Spiral X™ | The Vertical Spiral Revolution

From turbulence to precision: a simple change in axis, a giant leap in separation efficiency.

For decades, particle separation systems have been bound to a single way of thinking the horizontal axis. In mining, mineral processing, and fluid‑solid separation, the spiral inlet has been a trusted workhorse. But in every design, gravity has been treated as a background force, not a partner. The result? Turbulence that wastes energy, misplaces particles, and accelerates wear. Spiral X™ changes that.

The Insight

The idea didn’t come from a lab it came from a moment of curiosity.

While training in the gym, a misaligned stack of barbell plates caught the eye. They sat off‑centre on their vertical axis, and the imbalance was obvious. At the same time, deep in the review of spiral theory for a particle separation project, one question began to form:

If alignment matters so much in a barbell, what happens when we align the spiral itself with gravity?

That simple shift from horizontal to vertical became the foundation of Spiral X™.

The Ideology | Extending the Spiral

As development progressed, another insight emerged. While analysing density profiles and vortex path lengths, we began thinking about time the time particles spend in the separation zone.

In current PV recycling processes, aluminium and plastics are often stripped out in a separate first stage before finer separation. But what if we could remove that stage entirely by giving particles more residence time in the spiral?

A recent Micromachines study on spiral microchannels optimised designs with 2, 3, and 4 loops, achieving 97.5% separation efficiency. Inspired by this, we asked:

What happens if we extend the loop count to 5, 6, or 7?

More loops mean a longer path, more interaction between particles and flow, and greater opportunity for marginal‑density particles to migrate to their correct stream. This loop‑expansion concept could push separation efficiency beyond the current benchmark and potentially deliver single‑stage separation of metals and plastics at industrial scale.

The Principle

Spiral X™ takes the proven mathematics of the logarithmic spiral and re‑orients it so that gravity and centrifugal force work together. Instead of fighting turbulence, the flow is guided smoothly down a vertical spiral axis, stabilising the vortex and sharpening the separation cut.

Key advantages:

  • Sharper separation | cleaner split between heavy and light fractions.

  • Lower energy use | less turbulence means less wasted power.

  • Reduced wear | smoother entry reduces impact zones.

  • Higher throughput | stable flow allows more volume without loss of efficiency.

  • Greater stability | optimised mass distribution lowers the centre of mass.

The Algorithm

At the heart of Spiral X™ is a proprietary flow model a set of equations that define the spiral geometry, inlet curvature, and velocity profile for maximum efficiency in a vertical orientation. It’s not just theory: the algorithm is designed for CAD integration, CFD simulation, and real‑world fabrication.

From Concept to Impact

In traditional designs, turbulence is like static in a radio signal it drowns out the clarity you need. Spiral X™ tunes the system so the “signal” of separation comes through clean and strong.

Projected performance improvements:

  • Cut size (d₅₀) reduced by up to 15%.

  • Misplaced particles reduced significantly.

  • Energy savings in the range of 5–10%.

  • Wear life extended by design.

Industries Ready for Change

  • Mining & Minerals | sharper recovery, less reprocessing.

  • Mechanical Engineering | stable, predictable flow paths.

  • Fluid Processing | cleaner separation in food, chemical, and wastewater.

  • Resource Recovery | improved efficiency in recycling and waste‑to‑value systems.

Patents Pending

The Spiral X™ concept is currently under patent protection. We’re preparing to share full technical details, CFD results, and pilot data including the loop‑expansion trials in the coming months.

Be Part of the Reveal

We believe Spiral X™ has the potential to redefine separation technology across multiple industries. If you’re an engineer, researcher, or industry leader, we invite you to join our early access list.

Sign up today to:

  • Be first to see the full Spiral X™ model.

  • Access pilot program data.

  • Explore collaboration opportunities.

The spiral is coming.
And this time, it’s aligned with gravity and extended for even greater precision.

🌐 adam@hospmanagement.com.au | AU + 61 416 062 193.