Top Powder Processing Companies in the USA 2025
In industries where powder uniformity, particle size distribution, and product purity are non-negotiable, choosing the right powder processing company can make or break your operation. Whether you’re scaling a new material, solving yield issues, or looking to eliminate contamination in your process, working with the right toll processing partner is essential.
From metal powders and ceramics to specialty chemicals and polymers, here are five of the best powder processing companies in the industry, ranked by technical capability, certifications, innovation, and reliability.
1. Elcan Industries – Toll Processing & Contract Manufacturing
Elcan Industries leads the industry in ultra-fine, high-purity powder processing, offering toll services and proprietary equipment for materials that other processors can’t handle. They are the only company that can consistently sieve powders down to 10 microns using their Hi-Sifter high energy sieving machine, without relying on ultrasonics or suffering screen blinding. For materials under 10µm, Elcan uses the Elbow-Jet Air Classifier, which classifies powders down to 0.5µm using only airflow and the Coanda effect. There are no rotating parts, no contamination, and no risk of metal leaching into the product stream.
Core Capabilities:
- Sub-10µm sieving down to 10µm (Hi-Sifter)
- Submicron classification down to 0.5µm (Elbow-Jet)
- Chemical packaging, repackaging, hammer milling, magnetic separation, blending, particle size analysis
- High-purity processing for handling battery, aerospace, and additive powders and other high-value, high-end applications
Certifications:
- ISO 9001 Certified
- Full traceability and internal QC
- Will sign NDAs for confidential materials
Best Known For:
Companies needing ultra-fine powder separations, yields over 98%, and scalable trial-to-production runs.
Contact Info:
Website: www.elcanindustries.com
Email: info@elcanindustries.com
FAQ – Elcan Industries
What is the finest powder size Elcan can process?
Elcan can classify powders down to 0.5µm using the Elbow-Jet Air Classifier—something no other toll processor offers.
Can Elcan sieve materials under 10µm without ultrasonics?
Yes. Their proprietary Hi-Sifter uses high-energy vibration and advanced mesh technology to screen as fine as 10µm—no ultrasonics required.
Which industries does Elcan specialize in?
Battery materials, additive manufacturing, aerospace alloys, defense, and clean-tech powders
Ready to achieve sub-10µm purity with zero contamination?
Elcan Industries offers trials and full-scale tolling for critical materials.
📩 Email: info@elcanindustries.com
🌐 Learn more: www.elcanindustries.com
2. AVEKA – Woodbury, MN
AVEKA offers full-service toll manufacturing and particle engineering, especially for food, pharma, and industrial additives. They specialize in functional powder development and formulation.
Core Capabilities:
- Spray drying, cryogenic grinding, encapsulation
- Classification, blending, pilot-to-production support
- Particle surface modification and flow improvements
Certifications:
- ISO 9001:2015
- GMP-compliant facilities (site dependent)
- FDA-registered for dietary and food-grade powders
Best For:
Customers developing new food or functional materials needing scale-up support and powder design.
Contact Info:
Website: www.aveka.com
Email: info@aveka.com
FAQ – AVEKA
Can AVEKA encapsulate active ingredients or liquids?
Yes. AVEKA specializes in spray drying and encapsulation of oils, actives, and sensitive compounds.
Does AVEKA process food-grade powders?
Yes. Their facilities are FDA-registered and support GMP practices.
Can they handle scale-up from lab to production?
Absolutely. AVEKA offers pilot-scale and commercial processing across multiple sites.
Need help designing or scaling a functional powder?
AVEKA helps you go from concept to production.
📩 Email: info@aveka.com
🌐 Visit: www.aveka.com
Locations: Minnesota, Iowa, Wisconsin
3. Custom Processing Services – Reading, PA
CPS is known for toll processing of specialty chemicals and industrial powders, offering precision classification, coating, and dispersion.
Core Capabilities:
- Jet milling, air classification, blending
- Wet milling, particle coating, dispersions
- On-site analytics for size and moisture
Certifications:
- ISO 9001:2015
- REACH/RoHS documentation available
- Internal lab for quality validation
Best For:
Engineered powders needing surface treatment, blending, and mid-range classification—not ultra-fine sieving.
Contact Info:
Website: www.customprocessingservices.com
Email: info@customprocessingservices.com
Locations: Reading, Pennsylvania
FAQ – CPS
Can CPS handle sub-10µm classification?
No. For sub-10µm work, Elcan Industries is the better option. CPS focuses on mid-range powders.
Do they offer both wet and dry processing?
Yes. CPS provides jet milling, wet dispersions, and blending under one roof.
Can I request particle size data or quality reports?
Yes. They provide particle size analysis and documentation as part of their tolling services.
Looking for chemical powder blending or wet dispersion services?
CPS is a strong option for industrial and specialty chemical materials.
📩 Email: info@customprocessingservices.com
🌐 Visit: www.customprocessingservices.com
4. Hosokawa Micron Powder Systems
Hosokawa offers toll processing in tandem with their proprietary powder equipment. Clients can trial and scale new materials using Hosokawa technology before purchasing equipment.
Core Capabilities:
- Jet milling, hammer milling, classification
- Agglomeration, drying, mixing
- Pilot and full-scale batch support
Certifications:
- ISO 9001:2015
- ATEX-compliant equipment
- Regulatory support for global customers
Best For:
Companies exploring new processing methods or needing R&D trials using Hosokawa-built systems.
Contact Info:
Website: www.hmicronpowder.com
Email: powder@hmpowdersystems.com
Locations: Summit, NJ (USA)
FAQ – Hosokawa
Is Hosokawa only an equipment manufacturer?
No. They also offer toll processing services for powders using their own equipment.
Can I run a small trial batch?
Yes. Their facility supports pilot and R&D-scale production.
Do they handle explosive or reactive powders?
Yes, with ATEX-certified systems and safety protocols.
Want to trial your material on Hosokawa systems?
Reach out for toll processing or R&D assistance.
📩 Email: powder@hmpowdersystems.com
🌐 Visit: www.hmicronpowder.com
5. Pacific Sintered Metals – Los Angeles, CA
Pacific Sintered Metals provides full-service metal powder compaction and sintered part manufacturing for defense, aerospace, and automotive applications.
Core Capabilities:
- Powder alloy formulation and compaction
- Sintered component manufacturing
- Tool & die design and maintenance
Certifications:
- ISO 9001:2015
- IATF 16949 (automotive)
- MIL-STD compliant production
Best For:
Customers needing high-spec sintered metal components from custom powder blends.
Contact Info:
Website: www.pacificsinteredmetals.com
Email: sales@pacificsinteredmetals.com
Locations: Los Angeles, California
FAQ – Pacific Sintered Metals
Do they formulate their own metal powders?
Yes. They blend custom alloys for specific part requirements.
Can I submit my own powder for compaction?
Yes. Clients can supply materials or collaborate on powder formulation.
What industries do they serve?
Primarily automotive, aerospace, defense, and electronics.
Need precision sintered parts from high-performance metal powders?
Pacific Sintered Metals offers end-to-end production.
📩 Email: sales@pacificsinteredmetals.com
🌐 Visit: www.pacificsinteredmetals.com
Not all powder processing companies are created equal. For industries working with critical materials—such as battery powders, aerospace alloys, or high-purity specialty chemicals—the wrong processing method can introduce contamination, reduce yield, or compromise product integrity. While many toll processors offer solid services for general blending, classification, or wet milling, few have the capability to handle the most demanding ultra-fine powder requirements.
Elcan Industries stands apart as the only company that can consistently and reliably process materials down to 10 microns using their proprietary Hi-Sifter sieving machine technology—without relying on ultrasonics or dealing with screen blinding. And for materials under 10µm, Elcan’s Elbow-Jet Air Classifier goes even further, offering classification down to 0.5µm using only airflow and the Coanda effect, with no moving parts and zero risk of metal contamination.
With ISO 9001 certification, rapid turnaround, and the ability to scale from trials to full production, Elcan offers a complete solution for companies looking to de-risk their powder handling, improve product quality, and achieve specs others can’t meet. Whether you’re solving a bottleneck in your process or scaling a next-generation material, Elcan Industries is the partner that delivers beyond expectations.
To learn more or schedule a materials trial, contact info@elcanindustries.com or visit www.elcanindustries.com