Mixing ingredients may seem like a simple process, but it is more than just combining ingredients. When you have ingredients that you do not want to mix together or you have a large amount of ingredients to mix, the type of industrial mixer comes into play. Industrial mixers have revolutionized many different industries as they contribute an important role in large-scale production of all types. Any device that is designed to mix raw materials or ingredients together can be considered a mixer. However, for the purpose of this blog, we are referring to an industrial mixer as a piece of equipment that mixes materials together as a part of a larger production process. This could include mixers used in food processing, chemical processing, pharmaceutical products, plastic processing and more.
Industrial Mixer Categories
Categorizing industrial mixers and agitators can be more difficult than expected. Even if mixers look similar, they can be used for vastly different applications. On the other hand, mixers can have similar uses but look completely different. With this in mind, we are categorizing mixers mostly based on their design in this blog. Other ways mixers can be categorized include:
- Industry: Mixers are used in various industries and they may be categorized this way.
- Matter: Some mixers are designed to mix gases, liquids, solids or any combination thereof.
- Force: Difference mixers use different types of force to blend materials together, such as gravity, rotation, pressure, shear and more.
- Function: Some mixers are meant to combine two materials that do not normally combine, while others create a completely homogeneous mixture.
Keep in mind that this is not an exhaustive list. In this blog, we will look at some of the most common types of industrial mixers, how they work and the advantages and challenges of each type.
#1 Horizontal Ribbon Mixer
A ribbon mixer, also known as a ribbon blender, uses two intertwined metal strips, similar in shape to a double helix, to move material from one side of the mixer to another. As the material passes in each direction, it mixes together. Horizontal ribbon mixers are used in a variety of industries, including food processing and chemical, and are often used in mixing powders and other solids. They are easy to clean and offer precise mixing capabilities. A challenge of the horizontal ribbon mixer is there can be issues with mixing uniformity.
#2 Paddle Mixer
A paddle mixer is similar to a horizontal ribbon mixer, except that the mixing action and gentler. As the paddles move the material through the mixer, it creates a cohesive mix. This type of industrial or commercial mixer is often used with thick of viscous semi-solids, such as salad dressings or salsa. A paddle mixer provides efficient, gentle blending, but it can also experience weakness in mixing suspensions.
#3 Tumbler Mixer
A tumbler mixer turns and uses gravitation force mix materials, which are usually liquids. There are several different types of tumbler mixers, including a v-shaped mixer, double-cone mixer and slant mixer. A tumbler does not require an agitator or impeller, which is used for sensitive liquids. Tumber mixers are versatile with the various types of ingredients they can mix. They are large pieces of equipment that require floor space.
#4 Emulsifier
The emulsifier mixes together substances that are immiscible, which means they are unable to naturally blend. Oils are a popular substance used in emulsifiers. An emulsifier uses high amounts of pressure to force liquids through small filters and tubes, which breaks down their structure and allows the liquids to mix effectively. The emulsification process can be influenced by factors such as the amount of mechanical energy used and physiochemical limitations.
#5 Drum Mixers
Drum mixers are highly versatile pieces of equipment. They are available in many different types and configurations, but drum mixers tend to share the same design. They are made from large tanks called drums and they can be used for storage as well as mixing. Drum mixers are usually used for materials with low or medium viscosity, such as slurries or cement. They can hold a large volume of material, but they also require a learning curve for operation.
#6 Static Mixers
Static mixers are usually used to mix gases, liquids or liquids and gases together. It may use a series of blockages that force the materials together and break down the substances so they mix, similar to an emulsifier. Static mixers can run into challenges with capacity and mixing effectiveness.
#7 Planetary Mixer
A planetary mixer uses agitators moving in a circular pattern to mix materials in a bowl or tank. The mixing vessel may be stationary or rotating to aid the mixing action. It can use paddles, whisks or beaters to blend the material. Planetary mixers are typically used as commercial food mixers to blend dough and similar foods. They usually need a high volume of power to operate effectively, which can have limitations.
Which Industrial Mixer is Right for You?
There are several kinds of industrial and commercial mixers. Contact APEC today with any of your mixer questions. We can provide answers for which mixer is best for your system.
