Guide to Purchasing an Industrial Mixer - ASC Tornado

Any form of bulk processing machinery intended to mix or blend disparate ingredients into a homogeneous end product is an industrial mixer. All across the world, processing and manufacturing facilities use industrial mixing machines to mix materials like food, chemicals, pharmaceuticals, household goods, plastics, and minerals. Therefore, industrial mixers are an extremely vital component in any industry that manufactures these materials.

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It is important to efficiently operate and manage an industrial mixer, but at the same time, the industrial mixer must be one that is suited for the task. Industrial mixers are understandably designed for some specific processes, parameters, and materials, so a guide should be followed to avoid any incompatibility issues.

The following discussion highlights some vital points that should be kept in mind when purchasing an industrial mixer:

Type of Material to Mix

When it comes to choosing an industrial mixer based on the nature of the mixed material, there are several different types of industrial mixers to select from based on the application. Given below is the guideline for selecting the required industrial mixer on the concerned criterion:

Volume of Material

The volume of the material holds equal importance in consideration when buying an industrial mixer. The capacity of a mixer is a custom feature that can be set to meet the batch requirement. The batch volume is set to a value, and a mixer with the required capacity to produce that mix can be selected.

As an example, a standard drum mixer can have a capacity of up to 50-100 gallons (190-380 liters). An agitator mixer carries a capacity of 16-264 gallons (60- liters). So, whenever an industrial mixer is to be purchased, one should consider whether batch production is done or continuous production. The volume of each batch should match the capacity of the mixer.

Best Mixer Design

Finding the most suitable mixer design is often considered one of the most vital decisions in the selection process. There are a wide range of industrial mixers available on the market, with each having different working mechanisms, components, and mixing capacities. In addition, materials that can be mixed in the mixer also vary depending on their characteristics or specifications.

Suppose we make a comparison between two prominently utilized mixers, the drum mixer and tote mixer. It comes to attention that both differ from each other in several aspects. One of the distinguishing aspects is the type of material these mixers can mix. Suppose a choice is to be made between these two based on preference. In that case, it is safe to say that the drum mixer can be preferred over the tote mixer because the latter is an economical choice for mixing thin, non-viscous liquids only. In contrast, the drum mixer can be used to mix heavy materials such as concrete, slurries, and cement.

Blade Size Considerations

The blade is one of the most important components of an industrial mixer. The characteristics, types, applications, and materials used are crucial considerations when choosing mixing blades. Other crucial factors to take into account include the mixing blade count, bore size, and outer diameter. When determining the blades of the mixer, the following points must be kept in mind:

1. The diameter of the blade should be 1/3th of the diameter of the tank of an industrial mixer.
2. For heavier materials such as cement and gravel, the size of the blade should be increased.
3. If the viscosity of the mix is under centipoises, one set of blades should be used; if the viscosity is higher than centipoises, it should be mixed using two sets of blades 13-15 inches (33-38 cm) apart.
4. The material from which the blade is manufactured should be non-reactive to the mix in order to prevent impurification. Moreover, it should be able to bear high temperatures if necessary.

Electric Motor Considerations

When choosing an appropriate motor, it is important to properly grasp torque, energy economy, variable speed, blending environment, and mixer weight. Moreover, air motors are often chosen to operate an industrial mixer. However, the following points must be kept in mind while selecting a motor for an industrial mixer:

1. The most significant and precise measurement in mixing is torque. Due to their ability to load torque dynamically, air motors have a clear advantage in industrial mixing. An air motor essentially modifies its torque output to meet the required torque for the application.
2. Electric motor mixers with a single speed and direct drive are best suited for mixing recipes with low viscosities or light liquids. The benefit of a pneumatic direct-drive motor mixer is that overloading will not lead to motor failure because the motor will automatically stall under the weight. However, unless they're turning several hundred RPM, pneumatic motors don't produce torque steadily.
3. The horsepower of the motor driving the industrial mixer must range between 1/3hp to 5hp.

Accessory Considerations

Industrial mixers in the modern industrial era are often equipped with custom features. Not only do these industrial mixers come with all the basic features, but they include innovative accessories offering a wide range of services.

Needless to say, there are also some important considerations to look for while looking for these accessories in an industrial mixer:

1. Add-Ons

The best considerations for add-ons are subjective because every industrial mixer can have different add-ons. However, it’s generally good to consider if the add-on:

• Is of high quality
• Properly enhances the mixing capability of the mixer
• Can increase the capacity/efficiency of the mixer drum

2. Gear Reducer

With the use of gears, shaft placement, and gear arrangement, a gear reducer alters the rotational speed. A gear reducer is necessary for more viscous substances. It also converts low torque to high torque in an air/electric motor so the blade can move at the correct speed.

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3. Elevator

An elevator in an industrial mixer supports industrial mixers on a horizontal surface. They come with an adjustable height and moving speed in order to function smoothly.

4. Adjustable Blade

Adjustable blades are necessary when a heavy material is being mixed. Moreover, these adjustable blades work well with either dynamic or continuous mixing.

5. Hinged Access

Hinged access in a mixer that produces large batches makes it easy for the mixer to be cleaned, inspected, or emptied.

6. Tube or Threaded Pipe

Tubes or threaded pipes are required in an industrial mixer when an effective sealed environment is needed for transporting and mixing gasses, oils, and liquids.

Hybrid Agitators

Hybrid mixers combine the tumbling action of paddle mixers with the rolling pattern of ribbon mixers to create a double-reversing mixing effect. This increases the energy being transferred into the product. Hybrid agitators are a good fit for materials that tend to build up in the center of the mixer, as the combined mixing action promotes even product levels within the trough.

Fluidizing Paddle Agitators

Fluidizing Paddle Mixers provide sophisticated, dual-directional mixing action with multiple paddles. Fluidized mixing, through a combination of inward and outward motions. Fluidized paddle mixing technology is an excellent choice for bakery blends, nutraceuticals, detergent powders, and more.

Shaft Configuration | Seven Foundational Factors

Compromising on the configuration of your mixer's shaft will negatively impact the performance, maintenance requirements, and the long-term productivity of your mixing equipment. When considering new mixing equipment, there are seven key technical features that should be closely analyzed and vetted:

1. Shaft Diameter: Shafts with smaller diameters will have higher stress concentrations and, as a result, are more prone to breaks from fatigue failure.
2. Static Deflection: The shaft acts as a continuously loaded and simply supported beam. Excessive deflection promotes metal fatigue and speeds up seal wear.
3. Dynamic Deflection: Excessive deflection due to dynamic loading increases clearances between the agitator and the trough on the down-sweep side of the mixer; solid shaft designs (mentioned below) will have less deflection compared to hollow options, promoting better mixing.
4. Reduced Stress Risers: The use of stress risers should be minimized in order to avoid metal fatigue or potential shaft breakage. 
5. Solid, One-Piece Shaft: This design consideration reduces stress and minimizes agitator deflection.
6. Shaft Straightness: Welded shafts that are not re-straightened at the end of the fabrication process are prone to excessive warping. This will ultimately accelerate the wear of seals and bearings, creating higher long-term maintenance costs.
7. Paddle or Ribbon Clearance: Large and/or irregular gaps between agitator blades or ribbons translate to higher coefficients of variation and longer mixing times. This will directly impact mixing performance. 

Interested in an in-depth examination of the seven key principles of shaft design? 

Sealing Technologies | Insurance for Your Investment 

Utilizing the correct seals and preventative maintenance program for your mixer will protect and extend the life of your equipment. Seal choices can range from simple braided rope packing inside of a barrel-housing to mechanical seal options. Thanks to recent advancements, lip seals comprised of composite materials are available that offer better performance and sanitation than traditional packing seals, and are overall more affordable than mechanical seals. 

Benefits of Lip Seals in Composite Materials

• Non-porous material (unlike packing, which can retain media)
• Shaft-friendly materials prevent premature wear
• Easier, quicker maintenance
• Longer-lasting and resistant to degradation
• Cleanable and reusable
• Sanitary: FDA compliant and 3-A certified
• Proven longer run times
• More cost-effective than mechanical seals

Minimize downtime expenses and the potential for product contamination or leakage by selecting the right seal for your application. Taking a "one size fits all" approach to mixer seals can turn out to be a costly mistake.

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Conclusion | Getting Started 

When in the market for a new horizontal mixer, be sure to consider the basic elements of agitator design, shaft configuration, and sealing technologies for your operation. Keeping the fundamentals top of mind as you configure your mixer will ensure the end result is built to support your needs.

So... what's next? The optimal configuration of your mixer starts with a professional consultation. Your chosen equipment manufacturer should understand the importance of determining these key design elements listed above as your partner in crafting a cost-effective, high-performance mixing solution. Taking mixing 101 into consideration early on in the process will ensure your end result will provide years of optimal performance and satisfaction.

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