Design and Working Principle

The process is designed as a continuous, automated line to minimize operator exposure to hazardous chemicals.

Stage 1: Pre-Blending:

Active Ingredients (Technical grade) and fillers (Clay, Silica, etc.) are weighed and mixed in a Ribbon Blender to create a homogeneous pre-mix. This ensures the active ingredient is evenly distributed before grinding.

Stage 2: Ultra-Fine Grinding:

The pre-mix is fed into the grinding system.

• For Standard WP (D97 = 45 microns): We employ the Air Classifying Mill (ACM). It grinds and classifies in a single step, offering high throughput and precise top-cut control.
• For High-Value/Heat-Sensitive WDG (D97 < 10 microns): We use a Air Jet Mill. It uses compressed air to create particle-on-particle collision, ensuring no heat generation and ultra-fine micronization.

Stage 3: Post-Blending (Homogenization):

The ground powder is conveyed to a post-Blender (typically a ribbon blender) to smooth out any batch variations and ensure consistent active ingredient percentage (A.I. %) across the final lot.

Stage 4: Safety & Collection:

The entire system operates under negative pressure. For explosive materials (like Mancozeb or Sulphur), the system is designed as a Closed Loop with Nitrogen (N2) Inerting to keep oxygen levels below the Limiting Oxygen Concentration (LOC).

Model Description

RIECO provides scalable solutions from pilot to large-scale production.

Variant	Model	Application	Typical Capacity*	Target Fineness
AG-15-MS	ACM 15	Low Vol	80 – 150 kg/hr	325 Mesh (45 µm)
AG-15-SS	ACM 15	Low Vol	80 – 150 kg/hr	325 Mesh (45 µm)
AG-30-MS	ACM 30	Production	250 – 500 kg/hr	325 Mesh (45 µm)
AG-30-SS	ACM 30	Production	250 – 500 kg/hr	325 Mesh (45 µm)

*Capacities vary based on formulation density and active ingredient hardness.

Key Components

Component	Function	Technical Feature
Ribbon Blender	Pre/Post Mixing	Double-helix design for fast, homogeneous mixing of active ingredient and carriers.
Air Classifying Mill (ACM)	Fine Grinding	Integrated dynamic classifier; suitable for 90% of pesticide formulations. Built-in classifier avoids over-grinding and maintains product consistency.
Jet Mill (Spiral/Fluid Bed)	Micronization	No moving parts; ideal for heat-sensitive or high-abrasion chemicals (< 10 microns).
Pulse Jet Bag Filter	Product Recovery	Anti-Static (Conductive) filter bags prevent static discharge explosions. Achieves outlet dust concentration typically <10 mg/Nm³ (as per pollution norms).
N2 Inerting System	Explosion Prevention	Maintains O₂ < 8% (typical) using nitrogen purging for hazardous dusts.
Double Flap Valve	Air Sealing	Used instead of Rotary Valves for abrasive materials to reduce wear and leakage.

System Characteristics

Capacity Range	80 - 1500 Kg/hr
Output Finess	Min. 99% passing 45
Grade	TC, TK, WDP, WP, SP, Uria

Features & Benefits

• High Suspensibility: The precise cut-point of the ACM/Jet Mill ensures a narrow particle size distribution (Steep PSD), which allows the powder to remain suspended in water for longer periods (a critical quality metric for pesticides).

• Cross-Contamination Control: "Easy-Clean" designs with access doors and polished interiors allow for rapid changeovers between different products (e.g., Herbicide to Insecticide) without contamination risks.

• Uniform Quality for Formulations: Ensures proper suspension, dispersibility, and active ingredient performance.

• Dust-Free Operation: Closed-loop grinding reduces emissions and operator exposure.

• Explosion Safety: Explosion-proof design & systems for handling hazardous Agro-chemicals. Mancozeb, Sulphur, and Carbon-based powders are equipped with Explosion Suppression Systems or N2 Inerting loops monitored by Oxygen Analysers.

• Handling Sticky Materials: Specialized "Liner" and "Rotor" designs are available for hygroscopic or sticky materials (like Urea-based formulations) to prevent internal build-up.

• Low Temperature: High air volume in ACM and the cooling effect of expansion in Jet Mills ensure the active ingredients do not degrade due to heat.

Applications

• Insecticides: Cypermethrin, Deltamethrin formulations.

• Fungicides: Mancozeb, Sulphur (WP/WDG).

• Herbicides: Glyphosate, Atrazine.

• Fertilizers: Water-soluble NPK blending and grinding.