Which continuous mixers are suitable for detergent powders with high throughput and consistent homogeneity?
Suitable mixing systems for detergent powder
For detergent powders that are to be mixed at high throughput and with good homogeneity, continuous mixers with dynamically moved mixing tools are particularly suitable. Precise gravimetric dosing, a defined residence time distribution and a mixing geometry that compensates for dosing fluctuations are decisive. Continuous mixers with vertically mounted mixing tools can meet these requirements.
For complex formulations with liquid components, continuous ploughshare mixers are also well suited. They create a mechanically fluidised bed in which liquids and sticky constituents can be worked in readily. Where the demands on throughput and homogeneity are high, batchwise twin-shaft paddle mixers can be an option, since they work with short residence times and high mixing intensity.
Rotary drum mixers, by contrast, tend to make sense where the formulation is simpler and the bulk densities are similar. Ring-layer mixers are suitable above all for the targeted spraying on of liquid components, for agglomerating and for compacting, for instance with fragrances or surfactants. For detergent powders with a demanding formulation, vertical mixers, ploughshare mixers and twin-shaft paddle mixers are therefore usually the first choice.
The AMK for detergent powder at high throughput
The amixon® continuous mixer AMK is suitable for the production of detergent powder at high throughput and with constant homogeneity. It mixes gently and allows throughput and residence time to be set precisely.
The AMK series ranges from the AMK 50 with approximately 1 to 3 m³/h up to the AMK 3000 with approximately 45 to 135 m³/h. The residence time is defined and independent of the rotational frequency of the mixing tools. Mixing intensity and throughput can thereby be adapted to the formulation separately. For simple tasks, low fill levels are sufficient. With complex formulations containing solid and liquid additives, the fill level can be increased.
The SinConcave®/SinConvex® tool produces the three-dimensional forced restratification that is also known from the amixon® batch mixers. This creates a technically ideal random mixture with reproducible mixing quality. When the plant is started and emptied, no classic off-spec quantities arise at the ends of campaigns.
The AMK is likewise suitable for demanding formulations. Liquid components such as surfactants or fragrances can be mixed in microfinely without unnecessarily soiling the mixer. Moistening and temperature control are available on request. The mixing intensity ranges from gentle to de-agglomerating. The mixing chamber can be designed for ATEX Zone 20 and meets hygiene requirements. Wet or dry cleaning is possible.
Whether a continuous or a batchwise process is more economical depends on the campaign length, the formulation changes and traceability. The batch process is often at an advantage where formulations change frequently. The AMK plays to its strengths in long campaigns with high throughput. amixon® verifies control behaviour, homogeneity and changeover times in the pilot plant with the original product.