Scaling sustainable cement depends on controlled powder mixing

When Material Evolution developed a low-carbon alternative to cement, the main challenge was not the chemistry. It was scaling the process to industrial production while maintaining consistent material quality. To achieve this, the team partnered with Hosokawa Micron Group to define and optimize the mixing process.

From lab concept to industrial process

Instead of high-temperature clinker production, the material is produced by mixing powder-based inputs through an alkali fusion process. This reduces CO₂ emissions by up to 85% and enables the use of industrial waste streams. At scale, performance depends on one thing: how well the powders are mixed.

Mixing defines throughput and consistency

Together with Hosokawa Micron, a gravity-fed mixing and dosing setup was developed and tested on-site. During trials, throughput increased beyond expectations, reaching up to 6 tonnes per hour while maintaining consistent product quality.

The focus was not just on equipment, but on:

stable flow behaviour
repeatable mixing results

From pilot to continuous production

The result is a clear scale-up path, from batch production to a new facility with a capacity of 120,000 tonnes per year. This case shows that in new material processes, powder mixing is a critical control point for both quality and scalability.