Instant Beverage Granule Production Line
Complete Powder Mixing, Wet Granulation, Drying and Screening Solution
Instant beverage granules are widely used for instant tea, lemon drinks, fruit beverages, nutritional drinks and other convenient food products. Compared with fine beverage powders, granules can provide better flowability, easier handling, reduced dust and controlled particle size.
However, producing stable instant beverage granules requires more than simply mixing powder ingredients. A complete manufacturing process normally includes powder feeding, mixing, wet granulation, particle sizing, fluid bed drying and final screening.
Hywell Machinery provides customized instant beverage granule production lines for converting powder ingredients into uniform, free-flowing and easy-to-handle granules.
What Are Instant Beverage Granules?
Instant beverage granules are agglomerated beverage ingredients designed to be dissolved or dispersed in water before consumption.
Common products include:
Compared with very fine powders, granules can offer improved flowability, lower dust generation and easier feeding and packaging.
For manufacturers, the main objective is to produce granules with the required particle size, moisture content, strength, flowability and dissolution performance.
How Are Instant Beverage Granules Made?
A typical instant beverage granulation process is:
Raw Material Feeding → Powder Mixing → Wet Granulation → Granule Sizing → Fluid Bed Drying → Screening → Cooling → Packaging
The actual process depends on the product formulation, raw material characteristics, required production capacity and final product specifications.
A typical production line may include:
Closed Feeding System
Powder Mixer
High Shear Mixer Granulator
Basket Granulator
Static Fluid Bed Dryer
Vibrating Sieve
Cooling or Dehumidification System
Packaging System
The equipment configuration can be customized according to the customer's product and production requirements.
Instant Beverage Granule Production Process
1. Raw Material Feeding
The first step is feeding the beverage powder ingredients into the production system.
Typical raw materials may include:
Many of these materials are fine powders. Therefore, a closed powder feeding system can be used to reduce dust and unnecessary operator contact.
A closed feeding system can provide:
Reduced powder loss
Lower dust emission
Cleaner production conditions
Better material handling
Reduced contamination risk
Easier integration with automated production
For food and beverage production, hygienic powder handling is an important part of the overall production process.
2. Powder Mixing
After feeding, the different powder ingredients need to be mixed uniformly.
This is especially important when a formulation contains a large amount of powdered sugar together with small quantities of flavor, color, vitamins or other functional ingredients.
Uniform mixing helps ensure that the minor ingredients are evenly distributed throughout the main powder.
The mixing process should achieve:
Uniform ingredient distribution
Good dispersion of minor ingredients
Consistent batch quality
Reduced ingredient segregation
The powder mixer can be selected according to the formulation, batch size, material characteristics and required production capacity.
3. High Shear Mixer Granulator for Wet Granulation
After powder mixing, the material enters the High Shear Mixer Granulator for wet granulation.
The high-speed impeller provides intensive mixing, while the high-speed chopper helps break larger agglomerates and improve the uniformity of the wet mass.
The typical process is:
Powder Mixing → Binder Addition → Wet Agglomeration → Granule Formation
A controlled amount of liquid binder is added during the process. The binder helps the powder particles combine to form stable wet granules.
Advantages of High Shear Wet Granulation
Fast processing
Intensive mixing
Good distribution of minor ingredients
Uniform wet agglomeration
Good control of granule formation
Suitable for batch production
The binder type and liquid addition rate should be determined according to the actual formulation and material properties.
4. Basket Granulator for Particle Size Control
After wet granulation, the wet material can be processed by a Basket Granulator for further particle shaping and size control.
The basket granulator uses extrusion and cutting action to produce granules with a more controlled particle size.
Particle size is important because it affects:
For some instant beverage products, a target such as 2.5–3 mm diameter and 4–6 mm length may be required. However, this should be treated as a product-specific example rather than a universal specification.
The final particle size should be confirmed through material testing and customer requirements.
If Granules Are Too Fine
Very fine particles may result in:
If Granules Are Too Large
Oversized granules may result in:
Therefore, granulation and final screening need to be designed together.
5. Fluid Bed Drying of Instant Beverage Granules
After wet granulation, the granules contain residual moisture and need to be dried.
A Static Fluid Bed Dryer can be used to remove moisture from wet granules by passing heated air through the material bed.
The heated air provides direct contact with the granules, allowing moisture to evaporate efficiently.
Advantages of Fluid Bed Drying
Efficient moisture removal
Good heat transfer
Uniform drying
Controlled drying conditions
Suitable for granular materials
Compact process arrangement
Hywell's static fluid bed dryers are used for drying powder and granular materials in food, pharmaceutical and chemical applications. The manufacturer also lists granular materials within approximately 0.1–6 mm as a typical application range, with 0.5–3 mm described as a preferred range for many materials. Actual suitability depends on the material and process conditions.
6. Moisture Control and Anti-Caking
Moisture control is one of the most important factors in instant beverage granule production.
Excessive moisture can cause:
This is particularly important for sugar-based beverage products because many sugar-containing formulations are hygroscopic.
However, there is no single final moisture value suitable for every instant beverage product.
The target moisture should be determined according to:
For moisture-sensitive products, cooling and dehumidification can be added after drying.
This helps reduce the product temperature before packaging and reduce moisture absorption from the surrounding environment.
7. Final Screening
After drying, the granules are screened to remove oversized particles and excessive fines.
A Rotary Vibrating Sieve can be used for final particle classification.
The screening process helps achieve:
More uniform particle size
Better product appearance
Improved flowability
Reduced oversized material
Reduced excessive fines
More consistent packaging
Qualified granules can then be transferred to the cooling and packaging process.
Oversized and undersized material can be collected separately. Depending on the formulation and process design, some material may be returned for further processing.
8. Cooling and Packaging
After drying and screening, the granules should be cooled before final packaging when required by the product.
This is particularly important for hygroscopic products.
A cooling or dehumidification system can help:
Reduce product temperature
Reduce moisture absorption
Maintain free-flowing granules
Improve packaging stability
Improve storage performance
For moisture-sensitive instant beverage products, the packaging environment should also be considered as part of the complete production process.
Example of Lemon Instant Beverage Granule Formula
Different beverage products require different formulations.
An example lemon-flavored instant beverage formulation may include:
| Ingredient | Example Ratio |
| Powdered Sugar | 90% |
| Citric Acid | 3.1% |
| Powder Flavor | 5.5% |
| Trisodium Citrate | 0.66% |
| Whitening Agent | 0.25% |
| Natural Color | 0.20% |
| Sodium Bicarbonate | 0.15% |
| Xanthan Gum | 0.07% |
| Ascorbic Acid | 0.06% |
Note: This is an example formulation for process discussion only. The actual recipe, binder system and processing conditions should be determined by the product manufacturer according to the intended product, raw materials and applicable food regulations.
For high-sugar formulations, particular attention should be given to:
Powder mixing
Binder addition
Wet granulation
Drying
Cooling
Final moisture
Packaging humidity
Why Convert Beverage Powder into Granules?
Converting fine beverage powder into granules can provide several production advantages.
Better Flowability
Granules generally flow more easily than very fine powders, making conveying, dosing and packaging easier.
Reduced Dust
Granulation can reduce the amount of fine powder generated during material handling.
Better Particle Uniformity
Granulation followed by screening allows manufacturers to control the particle size distribution more effectively.
Easier Handling
Granules can be easier to convey, store and feed into packaging equipment.
Controlled Dissolution
Particle size and granule structure can be adjusted according to the required dissolution performance.
Reduced Powder Segregation
A properly designed granulation process can help reduce segregation between different powder ingredients.
Equipment for Instant Beverage Granule Production
A complete instant beverage granulation line may include the following equipment:
Closed Powder Feeding System
Used for hygienic and controlled transfer of powder ingredients.
Powder Mixer
Used to achieve uniform distribution of beverage ingredients before wet granulation.
High Shear Mixer Granulator
Used for intensive mixing and wet agglomeration of powder materials.
Basket Granulator
Used for particle shaping and granule size control.
Static Fluid Bed Dryer
Used to remove moisture from wet granules after granulation.
Vibrating Sieve
Used to classify dried granules and remove oversized or undersized particles.
Cooling and Dehumidification System
Used when the product requires controlled cooling and low-humidity handling.
Packaging System
Used to fill finished granules into sachets, bags, jars or other packages.
The complete equipment configuration depends on the material, formulation, capacity and final product requirements.
Hywell already has a broader granulation equipment portfolio covering fluid bed granulators, high-shear granulators and other granulation systems, so the beverage line can be designed around the actual material rather than forcing every product into the same equipment configuration.
Applications of Instant Beverage Granulation
The instant beverage granulation process can be used for various food and beverage products.
Instant Tea Granules
Used for instant black tea, green tea and other instant tea products.
Hywell has also supplied an instant tea granule production project in which tea powder and auxiliary ingredients were processed into individual instant tea granules.
Lemon Beverage Granules
Suitable for lemon-flavored instant drink products.
Orange Beverage Granules
Used for orange and other citrus-flavored instant beverages.
Fruit Beverage Granules
Suitable for selected fruit drink formulations.
Ginger Tea Granules
Suitable for ginger-based instant beverage products.
Nutritional Beverage Granules
Can be used for selected nutritional and functional beverage formulations.
Instant Soup Granules
Granulation technology can also be used for selected instant soup and savory food products.
Hywell's existing granulation applications also include instant tea, ginger tea, instant drink granules and other food granules.
Key Factors Affecting Instant Beverage Granule Quality
Particle Size
Particle size affects dissolution, appearance, flowability and packaging.
The granulator and screening system should therefore be selected according to the required particle size distribution.
Moisture Content
Moisture directly affects caking, flowability and storage stability.
The correct final moisture target should be established through product testing.
Granule Strength
Granules need enough mechanical strength to withstand conveying and packaging without generating excessive fines.
Dissolution Performance
The formulation, particle size and granule structure all influence dissolution performance.
Cooling Conditions
Hot granules may absorb moisture after drying if they are exposed to humid air.
Proper cooling can therefore be important for hygroscopic products.
Packaging Environment
For sugar-based and other moisture-sensitive products, a controlled packaging environment can help maintain product quality.
How to Choose an Instant Beverage Granulation Line
Selecting an instant beverage granule production line requires evaluation of the complete process rather than selecting individual machines separately.
Raw Material Characteristics
Important material properties include:
Particle size
Bulk density
Initial moisture
Flowability
Hygroscopicity
Heat sensitivity
Adhesion characteristics
These properties affect the selection of the mixer, granulator, dryer and screening equipment.
Product Formulation
Different formulations require different processing conditions.
A sugar-rich beverage formulation, for example, may require more careful moisture and cooling control.
Production Capacity
The production line should be designed according to:
Granule Size
The target particle size should be defined before selecting the granulator and screening system.
Final Moisture
The required final moisture should be established before the drying system is designed.
Dissolution Requirements
If fast dissolution is important, the granule structure and particle size should be considered during the entire production process.
Frequently Asked Questions
How do you make instant beverage granules?
A typical process includes powder feeding, powder mixing, wet granulation, particle sizing, fluid bed drying and final screening. The exact process depends on the formulation and required product properties.
What machine is used to make instant tea granules?
A complete instant tea granulation system may include a powder mixer, high shear mixer granulator, basket granulator, fluid bed dryer and vibrating sieve.
Can beverage powder be wet granulated?
Yes. Many beverage powder formulations can be processed using wet granulation. However, the binder, liquid addition rate and granulation conditions should be determined according to the specific formulation.
What dryer is used for instant beverage granules?
A fluid bed dryer is commonly used for drying wet granules because it provides efficient heat and mass transfer. The drying temperature and residence time depend on the product and material characteristics.
How do you prevent instant beverage granules from caking?
Caking can be reduced through appropriate granulation, sufficient drying, controlled final moisture, proper cooling, low-humidity handling and suitable packaging.
What particle size is suitable for instant beverage granules?
There is no universal particle size for all products. The required size depends on the product formulation, dissolution requirements, appearance and packaging system.
Can the instant beverage granulation line be customized?
Yes. The equipment configuration can be customized according to raw materials, formulation, capacity, particle size, moisture requirements and factory layout.
What information is needed for a production line quotation?
For a preliminary process design, the following information is useful:
The more complete the material information, the more accurately the granulation and drying process can be designed.
Why Choose Hywell Machinery for Instant Beverage Granulation?
Hywell Machinery provides powder mixing, granulation and drying equipment for food, pharmaceutical and chemical applications.
For instant beverage granules, Hywell can integrate:
Powder Feeding → Mixing → Wet Granulation → Particle Sizing → Fluid Bed Drying → Screening
The equipment can be manufactured according to different material characteristics, production capacities and product specifications.
Hywell's granulation solutions are also used for instant tea, seasoning granules, instant food products and other applications requiring controlled particle size and moisture.
Get an Instant Beverage Granulation Solution
Are you looking for an instant beverage granule production line?
Hywell Machinery can help you evaluate your powder ingredients and develop a suitable process for mixing, wet granulation, drying and screening.
For a preliminary equipment recommendation, please provide:
Product + Formula + Capacity + Initial Moisture + Final Moisture + Granule Size
Our engineering team can then recommend a suitable process and equipment configuration for your application.
Contact Hywell Machinery for a customized instant beverage granulation line.
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