Industrial mixers come in many forms, but their primary function is mixing ingredients. Some are powered by a motor, while a belt drives others. A countertop mixer has less horsepower than a floor mixer. Industrial floor mixers can use up to 2 HP and power through the thick dough. Industrial floor mixers are not recommended for continuous heavy-duty work.

Convective Mixing

Convective mixing in industrial mixers is an active process that uses mechanical agitation to mix materials. An impeller or turbulent gas flow conveys parts of the bulk material. This process is not ideal for mixing powders that are too cohesive. However, it is recommended to mix powders that are not corrosive.

Many industrial mixer designs use different mixing mechanisms. These mixers can combine several mixing mechanisms, such as agitator, diffusion, or shear. Diffusive mixing does not require an agitator but involves the random movement of solids. This process is slow and sensitive to segregation.

On the other hand, nonlinear mixing uses a mixer that multiplies the signal amplitude to create four output signals: the sum and difference. This is achieved by selecting similar resistor types for the emitter and collector of a nonlinear mixer. 

The process is also referred to as intensive mixing. It involves the transportation of the material inside the mixer. As a result, the material inside the mixer becomes less orderly. As the material travels, the components that need to be mixed are distributed over the other materials. With time, this process becomes more random. It is typically applied to free-flowing materials but is not always appropriate for mixing coarse materials. Because of differences in particle size, this process can result in segregation.

The mixing process is an essential step in the manufacturing process. It has a significant impact on the end product. The fluid industry is constantly changing, and new technology is developing. Companies can reduce operational costs by using new mixing techniques while guaranteeing a shorter production time. They can also combine mixing with dispensing equipment.

Intensive Mixing

There are several different types of mixers for different processes in the manufacturing industry. The basic types include batch and continuous mixers. Batch mixers are typically used for small batches and when quality control is essential. Continuous mixers are used for more effective production rates and can combine several different process streams. These mixers are more effective at eliminating batch-to-batch variations and can be more efficient. Kneaders are high-intensity mixers for materials that are cohesive or sticky.

Continuous mixers, on the other hand, operate continuously without interruption. This type of mixer continuously produces concrete without needing a batching system. Instead, raw materials are fed into the mixer, and workers collect the discharged concrete. This type of mixer is also the most popular in the construction industry.

Another type of mixing is liquid-solid mixing. This method is commonly used for dispersing or suspending solid materials. The solids are particles of granulated or powdery materials. The process is similar to blending immiscible liquids.

Ribbon mixers are used for bulk solids and powders. They require more maintenance than paddle mixers. Pharmaceutical industries typically use ribbon mixers.

Fluidization Mixers

Mixers are used to mix liquids or solids in various processes. The design of mixers varies according to their use. For example, some mixers can be used for mixing dry materials, while others are used for mixing wet materials. High-shear mills, agitators, and fluidization mixers are the three most common industrial mixers.

A static mixer has a corrugated plate with a series of parallel paths recombining as the fluid flows through it. The plate consists of alternate layers of grooves perpendicular to each other. These mixers shear large droplets into smaller ones because they must travel through small openings.

Fluidized mixers are generally gentler on products because they create less shear. As a result, they require less mixing time to achieve the desired homogeneity. They tend to use less power than traditional low-speed mixers. In addition, fluidization mixers may use blades, spirals, and ribbons.

Fluidization mixers can be used in a variety of processes. For example, they can be used for high-speed blending. These mixers can achieve mix ratios of 1:20,000 or even more. As a result, they can be used in several industries, including chemical and food preparation. They use an orbital pattern on a circular or elliptical axis.

Among them, rotor-stator mixers are one-shaft mixers with a stationary housing and an impeller. They are used for mixing multiphase and liquid-gas systems. Depending on the purpose of the mixer, they can handle very thick or highly cohesive materials. They also produce a high shear rate. As a result, they are particularly effective for chopping coarse particles. A stator acts as a guide while the rotor confines the particles.