【Anti-Powder Adhesion】 70% Improvement in Powder Clogging | Surface Modification via Gemini Treatment | For Rotary Valves and Powder Lines

Fuji Blastech (Thailand) Co., Ltd. provides contract processing services in Thailand for "Gemini Treatment," a surface modification technology that suppresses powder adhesion and clogging.

We can handle everything from single-item prototypes to mass production within Thailand for rotary valves, hoppers, chutes, powder line components, wire mesh for sieves, resin mesh, and more. We propose coating-less surface modification for manufacturing sites facing challenges with powder adhesion, caking, and clogging of food, pharmaceuticals, chemicals, and resin powders.

Table of Contents

• What is coating-less, powder adhesion-suppressing "Gemini Treatment"?
• Shortened lead times and reduced transportation costs through complete domestic processing in Thailand
• Facilities and processing technology
• Prototyping and test processing from a single piece & technical consultation in Japanese
• Frequently Asked Questions (FAQ)

What is coating-less, powder adhesion-suppressing "Gemini Treatment"?

At manufacturing sites handling powders such as food, pharmaceuticals, and chemicals, powder can adhere to the inner walls of piping, the inside of rotary valves, hoppers, chutes, and sieve meshes, leading to residual buildup, caking, clogging, and bridging. When powder flow is obstructed, it results in equipment downtime, reduced yield, and manual removal by operators, which ultimately lowers production efficiency.

Gemini Treatment is a surface modification technology that utilizes blast processing to form microscopic irregularities (dimples) on the workpiece surface, thereby reducing the contact area and frictional resistance with the powder. While a mirror-like smooth surface may appear slippery at first glance, it actually increases the contact area with the powder, sometimes making it easier for adhesion to occur. Gemini Treatment creates a state where powder slides easily due to these micro-irregularities, aiming to suppress adhesion, residual buildup, and clogging.

Furthermore, unlike coatings such as fluororesin, it does not form a film of a different material on the surface. Therefore, it is a processing method that can be easily considered for food, pharmaceutical, and chemical manufacturing sites that want to avoid the risk of foreign object contamination caused by coating peeling.

Shortened lead times and reduced transportation costs through complete domestic processing in Thailand

Conventionally, when performing specialized surface modification or blast treatment, workpieces were often shipped to specialized processing contractors in Japan. This resulted in long lead times and high transportation costs.

Our company operates its own factory in Thailand, equipped with the necessary facilities for surface modification and various blast treatments, along with processing know-how cultivated over many years in Japan. Since we can conduct test processing, technical consultations, and maintenance responses locally completing the entire process within Thailand we can eliminate round-trip transportation to Japan, leading to shortened lead times and reduced transportation costs.

Facilities and processing technology

In order to apply uniform and precise surface modification to complex-shaped workpieces such as molds, precision metal parts, and various rotary valves, not only processing know-how but also high-precision blasting equipment and control of microscopic abrasives are required.

Our local factory in Thailand is equipped with multiple units of air blasting equipment manufactured by Fuji Manufacturing, including the "PNEUMA-BLASTER" and the "Manual Equipment Series." From over 400 types of abrasives with different hardnesses, particle sizes, and shapes, we select and execute the optimal combination tailored to the material of the target workpiece and the characteristics of the powder particles to be prevented from adhering.

By utilizing our independently developed blasting equipment and quantitative injection units, we highly control the blasting pressure and the supply amount of abrasives. This allows us to form uniform micro-dimples without variation, even on complex three-dimensional shaped rotors and fine details. Consequently, by adjusting the surface roughness post-processing exactly as targeted, we form a surface-modified layer that combines sliding properties with durability.

Prototyping and test processing from a single piece & technical consultation in Japanese

The effectiveness of preventing powder adhesion varies depending on conditions such as powder particle size, hygroscopicity, oil content, moisture content, equipment shape, temperature, input volume, and cleaning conditions. Therefore, it is important to confirm the effectiveness using actual workpieces or test pieces before introducing it to mass production equipment.

We accommodate prototyping and test processing starting from a single piece. By evaluating under conditions close to the actual powder and operating environment, mismatch risks after implementation can be minimized.

In addition, technical consultation is available in Japanese. You can consult with us directly in Thailand regarding drawing verifications, processing ranges, evaluation methods, delivery times, and mass production rollout.

Frequently Asked Questions (FAQ)

Q: What is the difference between Gemini Treatment and coating?
A: Gemini Treatment is not a treatment that applies a coating agent to form a film. It is a technology that microscopically modifies the workpiece surface itself through blast processing. Therefore, it is easy to adopt in food, pharmaceutical, and chemical manufacturing sites where the risk of foreign object contamination due to coating peeling must be avoided.

Q: Can it be applied to stainless steel rotary valves?
A: Yes, processing is possible. Application can be considered for areas that come into contact with powder, such as the rotor and casing of rotary valves. Since the optimal processing conditions vary depending on the shape, dimensions, tolerances, and operating environment, we will provide a proposal after reviewing the drawings or the actual item.

Q: Can it be applied to wire mesh and resin mesh?
A: Processing for wire mesh and certain resin meshes can also be considered. Since conditions change depending on the mesh opening, wire diameter, material, strength, and type of powder, we recommend test processing with a sample first.

Q: Is it possible to request a prototype for just one piece?
A: Yes, we support prototyping and test processing from a single item. You can verify the effects of powder adhesion suppression and clogging mitigation with actual workpieces or test pieces prior to mass production implementation.

Q: For what types of powder is it effective?
A: It can be considered for various powders such as wheat flour, tapioca starch, silica powder, chemical powders, pharmaceutical raw materials, and resin powders. However, since effectiveness varies depending on powder characteristics and equipment conditions, we recommend evaluation using the actual powder.

※ If you would like to know more details, please download the materials or contact us using the inquiry form below.