In industries where precision, purity, and particle size consistency are critical, air classifiers are essential tools. These machines separate particles based on size, shape, and density—without the need for screens or mesh. Instead, air is used to classify powders into coarse and fine fractions.
What Is an Air Classifier?
An air classifier is a piece of equipment that uses airflow to separate fine particles from coarse ones. The finer particles are carried away by the air stream while the heavier particles fall due to gravity or centrifugal force. This method is particularly useful for materials that are difficult to sieve mechanically, especially ultra-fine powders under 100 microns.
What Industries Use Air Classifiers?
Air classifiers are heavily used in:
- Battery materials (e.g., cathode/anode powders)
- Additive manufacturing (e.g., titanium, Inconel)
- Ceramics and specialty chemicals
- Pharmaceuticals
- Pigments and powder coatings
- Aerospace and defense powders
These industries often work with high-value, highly sensitive materials where even minor contamination can compromise performance or safety.
The Problem with Traditional Air Classifiers
Many conventional air classifiers rely on a classifying wheel—a spinning component that plays a central role in separating particle sizes. Over time, this metal-on-metal contact can cause abrasion, leading to wear particles breaking off into the product stream. For industries that require purity at the parts-per-million level, this contamination is unacceptable.
Additionally, these moving parts require regular maintenance and can introduce downtime and inconsistencies in the separation process.
Why the Elbow-Jet Is a Game-Changer
Unlike conventional designs, the Elbow-Jet Air Classifier from Elcan Industries uses the Coanda effect—a working principle of fluid dynamics that bends airflow along surfaces—to separate fine and coarse particles using only air. There are no rotating parts, no classifying wheels, and no risk of metal contamination.
The result? Cleaner powders, consistent particle distribution, and superior material integrity—especially for ultra-fine separations down to 10µm.
Top 5 Best Air Classifiers for Fine Powder Separations
1. Elbow-Jet Air Classifier – Elcan Industries
The Elbow Jet Air Classifier leads the pack in terms of purity, efficiency, and innovation. It’s completely screenless and wheel-free design means materials are never at risk of mechanical abrasion or contamination. This is the only classifier that uses only airflow and the Coanda effect to make sharp particle separations—making it ideal for the most demanding industries.
Key Advantages:
- No moving parts = zero metal contamination
- Uses only airflow (Coanda effect) for separation
- Ultra-fine cut sizes down to 1 micron
- No screen blinding or maintenance downtime
- Ideal for battery powders, aerospace alloys, and specialty chemicals
- Testing and tolling available in Elcan’s NY facility
2. Whirlwind, Side Draft & Superfine – Sturtevant Inc.
A versatile line of air classifiers for a wide range of particle size targets. Sturtevant’s Superfine model can reach extremely fine separations, while the Whirlwind and Side Draft offer energy-efficient operation for general use.
Key Advantages:
- Multiple particle cut ranges (100–4,800 mesh)
- Proven performance across mineral and industrial applications
- Side Draft model offers lower energy consumption
- Good for cement, calcium carbonate, fly ash, etc.
3. Calciplex ACP, TTD & TSP Series – Hosokawa Alpine Group
Hosokawa Alpine’s air classifiers are known for their precision in fine powder applications. The Turbo Twin Double (TTD) is engineered for soft material classification, while the TSP and TTSP are optimized for dedusting fine pigments and toner.
Key Advantages:
- High precision cut points
- Ideal for pigment, toner, and powder coatings
- Broad range of classifier styles for different applications
- Suited for fine but less purity-sensitive materials
4. High Efficiency Air Classifiers – Williams Patent Crusher
Williams’ classifiers integrate seamlessly with grinding systems to improve throughput and consistency. These models are built for durability and are a reliable choice for bulk powder handling.
Key Advantages:
- Designed to enhance existing grinding systems
- Effective for minus 200 mesh separation
- Built for rugged industrial environments
- Ideal for aggregate, limestone, and general minerals
5. Model 100, 250, 500 – AVEKA
The AVEKA series offers a scalable solution from lab testing to full-scale production. While not the best for high-purity or ultra-fine cuts, it serves well in product development and moderate throughput applications.
Key Advantages:
- Scalable design for R&D to production
- Easy changeover between samples
- Suitable for less demanding particle separations
- Useful for pilot projects and testing facilities
If you’re working with high-value materials—like metal powders for 3D printing, battery-grade chemicals, or specialty additives—you can’t afford contamination, inconsistency, or screen failures. That’s why leading manufacturers are moving away from traditional air classifiers and switching to the Elbow-Jet.
With no rotating parts, no wear surfaces, and no metal leaching into your product, the Elbow-Jet delivers repeatable, ultra-fine classification using only airflow and the Coanda effect. Whether you’re looking to eliminate screen maintenance, improve yield, or validate performance before scaling up, Elcan Industries offers full-scale testing and toll processing at our facility in New York.
Contact us today at info@elcanindustries.com or visit www.elcanindustries.com to schedule a trial or learn more about how we can support your air classification needs.