When it comes to particle size reduction, not all processes are created equal. In industries like pharmaceuticals, food, and minerals, selecting the right method for reducing material size can mean the difference between passable and precision performance.
Milling and micronization are two common approaches. While the terms are sometimes used interchangeably, they serve different purposes and produce different results. Here’s a breakdown of what each process entails and how to choose the right solution for your application.
Milling: A Broad Approach to Particle Size Reduction
Milling is a general term used for mechanically reducing particle size by grinding, crushing, or cutting material. It’s one of the oldest and most versatile processing techniques, commonly used in applications where particles need to be smaller—but not necessarily ultra-fine.
Common types of mills include:
- Hammer mills
- Pin mills (like the Sturtevant Simpactor®)
- Jaw crushers
- Roller mills
Milling is typically used to achieve particle sizes ranging from hundreds of microns to a few millimeters. It’s a great fit for coarse to medium particle size targets, making it ideal for applications in mining, aggregate production, and food processing.
Micronization: When You Need Precision You Can Count On
Micronization, on the other hand, refers specifically to the process of reducing particles to micrometer (μm) or even sub-micrometer size—often under 10μm. This is not just fine grinding; it’s a specialized process that demands precision, speed, and control.
At Sturtevant, our Micronizer® Jet Mill is a perfect example of this high-performance technology. Using compressed air or gas, the Micronizer creates a high-velocity spiral that grinds particles through collisions—without mechanical contact. The result is a contamination-free, ultra-fine powder with tightly controlled particle size distribution.
Micronization is essential in industries where particle uniformity and surface area directly impact product performance. This includes:
- Pharmaceuticals (bioavailability of active ingredients)
- Cosmetics (smooth texture and even blending)
- Chemicals (reaction rates and solubility)
Key Differences at a Glance
| Feature | Milling | Micronization |
|---|---|---|
| Particle Size Range | ~100 microns to several millimeters | Typically <10 microns (often <5µm for pharmaceuticals) |
| Mechanism | Mechanical impact, crushing, cutting, or grinding | High-velocity particle collisions using compressed air or gas |
| Equipment Examples | Hammer mills, pin mills (Simpactor®), jaw crushers | Jet mills (Micronizer®) |
| Contamination Risk | Moderate – mechanical contact between parts may introduce impurities | Low – no mechanical contact in jet milling |
| Precision Control | Moderate control over particle size distribution | High control and narrow particle size distribution |
| Best For | Coarse to medium size reduction in food, minerals, and aggregates | Ultra-fine powders in pharma, cosmetics, specialty chemicals |
| Energy Usage | Varies depending on material and method | Generally higher due to use of compressed air or gas |
| Surface Area Impact | Less surface area generated per particle | Dramatically increases surface area per unit of mass |
| Output Texture | Granular or powdery, depending on mill type | Smooth, fine, consistent powders |
Choosing the Right Process for Your Application
The right particle size reduction method depends on your material characteristics, desired particle size, and regulatory needs. At Sturtevant, we work closely with our customers to determine whether milling or micronization offers the best value—and engineer a solution that meets their exact performance goals.
If you’re unsure which process is right for your operation, our team is here to help. We offer testing services and custom-engineered solutions to support everything from R&D to full-scale production.
Want to explore how Sturtevant can support your size reduction goals?
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