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Q & A on Industrial Mixers

We asked our users for their input on Industrial Mixers. Here are the results of 121 users familiar with Industrial Mixers.

Who Took Our Poll? | Design Trends | Applications and Use | Features | Buying Advice |

Who Took Our Poll?Top

Design TrendsTop

Q:
What new technologies are influencing industrial mixer design?
15 answers
Answers:
Mixer process control, speed control, electric drives, network capabilities, closed loop communication and feedback, bearing design. Heavy duty back-geared drives. Oscilating drives, variable speed drives, expanding blade agitators. In-drum agitators. IBC tote mixing, bung mount agitators. Agitator Speed Controllers.
~Nick S, Engineer, Minneapolis, MN
Safety, size and homogeneity with time factor, prevention of heat transfer through the mixing shaft to the product, also prevention of product leakage from the connection side places.
~Jabr yousef J, Project Manager, Amman, Jordan
Dispersion of additives in small quantities, Wear resistance, Maintenance, Safety
~BOUCHEMOUSSE JL, Technical Support, CHICAGO HEIGHTS, MI
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Q:
From your perspective, which companies are creating the most innovative industrial mixers?
14 answers
Answers:
I only know German and Chinese company's. In Germany e.g. Neumann, RVT. In China, Great Wall.
~Hubert B, Senior Quality Manager, Burghausen, Germany
Heidon, Tonson, Pulsair, Graco Inc., Dynamix, Charles Ross and Son
~Nick S, Engineer, Minneapolis, MN
Chemical plant and engineering, Silverson
~John Wilson, Process Engineer, Melbourne, Australia
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Applications and UseTop

Q:
What are some of the applications you have used industrial mixers for?
32 answers
Answers:
Powder, Plastic, Glass, Food, Feed, Medicated Premixes, Kitty Litter, Carbon Black, Rubber, Heavy Metals, Lawn & Garden Fertilizers, Dry Liquid Concentrates, Basically any dry particulate with or without liquid where uniformity in at the least cost of operation are required.
~Thomas C., Project Manager, Eau Claire,, U.S.
Agitating paint for industrial spray finishing, protective coatings, adhesives, sealants, sanitary, and process applications. Creating emulsions and dispersions. Shear sensitive material mixing. Waterborne mixing and aeration and foam prevention.
~Nick S, Engineer, Minneapolis, MN
In the company which I am working for (Wacker Chemicals Co.Ltd) we mix different fluids with different viscosity in sizes from Laboratory (smaller than 1 gal.) to very big ones ( more than 50.000 gal.).
~Hubert B, Senior Quality Manager, Burghausen, Germany
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Q:
Please share with us any “non-standard” applications that industrial mixers have been used for.
8 answers
Answers:
Chlorine gas dispersion in phenols and phenoxy liquids, homogeneous suspensions of metal particulates in solution to allow future processing.
~John Wilson, Process Engineer, Melbourne, Australia
Mix cocoa powder with sugar and lard, loading from the top and bottom discharge. Process has been done at high speed in a few seconds.
~Héctor E, Builder/Contractor, Guatemala, Guatemala
Food and sanitary mixing, Mixing of 2 component resin/catalyst materials.
~Nick S, Engineer, Minneapolis, MN
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Q:
Do you know of any disastrous mistakes that occurred due to the incorrect usage of industrial mixers?
14 answers
Answers:
Yes, gearbox failure due to mixer designed for mixing products whose viscosity is lower than actual value. Another case where mixing takes many times longer because a condition like foaming was not taken into account, restricting the mixing speed.
~Danial Irfachsyad, Research & Development, Jakarta, Indonesia
At a running test we found a wrong mixer shaft, he should mix the heavy fluid from down to up, but the company turned the drawing and he mixed it down..
~Hubert B, Senior Quality Manager, Burghausen, Germany
Specing the incorrect size of mixer for the product in question, which led to the ploughs being sheared from the drive shaft.
~Dave Hollingworth, Production Engineer, Newark, UK
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FeaturesTop

Q:
What would your design or feature "wish list" be for this product?
15 answers
Answers:
Temperature control, programmable, automatic sampling or online for viscosity check, easy cleaning or emptying of tank, visual monitoring.
~Sit CK, Process Engineer, Westborough, MA
Torque sensor Automatic speed determination based on liquid condition (temperature/conductivity homogeneity)
~Danial Irfachsyad, Research & Development, Jakarta, Indonesia
Speed control. Variable electric drive. Networking capabilities. Communication and control.
~Nick S, Engineer, Minneapolis, MN
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Buying AdviceTop

Q:
Do you have any advice for people relative to buying or using industrial mixers?
11 answers
Answers:
Focus on leading technology, and proven quality. Use a systems approach. Focus on big picture and complete system integration. Focus on correctly sizing mixer. Choose correct mixer based on size. Build in room to expand size and different applications. Create system flexibility.
~Nick S, Engineer, Minneapolis, MN
Check with the supplier about all minimum details about your process. It is not enough with the variables of the final product (viscosity, temperature, reactivity, etc), the flow pattern, speed and maybe another important conditions in order to obtain the desirable final result.
~Raul Faudoa, Engineer, Toluca, Mexico
Give as much information as possible on the products being mixed. This would avoid unnecessary pain due to wrongly selected mixer type. Whenever possible, do testing on the mixer that mimics closely to the real operating condition before purchasing.
~Danial Irfachsyad, Research & Development, Jakarta, Indonesia
Generally the specifics of each application are known by the purchaser and few suppliers generally can predict the mixing technology well unless testing is taking place in a plant or laboratory.
~John Wilson, Process Engineer, Melbourne, Australia
Ensure that they do trials first. Most companies have their own labs to do trials on as products act different under certain conditions.
~Dave Hollingworth, Production Engineer, Newark, UK
The product you get is only as good as your specification is!
~Hubert B, Senior Quality Manager, Burghausen, Germany
Check out what Continental Products has to offer.
~Thomas C., Project Manager, Eau Claire,, U.S.
Make sure mixer will re entrain solids if needed.
~Damon W, Engineer, Macon, GA
Impeller types versus mixing efficiency.
~Jay Ozkose, Process Engineer, Istanbul, Turkiye
Use a good supplier like Statiflo.
~Philip P, Research & Development, Macclesfield, UK
Choose a manufacturer properly.
~Polinda Chao, Marketing/Sales, Shanghai, Sri Lanka

Q:
Is there any advice you want to share with users to help them avoid common errors in selection or usage of industrial mixers?
12 answers
Answers:
Cheaper mixer does not necessarily give the cheapest overall cost over the operating lifetime. Additional hidden costs may come in the form of longer mixing time, rework due to incomplete mixing and higher energy cost. When hygienic/aseptic operating conditions are required, take special notice on sealing/cleanability features.
~Danial Irfachsyad, Research & Development, Jakarta, Indonesia
Work with distributors. Pick reliable companies. Don't under size your mixer. Don't choose wrong impeller configuration. Don't damage the material. Focus on reducing energy costs, and air consumption.
~Nick S, Engineer, Minneapolis, MN
Ensure the spec is correct, look at what you are mixing & decide if a continuous feed is needed or batch mixing required.
~Dave Hollingworth, Production Engineer, Newark, UK
Most common error is leaving all decisions to the supplier and not being involved.
~Raul Faudoa, Engineer, Toluca, Mexico
Refer to the above, generic designs for specialized applications rarely work.
~John Wilson, Process Engineer, Melbourne, Australia
Make sure you can pull the gearbox without removing the whole mixer.
~Damon W, Engineer, Macon, GA
Really define the process first and foremost
~Gabe T, Marketing/Sales, Kitchener, Canada
It depends on too many questions.
~Hubert B, Senior Quality Manager, Burghausen, Germany
Prove it or test it first.
~Thomas C., Project Manager, Eau Claire,, U.S.
Leave it to the experts
~Philip P, Research & Development, Macclesfield, UK
Look for a consultant
~Roberto B, Project Manager, Brisbane, Australia
Check the factory
~Polinda Chao, Marketing/Sales, Shanghai, Sri Lanka


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