Industrial mixers come in several different forms. There are static or motionless mixers, Geared mixers, Fluidization mixers, and Turbin mixers. Each industrial electric mixer has specific design characteristics that must be considered. The following information outlines the differences between these different types of mixers.
Static or motionless mixers
A static or motionless industrial mixer is a precision-engineered device that combines liquids and gases to produce a desired final product. These mixers often mix immiscible liquids and gases, disperse gas into a liquid, and blend gases. They are typically built with stainless steel, polypropylene, PVDF, and polyacetal components.
There are several different kinds of motionless industrial mixers. Some are designed to direct flow, enhance turbulence, or stack segments. These mixers vary in size and shape depending on the process being mixed.
Geared industrial mixers
Geared industrial mixers use a flat-bladed impeller to mix liquids. They must be sized based on the specific gravity of the liquid and its viscosity. Calculating the torque required is easy by calculating the impeller’s surface area against the liquid’s volume. In some cases, dual impellers are used. This can affect the motor size and rotational speed of the mixer.
It is essential to regularly clean and inspects industrial mixers and the components within. In addition to visual inspection, you should also inspect the mixer according to the manufacturer’s standard operating procedures. Check the impellers for debris and the coupled mixer shafts for corrosion and excessive wear. Also, check the anti-rotation keys and the interior mixing tank surfaces. Check all mechanical system components, including motor starters and motors. Performing routine inspections and maintenance on industrial mixers will save you money in the long run.
Fluidization mixers
Industrial mixers are a common component of a fluidization process. They are used to mix materials of varying density and viscosity. The design of a mixer is crucial for fluidization, as it must prevent the creation of dead zones within the mixing chamber. This can affect the quality of the end product. Some standard designs of mixing chamber valves include bomb doors, square flaps, and round hygienic valves.
Traditionally, industrial mixers have had a batch operation. This means they fill up with the product and media and mix until the product is ready to be discharged. Then, the mixed fluid is drained and emptied for downstream processing. After that, the machine is cleaned and ready for the next batch of material. On the other hand, continuous-feed mixers add media as the mixed fluid is drained. This makes continuous-feed mixers ideal for production processes, as they can operate continuously without shutting down.
Turbin mixers
Industrial mixers such as Turbin can be used in various industrial applications. The high-speed design of these units can quickly and efficiently blend large batches of products. They can also condition hazardous and non-hazardous waste and industrial by-products. They come in various models, including turbin mixers, paddle mixers, planetary mixers, and refractory mixers.
Turbin mixers are known for their high-speed turbine design. The high-speed turbine creates suction to circulate liquid within the vessel. The mixing arms are suspended from spring-action mounts and can ride over obstacles without damage. Their direct drive motor is suitable for starting and stopping the mixers while they are full of material.
Belt-driven mixers
There are two basic types of industrial mixers: belt-driven and gear-driven. Belt-driven mixers use simple straps to turn an agitator inside the mixing bowl. These machines tend to be easier to maintain, but you must be aware that they are prone to belt “slip,” which decreases the velocity ratio of the mixing system.
To choose the right belt, you should know the maximum horsepower of the machine. You can estimate the required horsepower by dividing the total horsepower by the corrected horsepower rating of a single belt. This value is determined by applying a service factor to the single-belt horsepower rating and is usually set within acceptable tolerances. Ensure the belts are identical and the pitch length is within the permissible tolerance.
High shear mixers
High-shear industrial mixers are essential for a variety of manufacturing processes. They can break down and blend ingredients to produce a homogeneous final product. This is especially useful for pet foods requiring a high amount of force during mixing. Another important application is in manufacturing paints, inks, and coatings. These products need to meet specific regulatory specifications. They are also designed to add value to the products.
High-shear industrial mixers feature high-speed chopping blades that turn at ultra-high speeds. A reamer powered by an electric motor is then passed through the impeller. This creates a high amount of revolving shear and power unit mass, allowing the materials to be pulverized into finer particles. High-shear mixers are distinguished by the geometric positioning of their primary impellers.
