Hollow sphere mixer for bulk materials: SpherHelics®
At its Paderborn site, amixon® manufactures ball mixers in more than 23 sizes for dry, damp and wet bulk materials. The spherical geometry facilitates cleaning. On request, the mixers can meet the hygiene requirements of the EHEDG, FDA and 3-A guidelines. amixon® highlights flexibility, real-time sensor technology and programmable targeted-jet cleaning lances as key selection criteria. Homogeneous mixtures are achieved after just 25 to 40 revolutions of the mixing tool. Even with component ratios of up to 1:100,000, the coefficient of variation in mixing quality is less than 5 per cent. amixon® ball blenders are available with working volumes ranging from 50 to 14,000 litres and are customised to individual requirements. At the technical centre, customers can test and compare ball blenders with coaxial and transversely mounted cutting rotors. Based on the test results, amixon® experts scale a wide range of sizes from 50 litres to 14,000 litres.
Hollow-ball mixer for 400-litre batches in the amixon® technical centre. It mixes all types of dry, moist and wet bulk materials/powders.
amixon® manufactures hollow-sphere mixers in 23 different sizes. The batch volumes range from 50 litres to 14,000 litres. The spiral-shaped mixing blades rotate around an inclined axis, which is tilted by 20° to 25°. The angle of inclination is determined by the size of the discharge fitting. The mixing effect remains constant in all cases. Spherical mixers with mixing tools mounted at an angle belong to the category of vertical precision mixers. When the materials to be mixed are agitated at an angle to gravity, gravity superimposes a transverse movement onto the upward conveyance. This intensifies the mixing process.
In principle, any rotationally symmetrical vessel is suitable as a mixing chamber, provided the mixing tool is adapted accordingly. The sphere represents a special case. It has neither edges nor corners and has the smallest surface-to-volume ratio. The surface area (A) of a sphere is calculated from the diameter (d) and the volume (V):
A = 6V/d
The low specific surface area is advantageous in terms of cleanability and when dealing with materials that tend to adhere.
Quality criteria that pay off in everyday use
Given the long service life of a powder mixer, the choice of mixer should be made with care. amixon® offers the ideal conditions. In addition to the amixon hollow-sphere mixers, all other amixon test mixers can also be compared on a one-to-one basis. All test mixers have a useful volume of 400 litres.
The mixing trials provide insight into the key quality criteria:
- efficient mixing processes
- optimal mixing quality
- flexibility with different fill levels
- easy incorporation of liquids
- Good residual discharge
- Quick cleaning (dry, damp or wet)
- Minimal use of cleaning water
- Short drying time after wet cleaning – even when cold
- Ergonomically designed inspection doors
- Affordable purchase price
- Reliable after-sales service
The SpherHelics ball mixer, type SH 1500, is designed for batches of 1.5 m³. The cutting rotor is arranged coaxially.
Given the long service life of a powder mixer, the choice of mixer should be made with care. amixon® offers the ideal conditions. In addition to the amixon hollow-sphere mixers, all other amixon test mixers can also be compared on a one-to-one basis. All test mixers have a useful volume of 400 litres.
The mixing trials provide insight into the key quality criteria:
- efficient mixing processes
- optimal mixing quality
- flexibility with different fill levels
- easy incorporation of liquids
- Good residual discharge
- Quick cleaning (dry, damp or wet)
- Minimal use of cleaning water
- Short drying time after wet cleaning – even when cold
- Ergonomically designed inspection doors
- Affordable purchase price
- Reliable after-sales service
The SpherHelics ball mixer, type SH 1500, is designed for batches of 1.5 m³. The cutting rotor is arranged coaxially.
Mixing quality and mixing efficiency
If the mixing tool is designed like a helix and its rotation creates an envelope volume that is slightly smaller than the inner diameter of the hollow sphere, then the volume flow displaced by the spiral mixer in the spherical mixing chamber can be calculated fairly accurately.
IV = π / 4 · (D² - d²) · Φ · S · n · ζ
- IV: Displacement volume flow
- D/d: Helix diameter outside/inside
- Φ: Filling degree
- S: Helix pitch
- n: Rotational frequency
- ζ : Speed coefficient
As a rule, the entire contents of the mixing chamber are thoroughly mixed once after approximately five revolutions for all amixon® mixers.
It is interesting to note that this formula also applies when the mixing tool rotates very slowly.
amixon® mixers usually achieve homogeneous mixing after just 25 to 40 revolutions. This even applies to two-component mixtures with a mass ratio of up to 1 : 100,000.
An ideal mixing quality is achieved when the material distribution cannot be further improved under practical conditions – regardless of the mixing principle or the mixing time.
The results of the mixing quality tests are reproducible. They meet the requirement that the coefficient of variation of the mixing quality of each 20-gram sample is less than 5%.
In this respect, all amixon® mixers can also mix particularly fragile goods ideally, gently and accurately.
If the mixing tool is designed like a helix and its rotation creates an envelope volume that is slightly smaller than the inner diameter of the hollow sphere, then the volume flow displaced by the spiral mixer in the spherical mixing chamber can be calculated fairly accurately.
IV = π / 4 · (D² - d²) · Φ · S · n · ζ
- IV: Displacement volume flow
- D/d: Helix diameter outside/inside
- Φ: Filling degree
- S: Helix pitch
- n: Rotational frequency
- ζ : Speed coefficient
As a rule, the entire contents of the mixing chamber are thoroughly mixed once after approximately five revolutions for all amixon® mixers.
It is interesting to note that this formula also applies when the mixing tool rotates very slowly.
amixon® mixers usually achieve homogeneous mixing after just 25 to 40 revolutions. This even applies to two-component mixtures with a mass ratio of up to 1 : 100,000.
An ideal mixing quality is achieved when the material distribution cannot be further improved under practical conditions – regardless of the mixing principle or the mixing time.
The results of the mixing quality tests are reproducible. They meet the requirement that the coefficient of variation of the mixing quality of each 20-gram sample is less than 5%.
In this respect, all amixon® mixers can also mix particularly fragile goods ideally, gently and accurately.
amixon® provides comprehensive and objective advice
Amongst suppliers of vertical powder mixers, amixon® plays a pioneering role worldwide. This is based on our experience with thousands of amixon® mixers that we have supplied globally since 1983. amixon® provides comprehensive and impartial advice on all matters relating to vertical precision mixers — including mixers with a spherical mixing chamber.
The amixon® product range is extensive. You can test it in Paderborn:
- KS: KoneSlid® mixers feature a counter-rotating cone inside, which serves as the discharge mechanism.
- VM: Vertical single-shaft mixers have cylindrical mixing chambers.
- SH: Hollow-sphere mixers have vertical or inclined mixing shafts. Our brand name SpherHelics® stands for the spherical mixing chamber and the amixon®-specific mixing helix.
- HM: Twin-shaft mixers have two cylinders that mesh with one another.
- AM: Cone mixers have cylindrical-conical mixing chambers.
We have not listed our vacuum mixing dryers and synthesis reactors here.
All amixon® mixers shown on the right are classic precision mixers that achieve ideal mixing qualities. In practice, the mixing results cannot be improved. The coefficient of variation of the mixing quality very quickly reaches a value of less than 5%. The mixing quality curve can be described as follows:
M(t) = M_∞ − (M_∞ − M₀) · e^(−k·t)
Where M(t) is the coefficient of variation of the mixing quality at time t. M_∞ is the asymptotically achievable mixing quality (final mixing quality). M₀ is the initial mixing quality. k is the design-related, individual mixing speed constant. t is the mixing time and e is Euler's number (approximately 2.71828).
Helical mixing tool in production.
Vertical precision mixers from amixon®.
Amongst suppliers of vertical powder mixers, amixon® plays a pioneering role worldwide. This is based on our experience with thousands of amixon® mixers that we have supplied globally since 1983. amixon® provides comprehensive and impartial advice on all matters relating to vertical precision mixers — including mixers with a spherical mixing chamber.
The amixon® product range is extensive. You can test it in Paderborn:
- KS: KoneSlid® mixers feature a counter-rotating cone inside, which serves as the discharge mechanism.
- VM: Vertical single-shaft mixers have cylindrical mixing chambers.
- SH: Hollow-sphere mixers have vertical or inclined mixing shafts. Our brand name SpherHelics® stands for the spherical mixing chamber and the amixon®-specific mixing helix.
- HM: Twin-shaft mixers have two cylinders that mesh with one another.
- AM: Cone mixers have cylindrical-conical mixing chambers.
We have not listed our vacuum mixing dryers and synthesis reactors here.
All amixon® mixers shown on the right are classic precision mixers that achieve ideal mixing qualities. In practice, the mixing results cannot be improved. The coefficient of variation of the mixing quality very quickly reaches a value of less than 5%. The mixing quality curve can be described as follows:
M(t) = M_∞ − (M_∞ − M₀) · e^(−k·t)
Where M(t) is the coefficient of variation of the mixing quality at time t. M_∞ is the asymptotically achievable mixing quality (final mixing quality). M₀ is the initial mixing quality. k is the design-related, individual mixing speed constant. t is the mixing time and e is Euler's number (approximately 2.71828).
Helical mixing tool in production.
Vertical precision mixers from amixon®.
The proof of the pudding is in the eating
Tests should be carried out before making a purchase decision. Trials in the amixon® technical centre are always informative. You can test several test mixers in parallel. This allows you to assess mixing efficiency, variety of applications, residual emptying and cleanability. In view of the long service life of powder mixers (20-30 years), this effort makes sense.
Typical questions could be:
- How often does the mixer need to be completely discharged (cleaning or product change)?
- Will this be necessary more frequently in the future?
- Can the mixer blender discharge itself completely?
- Can the remaining product be sold?
- or do the residues have to be disposed of?
- How long does the discharging process take?
- How large are the residues?
- How long does dry cleaning take?
- How long does wet cleaning take?
- How well can it be automated?
- ........
Tests should be carried out before making a purchase decision. Trials in the amixon® technical centre are always informative. You can test several test mixers in parallel. This allows you to assess mixing efficiency, variety of applications, residual emptying and cleanability. In view of the long service life of powder mixers (20-30 years), this effort makes sense.
Typical questions could be:
- How often does the mixer need to be completely discharged (cleaning or product change)?
- Will this be necessary more frequently in the future?
- Can the mixer blender discharge itself completely?
- Can the remaining product be sold?
- or do the residues have to be disposed of?
- How long does the discharging process take?
- How large are the residues?
- How long does dry cleaning take?
- How long does wet cleaning take?
- How well can it be automated?
- ........
Can customers test all mixers?
Answer from Mr Böning: Yes, of course. All mixer types, including our new SpherHelics®, are available. The batch size is a uniform 400 litres. This allows our customers to gain all the important insights. At the same time, these insights serve amixon® as valuable impetus for future developments.
Incidentally, it was not a great deal of work for amixon® to develop the new hollow-sphere mixer for all 12 sizes. As a contract manufacturer, we design each mixing plant individually anyway. We use our proven variant configurator for this. In addition, we have extensive expertise in the mixing mechanics of vertical mixers with mixing spirals – regardless of whether these are mounted vertically or at an angle.
In the manufacture of our hollow-ball mixers, amixon® relies exclusively on proven and reliable components. These include, in particular,
- the bearings of the mixing mechanism
- the mixing tool
- the drive
- the design and function of the dead-space-free shut-off valve,
- the Clever-Cut® inspection door with OmgaSeal® seal,
- the cutting rotors,
- the liquid supply and the sanitary flanges.
View of a spiral blending tool in the amixon® workshop.
Answer from Mr Böning: Yes, of course. All mixer types, including our new SpherHelics®, are available. The batch size is a uniform 400 litres. This allows our customers to gain all the important insights. At the same time, these insights serve amixon® as valuable impetus for future developments.
Incidentally, it was not a great deal of work for amixon® to develop the new hollow-sphere mixer for all 12 sizes. As a contract manufacturer, we design each mixing plant individually anyway. We use our proven variant configurator for this. In addition, we have extensive expertise in the mixing mechanics of vertical mixers with mixing spirals – regardless of whether these are mounted vertically or at an angle.
In the manufacture of our hollow-ball mixers, amixon® relies exclusively on proven and reliable components. These include, in particular,
- the bearings of the mixing mechanism
- the mixing tool
- the drive
- the design and function of the dead-space-free shut-off valve,
- the Clever-Cut® inspection door with OmgaSeal® seal,
- the cutting rotors,
- the liquid supply and the sanitary flanges.
View of a spiral blending tool in the amixon® workshop.
Data sheet for SpherHelics®
- Larger mixers available on request.
- The circumferential speed can vary greatly from about 0.8 m/s to about 3.5 m/s. As a rule, hollow-sphere mixers of the SpherHelics® type are operated as slowly rotating mixers.
- As a specialist welding company, amixon® has European, Japanese, Korean and American approvals for processing a wide range of materials. The materials of the amixon® mixers that come into contact with the product are optional: normal steel S355J2Ge, Hardox, austenitic stainless steels 1.4301, 1.4541, 1.4571, 1.4404, 1.4539, 1.4529, duplex stainless steels 1.44 62, 1.4162, 1.4363 as well as nickel-based materials Alloy 59-2.4605, Hastelloy-C22 and nickel.
- The agitators meet the highest hygiene requirements and comply with the EHEDG guidelines for dry and wet cleaning. In addition,
- they meet the FDA hygiene guidelines and the design requirements of the 3-A Sanitary Standards.
- Larger mixers available on request.
- The circumferential speed can vary greatly from about 0.8 m/s to about 3.5 m/s. As a rule, hollow-sphere mixers of the SpherHelics® type are operated as slowly rotating mixers.
- As a specialist welding company, amixon® has European, Japanese, Korean and American approvals for processing a wide range of materials. The materials of the amixon® mixers that come into contact with the product are optional: normal steel S355J2Ge, Hardox, austenitic stainless steels 1.4301, 1.4541, 1.4571, 1.4404, 1.4539, 1.4529, duplex stainless steels 1.44 62, 1.4162, 1.4363 as well as nickel-based materials Alloy 59-2.4605, Hastelloy-C22 and nickel.
- The agitators meet the highest hygiene requirements and comply with the EHEDG guidelines for dry and wet cleaning. In addition,
- they meet the FDA hygiene guidelines and the design requirements of the 3-A Sanitary Standards.
What criteria will be relevant in the future for companies to select the optimal powder mixer?
Consumers are fickle. Markets change rapidly. Companies must therefore be able to adapt their products and processes flexibly. This applies to recipes, manufacturing processes, cleaning and organisation. The role of the mixer in the value-added process must be determined individually for each mixing operation. To what extent does it determine product quality? Does it have strategic importance? Will future process engineering requirements be reliably met?
- The requirements of the target markets are increasing. Products must have defined properties. For example, dust-free, flowability and homogeneity are important properties. For health-related foods and dietary supplements, granulometry, colour distribution, bulk density and a natural appearance are also important. All these quality characteristics should be reproducibly fulfilled by one and the same mixer.
- Flexibility thus becomes a key criterion. Product life cycles are becoming shorter. Batch sizes vary. The mixer must therefore be able to reliably handle very different recipes and different batch sizes. The growing cleaning and sterilisation requirements must be easily met.
- A powder mixer that is versatile in terms of process technology strengthens your own development dynamics. It opens up new scope for product and process innovations. Mixers with a wide range of applications are a real competitive advantage. Being able to mix a powder mixture – no matter how heterogeneous – with minimal energy is a real competitive advantage.
- The sensor technology must record the mixing process in real time. Data-based optimisation increases process reliability and efficiency.
- Sustainability is becoming a prerequisite for investment. The focus here is on resource use and energy consumption. Good cleanability and a long service life reduce environmental impact and costs.
- A higher initial investment is justified
- if the total cost of ownership is reduced
- if new market segments are opened up.
The decisive factor is not the purchase price, but the value contribution of the mixing plant to the future viability of the company.
amixon® HM 2000 twin-shaft mixer in a nutrient production plant.
Three-dimensional flow in the double-shaft mixer
Consumers are fickle. Markets change rapidly. Companies must therefore be able to adapt their products and processes flexibly. This applies to recipes, manufacturing processes, cleaning and organisation. The role of the mixer in the value-added process must be determined individually for each mixing operation. To what extent does it determine product quality? Does it have strategic importance? Will future process engineering requirements be reliably met?
- The requirements of the target markets are increasing. Products must have defined properties. For example, dust-free, flowability and homogeneity are important properties. For health-related foods and dietary supplements, granulometry, colour distribution, bulk density and a natural appearance are also important. All these quality characteristics should be reproducibly fulfilled by one and the same mixer.
- Flexibility thus becomes a key criterion. Product life cycles are becoming shorter. Batch sizes vary. The mixer must therefore be able to reliably handle very different recipes and different batch sizes. The growing cleaning and sterilisation requirements must be easily met.
- A powder mixer that is versatile in terms of process technology strengthens your own development dynamics. It opens up new scope for product and process innovations. Mixers with a wide range of applications are a real competitive advantage. Being able to mix a powder mixture – no matter how heterogeneous – with minimal energy is a real competitive advantage.
- The sensor technology must record the mixing process in real time. Data-based optimisation increases process reliability and efficiency.
- Sustainability is becoming a prerequisite for investment. The focus here is on resource use and energy consumption. Good cleanability and a long service life reduce environmental impact and costs.
- A higher initial investment is justified
- if the total cost of ownership is reduced
- if new market segments are opened up.
The decisive factor is not the purchase price, but the value contribution of the mixing plant to the future viability of the company.
amixon® HM 2000 twin-shaft mixer in a nutrient production plant.
Three-dimensional flow in the double-shaft mixer
With this sophisticated product range, amixon GmbH underlines its process and quality leadership in vertical precision mixers / blenders
Hollow sphere mixers have interesting properties
SpherHelics® size SH 400.
amixon® already offers the most comprehensive range of vertical precision mixers, underscoring its 40-year market presence. With over 40 patent applications worldwide, we are positioning ourselves as an innovation leader and quality benchmark for powder mixers with vertically mounted mixing tools.
We started developing our hollow-ball mixer as early as 2021/22. It was extensively tested and then presented to the public in time for the company's 40th anniversary in 2024.
amixon® aspires to always be at the cutting edge and to be able to provide a competent answer to every question. We can only achieve this if our experiments are based on sound practical experience. Our goal is to impress our customers with our expertise and innovative solutions at all times.
SpherHelics® size SH 400.
amixon® already offers the most comprehensive range of vertical precision mixers, underscoring its 40-year market presence. With over 40 patent applications worldwide, we are positioning ourselves as an innovation leader and quality benchmark for powder mixers with vertically mounted mixing tools.
We started developing our hollow-ball mixer as early as 2021/22. It was extensively tested and then presented to the public in time for the company's 40th anniversary in 2024.
amixon® aspires to always be at the cutting edge and to be able to provide a competent answer to every question. We can only achieve this if our experiments are based on sound practical experience. Our goal is to impress our customers with our expertise and innovative solutions at all times.
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