane Hopper:

c x 1000
Dp = ___________
xg
B
(where 3dp<L)

The customer also receives the detailed data reports in tabular

format which record all measurement values shown in the graphs.
In some cases, the customer chooses to request additional testing
services on a fee basis. This may involve more testing on existing
samples or new samples that the customer wishes to evaluate.
73