Are there best practices for integrating single-shaft mixers with drum or IBC docking into existing production areas?
Yes. The integration of single-shaft mixers with drum or IBC mounting should be carried out in a structured manner. Structural, safety-related, process engineering, ergonomic and hygiene aspects are to be taken into account consistently throughout.
Room and layout analysis
The ceiling height must safely accommodate the overall height as well as all lifting and swivelling movements. In IBC applications, typically 3,500–5,000 mm are required. Swivelling and travel areas are also to be taken into account in the 3D planning.
The floor load capacity must absorb static and dynamic loads. These include the mixer, the lifting device and filled containers (up to approximately 1,500 kg). Point loads and vibrations are to be taken into account.
Traffic routes are to be dimensioned adequately. At least 1,200 mm of working space is typical. Material flow analyses avoid bottlenecks and collisions.
Utility and supply connections
Energy and utility connections should be located close to the installation site. Power (400 V, 3-phase), compressed air (6–8 bar) and, optionally, inert gas and cleaning media are customary.
In ATEX areas, the equipment category is to be matched to the zone classification. Earthing and dissipation of electrostatic charges are standard.
Ergonomics and operation
Manual lifting operations are to be avoided. Gripping systems or integrated lifting functions are suitable.
Operating panels are positioned ergonomically. They lie outside the danger zone but offer a direct view of the process.
Sight lines to the HMI, the emergency stop and the process areas must remain clear.
Safety concept
Moving areas are safeguarded, e.g. by protective fences, light curtains or laser scanners. Crushing and shearing points are to be minimised by design.
The mixer is integrated into the existing emergency stop concept. Restart procedures are clearly defined.
Emissions at interfaces are reduced by closed systems. Docking systems with seals or encapsulated lids are typical. For critical substances, extraction systems or double flap valve systems are used.
Continuous equipotential bonding prevents electrostatic risks.
Process and automation integration
The mixer is integrated logically into the material flow, e.g. between goods receipt and further processing.
Control takes place via common industrial interfaces. Relevant data points and states are defined.
Connection to higher-level production and control systems enables formulation management, batch records and traceability.
Hygiene and cleaning
A hygienically compliant design is decisive. This includes stainless steel surfaces, low roughness and minimal dead spaces.
CIP or WIP systems are integrated according to requirements. Utility connections and drainage are to be planned in.
Tool-free dismantling facilitates cleaning and maintenance. Clear cleaning procedures shorten set-up times.
Modularity and future-proofing
Mobile or modular designs increase flexibility.
Reserve capacities for utilities, control and sensors facilitate later extensions.
Digital planning with 3D models or digital twins reduces planning risks and improves layout, ergonomics and material flow.
Drum- and IBC-based mixing concepts: EM and COM
1. Single-shaft mixer EM – the standard drum as process vessel
The single-shaft mixer EM uses the standard drum directly as the mixing and process vessel.
It is designed for small production runs, development and just-in-time batches. amixon® offers sizes from 5 to 200 l. For filling and emptying, the drum rotates by more than 180°. During mixing it can be inclined by up to 25°.
The cross flow in the inclined mixing chamber makes high mixing qualities possible for dry, moist and suspended solids. A hand pallet truck, scales and standard drums are sufficient as infrastructure. The amixon® EM can be integrated into existing production rooms without additional conveying technology.
The mixing intensity is adjustable, optionally up to the use of cutting rotors (HighShearBlades). Microfine liquid addition is possible. The fill level lies between 10 and 100 %.
The amixon® EM is suitable for ATEX Zone 20. PLC programmes with ERP connection and barcode-supported real-time documentation are available.
2. Container mixer COM – the IBC as mixing chamber
With the COM design, amixon® offers a container mixing system in which the container itself serves as a closed mixing chamber. Typical batch sizes lie between 100 and 4,000 l.
The SinConcave®/SinConvex®-MultiPlane® helical mixing tool enters from above into the gas-tight sealed Mixtainer® or standard IBC. It mixes with high precision (component ratios up to 1:100,000) and then travels out again in reverse.
Since the container remains closed, no inspection doors are required. Weighing in, mixing and filling are separated spatially. A dockable Washtainer® enables automatic wet cleaning of the mixing tool.
3. IBC-based concepts where the available height is low
For production rooms with limited height, amixon® offers further IBC-based mixing solutions. These work dust-free and can be integrated even where space is restricted.
Shared strengths
All amixon® systems produce a technically ideal random mixture even at a low fill level.
The design has few dead spaces and is cleaning-friendly. Validatable cleaning procedures in accordance with EHEDG, FDA and 3-A are optionally possible. Rapid product changes make amixon® mixing systems particularly suitable for contract mixers and for operations with frequently changing formulations.
Selection in the pilot plant
amixon® determines the optimum combination of container logistics and mixing system in the pilot plant. Trials are carried out with the original product and are documented. The result is a robust basis for decision-making on design and investment.
Hygienic design as the foundation
Hygienic design is the constructional basis of all amixon® systems. Mixing tools are welded and ground free of joints. They are mounted exclusively at the top; a lower shaft passage is dispensed with.
Dead-space-free outlets and integrated washing systems enable validatable dry and wet cleaning in accordance with EHEDG, FDA and 3-A.
Verification in the pilot plant
Before the investment, verification takes place in the amixon® pilot plant. At the Paderborn site, 35 test units are available, complemented by international pilot plant locations.
The trials are carried out with the original product under real conditions. Mixing quality, product protection, energy input, cleanability and reproducibility are assessed. All results are documented and create certainty for the investment decision.