RD

3575 3 AVENUE P.O. BOX 286

MARION, IOWA 52302
PHONE 319/377-6371 FAX 319/377-1204
WWW.MARIONMIXERS.COM

Technical Feature/Benefit Analysis

Agitator Shafts

FEATURE: Shaft Diameter

BENEFIT: The agitator shaft transfers the rotational force produced by the
drive assembly to the paddles or ribbons. Assuming like materials and torque
requirements, smaller diameter shafts have higher stress concentrations than
larger diameter shafts. (Stress = Force / cross sectional area of material)
where Force = Torque / Radius of the shaft). The main shaft should be
designed to keep stress levels below the "fatigue limit" of the shaft material.
Smaller diameter shafts are more likely to break due to fatigue failure
than larger diameter shafts.

FEATURE: Static Deflection

BENEFIT: Static shaft deflection occurs due to the weight of the shaft,
arms, blades, ribbons, hardware, etc.. The shaft acts as a continuously loaded,
simply supported beam. Maximum deflection occurs about midway between
the bearing supports. Shaft Deflection = (W»L3 )/( E»I»76.8) where E is the
agitator shaft "moment of inertia." To decrease deflection the shaft's cross
sectional moment of inertia needs to be increased. The moment of inertia of a
solid 4I5/V shaft is more than 2 times that of a 4'/2" I.D. (5" O.D.). schedule 80
pipe. Excessive shaft deflection will promote metal fatigue and accelerate
seal wear.

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FEATURE: Dynamic Deflection
BENEFIT: Dynamic shaft deflection occurs when the mixer is operating. In
general, the force exerted by the "down-sweep" side of the agitator is greater
than that of the "up-sweep." Unlike static deflection which bends the shaft
downward, dynamic deflection forces the axis of the shaft upwards towards the
upsweep side of the mixer. The exact angle of deflection is dependent on
variables such as: paddle or ribbon design, material flow characteristics,
product loading, etc. Excessive shaft deflection, due to dynamic
loading, will increase the clearances between the agitator and the
trough on the "down-sweep" side of the mixer. Solid shaft designs
will have less deflection than hollow shafts (of similar diameter); thus
promoting better mixing action.

FEATURE: Reduced Stress Risers

BENEFIT: Industrial mixers are a capital investment intended for
decades of productive service. Even though horizontal blenders operate at
relatively low speeds (25 to 45 rpm's). over several years they can become
subject to metal fatigue. For example... a mixer running for 2 shifts per day
for 20 years will rotate approximately 175 million times. To avoid metal
fatigue (and breakage) in the main shaft, stress risers should be
minimized. For bolted arm agitators, key ways must have radius comers.
For welded agitator assemblies, "drilling and pinning'' the arms to the
main shaft prior to welding should be avoided.

FEATURE: One Piece Shaft

BENEFIT: As described above, the agitator shaft of a mixer is subjected
to several rotational and bending stresses. Within the industry today, there are
mixers using "stub shaft assemblies... for easy agitator removal when required."
This feature allows the manufacturer of these mixers to build the agitator
assembly completely outside of the mixer. Stub shaft assemblies rely on
threaded fasteners (which are much smaller in cross sectional area than the
main shaft) to transfer the energy created by the mixer drive assembly. One
piece, solid core, agitator shaft material should be used to reduce
Stress loading and minimize agitator deflection. If removal of the
agitator is a concern, mixers are available with bolted and gasket end plate
designs.

FEATURE: Shaft Straightness

BENEFIT: Welded agitator assemblies are used in applications where
cleaning the mixer is a concern. All mating surfaces have welded fillets which
are ground and polished to a specified finish. During fabrication, the heat
created by welding and grinding these surfaces will warp the agitator
shaft. Many times the deformation is not noticeable to the naked eye. As a
final step in the fabrication process, the shaft should be re-straightened.
Excessive warping ("run-out" > .005") will accelerate wear of seals and
bearings; thus creating higher, long term maintenance Costs.

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 FEATURE: Blade or Ribbon Clearance
BENEFIT: Independent studies have proven that clearances between the
agitator blades or ribbons and the trough can significantly impact mixing
performance. Larger gaps produce higher coefficients of variation and
longer mixing times. For most applications the gap between the mixer's
agitator and trough should be .020" or less. (Note: Some applications require
larger gaps to prevent degradation of the product being mixed). To verify
accurate agitator clearances, documented quality control tests are
to be conducted to measure residual material clean-out.

Technical Feature/Benefit Analysis

Drive Components

Drive Assembly

FEATURE: Horse Power Selection “H” Factor

BENEFIT: Horse power calculations are the most important
considerations in designing a mixer to match a given application. Based on
horse power requirements, components such as shaft, gear reducer, bearings
and seals are sized. Horse power selection is based on variables such as:
mixer length and diameter, batch size, agitator speed, size of blades or ribbon,
number of arms, start-up conditions and properties of the product being
mixed. Computer models of the mixer "drive train" predict safety factors for
critical components. An under powered (or under sized) drive train will
have limited safety margin. For long term production needs,
undersized drive trains may have increased maintenance and down-
time.

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 FEATURE: Application Experience “C” Factor
BENEFIT: Application experience is key to the selection and design of a
mixer. Variations in product characteristics, mix times, temperature and
moisture content will effect the quality and quantity of the customer's finished
product. Through years of proven application experience, product
characteristics have been ranked according to energy requirements and
mix speed. New applications are compared against this proprietary list.
Energy consumption ("C" factor) and agitator "tip" speed are critical
components to the horse power calculation described above.
Documented case studies and laboratory experiments with test
equipment are needed before designing the "right mixer for the
job."

Motor
FEATURE: Locked Rotor Torque
BENEFIT: The National Electrical Manufacturer's Association (NEMA)
is a self governing organization for producers of cast iron motors. NEMA
has created minimum standards for duty ratings, energy efficiency and
torque. All motor manufacturers publish actual performance data on their
motors. Not all brands of motors are built alike... consult actual
motor performance data before specifying a motor. An important
characteristic to consider when selecting a motor is the locked rotor torque.
Locked rotor toque capabilities, may determine if the mixer will start
under loaded conditions.

Gear Reducer

FEATURE: Shaft Mount

BENEFIT: Shaft mounted gear reducers provide speed reduction and
transfer of torque from the motor. Double tapered bushings ensure exact
alignment of reducer with the center line of the agitator shaft (even with
controlled amounts of shaft deflection). Shaft mounted designs reduce the
number of exposed moving components, thus reducing ongoing maintenance
requirements Shaft mounted reducers without double tapered bushings
may fret and weld to the agitator shaft, making routine maintenance
more difficult.

FEATURE: Duty Rating “Class II Service Factor”

BENEFIT: Gear reducers are designed based on horse power
requirements and overall speed reduction. Operating conditions
experienced with mixing applications may require a Class II service factor be
applied when sizing the gear reducer. The rating is recommended based on
previous experience of difficult mixing applications. This rating applies a
140% safety factor to the actual horse power requirements for the
application. Class II service factors facilitate reduced stresses on the
internal bearing surfaces and decreased wear of the gear face as a
result of shock loading from the mixer.

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Bearings

FEATURE: Radial and Thrust Loads

BENEFIT: Double interlocking bearings, designed to carry radial and
thrust loads should be used to support the main agitator shaft.
Mixer agitators are designed to move product around and along the axis
of the mixer. The force required to move the customer's product laterally
(or toward the discharge openings) is transmitted through the bearing.
Bearings should be sized for "heavy service" applications. Bearings
should be statically self aligning within the bearing housing to
accommodate any controlled shaft deflection. Failure to accommodate all
of the features listed above may reduce bearing life and increase
maintenance.

FEATURE: Externally Mounted

BENEFIT: Main shaft bearings typically operate at slow rpm's for long
periods of time. Protection against dusty and dirty environments is
essential. It is important to mounted bearings away from seal housing
areas. Since most seals have controlled amount of leakage,
horizontal ledges below the seal housings should be eliminated.
Isolation of the main shaft bearings from the seal housing will
reduce maintenance and prevent costly down-time.

FEATURE: Expansion Type

BENEFIT: A set of main shaft bearings should consist of (1) expansion
and (1) non-expansion type bearing. The non-expansion bearing transfers the
thrust loading of the agitator which is described above. The expansion
bearing accommodates for changes in length of the main shaft. Variations
in temperature (especially on jacketed mixers) will cause the metal shaft to
expand and contract. Without the use of an expansion type bearing, the
life expectancy of both bearings may decrease and maintenance
increase.

FEATURE: Positive Position

BENEFIT: Non-homogeneous or unevenly distributed batches may
cause cyclical loads on the bearings in both the vertical and horizontal axis.
Bolts positively fasten the bearing to bearing plate in the vertical axis. Metal
stops are welded to the bearing plate to prevent any movement in the
horizontal axis. Without the use of welded positioning blocks, the
movement of the agitator will work the bolts back and forth until the shaft
moves out of alignment.

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 Technical Feature/Benefit Analysis
Structural

Trough and Ends

FEATURE: Plate Thickness

BENEFIT: The structural integrity of the mixer starts with the trough
and end plates. Based on the abrasive properties of the customer's product,
the rolled trough of the mixer is subject to wear. Often the wear will be
most pronounced around the discharge area. Undersized trough
material will lessen the productive "life span" of the mixer. In general,
material thickness should be at least...
For mixers 12" to 27" dia. 7 gauge
For mixers 36" to 54" dia. 1/4"thick
For mixers 66" to 72" dia. 3/8" thick

Trough Wall

FEATURE: Horizontal Support

BENEFIT: Structural supports, welded the length of the mixer are designed to
transfer lateral loads to the end plates. Undersized stiffeners may allow the
trough sides to deflect and fatigue as the agitator forces product against
the trough side walls. First signs of fatigue may appear at the welded
connection of the trough and the end plates. In
general, structural support members should be at least.
For mixers T to 21/,' long 1½" x 1½" x 3/16”
For mixers 3’ to 9’ long 2” x 2” x ¼”
For mixers 10’ to 14’ long 3” x 3” x ¼”
For mixers 16’ to 20’ long 4” x 4” x 5/16”

Bearing Plate and Gussets

FEATURE: Material Thickness

BENEFIT: Bearing plates and gussets transfer loads produced by the main
shaft and drive assembly to the mixer. Often times, worst case loading occurs
when mixing unevenly distributed batches of material. This situation creates
cyclical, impact loads. Undersized bearing plates and gussets may deflect and
distort allowing increased wear on bearings, seals and end plates. In general,
bearing and gusset plates should be plasma cut for appearance and fit and have
dimensions at least.
For mixers 12" to 27" dia. 1/2" thick
For mixers 30" to 66" dia. 3/4" thick
For mixers 72" in. dia. 1" thick

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Welding
FEATURE: Equipment and Process
BENEFIT: Welding is a "core technology" for any manufacturer of industrial
mixers. MIG and variable frequency TIG are preferred weld processes
depending on the weld application and location. All welding should be
performed, in compliance with ASME standards while fixtured "in position" (ie: not
up side down). This practice creates symmetric heat penetration and uniform weld
legs. Before a mixer is completely assembled, it should be rotated to each of the 6
surfaces for welding (i.e.: top, bottom, sides and ends). Short-cuts in welding
set-up may create weaker welds and increased splatter.

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 RD
3575 3 AVENUE P.O. BOX 286
MARION, IOWA 52302
PHONE 319/377-6371 FAX 319/377-1204
WWW.MARIONMIXERS.COM

Dare to Compare
November, 2007

Agitator Design
By Doug Grunder
President, Marion Mixers, Inc.

“What’s better, a ribbon or a paddle?” Let’s Compare.

Ribbon Agitator

• Good when blending materials of like size.

shape and density such as powders or granular ingredients.
• Lateral scrubbing action of inner ribbon against the outer ribbon produces
heat. This can be useful when coating ingredients.
• Choppers can be added when incorporating liquids or pastes and to disperse
minor ingredients.
• Ribbon agitators are most commonly used in the food industry where bulk
products are repeatedly blended.

Ribbon Double Ribbon Chopper

Flighting

Paddle Agitator

• Good when blending materials of dissimilar size, shape and density.

• Paddles scoop ingredients from the bottom of the trough and lift them into
the product stream.
• Low shear mixing is useful when blending friable or oversized ingredients.
• Choppers are often used in conjunction with paddle agitators to reduce
product size, incorporate colorants or other minor ingredients.
• Sanitary paddle agitators are the easiest to clean and sanitize.
• Paddle agitators are fitted with tighter clearances with the trough than
ribbons to allow more efficient clean-out at the end of each batch.

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 • Paddle agitators are efficient with batch sizes down to 20% of the rated
capacity of the blender.
• Bolted paddle agitators are frequently used in abrasive or corrosive
applications where maintenance is a concern.
• Bolted style paddle agitators can be modified in the field to increase or
decrease agitation points to accommodate changes in the customer’s
products.
• Paddle style agitators can be used in both batch and continuous style mixers.

Welded Arm Welded/Paddle Bolted Arm

Bolted Paddle Bolted Paddle

Hybrid Agitator

• Combine the benefits of both the ribbon and the paddle agitator designs.
• Inner ribbon flighting moves product towards the end-plates, thus leveling the
product load.
• Outer paddles provide tight clearances for efficient mixing and thorough
clean-out.
• Choppers can be added with hybrid agitators to provide controlled amounts of
mixing energy.

Hybrid
Paddle/Ribbon