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5 Things to Consider when choosing an Industrial Mixer

5 Things to Consider when choosing an Industrial Mixer

When manufacturing products for the food, nutrition, bakery and chemical sectors, it is likely that you will need to blend a mix of powder ingredients. In the majority of applications, blending is the most important process to increase the value of the product.  If you are handling a wide range of ingredients, some of these may pose an allergen risk and whilst several manufacturers are willing to make significant investments by installing the highest speed mixers and packing lines, it does not necessarily mean it will deliver a strong return on investment and long-term efficient solution.

The most important thing to consider is whether to batch or continuously manufacture. If you need to swap recipes on a regular basis or produce the same product day in day out, then your application will be better suited to certain blender types.

If you only have a requirement to manufacture one recipe in a large volume with no regular changes needed then you should continuously process with a fixed mixer coupled to the upstream and downstream processes. However, with more manufacturers finding that consumers are requesting recipe variety, changes need to be made quickly and efficiently. If you are finding that you need to change recipes and use varied ingredients regularly then batch processing would be the best way to manufacture.

Even if you are an experienced powder processing professional, technology moves on and the choice of mixers continues to expand. To help you select the right industrial mixer for your application, we have listed 5 key considerations for manufacturer’s who are looking to select an industrial powder mixer for blending as part of a batch processing programme.

The Characteristics of the Powder

Are you handling free-flowing powders with similar particle sizes?  If this is the case and you know that your recipe will mix easily then a gentle blending programme will be best suited using either a tumble-blender or ribbon blender. 

If you are handling sticky, cohesive powders and need them to mix homogeneously, you will need to work the mixture to force the particles to fold together. A blender that offers high shear capability in the form of intensifiers would be required.  It is vital that the right amount of shear is applied to blend the particles. If this process is mismanaged then particle degradation and heat may build-up in the mixture.

The Size of the Batch Being Produced

Although large blenders have the ability to accommodate a full order size, it is likely that the load time and cleaning times will increase. Considerations need to be given to the time it takes to fill the blender by ripping and tipping 25Kg sacks and then to discharge the mixed product to a packing line - you also have cleaning! Whilst the mixer is being loaded, emptied and cleaned it is not in use, leading to large amount of downtime.

If your customers require the same order sizes each time then a fixed mixer may work well until variable batch sizes are required. When using a tumble blender, you will be given the ability to blend a range of batch sizes in one blender as the mixing is done in the IBC (Intermediate Bulk Container). This gives you the option to choose the size of the container needed and reduce the amount of downtime.

Understand the True Mixing Time

Try not to be misled by the suggestion of a 4 minute blend time. The full end-to-end process time that includes all stages of blending from filling through to packing and cleaning needs to be taken into account. The time it takes to get your mixer back into operation and ready for the next batch could actually mean 2 hours to load and then 3 hours for packing.

Whilst IBC Blending might take a little longer to complete a full blend cycle, the formulation can be completed off-line. As the IBC is also removed from the blender and packed separately the mixer can be re loaded and set back into action. By running the filling, mixing and packing process steps in parallel means you save a significant amount of time, with the added benefit that the blender...

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Joel Low

Joel Low

Regional Sales Manager, MATCON Limited

Matcon IBC Systems help customers innovate and stay ahead of the competition. Our Cone Valve technology means that no matter what you might want to manufacture in the future, you will have the ability to handle the ingredients and recipes effectively – a future-proof solution! We work in partnership with you to create the right system design to fulfill your business needs.

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