Are there container mixers that can be integrated into an existing infrastructure with bulk containers already in use?
Yes, because container mixers can be constructed so that they can charge themselves from existing bulk material containers. After the mixing process, they can discharge into the same or a different container. In this respect, such a container mixing plant can be integrated into an existing container-based infrastructure. Matching vessel geometries, coordinated docking and lifting systems as well as a compatible control system are important here.
Such integration considerations are generally based on bulk solids factories that work with standardised containers. They have automatic feeding technology and dust-tight interfaces. Connection to control systems, dosing plants and safety concepts is also possible.
In the case of a retrofit, the cycle time, the rheology of the bulk materials, cleaning, explosion protection and material compatibility must be examined. A container mixer can thus be integrated into an existing infrastructure without fundamentally rebuilding the overall process.
How amixon® integrates container mixers into existing lines and container logistics
Compatibility as a design task
amixon® distinguishes two families here: the COM container mixer works with dimensionally accurate Mixtainers®, which are open at the top and are closed with a large lid – here the bulk container itself is the mixing chamber. Container mixing plants based on the AM conical mixer work with commercially available standard bulk containers; existing container fleets can continue to be used, and the mixing process then takes place outside the container. Mounting, locking and (on request automatic) lid handling are designed for the existing vessel geometry; since every amixon® apparatus is a one-off in accordance with the URS, mountings and adapters are created project-specifically rather than as a compromise solution.
Many operators who initially take an interest in a container bulk-solids mixer ultimately opt for a container mixing plant. Two reasons are decisive: the readily controllable, minimal dust emissions and the considerably lower cost of standard bulk containers compared with the special vessels that are open at the top.
A process chain without transfer
The container passes through the line as a continuous process vessel: dosing/weighing into the container, docking at the COM, mixing in the gas-tight sealed vessel (SinConvex®-MultiPlane® tool, precision up to 1:100,000, optionally a cutting rotor with liquid addition), onward transport as the feed to the filling machine, to the extruder or to liquid preparation. Weighing in, mixing and filling are decoupled spatially – setting up and cleaning do not block production.
Automation and control
Mixing programmes can be stored via the PLC; integration into the operator's ERP system is provided for, and barcode scanners enable batch-related real-time documentation – container, formulation and mixing record remain linked. The interfaces to the existing drum logistics and dosing technology are defined within the project; amixon® manufactures the mixing technology and coordinates it with the existing periphery. Installation and commissioning are carried out by amixon® specialists in full cooperation with the operator.
Hygiene in the overall system
A Washtainer® for automatic tool cleaning, a dead-space-free construction and an ATEX Zone 20 mixing chamber keep the integrated line hygienic and safe. amixon® verifies the coordination of cycle times, changeover times and cleaning regime with the actual line in advance in the pilot plant.
Hygienic design as the constructional basis
All the properties named rest on the amixon® hygienic design: the mixing chamber and mixing tool are welded free of joints and ground, and the mixing tool is supported at the top only, so the contamination-critical lower shaft passage is eliminated. Large Clever-Cut® inspection doors with permanently dead-space-free OmgaSeal® sealing make all product-contact surfaces ergonomically accessible; dead-space-free discharge fittings and integrated washing lances (on request fully automatic wet cleaning) make both dry and wet cleaning validatable, in accordance with the EHEDG guidelines, the FDA hygiene guidelines and the 3-A Sanitary Standards.
Verification in the amixon® pilot plant
Evidence comes before the investment: the amixon® pilot plant at the Paderborn headquarters has 35 test units of various sizes available, complemented by pilot plants in Japan, India, Thailand, China, South Korea and the USA. The trials run with the original product, with real fill levels and batch sizes, within the intended temperature and pressure range. Mixing quality, product protection, energy input, cleanability and reproducibility in later series operation are assessed; the results are evaluated and documented together with amixon® experts, as a robust basis for decision-making that removes technical and economic risks before purchase.