- InterProcess Sp. z o.o.
Lump Breaker LBS – Efficient Size Reduction and Screening of Bulk Solids
The lump breaker LBS (also referred to as a delumper, lump crusher or deagglomerator) is a compact unit designed for crushing, delumping and deagglomeration of bulk solids that tend to form lumps, agglomerates and clumps. The machine has been engineered for demanding production environments in the food, pharmaceutical, chemical and cosmetics industries. Thanks to the low-speed shaft, the size-reduction process relies on a breaking and shearing action rather than grinding – minimising dust generation, limiting product temperature rise and preserving its physicochemical properties.
The unit is available in three frame sizes (LBS2020, LBS3030 and LBS3050), allowing the optimum size to be matched to the process throughput – from laboratory and pilot applications to high-capacity production lines. The LBS lump breaker integrates easily with feeders, bulk bag dischargers, vacuum conveying systems and process control systems.
How Does the LBS Lump Breaker Work?
Bulk material containing agglomerates, clumps or lumps is fed into the lump breaker through the inlet flange. Inside the housing, a low-speed rotating shaft carries interchangeable blades. The blades rotate close to a sizing screen that acts as a particle-size barrier – the material is broken by a shearing and cutting action and then forced through the screen apertures. The maximum outlet particle size is determined by the mesh size of the screen fitted (available from 1 mm to 25 mm).
The crushed material passes through the screen and leaves the unit via the outlet flange, from where it is directed to the next process stage – pneumatic conveying, feeding, blending or packaging.
✂️ Breaking and Shearing
Minimal heat and dust generation, product structure protection – unlike grinding, no particle degradation occurs
🔄 Interchangeable Screens
Sizing screens with apertures from 1 to 25 mm – quick particle-size changeover, tool-free disassembly option
⚡ Low Energy Consumption
Low shaft speed, power draw 1.1–4 kW, minimal number of wear parts
LBS Model Comparison
The LBS lump breaker is available in three frame sizes. Model selection depends on the required throughput, connection-flange dimensions and process specifics:
| Parameter | LBS2020 | LBS3030 | LBS3050 |
|---|---|---|---|
| Inlet flange | 200 × 200 mm | 300 × 300 mm | 300 × 500 mm |
| Approximate throughput | up to 1.5 m³/h | up to 6 m³/h | up to 11 m³/h |
| Motor power | 1.1 kW | 2.2 kW | 4 kW |
| Screen range | 1–25 mm | 1–25 mm | 1–25 mm |
| Housing material | AISI 304 / 316L | AISI 304 / 316L | AISI 304 / 316L |
| ATEX design | Optional | Optional | Optional |
| Typical application | Laboratory, pilot, small batches | Production lines, feeding, blending | High throughput, bulk bag discharge, silos |
Design options: glass-bead blasted or electropolished surfaces, FDA-compliant seals, flanged or Tri-Clamp connections, tool-free screen removal, hygienic design (GMP, HACCP) or dust-tight design (ATEX Zone 21/22). We configure each unit individually to suit your project.
Where Is the LBS Lump Breaker Used?
The LBS lump breaker is used wherever bulk material must be freed of lumps and agglomerates before the next process stage. The most common scenarios include:
After Silo Storage
Materials compacted under pressure and moisture. The LBS restores a uniform particle structure.
Upstream of Feeding and Weighing
Uniform particle size is critical for the accuracy of screw and vibratory feeders.
Below a Bulk Bag or Sack Tip Station
Products compacted during transport require lump breaking before further processing.
Prior to Tabletting and Granulation
Particle-size control ensures tablet and capsule uniformity in the pharmaceutical industry.
After Drying or Blending
Deagglomeration of material leaving dryers or mixers to the desired particle fraction.
Upstream of Pneumatic Conveying
Eliminating oversized particles prevents blockages in conveying lines.
Frequently Asked Questions (FAQ)
The maximum outlet particle size is determined by the mesh size of the sizing screen fitted. Available screens have apertures from 1 mm to 25 mm. In practice, the outlet particle size may be smaller than the screen aperture, as the material is also broken into finer fragments during the crushing process.
Yes. The lump breaker operates at low speed and relies on a shearing action rather than grinding. As a result, product temperature rise is minimal, making it safe to process heat-sensitive materials such as chocolate, active pharmaceutical ingredients (APIs), enzymatic products or flavour-enriched powders.
Model selection depends on the required throughput and connection dimensions. The LBS2020 (up to 1.5 m³/h) is suited to laboratory and small-scale applications. The LBS3030 (up to 6 m³/h) is a versatile model for typical production lines. The LBS3050 (up to 11 m³/h) is designed for high-throughput processes. Our engineers will help you select the optimum model after analysing your process.
Yes – the LBS is available in an optional ATEX design for operation in dust and gas explosion-hazard zones (Zone 21/22). The design includes appropriate seals, antistatic earthing and certification in accordance with Directive 2014/34/EU.
Yes. We offer trials on the customer’s actual material, allowing you to verify the unit’s performance and select the optimum parameters (screen size, blade type) before purchase. Tests are carried out on our equipment – contact us to arrange a date.
Need a Size-Reduction or Delumping Solution?
Contact us and our engineers will prepare the optimal solution tailored to your process. We also offer trials and testing of our equipment on your material.
Why Choose Our Solutions?
Individual approach – we select the model, screen and blades to suit your material and process
Trials on customer material – we verify equipment performance before purchase
Process integration – feeders, bulk bags, pneumatic conveying, control systems
Multi-industry experience – food, chemical, pharmaceutical, cosmetics
Safety and hygiene – ATEX, FDA, GMP and HACCP designs
Technical support and service – rapid response, spare parts, 24/7 availability