A Comprehensive Guide for Choosing an Industrial Mixer / IBC Blender for Powders

This insightful infographic guide will assist you in evaluating the essential criteria for selecting a blender.

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The infographic outlines the vital questions one should consider when assessing the suitability of an industrial mixer; some of these inquiries may be familiar, while others could be novel. All questions are conveniently categorized for easier use and include a straightforward yes/no checkbox for your completion.

Fill out the form on the right to download this infographic, print it, and systematically go through the steps to ensure that you choose the right industrial mixer for your requirements.

Introduction

Batch mixing forms the backbone of numerous manufacturing processes globally. From food and beverage production to pharmaceutical operations and industrial chemical creation, batch mixing is prevalent in almost every manufacturing sector. Despite its ubiquity, several intricacies dictate the appropriate types of equipment for specific processes. Factors like the addition of powders, product viscosity, batch composition, and automation all play crucial roles in equipment selection. In this article, we will elucidate batch mixing and highlight three crucial factors that influence the selection of batch mixing equipment.

Understanding Batch Mixing

Batch mixing, or batch blending, refers to the process of combining two or more ingredients in a single operation. This can range from a simple task, such as preparing cookie batter, to a more complex one, like mixing components for a new fuel additive. While conventional, batch mixing contrasts with continuous or inline blending, a more advanced alternative.

Even though batch mixing is recognized as a traditional method for manufacturing products, various factors determine the design of the system and the equipment type utilized. Recognizing what to look for in system design is essential for ensuring that each batch is produced as intended and that the batch mixing system maintains its operational integrity over time.

Selecting Batch Mixing Equipment

Numerous factors can influence the type of batch mixing equipment one should select. Below are three critical elements to consider when deciding on the appropriate batch mixing equipment for your system.

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1. Number and Type of Ingredients

The quantity and composition of ingredients can significantly impact the type of equipment chosen for a batch mixing system. Additions like powders, highly viscous liquids, or hazardous materials can all influence the equipment selection.

When dealing with powders, you may need screw augers, supersack handling systems, specialized raw material storage, and additional rotary valves. The viscosity of materials, whether due to powder addition or inherent characteristics, will guide the selection of pumps and pipe sizes. Additionally, it may dictate whether a ribbon blender, high shear mixer, or alternative industrial mixer should be integrated. Factors concerning hazardous materials may affect the necessary electrical classification for control panels and instruments, possibly altering tank design or material construction. The number of ingredients used will largely influence the size or quantity of tanks, mixers, pumps, and other equipment.

2. Level of Automation

The desired degree of automation will dictate the equipment types chosen when selecting batch mixing machinery. Opting for a highly automated system can enhance batch consistency by reducing human error. Nevertheless, not every scenario requires a fully automated system. Ultimately, there isn't a one-size-fits-all solution for how automated a batch mixing system should be. Each system should be designed and automated according to its specific needs.

Several aspects impacted by the choice between automated and manual components include raw material addition, batch start/stop processes, and final product handling. In highly automated setups, ingredients are automatically added using pumps and flow meters, batches commence once all ingredients are included, and finished products are sent for further processing automatically. Conversely, less automated systems often involve multiple manual ingredient additions, requiring an operator to initiate and monitor the batch while final products might necessitate manual transfer to subsequent stages.

3. Washouts and Changeovers

What occurs after a batch has been completed? Will the system create another unique batch? Is it transitioning to a different SKU, or will it remain idle? The washout and changeover schedules will directly affect the system’s integrated equipment. For instance, a design that incorporates two tanks allows one to produce while the other undergoes cleaning. If washouts are mandatory, a Clean-in-Place (CIP) system may also be essential.

Depending on batch compositions, a continuous mixing system or a Late Product Differentiation (LPD) skid might be more appropriate than a traditional batch mixing setup. For inquiries concerning the optimal design of a washout or changeover system, it's recommended to consult a design/build firm with expertise in batch mixing systems.

Conclusion

In summary, while batch mixing may seem straightforward, it necessitates careful engineering to navigate its complexities. Key factors such as the number of ingredients, their composition, desired automation levels, and washout/changeover requirements are vital considerations influencing equipment selection.

If you seek further assistance in selecting your batch mixing equipment, explore EPIC’s batch mixing capabilities or reach out to us at 314-806- to consult an engineer.

For more insights on powder mixing equipment, feel free to contact us.