Types of Mixers

Chapter 1: Principle of Mixers

Common mixing states are solid to solid dispersion, solid to liquid, liquid to gas, and the two forms of liquid to liquid with one being miscible liquids and the other immiscible ones. The degree of mixing is the function of the magnitude of the eddy currents or turbulence and the forces that oppose them. When the opposing forces are higher, it is necessary to increase the degree of mixing.

What is a Mixer?

A mixer is a complex and precision piece of equipment that blends, emulsifies, homogenizes, and combines various types of ingredients that are essential to a manufacturing or production process. Mixing is part of the production of commercial and industrial products including pharmaceuticals, cosmetics, and foods each of which require precision control for mixing of unlike and dissimilar chemicals and materials.

The quality of a mixer is determined by its repeatability and the consistency of its mixing. The challenge of the process is the properties of the materials being mixed since each variation and difference requires special handling. The initial steps of mixing involves a thorough in depth study of the materials such that the mixing process will be successful. As with many industrial functions, mixing requires a customization of equipment to exactly meet the needs and conditions of the manufacturing process.

In a discussion of mixers, it is critical to understand the difference between blending and mixing, which may seem to be the same function. Blending is a gentler process with the goal of creating a uniform, cohesive distribution of each material. The result of the process is a completely new and unique substance. With mixing, the combined ingredients are placed together but can separate back to their original form. This aspect of mixers has to be carefully considered when making the selection of a mixer. In the majority of cases, the goal is to create a new homogeneous substance, which is the result of blending.

The varieties of industrial mixers include compact ones capable of combining plastic polymers for the production of plastics and mixers for pulverizing and mixing of pellets and stones. The mixing process is defined by its efficiency, quality, durable equipment, and dependability. It is at the center of industrial applications and processes.

Considerations When Choosing an Industrial Mixer

Characteristics of Material to be Mixed

The beginning of the process of selecting a mixer is a careful study of the media to be mixed, which varies by industry. Typical materials include liquids, emulsions, slurries, pastes, solid with liquid, and powders or granular materials. The consistency, properties, and characteristics of the media help to narrow the choice of mixer to one that fits the needs of an application.

The properties of materials vary by their shape, density, size, and static that determine their interactivity. Each of these factors influence the blending process.

• Shape - Materials come in all shapes and forms such as triangles, oblong shapes, or flakes, all of which provide resistance to the blending process. A mixer needs to change the physical shape of particles to create the perfect blend.
• Density - Density affects the flow of particles. Ones with similar density flow at the same rate and blend easily.
• Size - When particles have different sizes, the smaller particles will lodge in the spaces between the larger particles. Prior to the blending process, the larger particles need to be prepared to create the correct blend.
• Static - During the blending process, particles generate friction that causes them to act erratically and create static, which is handled by static arrestors that dissipate the electrical charge.

In many situations, manufacturers customize their equipment with special features, capabilities, and additions to meet particular functionalities. The many versions of materials require a mixer that meets their characteristics and properties. An important aspect of materials is their volume. Batch volumes have to meet the capacity of a mixer to ensure proper mixing. Drum mixers may have a capacity of 50 to 100 gallons (190 to 380 liters) while an agitator mixer has a capacity of 16 to 264 gallons (60 to 1000 liters).

Type of Material for a Mixer

Liquid Viscosity

The resistance of a liquid to the mixing process is determined by its viscosity, which is a measurement of how molecules move past each other. The resistance of movement of the layers is the measure of viscosity or the resistance to the mixing. The various values of viscosity of liquids are listed on data sheets and are measured using centipoise (cps) with one cps being the viscosity of water and laminar. Cps values can be very high depending on the type of material.

As viscosity rises, the flow of materials becomes more laminar, which requires that the mixer design be capable of meeting the necessary agitation level or mixture homogeneity. For high viscosity mixing, torque and the mixing blades or impeller type are an essential part of the process.

Mixing is defined by torque, which is horsepower divided by RPMs. Horsepower defines nothing, which is why high viscosity applications require increased torque or lower RPMs. Increased torque results in increased drive and larger mixer shafts and impeller diameters. Special impeller designs are suited to bite into and move or entrain a viscous fluid.

Higher viscosity fluids are either pseudoplastic or thixotropic, not laminar. Laminar, which is high momentum diffusion and low momentum convection, fluids are not as common. Psuedoplastic and thixotropic fluids are shear thinning where the latter is time dependent and is like trying to get ketchup out of the bottom of a bottle. Turning the bottle over has no effect. When the bottle is shaken, the fluid thins as it is sheared and flows easily.

Mixers with gearboxes that can reduce RPMs and increase torque produce the best results for high viscosity mixing. The increase in torque requires that the diameter of the mixer shaft be sufficient to drive impellers with broad blades and an aggressive pitch to maximize surface contact.

Vessel Capacity

Small tanks are super pumpers while larger tanks are the opposite. This helps explain why large 100,000 barrel oil tanks use side entering mixers requiring hours or days to blend. It also explains why there are so many small support mixers that are required to support just a very few large tanks. The small vessels make the product, and the large tanks store the product.

Mixing Time

The process of blending involves numerous stages, from loading to packing and also to cleaning. Thus, knowing the true time taken by the mixer to blend the products is best. Each mixer has a typical average true mixing time. Some time is estimated for loading while the other is for packing. For the completion of the cycle, it takes longer.

Ease of Cleaning

There are certain types of mixers that consist of many parts which are moving and these cause the dislodging of the product. These products can adhere onto the bearings, walls of the mixer, and the paddle. It might be viewed as a waste because it is a huge amount of product that is being lost. It is also a highly likely carrier, which causes cross contamination.

Therefore, there is a need to take into consideration the total amount of time in drying the parts of the mixer as well as cleaning. However, it takes a long time to both remove the parts and return them. Care and having patience are required in returning the parts. The main goal in selecting the correct or appropriate mixer is to be able to maintain and have a process that is so efficient when manufacturing the product therefore carefulness is always needed.

Tip Speed

The tip speed refers to the distance an impeller travels in a set amount of time. It is calculated by multiplying the diameter of the impeller by pi, which is the circumference of the impeller at its outermost point. When the circumference of the impeller is multiplied by its rpm or rps, the resulting answer is the tip speed, which is quantified as feet per min or meters per second.

With dry material mixers, the tip speed is the key parameter regarding cycle times, which are shorter with faster tip speeds. Slow speed mixers, such as ribbon blenders, have a tip speed of 1.4 meter per second while medium speed mixers, such as horizontal mixers, have a tip speed of 6 to 10 meters per second. High speed mixers, like vertical high speed mixers, have a tip speed of 28 to 40 meters per second.

When the tip speed is above a certain point, fluidization is reached where dry material behaves like a liquid. This reduces cycle times for a homogeneous mix, which is much like the difference between stirring ingredients in a bowl by hand and using a food processor or blender. Vertical and horizontal high speed mixers achieve fluidized mixing while ribbon blenders do not.

Additional mixing speed requires additional power. Ribbon blenders require 1 HP per 100 lbs. (45.3 kg) to 200 lbs. (90.7 kg) of material while vertical high speed mixers mix less than 4 pounds (0.45 kg) per 1 HP.

Tip speed has an impact on the dispersion of agglomerated particles. Dry material mixing includes mixing larger particles with very small agglomerated ones. To get a homogeneous blend, it is necessary to separate small particles that stick together, such as mixing plastic powder with a pigment. Pigments are micron (µ) size particles that are stuck together and take a certain amount of energy to separate the particles.

Vertical mixers have the energy to fluidize the mixture and separate the small agglomerated particles. Medium speed horizontal mixers can complete the separation but not to the degree of the vertical high speed mixer. If a medium speed mixer has high speed choppers installed, the tip speed of the chopper blades are about the same speed as the tip speed of the main mixing blades in a high speed mixer. This can help with dispersion of agglomerated ingredients.

Chapter 2: Types of Mixers

The selection of a mixer is predicated on how it will be used and the kind of chemicals, liquids, gases, granules, and pellets that will be combined. The industrial mixer world has a line of mixers that meet the needs of any type of material including materials that would seem to be unable to be mixed. The three general categories of mixers are diffusing, shearing, and convection, each of which has a different construction, types of impellers, speed, and function. A general understanding of each type is beneficial in selecting the correct mixer for an application.

Tumbler Mixers

Tumbler mixers are diffusion mixers that rotate to mix materials and include air in the mixing process. They have a tumbling rhythm and do not use impellers as part of the mixing process. Tumbler mixers are used to mix solids and powders and, in special cases, liquids.

Solids are rotated by the tumbler as if they are being stirred as gravity is constantly pulling the mixture back to the bottom of the drum. The configurations of tumbler mixers include octagonal, cone, and V shape.

High Shear Mixers

High shear mixers, known as high shear reactors (HSRS) or rotor stator mixers, are used for solid and liquid materials for emulsification, homogenization, dispersion, particle size reduction, and disintegration. They are high speed machines with powered mixing blades known as shears. Materials mixed by a high shear mixer are unlike miscible materials that can be mixed easily using a low shear mixer.

The use of high shear mixers is required for ingredients that do not blend easily, are immiscible, and require more stringent and aggressive measures, such as liquids with different viscosities or contain solids that need to be broken down. The most common form of high shear mixing is dispersion that uses high speed and high shear processing with more horsepower. As dispersion blades rotate, they make contact with particles and break them apart. A horizontal laminar dissolves or disperses the flow coming from the blades into upward or downward flow.

High shear mixers can mix liquids and solids that would typically not mix such as oil and water. The high shear mixers can emulsify immiscible materials. They have traditionally been used in the rubber industry but have become applicable in other industries like chemical, food, pharmaceutical, cosmetics, and adhesive industries.

High Speed Mixers

High speed mixers are typically used where a substance needs to be cooled, granulated, or dispersed to move it quickly and prepare it for the next processing step. They can be used in industries like food processing, pharmaceuticals, and paint production. The high speed mixers can be found in sizes and shapes ranging from lab mixers which can be small and high speed to industrial-sized high speed mixers.

Ribbon Blender

Ribbon blenders are used for blending powders and are most often used for solid on solid mixing. The design of ribbon blenders makes it possible to have fast and efficient mixing cycles that can range from a few minutes to less than twenty minutes with a tip speed of about 1.4 meter per second. Although the process happens quickly, the ribbon agitators move at a slow speed to create a gentle folding action.

Even though a ribbon blender is capable of mixing products effectively and attaining homogeneity, it has a high cost compared to paddle mixers and is more difficult to maintain.

Paddle Mixer

These types of mixers are utilized in the mixing of solids, viscous or slurry liquid mixing, and wet-dry mixing. They consist of a central shaft axis for the holding of the blades. They are frequently utilized in dry mixing, but they can also accommodate liquid-solid mixing.

Agitator Mixers

These types of mixers are used for applications that are liquid or flowable. Top-load washing machines have agitation in the move that can be seen. They consist of an agitating blade in the center that remains stationary while the water is being agitated in the washing machine during its rotation. Agitators that are utilized in the processing of food and beverages industrially have a similar principle and configuration.

A common mixing application is solid suspension. Agitators are used to refer to mixers where the entrained fluid appears to agitate and surge in the tank but is never uniform. These types of mixers do not agitate like a washing machine.

Agitator mixers are used for dissolving gases into a liquid, the suspension of solids in a liquid, blending miscible liquids, connecting or dispersing liquids that are not able to mix and the transfer of heat in a liquid. They are classified as axial or radial, which refers to the angle at which the impeller blade makes contact with the liquid and the rotation plane. Agitator mixers are used for the most viscous materials imaginable. Other mixers are used for most materials for shear thinning and are better at processing.

Axial Flow Impellers

In this type of agitator, there is a creation of an angle that is less than 90 degrees with the rotation plane, by the blade itself. Due to this, the occurrence of the locus of flow happens along the impeller’s axis.

Radial Flow Impellers

In these types of agitators, there are radical flow blades that are parallel to the impeller axis. Because of this, radial flow impeller releases flow beside the radius of the impeller in distinctive designs.

Rotor Mixers

The metal blades of a rotor mixer are installed at the bottom of a container and can spin at variable speeds. This is typically found in blenders.

In some cases, rotor mixers can operate with various attachments which can be detachable. They can thus be applied in industries where there is a need to mix multiple jobs. The rotor mixers can be used in industries such as food production, adhesives, pharmaceuticals, and chemical processing.

Static Mixers

Static mixers have a mixing element that has the shape of a twisted ribbon, helix, or other form that is placed in a cylinder. They do not have any moving parts because the mixing element disrupts and blocks the flow of liquids or gases that are forced through one end of the cylinder.

As liquids or gases flow through the cylinder of a static mixer, the shape of the element causes turbulence that mixes the materials by breaking down their molecules. Static mixers disperse gases into immiscible liquids to form a homogenous solution. They are not used for mixing solids, granules, or powders.

They are typically used in production lines that prefer continuous material flow to batch mixing. Thus, static mixers can facilitate smooth operation and faster mixing by mixing constant and steady liquid streams. Static mixers allow a high level of control over the extent of mixing needed. This would depend on the intended outcome where some outcomes are homogenous while others are less precise.

Static mixers are typically used in industries like chemical, cosmetic, automotive, pharmaceutical, and water treatment industries. Static mixers are effective when used with low viscosity liquids and materials.

Disperser Type

A disperser uses concentrated and high speed force to disintegrate, dissolve, and dissipate solids that can be found in powdered materials or liquids. Mixing shafts can have blades that are disc shaped attached to them and make the blades have maximum speed rotation. This yields proper flow, dispersion, and consistency during the blending and mixing process.

Dispersers are typically used in food production as part of solid ingredients liquifying processes or even solidifying materials during storage. Generally, the dispersers are used in processes with substances that are incompatible and would typically require extra force to yield a proper mix and blend. Examples of such substances can be found in adhesives, cosmetics, and pharmaceutical production.

Emulsifier Mixers

These types of mixers are utilized in mixing immiscible liquids. Examples of two substances that are completely not miscible are oil and water. In the cases when there is a requirement of a totally homogenized and emulsified mixture like in making sunscreen, lipstick, lotion, and mixing cosmetics, an emulsifier is utilized.

This mixer is a special type of mixer that not only utilizes pressure for the complete mixing of liquid-liquid substances, but also incorporates isolated vacuum-filled equipment as well as high shear. There is the incorporation of a centrifugal force in vacuum emulsifier homogenizers. The materials are driven by this force into the work head for their breakdown into smaller particles. In the case of cream and milk, cream consists of fat molecules that are large, which separate from milk because of the big difference between the sizes of the molecules; emulsification is responsible for the breaking down of the cream molecules so that they become similar to milk molecules in their size.

Homogenizer Mixers

These types of mixers are utilized in the combination of liquid-liquid mixtures and solid-liquid mixtures. There is an application of extreme force by this mixer. It also applies extreme shear and pressure on the materials or liquid as well, to homogenize the mixture.

Heavy Duty Mixers

These types of mixers are utilized in the mixing of viscous and pasty substances. When a single shaft mixer is run with slurries that are very thick like pasty ingredients, wax compounds, and putty. This would normally cause buckling and failure in mixing equipment. Thankfully, there are heavy-duty mixers designed for mixtures that reach high viscosity above 750,000 centipoises. These heavy-duty mixers include planetary and multi-shaft mixers.

Batch Mixers

Batch mixers have a cylindrical design that allows ingredients to be loaded at one end while the mixed product is dispensed at the other end. They have a high capacity capable of preparing batches of up to thousands of gallons or thousands of liters. The design of batch mixers makes it possible to control the combination of ingredients to ensure the quality of the mixture. Batch mixers can be horizontal twin shaft mixers, ribbon blenders, paddle mixers, and top entering mixers with powder mixers being a separate class that are almost always batch mixers.

In general, batch mixers are small volume mixers with fast blend times or process times. Finished product is sent to large storage vessels or for further processing. It is common to have several batch tanks fed into one large mix tank, which is especially true if the products are nearly similar and for easy long term blending.

Batch mixing is chosen for products requiring quality testing and is ideal for powdery ingredients that are chemically sensitive and susceptible to change over time. Ingredients can be added in portions such that the mixer can perform multiple mixing processes at one time.

Batch mixers can come with discharging doors and discharging blades to increase the speed of discharging. Depending on the mixing system, batches can be dispensed into containers, barrels, or onto conveyors. A common type of batch mixer is a drum mixer that comes in a wide variety of types, sizes, and configurations

Drum Mixers

Drum mixers have single or multiple blades attached to the inside walls of the drum with a frame that supports the drum as it rotates. As the drum rotates, the blades on the interior walls lift the ingredients and raise them to the upper wall of the drum. At the apex of the rotation, the ingredients fall back to the underside of the drum to repeat the process.

Of the various types of mixers, drum mixers are widely used for their transportability, tight seal, and the small footprint of some models. They are capable of mixing materials with different particle sizes and are used to mix materials with low to medium viscosities, such as adhesives and slurries. They are classified as batch mixers because they mix one batch at a time.

Continuous Mixers

Continuous mixers mix, load and continuously discharge the mix until the mix is completed. A screw feeder continuously loads material into the mixer. Continuous mixers are used for large projects like dams, high rise buildings, and bridges. They are the best option for projects of high volume requiring speed and efficiency. Continuous mixers are only used when mix ratios differ between the batches.

In a continuous mixer, steady state steady flow (SSSF) is achieved when the mixture no longer changes and is not immediately accomplished. Once SSSF is established, the process can be shut down and started in the future. As long as the screw feeder and continuous processor are in unison, SSSF will be achieved. The purpose of continuous processors is to maintain a consistent mix ratio where upset condition outputs are recycled back into the process over time in small volumes to achieve a near consistent product.

When more specific ratios are required, batch mixing is a better option, typically. Some manufacturers utilize continuous mixing for the smoothing out of multiple various batch mixes to make the finished product more homogeneous. The batch is removed from the mixing equipment and then the new batch is fed into the continuous mixer.

There are a number of benefits that are offered by a continuous mixer that are found with batch mixing. Continuous mixing requires a smaller number of staff and is much faster. The process of feeding ingredients in this type of mixer is automated and the feeding out of the batches is done automatically with no need for removal or refilling.

Acoustic Mixers

Acoustic mixers use an energy efficient mixing process which is very rapid. The mixing process can be faster than the conventional mixing processes by 10 to 100 times. With this process, less heat is imparted into the mix.

The acoustic mixing process is also repeatable from mix to mix. Thus, it is able to mix any combination of materials. Acoustic mixers can be found in commercial batch systems to continuous operations. They can come with capabilities to be cleaned in place with no rotating hardware that might need cleaning.

Fluidization Mixers

The mechanical fluidization process includes the division of particles and perturbation that is through impingement. To cause turbulence, a rotating element is used. The rotating element causes rapid churning in the tank among the materials. They enter into motion through the solids just like they are a hydrous substance. This process involves double paddle mixers and plow mixers.

Convective Mixers

Convective mixers have a short mixing period. This type of mixer is preferred by some industries because of its faster working rate. Convective mixers are less practical for operations that are diffusive. They are firm physically and contain resolute shelves with an impeller. Ribbon blenders, vertical screw blenders, and paddle blenders are mixers classified under this category.

Dough Mixer

Dough mixers are an integral part of the mixing of dough or batter using powerful motors and various types of attachments. The force of a dough mixer mixes and aerates ingredients, such as whipping cream, kneading dough, and mixing cake batter. They are capable of mixing over twenty types of ingredients for all kinds of baking including dumpling skins and the ingredients for noodles.

Dough mixers are able to mix any volume and weight of ingredients, easily and efficiently. They can have a capacity of over 240 kg (530 lb) and are mainly used in the baking industry. The two most common types of dough mixers are planetary and spiral with spiral mixers being ideal for mixing bread dough.

Spiral Mixers

Spiral mixers have a pulley system powered by a motor to rotate the bowl and a motor to rotate the spiral arm. Since the system does not have any gears, its motion is smoother, more uniform, and quieter. Spiral mixers are capable of mixing any volume of ingredients using gentler action.

The motion of a spiral mixer can be in one or two directions, which helps in improving mixing consistency. The two direction or bi-direction of spiral mixers make them easier to clean and use. Additionally, they have an absorption rate (AR) of 80% to 90%, a factor that lowers the amount of necessary ingredients per mixing batch. The sizes of spiral mixers range between 180 lbs. up to 440 lbs. with a footprint to fit any size mixing operation.

The mixers described above are a small sampling of the many mixers that manufacturers supply in standard designs. There is an endless number of mixers that are used by industrial operations to meet the ever changing needs of customers. The extent of mixers runs the gamut from usual mixer designs to custom manufactured types to fit special and unusual applications.

The table below provides examples of other unique and productive mixer designs that provide a highly efficient and effective blending process.

Mixer Type

Mixer Extruder

A mixer extruder is a combination of high shear mixer and low to medium pressure extruder that kneads, mixes and extrudes. It can be a standalone processor or be used in combination with other mixing methods. Mixer extruders are used for mixing solids and liquids into viscous, homogeneous paste.

The configuration of a mixer extruder includes a single horizontal shaft with a screw that moves material through the chamber. Material is fed from a hopper and forced by the screw to the stationary anvil, which is attached to the housing. The material is continuously kneaded and mixed.

High pressure mixer extruders are used for mixing materials for high pressure extrusion while twin screw low pressure mixer extruders are used for high powder content or continuous mixing applications. Mixer extruders are known for reducing process times from weeks to 45 minutes. They economically improve the physical characteristics of materials such as strength and are used for waste processing, improving compounding, and working with high solids or powder content.

Kettle Mixers

Kettle mixers are high production, high volume mixers designed for high volume production. They heat and cook liquids using a steam jacket that covers the lower portion of the mixer to achieve uniform cooking. The mixer portion of a kettle mixer is a variable speed unit that can be adjusted to fit different types of materials. Most units have two agitators with one for scraping and one as a secondary mixer.

Kettle mixers are powered by gas, electricity, or direct steam with capacities that range from 20 gallons (75.7 liters) up to 100 gallons (378.5 liters). Twin kettle mixers can mix two large volumes at the same time. Kettle mixers are mounted on three pronged legs with flanged feet or a modular base. Tilting kettle mixers have a handle to enable pushing the kettle over to pour the contents while stationary mixers have valves with a spout to remove the contents.

Vacuum Mixers

Vacuum mixers eliminate voids in a mixture and improve dispersion, degassing, and enhance drying at lower temperatures. The pressure of a vacuum mixer is lower than atmospheric pressure with fewer gas molecules per unit of volume than the ambient air. The void free mixtures created by vacuum mixtures add to the strength and precision of parts as well as remove oxygen to prevent decomposition of sensitive ingredients and stop potential chemical reactions or microbial growth.

Batch mixers can be configured to be vacuum mixers including single shaft mixers like high speed saw tooth dispensers or rotor stator mixers for the production of low viscosity materials. Vacuum mixers mix ingredients in an environment devoid of air to prevent bubbles from forming in a mix that can lead to foaming, formation of air pockets, fouling of heat exchangers, and cavitation. Mixing speed, level of vacuum, batch volume, particle size, and heating or cooling requirements are factors to consider when selecting a vacuum mixer.

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Chapter 3: Applications for Mixers

The different types of mixers can be broadly measured by the many industries that rely on them for processing, blending, and treatment of various types of materials. Mixers take on the characteristics of the industries they serve and provide unequaled performance and quality.

Adhesives and Sealants

The adhesive and sealant industry require the blending and mixing of miscible fluids and the dispersion of high viscosity dissimilar materials. Mixing is the most critical aspect of adhesive and sealant production that include the homogenization of adhesive emulsions, the dissolution of polymers into solvents, and the mastication of rubber. Mixing equipment determines efficiency and product quality.

Batteries and Electronics

There are several uses for mixers in the battery and electronics industry, which include the production of aluminum oxide silicone gels, pastes and slurries, and conductive ink. The selection of a mixing process is built on the idea that each substance is unique and must have a mixer that matches its characteristics, properties, and blending.

Medical Cannabis

Mixers are used in medical cannabis production by blending emulsions and solutions containing hash oil, CBD, THC, and cannabinoids. High speed dispersers are used for cannabinoid extraction while multi-shaft mixers are used for batching products. Throughput ribbon mixers are used for ingredient preparation.

Cosmetics

The cosmetics industry depends on high quality mixers to ensure the proper production of their highly sensitive products. The use of mixers ensures that cosmetic solutions have the correct consistency and texture. Shearing mixers and multi-shaft mixers provide the speed for emulsification, powder wet out, and particle size reduction.

Food Industry

The food industry relies on mixers for every aspect of the production of their products since mixing is an essential part of quality foods. A key requirement for food production is adherence to the standards enacted by the Food and Drug Administration (FDA) that keeps a close eye on any products for human consumption and use.

The many processes involved in food production involve dry blending, emulsification, high-speed powder induction, dissolution, dispersion, and high-viscosity mixing. Every type and form of blending and mixing application is used by the food industry since at the heart of the preparation of food is some form of mixing operation. Juices, fortified milk, vegetables, and chopped meats are manufactured using high shear mixtures.

Plastics and Composites

The rapidly growing and ever changing plastics and composites industry rely on efficient and effective mixing for the production of their products. Polyamides, plastisols, and injection molding formulations are brought together, blended, or mixed during the plastic production process.

Inks, Paints, and Coatings

Of the many mixing and blending processes one of the most demanding is the ink, paint, and coating processes. For proper bonding between an ink, paint, or coating and a surface, the mixture must be created using the highest precision and accuracy to ensure the best results and the quality of the product. The success of the process depends on the use of dispensers, shear mixers, and multi-shaft mixers.

Chemical Industry

As with pharmaceuticals, food, and cosmetics, the chemical industry depends on proper mixing for the success of its products. High to low viscosity mixing is used for dry blending, particle size reduction, emulsification, homogenization, and powder reduction. Materials that are blended or mixed include abrasives for shaping and finishing, coal suspension for the processing of synfuel, flotation reagents, lubricants and oils, and propellants, to name a few.

The eight industries listed above are a small sampling of the many industries that rely on mixing technology for the production of their products. Essentially, any industry that requires the addition of one substance to another substance necessitates the use of some form of mixing or blending process. The industrial mixer industry is a vibrant and ever growing aspect of industrial production that is ready to meet the needs of their customers with high quality products.

Chapter 4: Benefits of Mixers

The goal of any industrial operation is to provide high quality products at a lower cost in less time. Industrial mixers are designed to meet the exact specifications and requirements of an industrial operation. Manufacturers examine the types of materials to be blended, homogeneity requirements, and efficiency in order to select mixers with the ability and processes capable of meeting the needs of any application.

Cost Savings

Mixers are designed to meet the needs of customers with efficient and streamlined production methods. The increased efficiency saves money on energy, materials, and labor. Mixers are durable and long lasting and require little regular maintenance and repair.

Improved Efficiency and Lean Manufacturing

Every manufacturer is interested in improved efficiency. Highly engineered and crafted mixers produce higher quality products in less time since they are chosen to meet the exacting demands of an application. This is beneficial in that products are produced in a shorter time. Materials being processed quicker reduces the amount of time and energy required for production and aligns with lean manufacturing.

Greater Control

Manufacturers select mixers that meet their needs, which provides them with greater control over the mixing process. Every customer has specifications, standards, and requirements that have to be met for the success of their products. The right mixer gives users the necessary control for blending materials to their exacting specifications. Mixers allow users to customize, design, and change their mixer to their standards ensuring that end products meet their needs and requirements.

Increased Flexibility and Diversity

Users can make changes and adjustments to the design and performance of a mixer as needed. Mixers can easily be adapted for different materials and processes. Mixer manufacturers are aware that no one mixer can meet the mixing needs of every customer. Changes, adjustments, and adaptations have to be made such that the chosen mixer fits into a production process.

Conclusion

• Common mixing states are solid to solid dispersion, solid to liquid, liquid to gas, and the two forms of liquid to liquid with one being miscible liquids and the other immiscible ones.
• A mixer is a complex and precision piece of equipment that blends, emulsifies, homogenizes, and combines various types of ingredients that are essential to a manufacturing or production process.
• In a discussion of mixers, it is critical to understand the difference between blending and mixing, which may seem to be the same function. Blending is a gentler process with the goal of creating a uniform, cohesive distribution of each material.
• The selection of a mixer is predicated on how it will be used and the kind of chemicals, liquids, gases, granules, and pellets that will be combined.
• The goal of any industrial operation is to provide high quality products at a lower cost in less time. Industrial mixers are designed to meet the exact specifications and requirements of an industrial operation.

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