Zinc isn’t just for vitamins and sunscreen anymore. With the rise of next-gen batteries, advanced coatings, transparent electronics, and clean-tech reformulations, demand for high-purity zinc oxide powder processing is climbing fast. But these industries require precision particle control—and traditional screening technologies can’t keep up.
Elcan Industries is helping companies stay ahead with high-efficiency sieving and toll processing services that eliminate screen blinding and deliver uniform particles down to 10 microns and below. Whether you need to process zinc oxide powders for cosmetics or simply to dial in a particular particle size distribution for battery R&D, our Hi-Sifter sieving machine technology and contract manufacturing services provide a scalable solution.
What’s Driving Zinc Oxide Powder Demand
Battery Breakthroughs
As demand for safer and more affordable energy storage increases, zinc-based battery chemistries, such as zinc-air and zinc-ion, are gaining traction as alternatives to lithium-ion. These batteries are especially promising for grid-scale and long-duration storage because they use abundant, non-flammable, and recyclable materials. With lithium supply chains under pressure, manufacturers are turning to zinc as a stable, low-cost alternative—but that shift requires dependable access to highly uniform powders.
Semiconductor and Electronics R&D
Zinc oxide (ZnO) is being explored as a next-generation material for transparent electronics, UV sensors, and flexible semiconductors. As traditional silicon approaches its physical limits, materials like ZnO are drawing increased interest and R&D investment. These applications demand powders with ultra-fine particle sizes and absolute purity—meaning precision screening is critical during material preparation.
Cosmetics and Pharma
Zinc oxide remains a staple in skincare and over-the-counter pharmaceuticals for its antimicrobial and UV-blocking properties. With regulatory pressure building against chemical-based sunscreens, many personal care brands are reformulating with ZnO as the active ingredient. That shift is increasing demand for medical- and cosmetic-grade zinc oxide, which requires very precise particle size distributions and more importantly, contamination-free processing.
Zinc-based powders are essential for anti-corrosion coatings used in infrastructure, automotive, and aerospace. As infrastructure investment increases, so does the need for consistent, flowable zinc powders in primers and galvanizing applications. Variations in particle size or moisture content can degrade coating performance, making advanced sieving technologies an essential part of the production process.
Environmental and Regulatory Trends
Zinc is also emerging as a cleaner alternative to toxic elements like cadmium and lead in pigments, stabilizers, and electronics. As environmental regulations tighten, manufacturers are under pressure to eliminate hazardous substances and find greener substitutes. Zinc and zinc oxide are increasingly filling that gap—but only when available in the right form and purity.
Common Challenges in Zinc Oxide Powder Processing
Zinc oxide and similar powders pose real challenges for traditional screening systems. These materials are often electrostatic, cohesive, or hygroscopic—causing them to clump, blind mesh screens, or fail to separate properly.
Common Pain Points:
- Screen blinding caused by static or sticky powder
- Inability to sieve below 44 microns without ultrasonics
- Material loss due to inefficient separation or excessive oversize
- Inconsistent particle distributions that hurt downstream performance
- Excessive downtime for screen cleaning or changeouts
These issues are especially problematic in industries like batteries, cosmetics, and coatings, where performance and purity are non-negotiable. A small amount of oversize in a pharmaceutical batch or battery slurry can result in failed QA testing or reduced efficiency. That’s where Elcan comes in.
Elcan Industries: Zinc Oxide Sieving Down to 10 Microns
Elcan’s Hi-Sifter high-energy screening system was designed specifically to handle fine, difficult powders like zinc oxide. Unlike traditional vibratory sieves, the Hi-Sifter sieving machine uses a high-frequency, vertical energy motion that keeps the mesh screen clear and the powder flowing—without requiring ultrasonics.
Hi-Sifter Advantages:
- Particle separation down to 10 microns
- No screen blinding, even with cohesive powders
- Higher throughput compared to conventional systems
- Fully enclosed stainless-steel design for sanitary applications
- Easy screen change-outs with minimal downtime
- Multi-deck configurations available for precision multi-cut screening
This machine is already in use processing zinc and other metal powders for customers in the battery, aerospace, and pharmaceutical industries. It has consistently delivered 98% product yield and 99% separation efficiency, even at the finest particle sizes.
Learn more about the Hi-Sifter here: Hi-Sifter Sieving Machine
Toll Processing Services for Zinc Oxide Powders
Don’t have the in-house equipment to run high-performance screening? Elcan offers full-service toll processing at our facility in Tuckahoe, NY.
With years of experience screening zinc oxide, we offer:
- Precision toll screening down to 10 µm
- Batch and high-volume production runs
- In-house materials testing before scale-up
- Contamination-free handling with fully polished contact surfaces
- Packaging and repackaging into drums, pails, or supersacks
Our tolling clients include companies developing zinc-air batteries, cosmetics manufacturers, and coatings producers who require consistent, tight spec powders.
Whether you’re prototyping a new zinc-ion battery chemistry or trying to meet FDA compliance on cosmetic-grade ZnO, our tolling services give you access to world-class equipment and decades of expertise without the capital investment.
Explore our tolling services: Toll Processing Overview
Trusted by Industry Leaders
Elcan Industries has been solving powder screening challenges for over 30 years. Our equipment is used by companies in:
- Battery Materials
- Additive Manufacturing
- Fine Chemical Production
- Pharmaceutical Processing
- Specialty Coatings
Zinc and zinc oxide aren’t just commodity powders anymore—they’re strategic materials. And as demand grows, so does the need for reliable, scalable processing solutions.
Ready to Sieve Your Zinc Oxide
If you’re struggling to screen zinc oxide or other challenging powders, we invite you to send us your material for testing. We’ll show you exactly how the Hi-Sifter performs compared to conventional screening equipment, and how Elcan can become your processing partner.
✉️ Contact us to schedule a free trial run at our NY facility!
🌐 Learn more at elcanindustries.com