What DustMASTER does

DustMASTER Enviro Systems is a division of Mixer Systems, Inc., headquartered in Pewaukee, Wisconsin, that designs, engineers, and manufactures industrial batch mixers, batch plants, and material handling equipment primarily for dust conditioning, material processing, and environmental applications. Established as a division in 1984 and operating from an 86,000-square-foot manufacturing facility, DustMASTER serves industrial customers across ten vertical markets including waste-to-energy, mineral processing, refractory manufacturing, grey iron foundry, coal-fired electrical generation, cement manufacturing, frac sand, aggregate, biomass power, and general product manufacturing. The company's core value proposition is converting hazardous or difficult-to-handle industrial dusts and byproducts (fly ash, silica dust, cement kiln dust, foundry dust, baghouse dust) into dust-free, safe-to-transport forms suitable for landfill disposal or recycling.

DustMASTER's product portfolio centers on four mixer architectures — the Turbin pan-style mixer (the industry-standard design for over 70 years with capacities of 20–250 tons/hour), Horizontal Shaft Paddle Mixer, Planetary Mixer, and Twin Shaft Mixer — supplemented by refractory-specific variants, continuous-mix Pug Mills (50–400 TPH), Skip Hoists, Stokar material handling vehicles for metal production, and a full accessories line including PLC-based control systems, conveyors, batching equipment with load cells, hoppers, silos, and automatic washout systems. Equipment is built-to-order at the Pewaukee facility using heavy-duty cast Ni-Hard components for abrasion resistance, with proprietary concave paddle geometry enabling stabilized mix in as little as 30 seconds using 8–25% water addition depending on material.

DustMASTER generates revenue through three primary streams: one-time capital equipment sales of custom-engineered mixers and batch plants (quote-based pricing, no public list pricing), recurring spare parts (a 40,000-SKU inventory with 97% of orders shipped within 24 hours), and professional services including material testing, engineering, installation, startup, operator training, and turnkey project management. Go-to-market is enterprise field sales executed through a network of regional manufacturer representatives covering the United States, Canada, and Mexico, supported by inside sales at headquarters, trade-show presence at events such as the Powder Show and EPIC, and a content-rich website serving as the top-of-funnel lead generation channel. Following a July 2023 ownership transition in which the founding Boles family sold a majority stake to a Milwaukee-based growth partner and Mixer executives, new CEO Doug Duley and President Nicholas Passint lead the business.

Name

DustMASTER

Legal name

DustMASTER Enviro Systems

Website

https://dustmaster.com

Company type

Private

Founded year

1984

Operating status

Operating

Headcount range

1–10 employees

Short description

DustMASTER Enviro Systems, a division of Mixer Systems, Inc., designs and manufactures industrial batch mixers, batch plants, and material handling equipment for dust conditioning across waste-to-energy, mining, cement, foundry, and refractory industries, operating from an 86,000-square-foot facility in Pewaukee, Wisconsin.

Ownership category

akta.pro rank

Product category

Industrial Mixing Equipment

NAICS

Other General Purpose Machinery Manufacturing (3339), Agriculture, Construction, and Mining Machinery Manufacturing (3331)

SIC

Special Industry Machinery (No Metalworking Machinery) (3550), General Industrial Machinery & Equipment, Nec (3569)

akta.pro primary industry

Chemical Processing Equipment (Reactors, Mixers, Agitators) (IMAHAEAA)

akta.pro secondary industry

Dust Collection & Air Filtration Equipment (Industrial) (IMAHALAF)

Keywords

• Industrial batch mixers
• Dust conditioning equipment
• Material handling systems
• Refractory mixing equipment
• Batch plant equipment

Headquarters

HQ city

Pewaukee

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Personnel, Infrastructure, Technology or R&D, Marketing or Sales

Revenue model

1. Industrial Mixer and Equipment Sales: DustMASTER generates primary revenue from designing, engineering, and manufacturing industrial batch mixers, material handling equipment, and complete batch plant systems. Equipment is built to order with customizable specifications for capacity, control systems, and optional features.
2. Parts and Spare Parts: The company maintains an inventory of 40,000 service and wear spare parts. Parts are shipped within 24 hours for customer orders to keep systems running.
3. Service and Installation: Comprehensive services including equipment application sales/engineering, material testing, control system design and integration, installation by MSI authorized crews, startup supervision, operator training, new plant construction, facility modernization, and turnkey project management.

Go-to-market motion1 record

Distribution channels1 record

Marketing channels3 records

Core offering

DustMASTER designs, engineers, and manufactures industrial batch mixers, batch plants, and material handling equipment for processing dusts and other industrial materials. Their product line includes Turbin pan-style mixers, Horizontal Shaft Paddle Mixers, Planetary Mixers, Twin Shaft Mixers, Pug Mills, Skip Hoists, and Stokar equipment, with PLC-based controls for automation. Equipment is built to order at their 86,000 sq ft Pewaukee, Wisconsin facility and serves industries including waste-to-energy, mining, cement, foundry, refractory, and aggregate operations.

Product overview

DustMASTER Enviro Systems offers a comprehensive portfolio of industrial mixing and material handling equipment as a division of Mixer Systems, Inc. The product line centers on four distinct mixer styles—Turbin Mixer (pan-style), Horizontal Shaft Mixer, Planetary Mixer, and Twin Shaft Mixer—each designed for specific material processing needs. Supporting the mixers are refractory-specific variants, Pug Mill continuous mixers, Skip Hoist lifting equipment, and Stokar material handling vehicles. The ecosystem is completed with a full range of accessories including batching equipment, PLC-based control systems, conveyors, hoppers, silos, and automatic washout systems. All equipment is manufactured in-house at the 86,000 square-foot Pewaukee, Wisconsin facility and designed to function as an integrated system. The company serves diverse industries including mineral processing, cement manufacturing, waste to energy, aggregate, refractory, frac sand, biomass power, grey iron foundry, and general product manufacturing.

Differentiator

Problem solved

Functional benefit

Products and services

• Turbin Mixer Pan-style high-intensity mixer with concave mixing paddles and three-dimensional mixing action, capable of 20 to 250 tons/hour throughput. Industry standard for over 70 years for processing abrasive and difficult-to-mix materials with 600 feet per minute paddle tip speed and 100% stabilized mix in 30 seconds.
• Horizontal Shaft Mixer Economical paddle mixer with cross-current mixing action, available in 8 to 81 cubic feet capacity. Features PLC-based control system and heavy-duty abrasion/corrosion resistant components including cast Ni-Hard paddles and bolted-in segmented drum liners.
• Planetary Mixer Counter-current mixer achieving homogeneous mix in as little as 30 seconds. Suitable for fly ash, baghouse dust, foundry sands, powdered metals, cement kiln dust and dry chemicals. Capacities from 0.5 to 4 cubic yards with cast Ni-Hard paddles and abrasion-resistant steel liners.
• Twin Shaft Mixer High volume, high shear mixer achieving mix times of 60 to 90 seconds with output capacities of 4 to 6 cubic yards. Features air purge shaft seals, single drive motor, cast steel mixing arms, and abrasion resistant cast Ni-Hard lining with hydraulic discharge door.
• Refractory Mixers Heavy-duty batch mixers designed for extreme industrial environments, mixing dry, semi-dry and low-moisture refractory castable materials. Includes Prashak horizontal shaft paddle mixers, Turbin Mixer XL series, and planetary mixers with 7.5 hp to 100 hp motors.
• Pug Mill Continuous mixing system with dual independently operating shafts, each with separate motor, V-belt, and gear reducer. Models include 50P, 125P, 250P, and 400P with capacities from 50 to 400 tons per hour and dual motor ranges of 10 to 30 hp.
• Skip Hoist Compact, space-saving skip hoists for fast, dependable lifting. Low-profile roll-over or bottom-dump designs with capacities from 3 to 100 cu. ft. Heavy-duty construction with oversized frame and track.
• Stokar Electrically-powered and hydraulically-controlled vehicle for stoking, skimming and charging operations in metal production. Model EH-90 built specifically for electric furnace demands. Designed for over 20 years of operational life.
• Accessories Complete range of performance-proven components including batching equipment with load cells, system controls in three series, conveyors (screw, troughing and pocket belt types), batching hoppers, equipment superstructure, material handling equipment, charging hoppers, storage hoppers/silos, and automatic washout systems.

Quantifiable outcome

• 30-second mix time capability with as little as 8% water
• +4 more outcomes

Named customers3 records

Segments10 records

Ideal customer profiles5 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature7 records

Partnerships

Five partnerships are on record, tiered minor.

• American Foundry SocietyminorOthersIndustry association membership supporting the foundry sector. DustMASTER serves grey iron foundries managing dusts from baghouse, grinding, molding and handling operations, as well as spent sand.
• Coal Users GroupminorOthersIndustry association for coal users. DustMASTER supports coal-fired electrical generation industry managing FBC and PRB fly ash for Clean Air Act compliance.
• American Coal Ash AssociationminorOthersIndustry association for coal combustion products. DustMASTER provides systems for processing fly ash and other coal combustion byproducts.
• Lignite Energy CouncilminorOthersIndustry association for lignite energy producers in North Dakota region. DustMASTER serves biomass and coal-fired power generation managing byproducts.
• The Portland Cement AssociationminorOthersIndustry association for cement manufacturers. DustMASTER provides systems for stabilizing cement kiln dust (CDK) for landfill disposal.

Scale indicators7 records

Recent moves8 records

Expansion highlights5 records

Direct peers

• Charles Ross & Son: U.S. manufacturer of industrial mixers, blenders, and dispersion equipment. Comparable product breadth across planetary, twin-shaft, and horizontal mixers for industrial customers similar to DustMASTER's.
• Marion Mixers: U.S. manufacturer of horizontal paddle mixers and material processing equipment. Overlaps with DustMASTER's Horizontal Shaft Mixer line in mineral processing and chemical applications.
• Paul O. Abbe: U.S. manufacturer of industrial mixers, dryers, and ball mills serving refractory, mining, and chemical processing with similar heavy-duty mixer portfolio to DustMASTER.
• Hockmeyer Equipment: U.S. manufacturer of industrial mixers, dispersers, and high-viscosity mixing equipment. Comparable in end-market verticals including mineral processing and bulk material handling.
• Greerco: U.S. manufacturer of industrial mixers and homogenizers for chemical, pharmaceutical, and industrial processing. Comparable in mixer technology and customer profile.
• Eirich: German manufacturer of industrial mixers including pan mixers, intensive mixers, and complete mixing plants. Closest direct competitor to DustMASTER's Turbin pan-style mixer in refractory, foundry, and bulk dust processing applications.
• BHS-Sonthofen: German maker of mixing, crushing, and recycling equipment. Competes with DustMASTER in industrial process mixing for hazardous dust, foundry sand, and waste-to-energy applications.
• WAM USA: Subsidiary of WAMGROUP producing industrial mixers, conveyors, and material handling equipment. Competes with DustMASTER in bulk solids processing and dust-handling applications.
• IKA Works: German manufacturer of industrial mixing, processing, and homogenization equipment. Broad product line overlaps with DustMASTER's planetary and twin-shaft mixers in industrial applications.

Broad incumbents

• Schenck Process: Global broad-line industrial process equipment supplier covering mixing, conveying, weighing, and dust collection. Adjacent overlap with DustMASTER's material handling and dust conditioning offerings, with broader scale and international footprint.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks6 records

Key highlights6 records

Customer concentration

• Xx.com/dustmstrenvsys

Revenue estimate

Valuation estimate

Number of profiles

Profiles3 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about DustMASTER