Tips to choose the exact right dry powder mix plant
Author：ANT CONSTRUCTIONS Comefrom： Createdate：2021/5/21 11:11:38 Hits：63
Tips to choose the exact right dry powder mix plant
One of the most significant functions and consequently one of the most important aspects in a powder processing system is blending. In most dry powder mixing applications, it is the major source of increasing the value of the products that go into the process. This is the case in producing high quality dry powder products.
An increasing challenge in the powder handling industry is how to accommodate a wide recipes and vast array of different ingredients. Some companies have been willing to spend significant amounts of capital installing the highest-speed mixers and packing lines to achieve high efficiency and throughput. But just because a mixer is high speed, does not necessarily mean that it provides the best process solution.
Whether a beginner or seasoned professional, choosing a mixer from the extensive options available can be confusing and overwhelming. This article poses some questions to consider during the mixer machine selection process.
Mixing by Batch or continuous production?
Before selection, the most important decision is to choose mixing by batch or continuous production. Does the process require swapping recipes on a regular basis or will the same product be produced day in, day out? If there are no changes to be made, then it makes sense to consider continuous processing with large, fixed mixers that are coupled to the upstream and downstream processes. However, many manufacturers are finding that consumers’ desire for more variety results in more recipes being added to the ever-expanding product formula. The consequence of which is more recipe changes than ever before. This leads to the need for a close examination of how mixing will be conducted. In this case, batch processing is the only way.
When selecting a mixer for powder mixing plants, consider below points, which refer mainly to the case for batch processing given this is an expanding area of consideration.
1. Powder characteristics
A free-flowing powder with similar ingredient particle sizes will mix easily. A gentler blending approach will work well here, such as twin shafts with paddles mixer or ribbon mixer.
On the other hand, for cohesive, sticky powders to mix homogeneously, work needs to be applied to the material, forcing the particles to fold and join. In this case, blenders that offer high shear in the form of knives or intensifiers are required. Applying the right amount of shear is vital to intermesh and blend the particles.
2. Batch size
Big is not necessarily better for blender machine. The blender might be large enough to match the order amount and batch size, but pay attention to loading times. If your raw materials come in bag, consider how long it will take to fill by opening and tipping 25-kilogram sacks of ingredients, the dosing time, the materials conveying time, the mixing time in mixer, then think about how long it will take to empty the product to packing. etc.
3. Mixing time
Do not be fooled by claims of only a four-minute blend time. It is important to weigh up the full end-to-end process stage of blending, from filling the mixer to emptying it and getting it ready to go back into operation, a lot of other process also need spending time except mixing, such as materials preparing, conveying, dosing, packing, etc.
4. Changeover time
If several recipe changes are being made throughout the day, using a fixed mixer can be inflexible. A clean-down will need to be conducted each time, thereby increasing the full end-to-end blending time even further.
5. Risk of chemical reaction
With increasingly more different feature chemical additives which are easy happen chemical reaction in mixing, it can be challenging to manage changeovers and clean-downs. Particularly tricky are the fixed mixers and inline conveying systems because these systems are coupled, so it can take a long time to clean down between recipes and to ensure cleanliness.
If different recipes are to be mixed on the same mixer, then consider the risk of cross-contamination if cleaning is not done properly. To mitigate the risk, some companies dedicate different mixing lines for different products which chemical additives are easy happen chemical reaction .
6. After mixing segregation risk
Even though the fixed mixer may be providing well-blended material, this does not guarantee production of a quality product as it needs to be transferred out of the mixer. This is when segregation of the mix might occur as air displaced by powder leaving the mixer carries the “fines” back up through the powder. This is further exacerbated if large product transfer heights are involved. In this case, the particles have more chance to move apart and de-mix the blend as some will move faster than others depending on their particle density and characteristics.
Consider the ease of discharge from the fixed mixer. Ensure the mixer empties fully with no residual product held up. Consider the opening size of the discharge point because some powders might be sticky and will have poor flow properties and are likely to become stuck. Then again, the free-flowing products could suffer from a core flow through these discharge points, which will cause segregation.
Ant Construction Machinery mixer help to reduce the issue of segregation. Not only is the product mixed within the mixer, but it is also then transported to feed to packing where it is coupled to the infeed hopper, reducing the drop height. A note of caution, not all mixers are equal. Those with butterfly valves can still have product segregation issues due to core flow and rolling of particles. Where this is a high risk, it is worth using cone valve mixer, which offer the best protection against segregation due to product flowing under mass-flow discharge with all particles moving down through the bin in unison.
7. Factory space
Beyond mixer size, consider what space is needed around the mixer for loading and unloading product and cleaning. Also, check on what ceiling height is necessary for access above and below.
Ant Construction Machinery blenders tend to have a small footprint and head height, so if space is an issue, then it is worth exploring these further. Ant Construction Machinery blenders can be located in open areas with low hygiene control since they provide a closed process.
