When you choose to have an industrial mixer in your facility, you need to be sure that the mixing process will be able to meet the goals you have set for your business. These include heat transfer, accurate mixing portions, and agglomeration.
Accurate mixing portions
The accuracy of mixing portions of an industrial mixer can profoundly affect the end product. It can be measured in various ways. These include the measurement of the rotational speed of the impeller.
Several different mixers are available, each of which can be classified based on the process they are designed to facilitate. They also vary in complexity and price. Choosing the suitable mixer requires understanding the process’s relevant technical and design aspects.
The primary function of a mixer is to mix materials thoroughly. Mixers can provide agitation and heat transfer, as well as other benefits. Their rheology is often manipulated to improve the efficiency of specific processes.
The process of mixing is a balancing act between achieving the best results and reducing the risk of contamination. It involves numerous stages and requires some form of drying. A good mixing ratio is necessary to produce a quality product. Various methods are used to achieve this, including blending and packing.
Agglomeration
Agglomeration is a process in which powdered substances form larger particles. It can improve the transportability of a product and the handling and processing of the material. However, not all materials respond adequately to agglomeration.
Several factors influence the formation of agglomerates. It is up to the mixing process operator to control these factors to achieve the desired result.
One crucial factor that influences agglomeration is the speed of the mixer. If the rate is too high, the agglomerates may pulverize or grow in size. The amount of binder liquid should also be maintained as low as possible.
Another factor that influences agglomeration is moisture. If the product contains less water, it may become clogged and block the equipment.
Heat transfer
Industrial mixers are used in a wide variety of fields. They are designed to combine elements, homogenize mixtures, or reduce the size of particles. Generally, a mixer vessel is modeled as a vertical cylindrical cylinder. However, mixers can also have dish-shaped bottoms.
A typical batch mixer consists of an impeller, a vessel, and some blades. This vessel might have a flat or curved bottom, depending on the fluid type. The amount of heat exchange per unit of time in a mixer vessel is expressed in terms of overall heat transfer coefficient (U) and temperature difference (T) – or Kcal/hr.
The heat transfer area of a mixing vessel is one of many essential factors. However, it affects a vessel’s overall heat transfer performance.
Solids suspension
Many industrial processes require the suspension of solid particles in a liquid. The purpose is to enhance mass transfer by maximizing the contact between the stable and the liquid phases. There are several ways to accomplish this goal.
First, a proper mixer design and flow are essential. To optimize the mix, it is crucial to consider the material’s shear level and viscosity.
Another factor to be considered is the settling rate of the suspension. Again, it will help to determine the amount of pumping required.
It is also essential to consider the vessel’s diameter and the batch’s height. A larger volume means more mixing and the need for a higher impeller.
Finally, it is essential to consider the drag model for the solids suspension. It will help justify the model inputs.
Cost
Industrial mixers are used in a wide variety of industries. They are most commonly found in chemical laboratories, food manufacturers, and pharmaceutical labs. Mixers can be used to mix various materials at different speeds and temperatures.
The industrial mixer market is expected to rise with the increasing demand for packaged foods and ready-to-eat products. However, several factors must be considered before deciding to buy a mixer. It is essential to consider acquisition cost and the whole life cost.
New technologies and energy-efficient devices are driving the growth of the industrial mixer market. These devices allow the mixing process to be automated and guarantee consistent quality. As a result, the cost of operation can be reduced.
Currently, there are hundreds of mixer manufacturers worldwide. Some are privately owned, while others are part of corporate conglomerates.