Understanding How a Liquid Mixer Works
The liquid mixer is a versatile piece of equipment used for blending, dispersing, and suspending powders in immiscible liquids. However, understanding how it works is not straightforward. The fluid motion depends on a number of factors including the viscosity, density characteristic and size characteristics of the materials.
Center mounting the mixer creates strong rotational flow (Figure 1). While it pulls powder into the liquid, the swirling doesn’t promote side to side or top to bottom mixing.
Choosing a Mixer
It’s important to have the right mixer for your industrial mixing or blending application. Choosing the wrong mixer can result in costly mistakes and unexpected mixing results. To ensure you have the correct mixer for your application, know what you’ll be using it to mix, and the type of material you’ll be working with.
Knowing the liquid’s viscosity will help you determine what type of mixer is needed. It’s also important to consider the torque requirement, which is determined by a combination of factors such as motor size and gearing.
There are a variety of different portable mixers to choose from, and each one is designed for specific applications. For example, high shear mixers are used to apply emulsification, disintegration, particle size reduction, blending of fluids with varying viscosities, and homogenization. They are ideal for a wide range of industries including food prep, automotive, pulp and paper, and chemicals. In addition to these industrial mixers, there are other types of mixers that can be used to mix a variety of ingredients, such as ribbon mixers and paddle mixers.
Design
The mixer design you choose depends on the type of liquid and application you are mixing. For example, paddle mixers are a great option for wet and slurry mixing. They can be configured to fit your process with a variety of rotor and stator combinations. SPX FLOW application engineers can optimize a paddle mixer for your specific process to provide efficient and consistent mixing.
Shear-based mixers use a system of shear to create a uniform mixture of liquids with different viscosities. This Labeling Machine can reduce the amount of energy required, which saves on utility costs. However, shear can also cause a fluid to appear less viscous, so it is important to find the right balance between shear and air entrainment.
A continuous liquid mixer can help you achieve the best possible product quality in a single pass. This allows you to mix, emulsify and homogenize all in one go, eliminating the need for multiple passes through your blending system. This method of blending can be ideal for food, pharmaceutical and chemical processing. It can be used to create a wide variety of products including emulsions, liquid dispersions and high-hear homogenizing.
Installation
Mixers are used to combine liquids to form a homogeneous mixture. They can be used for a number of industrial applications, from making drinks to producing biodiesel. They can also be used for emulsifying and homogenizing. You may have even seen a mixer in action when you purchased paint at a hardware store.
Mixer installation should be done with the proper precautions in place to ensure safety. It is important to keep the mixer away from any flammable or toxic substances and make labeling machine manufacturer sure it is not exposed to vibration. In addition, it is important to use the correct wiring for your mixer. This will protect it from damage and ensure it runs correctly.
A mixer with a self-pumping design reduces energy consumption by using the process vessel as a pump. This can save you up to 80% of the energy required for an external pump. Additionally, a water flush seal design means less maintenance and longer seal life. GEA can custom-design your mixing system to meet the specific needs of your business. From large capacity mixing systems in food processing to small scale mixing in cleanrooms to mine slurry applications, we have the solution for you.
Maintenance
Mixer operation depends on a delicate balance of all the process components. When one element is out of whack, the whole thing can fall apart. This is why it is so important to keep on top of routine inspection and maintenance schedules.
A good preventative maintenance checklist includes examining the mixer for signs of wear and tear or damage. It also focuses on the drive system, including lubrication.
This is especially important if the mixer will be used with volatile or corrosive materials. The air-purged seal and stuffing box should be checked regularly for leaks. Lip-seals should be inspected for leakage and the seal material replaced if it becomes incompatible with the material being mixed.
Other things that are important to include on a preventive maintenance checklist are checking the electrical cord and plug for damage, ensuring the mixer is properly grounded and calibrating any sensors or control systems used with the mixer. The best tank mixer maintenance tips also include regular cleaning and washing of the mixing attachments to remove any buildup that could affect the machine’s operation.
Safety
As with any industrial equipment, the safety of a mixer depends on a delicate balance between all components in the system. Process changes and variations upstream of the pin mixer may cause issues that can seem linked to the mixer but are actually a result of other factors in the system.
Spray nozzles can become blocked with product and require flushing to keep them clear, especially with hot liquids. Humidity levels can also impact mixing; a vented piping system that allows moisture to escape but prevents condensation from returning can improve performance and reduce maintenance time and costs.
Mixing times can increase as the process becomes more efficient, and it’s important to maintain a well-balanced mixture without over- or under-mixing. Checking the CV of a sample of the end product can help to identify if mixing cycle times need to be adjusted.
Always switch off (and remove the plug from the socket with mobile units) the mixer and any other electrical machinery before working on them. Make sure that they are securely fixed to a holding base and that they can’t be accidentally pulled or shifted. Make sure that everyone is wearing the prescribed items of personal protective equipment for the specific application.