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Classification of mixing
A. Mixing of solids
B. Mixing of liquids
C. Mixing of immiscible liquids
Mixing of solis
In the manufacture of tablets or granules normally a number of additives are added.
Therefore mixing of powder becomes essential part of the process.
Mixing is considered as a critical factor especially in case of potent drugs and low dose
drugs where high amounts of ad!uvants are added.
The diverse characteristics of particles such as si"e shape volume surface area density
porosity flow charge contribute to the solid mixing.
#epending on their flow properties solids are divided into two classes as cohesive and
non cohesive.
M!c"anism of mixing of solis
#$ Con%!cti%! mixing&Mac'o mixing:
Inversion of the powder bed using blades or paddles or screw element in which
large mass of material moves from one place to another.
($ )"!a' mixing:
In this type forces of attraction are bro$en down so that each particle moves on its
own between regions of different components and parallel to their surface.
*$ Diff+sion mixing&Mic'o mixing:
Involves the random motion of particle within the powder bed thereby particles
change their position relative to one another.
Classification of !,+i-m!nt fo' soli mixing
.as! on flo/ -'o-!'ti!s:
%. &ree flowing solids' e.g.' ( cone blend #ouble cone blender
). Cohesive solids' e.g.' *igma blender +lanetary mixer
Based on scal! of mixing'
%..atc" t0-!1small scal!2: e.g.' Mortar and pestle ( cone blender #ouble cone blender
,ibbon blender *igma blender +lanetary paddle &luidi"ed mixer
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). Contin+o+s t0-!1la'g! scal!2: e.g.' barrel type "ig"ag type
Do+3l! con! 3l!n!'
It consists of double cone on rotating shaft.
It is usually used for small amount of powders.
It is efficient for mixing powders of different densities.
Material is loaded and emptying is done through the same port.
The rate of rotation should be optimum depending upon the si"e shape of the tumbler
and nature of the material to be mixed.
The rate of rotation commonly ranges from -./%..rpm.
Do+3l! con! 3l!n!'
Mixing of 4l+is
M!c"anism:
.+l5 t'ans-o't: Movement of large portion o a material from one location to another
location in a give system. ,otating blades and paddles are used.
T+'3+l!nt mixing: 0ighly effective mixing is due to turbulent flow which results in
random fluctuation of the fluid velocity at any given point within the system. &luid
velocity at a given point changes in - directions 12 3 and 45.
6amina' mixing: Mixing of two dissimilar liquids through laminar flow i.e. applied
shear stretches the interface between them. *uitable for liquids which require moderate
mixing.
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Mol!c+la' iff+sion: Mixing at molecular level in which molecules diffuse due to
thermal motion.
Mixing A--a'at+s fo' fl+is
A Container and
A Mixing #evice or Impeller
Mixing D!%ic!
Based on shape and pitch the are classified into - types
+ropellers
Turbines
+addles
P'o-!ll!'s
It consists of number of blades generally - bladed design is most common for liquids.
Blades may be right or left handed depending upon the slant of their blades.
Two are more propellers are used for deep tan$.
*i"e of propeller is small and may increased up to ..6metres depending upon the si"e of
the tan$.
*mall si"e propellers can rotate up to 7...rpm and produce longitudinal movement.
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A%antag!s of -'o-!ll!'s:
8sed when high mixing capacity is required.
9ffective for liquids which have maximum viscosity of )..pascals.sec or slurry up to %.: solids
of fine mesh si"e.
9ffective gas/liquid dispersion is possible at laboratory scale.
Disa%antag!s of -'o-!ll!'s:
+ropellers are not normally effective with liquids of viscosity greater than 6pascal.second such
as glycerin castor oil etc.
T+'3in!s
A turbine consists of a circular disc to which a number of short blades are attached.
Blades may be straight or curved.
The diameter of the turbine ranges from -./6.: of the diameter of the vessel.
Turbines rotates at a lower speed than the propellers 16./)..rpm5.
&lat blade turbines produce radial and tangential flow but as the speed increases radial
flow dominates. +itched blade turbine produces axial flow.
A%antag!s of T+'3in!s:
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Turbines give greater shearing forces than propellers through the pumping rate is less.
Therefore suitable for emulsification.
9ffective for high viscous solutions with a wide range of viscosities up to ;.. +ascal.
*econd.
Pal!s
A paddle consists of a central hub with long flat blades attached to it vertically.
Two blades or four blades are common. sometimes the blades are pitched and may be
dished or hemispherical in shape and have a large surface area in relation to the tan$ in
which they are used.
+addles rotate at a low speed of %..rpm.
Us!s of -al!s:
+addles are used in the manufacture of antacid suspensions agar and pectin related
purgatives anti/diarrheal mixtures such as bismuth/$aolin.
A%antag!s of -al!s:
(ortex formation is not possible with paddle impellers because of low
speed mixing.
Disa%antag!s of -al!s:
Mixing of the suspension is poor therefore baffled tan$s are required.
7o't!x fo'mation
A strong circulatory flow pattern sometimes manifests into formation of a vortex near the
impeller shaft.
E,+i-m!nt fo' 6i,+i mixing
%. Air !et mixer
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). <et mixer
-. &low mixer or line mixer or pipe mixer
A%antag!s of li,+i mixing
=iquid mixing promotes heat transfer between liquid and a heating source. This step is
essential in the crystalli"ation of drug substances. 8niform heat transfer in the solution
yields crystals of same si"e.
=iquid mixing is essential in the manufacture of number of dosage forms.e.g.'
*uspensions
9mulsions
*olutions
Aerosols
Mixing of immisci3l! 6i,+is
Carried mainly in the man+fact+'! of !m+lsions and the equipment used for the preparation of
an emulsion is $nown as emulsifier. Also $nown as homogeni"er as it results in fine emulsion.
&ine emulsion is prepared in ) stages.
In %
st
stage coarse emulsion is prepared by using one of the following process'/
>edge wood
Mechanical blender
0and homogeni"er
+orcelain mortar and pestle
Mil$ sha$e mixer
+ropeller in a baffled tan$
*ometimes the above equipment directly gives fine emulsion.
?therwise coarse emulsion is sub!ected to homogeni"er in the )
nd
stage to get fine
emulsion by using following process'/
*ilverson emulsifier
Colloidal mill
,apisonic homogeni"er
4acto's infl+!ncing s!l!ction of an !m+lsifi!'
%. Q+antit0 of !m+lsion to 3! -'!-a'!: batch wise or continuous operation
). 4lo/ -'o-!'ti!s of li,+is: @ewtonian plastic pseudo plastic or dilatant.
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-. T!m-!'at+'! maint!nanc!: mixing will be effective at high temperatures provided the
material is stable.
A. D!si'! 'at! of cooling: if elevated temperatures are applied
E,+i-m!nt
*ilverson emulsifier
Colloidal mill
,apisonic homogeni"er
)il%!'son mix!' 8Em+lsifi!'
P'inci-l!:
It produces intense shearing forces and turbulence by use of high speed rotors.
Circulation of material ta$es place through the head by the suction produced in the inlet
at the bottom of the head.
Circulation of the material ensures rapid brea$down of the dispersed liquid into smaller
globules.
It consists of long supporting columns and a central portion. Central portion consists of a
shaft which is connected to motor at one end and other to the head.
0ead carries turbine blades.
Blades are surrounded by a mesh which is further enclosed by a cover having openings.
Us!s:
8sed for the preparation of emulsions and creams of fine particle si"e.
A%antag!s:
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*ilver son mixer is available in different si"es to handle the liquids ranging from a few
milli liters to several thousand liters.
Can be used for batch operations as well as for continuous operations by incorporating
into a pipeline through which the immiscible liquids flow.
Disa%antag!s:
?ccasionally there is a chance is clogging of pores of the mesh.
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