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UPFLOW successfully designed and supplied multiple customized Synthetic Graphite Air Mixing Systems for a battery material manufacturer, providing an advanced powder mixing solution specifically developed for handling fine artificial graphite materials used in high-performance industrial applications.
Unlike conventional mechanical mixing processes, the air mixing technology uses controlled airflow to create internal powder circulation, allowing fine powder materials to achieve efficient and uniform blending without relying on traditional rotating mixing elements that may introduce additional mechanical wear or create challenges during cleaning and maintenance.
For this long-term cooperation project, the customer has signed four separate contracts with UPFLOW and purchased a total of 12 air mixing systems, demonstrating the customer’s continued recognition of UPFLOW’s powder processing capability and customized equipment design experience.
The supplied systems were designed with a mixing volume of 60m³ per unit, allowing each batch to process up to approximately 30 tons of synthetic graphite powder, while achieving a mixing time of less than 30 minutes and a mixing uniformity requirement with a CV value of ≤5%.
Synthetic graphite is an important carbon-based material widely used in lithium-ion battery applications, where consistent material quality and uniform powder distribution are critical factors affecting downstream production performance.
For battery material manufacturers, the mixing process is not simply a matter of combining different powders together, but requires precise control of powder movement, uniformity, contamination prevention and production efficiency, especially when handling fine powders with particle sizes below 20μm.
The European customer required a large-capacity powder mixing system capable of:
Processing large batches of synthetic graphite powder
Achieving high mixing uniformity
Reducing mixing time
Preventing powder leakage during operation
Supporting automated production management
Integrating with existing powder conveying processes
Based on these requirements, UPFLOW developed a customized air mixing solution designed around the customer’s production capacity, material characteristics and automation requirements.
For battery material manufacturers, efficient powder processing requires not only uniform mixing but also reliable material handling solutions. UPFLOW also provides customized battery material powder handling solutions for lithium battery materials including cathode powders and other fine industrial powders.
Synthetic graphite powder used in battery material applications typically requires strict control of material consistency because even small variations in powder distribution may influence downstream processing stability.
In this project, the handled material had a particle size below 20μm and a bulk density of approximately 0.85 t/m³, meaning that the mixing system needed to achieve effective powder circulation while maintaining a controlled operating environment for fine powder processing.
The major engineering challenges included:
Achieving uniform mixing of fine graphite powder
Handling large batch volumes
Preventing powder leakage during mixing operation
Maintaining clean internal surfaces
Providing accurate weighing and batch control
To address these requirements, UPFLOW designed a large-volume air mixing system with optimized internal airflow circulation, dust collection integration and automated control functions.
The customized Synthetic Graphite Air Mixing System supplied by UPFLOW was designed with a single-unit volume of 60m³ and a maximum loading capacity of approximately 30 tons per batch.
The complete system configuration included:
60m³ air mixing chamber
Powder feeding inlet system
Top-mounted dust collector
Mixing air circulation components
PLC and touch-screen control system
The material enters the mixer through the customer’s pneumatic conveying system and passes through a DN300 pneumatic feeding valve before entering the mixing chamber. After the mixing process is completed, the material is discharged through the DN300 outlet butterfly valve and variable-frequency rotary valve before being transferred to the next production process through the customer’s conveying system.
This integrated design allowed the air mixing equipment to work seamlessly with the customer’s existing powder handling process.
With a 60m³ mixing volume and a maximum batch capacity of approximately 30 tons, the system was designed for large-scale industrial powder processing requirements.
The system was designed to achieve a mixing uniformity CV value of ≤5%, meeting the customer’s requirement for consistent synthetic graphite powder blending.
The equipment incorporated weighing sensors with accuracy requirements of C3 level or above, together with PLC and touchscreen control, allowing operators to manage the mixing process through either local operation or integration with the customer’s centralized control system.
To prevent powder leakage during operation, the system was equipped with dust collection equipment with filtration accuracy up to 1μm, while the exhaust dust concentration requirement was controlled below 10mg/m³.
The internal material-contact surfaces were manufactured using SUS304 stainless steel with mirror polishing requirements, helping maintain cleanliness and reduce material contamination risks.
One important feature of this project was that the air mixing system was not used as an independent machine, but as part of a complete powder processing line.
The process flow included:
Customer pneumatic conveying system → pneumatic feeding valve → 60m³ air mixing system → dust collector → mixing chamber → discharge butterfly valve → rotary discharge valve → customer pneumatic conveying system
Through this integrated configuration, the customer could achieve automated material feeding, large-volume powder mixing and controlled material discharge within one continuous production process.
Through multiple cooperation phases and four separate equipment contracts, UPFLOW supplied a total of 12 customized air mixing systems for the European customer, providing a reliable solution for synthetic graphite powder processing.
The project demonstrated UPFLOW’s capability in designing large-scale powder processing equipment for demanding applications where mixing uniformity, automation, cleanliness and production efficiency are critical requirements.
By combining air mixing technology, automated control systems and customized engineering design, UPFLOW helped the customer improve powder processing efficiency while maintaining stable product quality for advanced material manufacturing.
In addition to pneumatic conveying systems, UPFLOW provides customized powder processing solutions including:
Air Mixing Systems
Automatic Feeding Systems
Powder Unloading Equipment
Powder Handling Integration Solutions
With experience serving industries including battery materials, chemical powders, pharmaceutical materials and other advanced manufacturing applications, UPFLOW develops customized equipment according to material characteristics, production requirements and process conditions.
In addition to synthetic graphite powder processing, UPFLOW has also developed powder handling knowledge for other lithium battery materials, including Lithium Cobalt Oxide (LCO) pneumatic conveying systems and Lithium Iron Phosphate (LFP) powder handling solutions.
An air mixing system uses controlled airflow to create powder circulation and achieve uniform mixing of fine materials such as synthetic graphite powder.
Fine graphite powder requires careful handling to maintain uniformity and prevent contamination, and air mixing provides an effective solution for large-volume powder blending.
UPFLOW can customize powder mixing systems according to customer requirements, including large-volume systems such as the 60m³ graphite mixing equipment supplied in this project.
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