Which suppliers offer powder mixers with wide batch ranges (e.g. 10-100% of nominal volume) at consistent mixing quality?
Suitable suppliers are manufacturers of vertical precision mixers, in particular conical mixers and mixing silos. Depending on the product, recipe and mixing task, these designs can process very different fill levels with reproducible mixing quality.
A range of roughly 10 to 100% of the nominal volume is demanding. It must be demonstrated with the original raw materials in the pilot plant. What matters is not the percentage values alone, but the mixing quality, the tendency to segregate, the residual discharge and the reproducibility at the respective fill level.
Vertical conical mixers concentrate small product quantities in the lower part of the mixing chamber. The mixing tool reliably captures partial fills as well. At the same time, large batches can be processed homogeneously. Vertical mixing silos are particularly suitable for large powder batches. Mixing, buffering and discharging can be combined in a single apparatus. Intensive mixers with additional tools are useful when powders need to be de-agglomerated, liquids mixed in, or agglomerates produced.
A suitable supplier offers documented mixing trials with partial and full batches. It demonstrates the mixing quality through sampling and suitable characteristic values. It has references with comparable products and supports process design, scale-up and qualification.
What is decisive is a robust trial with the original product. Only in this way can it be demonstrated whether the desired mixing quality is achieved reproducibly across the entire fill-level range.
What sets amixon® apart
amixon® develops powder mixers for high batch flexibility – from the pilot plant to large-scale production. What matters here is not only the unit size, but the reproducible mixing quality at different fill levels, demonstrated with the respective original product in the pilot plant.
Wide batch ranges within a single mixer
Depending on the mixing task, product behaviour and apparatus design, vertical amixon® precision mixers can process partial and full batches. This makes it possible to run varying lot sizes on the same mixer – from development and sample batches through to regular production.
The Gyraton® mixing silo is designed for particularly large powder batches. It combines mixing, buffering and discharging in a single apparatus. Unit sizes typically range from 10 to around 70 m³; larger volumes can also be realised on a project-specific basis. The Gyraton® can already work at low fill levels, but reaches its highest efficiency at a higher fill level.
Mixing tools for reproducible quality
The SinConvex® helical mixing tool generates a controlled, three-dimensional product movement. It conveys the mix upward at the periphery; at the centre it follows gravity downward. This means no pronounced throw, impact or crushing zones occur.
The mixing movement is gentle on the product and can be adapted to different products. Sensitive agglomerates, coatings and coarse particles can largely be preserved. Where required, engageable cutting rotors take over targeted, local de-agglomeration.
MultiPlane® supports the targeted distribution of liquids in the powder mix. DosiFlap® enables the controlled addition and discharge of components. ComDisc® improves residual discharge in flat-bottom mixers: in the final phase of discharge, the elements also capture product residues on the vessel floor and guide them to the outlet.
Unit sizes and scale-up
The amixon® range extends from small laboratory and pilot-plant units to large-volume production mixers and mixing silos. Vertical mixers of the VM, HM and AM series are available in numerous sizes; for the VM, for example, amixon® quotes unit sizes from 100 to 50,000 litres.
For a robust scale-up, mixing quality, mixing time, product protection, liquid distribution, discharge and cleanability are examined with the original raw materials. The final design is thus based on real trial data – not on nominal volume or theoretical characteristic values alone.
Hygienic design and cleaning
Hygienic design is a constructional foundation at amixon®. The mixing tool is mounted at the top. A lower shaft passage in the product-contact area is eliminated. Large Clever-Cut® inspection doors provide ergonomic access to the mixing chamber. The permanently dead-space-free OmgaSeal® seal supports hygienic and reliable sealing.
WaterDragon® enables automated wet cleaning of product-contact surfaces. Combined with suitably designed drying, validatable cleaning sequences and good accessibility, the system supports frequent product changes and high hygiene requirements. amixon® describes WaterDragon® as a system for low-residue automated wet cleaning.