In short: Meter the liquid slowly onto a moving bed of carrier silica, stop before the powder darkens or balls, and judge the result by flow through a funnel and by caking after warm storage, not by how much liquid the silica can theoretically hold. Sensilchem starts premix carrier trials with CENSIL 260P and moves up the gradient to 265P or 280P only when the target load is held but flow suffers.
Charge the silica into the blender and run it at the slowest speed that keeps the bed turning over. Liquid dripped onto a static heap wets one spot and forms a lump that never comes apart.
Spray or drip a quarter of the target liquid, mix for a few minutes, and look at the powder before adding the next quarter. Note the point at which the colour deepens or the powder begins to roll into small balls.
The load at which the powder still runs through a funnel without tapping is the working load. The point where it first balls up is the ceiling, and a product made at the ceiling will cake in the bag.
Pass the same mass of loaded powder through the funnel and time it, or watch the angle it settles at. Record the load and the flow result together; that pair is the number the plant needs.
Fill jars, press lightly, and hold them warm for one to two weeks. Tip the jar: free-running powder passes; a powder that holds the shape of the jar has caked and the load was too high for that grade.
If the target load caked on the base grade, repeat on the next grade up instead of pushing more liquid into the same silica. The gradient exists so that the plant does not change platform, only the step.
Viscous, hygroscopic liquids such as choline chloride solution and some organic acid blends. They need a higher-loading carrier and a slower addition, and they are the case where CENSIL 280P earns its place.
Usually, but the load that survives pelleting is lower than the load that flows in a bag. Run the pellet trial with the loaded premix rather than assuming the powder result carries over.
The material you use now, the formulation or resin, the equipment and the target you need to hit. That is enough for us to say whether we have something worth testing.
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