Choosing a Liquid Mixer
Mixing industrial liquids is often a matter of using light agitation to encourage normal advection. This is especially true for miscible liquids that mix well with each other.
For example, when mixing liquids with varying viscosities, adding the lowest-viscosity component first allows the mixer to operate at its maximum efficiency. It also reduces energy consumption, saving you money on utility bills.
Types
Mixing of fluids is at the heart of many industrial applications and processes. Mixers come in a wide range of sizes and designs, but they are all designed to achieve the same goal. Mixer selection starts with a study of the fluid to be mixed, including its viscosity. Then, mixers can be classified into categories based on their ability to handle the commodity.
Liquid-liquid mixing is necessary in industries as varied as making drinks and detergents, producing biodiesel and preparing fertilizers. You even see this type of mixing in action when you make a smoothie or pour milk into your kids’ cereal. But large industries need heavy-duty mixer skids capable of blending emulsions and slurries with solids, other liquids or gases.
In some cases, the slurry’s viscosity is so high that normal mixing equipment fails to work. For these situations, there are special mixers designed for high-viscosity slurries. These mixers use a unique technology called resonant acoustic mixing. It uses sound energy to induce Faraday disturbances that create “fingers” of the thinner liquid entering the thicker one, effectively lowering the overall viscosity.
Another type of application for a liquid mixer involves dissolving solids into liquids. This process requires a mixer that is capable of producing an acceptable shear and vortex without creating air entrainment. Some solids agglomerate during storage and transportation, which is difficult to address with traditional mixers. Fortunately, there are mixers designed for this purpose that can break up these agglomerates, which are sometimes called lumps.
Applications
Mixers are used for a variety of liquid mixer mixing applications. Some are designed for continuous liquid mixing, where the product is constantly flowing through the system and producing a homogeneous mixture. This type of blending reduces downtime and the amount of time needed to clean out the system.
Other mixers are used for emulsifying or dispersing solids into a liquid. These types of processes involve incompatible substances that require additional force to yield a proper mix and blend. For example, combining oil and water produces a solution that is not miscible and requires an emulsifier to break down the fat molecules so they will flow with the water molecules.
These types of mixers are also utilized for dispersing gas bubbles into a liquid. These gases can agglomerate into lumps in the liquid, which can result in poor product quality. Using high shear deagglomeration mixers like the Silverson Flashblend can break up these agglomerates and create a smooth, consistent mix in the liquid.
Some mixers are equipped with sensors that monitor factors like temperature, pressure and flow rate. This data can be used to control the mixing process and create a better end product. This can also help reduce energy consumption in the production of a product. The use of smart technology is becoming increasingly prevalent in industrial equipment, including tank mixers.
Design
For some applications, mixing just one batch of liquid at a time is the best way to get the job done. This is often the case for industries that produce a wide range of different products, such as paint and fragrances. Batch liquid mixers are often used in conjunction with a continuous mixing system to provide the best of both worlds.
In most industrial applications, the liquids being mixed need to be miscible or at least soluble in each other. This can often be achieved with the pumping action of a mixer, but when shear is required, it requires a special design that balances flow and shear intensity.
Mixing varying viscosities of liquids also requires a careful balance of power and Packaging Machinery Supplier shear, with lower viscosity fluids requiring less shear to achieve the same level of homogeneity as higher viscosity fluids. Increasing shear too much can increase air entrainment and waste energy, while reducing shear too little results in incomplete mixing.
Finally, many processes require dispersing soluble solids into the liquid stream. This can be a tricky processing challenge, but Mixquip’s Series 620 powder-into-liquid mixer is designed to drive the solid into the liquid stream, rather than pulling it in like traditional ribbon blenders. This allows the mixer to easily disperse and hydrate powders, flakes, or additives into liquids without floating or agglomeration, even with high viscosity products and varying temperatures.
Maintenance
A liquid mixer requires regular maintenance to ensure it works properly. Always make sure the machine is turned off (and unplugged for mobile units) before attempting to adjust, clean or service it. Always wear safety glasses and gloves to avoid getting splattered or scratched by the moving parts. Also, be careful to keep any flammable materials away from the equipment, as well as loose clothing or accessories that could catch on moving parts.
Wipe Down The Mixer Regularly: Be sure to wipe down the mixer with a damp cloth after every use. This minimizes buildup and reduces the risk of corrosion. Additionally, it’s important to wipe down the internal components regularly as well. Doing so helps to prevent debris from building up and blocking vital ports, which can lead to poor mixing or even a breakdown.
Check the Air-Purged Seal and Lip Seals Regularly: These mechanical seals should be inspected regularly for signs of wear or damage, particularly when working with volatile or corrosive ingredients. The stuffing boxes should be inspected as well to ensure they’re tight and in good condition.
Lubricate Moving Parts: Mixer components like the sliding bowl height adjuster should be oiled regularly. This will help to minimize wear and tear, as well as improve efficiency. Likewise, the grease in the bearings should be checked and replaced when necessary.
