When manufacturing products for the food, nutrition, bakery and chemical industries, you may need to blend powder ingredients. In most applications, blending is the most important process for adding value to your product. Let WANTONG show you some things to consider.
If you need to produce only one recipe in high volume without regular changes, then you should use a stationary mixer connected to the upstream and downstream processes for continuous processing. If you find that you need to make regular formulation changes and use different ingredients, then batch processing would be the best way to manufacture.
Even if you are an experienced powder processing professional, technology is constantly evolving and mixer options are expanding. To help you choose the right industrial mixer for your application, we have listed a few key considerations.
Are you working with free-flowing powders with similar particle sizes? If this is the case and you know that your recipe will mix easily, then a gentle mixing procedure will be best suited to a drum mixer or belt mixer.
If you are working with sticky, tacky powders and need to mix them uniformly, the mixture needs to be processed to force the particles to fold together. A mixer that provides high shear capacity in the form of an intensifier is required. It is critical to apply the right amount of shear to mix the particles. If this process is not managed properly, particle degradation and heat may accumulate in the mixture.
V dry fine additives tea powder granule mixer mixing machine
Try not to be misled by the 4 minute mixing time recommendation. The complete end-to-end process time needs to be considered, including all mixing stages from filling to packaging and cleaning. The time it takes to get your mixer back up and running and ready for the next batch can actually mean 2 hours to load and then 3 hours to package.
By running the filling, blending and packaging process steps in parallel means you can save a lot of time, with the added benefit of not having to clean the mixer.
W food grade powder rotary double cone drum blender mixer
Some stationary mixers with multiple moving parts can lead to product loss. All stationary mixers inevitably have some product left in the bottom of the mixer bowl or stuck to the side walls, paddles or bearings. This not only leads to significant waste over time, but also to potential contamination from batch to batch.
If you need to disassemble a stationary mixer, remove the contact parts, and then perform a full wet wash with drying time in mind, the mixer will not operate for a long time.
Higher efficiency in the mixing process stage can increase throughput, resulting in more batches being produced in a single shift.
A drum mixer will reduce the number of operators needed for cleaning and can efficiently produce a variety of formulations and batch sizes.
It is important that you do not choose the option that seems the cheapest in the short term. Remember not to focus on mixing time and be blown away by fast mixers, which can actually lead to significant downtime and poor ROI. Make sure you invest in a flexible manufacturing system that will give you a competitive advantage.
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