Dusting challenges in food manufacturing 

Anticaking agents are essential for keeping powdered foods like salt, spices, and dairy blends free-flowing. But behind the scenes, the dusting these agents produce during processing creates problems that go far beyond a messy production line.

The real cost of dust

Dusting doesn’t just create a mess—it directly impacts profitability. When powders lose material during processing, raw material costs rise, and yield efficiency drops. In high-volume operations, even small losses quickly compound into significant financial impact.

The problem doesn’t stop there. Dust accumulation on equipment forces more frequent cleaning, which means downtime and higher labor costs. This operational burden adds complexity to production schedules and resource planning.

While anticaking agents are designed to improve stability, studies show they require precise dosing matched to powder composition and ambient humidity to avoid waste and maintain flow^1,4. This precision raises process complexity and demands tighter control.

Adding to the challenge, clean-label pressures complicate procurement. “Natural” or alternative agents often need higher doses or advanced particle engineering to deliver equivalent functionality^2,3. These adjustments can increase both formulation costs and technical hurdles. 

Safety isn’t optional

Dusting generates airborne particulates that pose occupational respiratory risks. Inhalation of fine particulates during handling still requires strict control measures; these include enclosed transfer systems, local exhaust ventilation, and personal protective equipment (PPE).

Research on particulate systems shows that surface chemistry and particle size govern dispersibility, reinforcing the need for engineering controls alongside formulation adjustments. Regulations add another layer of complexity: additives must be used at the minimum effective level to achieve their intended technological effect. Labelling and usage limits are enforced across jurisdictions, tightening formulation windows and potentially increasing CapEx and OpEx for dust mitigation^2, 3.

A smarter approach to dust control

Anticaking agents play a critical role in preserving product quality and shelf life, but their application can introduce complex challenges - especially when it comes to dusting. The key to managing these risks lies in a holistic strategy that combines matrix-specific dosing, packaging and humidity control, and engineering safeguards. This approach helps manufacturers strike the right balance between cost efficiency, worker safety, and regulatory compliance^1,2,3.

To address safety concerns without compromising cost or performance, Omya conducted a comparative evaluation of its anticaking solutions against other commercially available alternatives. The tests focused on dusting behavior during handling of the food powder containing the anticaking agent, a factor with major implications for worker safety and operational efficiency.

Using the DustView II (PALAS GmbH, Karlsruhe, Germany), Omya tested two representative food matrices: milk powder and a seasoning blend. The DustView II uses laser beam attenuation to measure airborne particulates, producing a Dust Number (STZ) that combines peak dust concentration with residual dust levels 30 seconds later. The scale ranges from 0 (no dust) to 100 (very dusty), offering a clear benchmark for dustiness.

Figure 1 shows the results for milk powder, where Omyafood 120 generated significantly less dust than silicon dioxide and calcium silicate, with levels comparable to milk powder alone. 

Figure 2 presents similar findings for the seasoning blend, reinforcing the agent’s low-dust profile across different applications.

What makes Omyafood 120 stand out is its micron-sized, porous structure, which traps moisture preventing particle adhesion and caking. Its rough surface texture reduces mechanical interlocking and friction, improving flowability. These physical properties translate into better handling, reduce cleaning frequency, and enhance safety in production environments.

Figures 3 and 4 further illustrate how Omyafood 120 compares to conventional agents in improving powder flow and stability in milk powder applications.

Measurement methods

Dust number assessment 
Dusting behavior was quantified using the DustView II (PALAS GmbH, Karlsruhe, Germany), a device that evaluates the dustiness of powders through an optical method based on laser beam attenuation. For each test, a 50 ml sample was used—measured and standardized across all trials. The sample was placed in the receptacle at the top of the vertical pipe, and the measurement was initiated. Upon completion, two key metrics were recorded: the 30-second dust value (2 Hz) and the Dust Number (STZ), which combines peak dust concentration with the residual level after 30 seconds. All measurements were performed in duplicate, and the resulting data were visualized in Figure 1 (milk powder) and Figure 2 (seasoning blend).

Flowability and caking evaluation 
Powder flow properties were assessed using the FT4 Powder Rheometer with the shear cell method. This technique applies a normal force to a powder bed and measures the shear stress required to initiate flow, generating a flow function that classifies powders from very cohesive to free-flowing (Figure 3). 
Caking was also evaluated using the FT4 Powder Rheometer. Due to the non-homogeneous nature of caking, the depth of the crust formed at the top of the vessel was measured to determine the extent of agglomeration. These results are presented in Figure 4.

To explore practical ways of tackling dusting and improving efficiency, take a closer look at Omya’s powder flow solutions.

References

1. Lipasek, R. A. (2012). Effects of anticaking agents and storage conditions on the moisture sorption, caking, and flowability of deliquescent ingredients. Food Research International, 48(2), 770–780. 

1. Afzaal, M., Saeed, F., Ahmed, A., Islam, F., Khalid, M. A., Hussain, M., & Anjum, W. (2022). Anticaking agents in food nanotechnology. In Application of Nanotechnology in Food Science, Processing and Packaging (pp. 141–151). Springer.

1. Yapıcı, E., Karakuzuİkizler, B., & Yücel, S. (2020). Anticaking additives for food powders. In Food Powders: Properties and Characterization (pp. 109–123). Springer.