EYH Dry Granule Mixer

Types of Mixers

The choice of a mixer hinges on its intended use and the specific materials involved, such as chemicals, liquids, gases, granules, and pellets that need to be mixed. The industrial mixer domain offers a range of mixer types to cater to a variety of materials, even those that might initially appear challenging to blend. Mixers can generally be categorized into three main groups: diffusing, shearing, and convection, each distinguished by unique construction, impeller types, speed, and function. Gaining a fundamental understanding of these categories is essential when selecting the right mixer for a particular application.

Tumbler Mixers

Tumbler mixers fall into the diffusing mixer category. These mixers rotate to combine materials and introduce air into the mixing process. Tumbler mixers follow a tumbling rhythm and do not employ impellers during mixing. They are commonly used for blending solids, powders, and, in some cases, liquids. The tumbler’s rotation stirs solids as gravity continuously pulls the mixture back to the drum’s bottom. Tumbler mixers come in various configurations, including octagonal, conical, and V-shaped designs.

Tumbler Mixer, High Shear Mixers

High shear mixers, also known as high shear reactors (HSRS) or rotor-stator mixers, belong to the shearing mixer category. These high-speed machines use powered mixing blades, known as shears, to blend solid and liquid materials. They excel in tasks like emulsification, homogenization, dispersion, particle size reduction, and disintegration. High shear mixers are essential when dealing with materials that don’t easily blend, are immiscible, or require rigorous mixing, such as liquids with varying viscosities or those containing solids that need to be broken down. The most common application for high shear mixing is dispersion, where high-speed rotation and intense shear action break down particles. High shear mixers can effectively blend liquids and solids that typically don’t mix well, like oil and water. While they were traditionally used in the rubber industry, high shear mixers are now widely applicable in various fields, including chemicals, food, pharmaceuticals, cosmetics, and adhesives.

High Shear Mixer/ High Speed Mixers

High-speed mixers are typically employed to rapidly cool, granulate, or disperse substances for subsequent processing. These mixers find applications in industries such as food processing, pharmaceuticals, and paint manufacturing. High-speed mixers come in various sizes and shapes, ranging from small, high-speed lab mixers to larger industrial units.

Ribbon Blenders

Ribbon blenders are designed for powder blending, primarily for solid-to-solid mixing. Their unique design allows for swift and efficient mixing cycles, often ranging from a few minutes to under twenty minutes, with tip speeds of about 1.4 meters per second. Despite their quick mixing, ribbon blenders operate at a slow blade speed, resulting in a gentle folding action. While ribbon blenders are effective at achieving homogeneity, they tend to be more costly than paddle mixers and may require more maintenance.

Paddle Mixers

Paddle mixers are versatile and used for mixing solids, viscous liquids, and wet-dry mixtures. They feature a central shaft axis with blades for mixing and are commonly employed in dry mixing, although they can also handle liquid-solid blending.

Paddle Mixer, Agitator Mixers

Agitator mixers are suitable for applications involving liquid or flowable materials. These mixers utilize agitating blades in the center, which remain stationary while the fluid is agitated during rotation. They are commonly used in industrial food and beverage processing, employing a principle and configuration similar to top-load washing machines.

Axial and Radial Flow Impellers

Agitator mixers can be further classified into axial and radial flow impellers based on the angle at which the impeller blade contacts the liquid and the rotation plane. These mixers handle materials with varying viscosities and are ideal for tasks such as solid suspension and blending miscible or immiscible liquids.

Axial and Radial Flow Impellers, Rotor Mixers

Rotor mixers consist of metal blades installed at the bottom of a container, capable of variable-speed rotation. They are commonly found in blenders and can operate with various detachable attachments, making them suitable for various tasks in industries such as food production, adhesives, pharmaceuticals, and chemical processing.

Rotor Mixer, Static Mixers

Static mixers have mixing elements shaped like twisted ribbons, helices, or other forms placed within a cylinder. Unlike other mixers, static mixers lack moving parts. The mixing element disrupts and blocks the flow of liquids or gases forced through one end of the cylinder. As the fluids flow through the cylinder, the element’s shape induces turbulence, effectively mixing materials by breaking down their molecules. Static mixers are ideal for dispersing gases into immiscible liquids to create a homogeneous solution. They are commonly used in continuous material flow processes, offering precise control over the degree of mixing required.

Disperser Type

Dispersers use concentrated high-speed force to disintegrate, dissolve, and disperse solids found in powdered materials or liquids. Mixing shafts often feature disc-shaped blades that rotate at maximum speed, ensuring proper flow, dispersion, and consistency during the blending process.

Emulsifier Mixers

Emulsifier mixers are employed for mixing immiscible liquids, such as oil and water. These specialized mixers utilize pressure for thorough liquid-liquid mixing and incorporate vacuum-filled equipment along with high shear. They apply centrifugal force in vacuum emulsifier homogenizers, breaking down materials into smaller particles. For instance, in cream and milk, where cream contains large fat molecules that separate due to their size, emulsification reduces the size of the cream molecules to match those of milk molecules.

Homogenizer Mixers

Homogenizer mixers blend liquid-liquid and solid-liquid mixtures, applying extreme force, shear, and pressure to achieve homogenization. They are crucial for mixing substances that are inherently difficult to blend, such as immiscible materials or those requiring thorough mixing.

Heavy Duty Mixers

Heavy-duty mixers are employed in the mixing of highly viscous and pasty substances, which would typically cause buckling and failure in standard mixing equipment. These mixers are designed to handle materials with viscosities exceeding 750,000 centipoises. They come in various designs, including planetary and multi-shaft mixers, accommodating a wide range of applications.

Batch Mixers

Batch mixers have a cylindrical design that allows for ingredient loading at one end and product dispensing at the other. They are capable of preparing batches ranging from a few gallons to thousands of gallons. Batch mixers enable precise control over ingredient combinations to ensure high-quality mixtures. They come in various configurations, including horizontal twin shaft mixers, ribbon blenders, paddle mixers.