Mixing& Blending

 OBJECTIVE-(Hetrogenius to Homogenius)
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AGITATION:- Agitation (action), putting fluid into motion by shaking or stirring,
often to achieve mixing.
An agitator is a device or mechanism to put something into motion by shaking or
stirring.
Purpose of agitation:
 Intensification(An intensification is an increase in strength or magnitude (or
intensity) of transport processes in agitated batch(heat and mass transfer)
 Preparation of materials of required properties(suspension, emulsion)

Mixing:  Mixing may be defined as a unit operation that aims to treat two or more
components, initially in an unmixed or partially mixed state, so that each unit
(particle, molecule etc.) of the components lies as nearly as possible in contact
with a unit of each of the other components
BLENDING :means to mix smoothly and inseparably together during which a
minimum energy is imparted. The terms MIXING and BLENDING are commonly
used interchangeable in the pharmaceutical industry.
Bafle-A device used to restrain the flow of a fluid, gas, etc. Tank baffles are small
vertical paddles(short pole) added to the sides of mixing tanks to improve mixing

 A baffle is a device used to alter the flow pattern in a tank.Baffles are

typically introduced to prevent vortex formation&convert
tangential(rotational) flow into axial (vertical) flow

 Baffles are always used in turbulent flow systems (low viscosity fluids)

 Baffles are not used in laminar flow (high viscosity fluids)

What is Mixing, Blending?

“Mixing is the process of thoroughly combining different materials to produce a

homogenous product.” The mixture is generally a combination of dissimilar
materials.

e.g. coal ash and cement are blended in a specified ratio to produce Pozzocrete
cement. In other cases, a chemically homogenous material may be mixed to
produce a uniform lot of a desired weight/volume with consistent particle size
distribution, color, texture, and other required attributes(Ice cream,paint &dyes)

Difference between Blending & mixing:-

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The terms "mixing" and "blending" are often used interchangeably, but
technically they are slightly different. Blending is a process of
combining materials, but blending is a relatively gentle process
compared to mixing. In terms of the phase of material, blending is the
process of solid-solid mixing or mixing of bulk solids with small
quantity of liquid. The terminology mixing is more closely associated
with liquid-liquid, gas-liquid, and viscous materials.
Applications-

Mixing and Blending are the most demanding unit operations in the
chemical process industries. Industries such as pharmaceutical and
foods also rely heavily on mixing and blending technology. Some
common examples are as follows.

Chemical Process Industry: Mixing and blending of specialty chemicals,

explosives, fertilizers, dry powdered detergents, glass or ceramics, and rubber
compounds.

Pharmaceutical Industry: Blending of active ingredients of a drug with

excipients like starch, cellulose, or lactose.

Food industry: Preparation of cake mix, spices, and flavor

Mechanism of Mixing:-(3D)
. For mixing to be effective, fluid circulated by the impeller must sweep the
entire vessel in a REASONABLE TIME. In addition, the velocity of fluid leaving the
impeller must be sufficient to carry material into the most remote parts of the tank.
Turbulence must also be developed in the fluid; mixing is certain to be poor
unless flow in the tank is turbulent.
All these factors are important in mixing .Large liquid-circulation loops developed
in combination of three physical processes: (3D).
1)distribution, 2)dispersion and 3)diffusion
Distribution:-The process whereby materials are transported to all regions of the
vessel by bulk circulation currents is called distribution. Distribution is an
important process in mixing, but can be relatively slow. In large tanks, the size of
the circulation paths is also large and the time taken to traverse them is long; this,
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together with the regularity of liquid pumping at the impeller, inhibits rapid
mixing.
( Distribution( spread over an area.)-is often the slowest step in the mixing proces
However, if the rotational speed of the impeller is sufficiently high,superimposed
on the distribution process is turbulence. Turbulence flow occurs when fluid no
longer travels along streamlines but moves erratically in the form of crosscurrents.
The kinetic energy of turbulent fluid is directed into regions of rotational flow called eddies;
<a circular movement of water causing a small whirlpool. whirlpool a quickly
rotating mass of water in a river or sea into which objects may be drawn>.
Masses of eddies of various size coexist during turbulent flow. Large eddies are
continuously formed by action of the stirrer; these break down into small eddies
which produce even smaller eddies. Eddies, like spinning tops, Posses kinetic
energy. When the eddies become so small that they can no longer sustain rotational motion,
their kinetic energy is dissipated as heat.
Dispersion:-( action or process of distributing things )The process of breaking up bulk
flow into smaller and smaller eddies is called dispersion.
Dispersion facilitates rapid transfer of material throughout the vessel. The
degree of homogeneity as a result of dispersion is limited by the size of the
smallest eddies which may be formed in a particular fluid.
Diffusion:-The result of diffusion(physical process of atoms or molecules moving
apart within a gas or liquid. )
is a gradual mixing of material such that the
distribution of molecules is uniform.
Factors influencing mixing –
a)Mechanism of mixing(3D) b ) Density of the particles c)Particle size
d)Particle shape e)Particle charge

Types of mixtures

. Positive mixtures - Positive mixtures are formed from materials such as gases or
miscible liquids which mix spontaneously and irreversibly by diffusion, and tend
to approach a perfect mix.
• Negative mixtures- With negative mixtures the components will tend to separate
out. If this occurs quickly, then energy must be continuously input to keep the
components adequately dispersed, e.g. with a suspension formulation, such as
calamine lotion.
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Importance of Mixing Technology

Mixing is a critical process because the quality of the final product and its
attributes are derived from the quality of the mix.

Improper mixing results in a non-homogenous product that lacks consistency with

respect to desired attributes(quality) like chemical composition, color, texture,
flavor, reactivity, and particle size.

The wide variety and ever increasing complexity of mixing processes encountered
in industrial applications requires careful selection, design, and scale up to
ensure effective and efficient mixing. Improved mixing efficiency leads to shorter
batch cycle times and operational costs.

MODERN MIXERS:-

Today's competitive production lines necessitate robust(strong)equipment that are

capable of

a)fast blend times b) lower power consumption c) equipment flexibility

d)ease of cleaning, and e) gamut(complete range) of customized features.

In addition to blending components, many modern mixers are designed to

combine different process steps in a single equipment, e.g. coating, granulation,
heat transfer, drying, etc.

A mixer is no longer a generic production tool, but a critical and decisive business
tool. This is because profitability and competitive advantage are dependent upon
subtle improvements in Product Quality through gains in mixing performance and
efficiency.

Types of Mixing Equipment

Opeartion of mixing equipment:-

The operation of the mixing equipment may be batch or continuous depending

upon the required production capacity, product quality, pre and post mixing
equipment, type of mixer, etc.
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Mixing equipments are classified based on the type of materials being mixed. The
three main classifications of mixing equipment are:

1) Blenders 2) Agitators 3) Heavy Duty Mixers

1. Blenders: Mixers for Solid-Solid Blending

Considering the large industrial operations requiring the blending of bulk solids,
there is a wide range of blender technologies available. Depending on the
principle, mechanism of mixing, blenders is classified as follows:

· Tumbler Blenders : Double Cone Blender, V-Blenders

· Convective Blender: Ribbon Blender, Paddle Blender, Vertical Screw Blender

· Fluidization Blenders / Mixers: Double Paddle Mixer (Forberg Mixer)

2. Agitators: Mixers for Liquid-Liquid, Liquid- Gas Mixing

A variety of process functions like

 Blending miscible liquids, contacting or dispersing immiscible liquids,

 Dispersing a gas in a liquid, heat transfer in agitated liquid,

 Suspension of solids in liquids, etc. are carried out in agitated vessels by

rotating impellers.

 IMPELLERS
 Impellers are THE COMPONENT OF THE MIXER WHICH IMPARTS FLOW.
 Their purpose is to transfer the energy driven by the motor to the
contents of a tank as quickly and efficiently as possible. ... Selecting an
impeller based on the unique needs of the application is vital in ensuring
the production of an equal mixture,
 The impeller is the component of a mixer that does the actual
mixing and produces the results. That's because when it rotates, it
creates fluid flow and shear
 This can be used to combine materials in the form of solids, liquids and
gas .
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 What do you mean by impeller?

 What is the purpose of the impeller?
 Which impeller is more efficient for mixing?
 What is difference between propeller and impeller?
 What is agitator in reactor?
 What is impeller and its types?

The impellers are classified into two types, axial and radial, depending on the
angle that the impeller (also known as agitator) blade makes with the plane of
impeller rotation.

 Axial Flow Impellers: The impeller blade makes an angle of less than
90° with the plane of impeller rotation. As a result the locus of flow
occurs along the axis of the impeller (parallel to the impeller shaft)
 AXIAL FLOW PATTERNS
 Axial flow impellers have an up and down flow pattern, ideal for
applications where solids suspension or stratification is a challenge.
The flow pattern produced by typical axial flow impeller produces an
excellent top to bottom motion when the agitator is center mounted, and
the vessel is fully baffled (see Fig 1B). If the baffles are removed, the
fluid in the vessel will swirl and vortex resulting in a rather poor mix.
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 AXIAL FLOW IMPELLERS
 Propeller: The propeller is typically used in mixers that are small and portable.
This type of impeller tends to be heavy and quite expensive in larger sizes.
 A propeller is a device with a rotating hub and radiating blades that are set at a pitch to
form a helical spiral, that, when rotated, exerts linear thrust upon a working fluid, such as
water or air.


 Pitched Blade:( to set up and fix firmly in place) A pitched blade impeller is
used when a balance of flow and shear is required. It is especially useful in
applications where 2 or more liquids are blended, and is well suited for
situations with low bottom clearance or low liquid submergence.

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 Hydrofoil: The hydrofoil impeller offers the best high flow design. It is known
for its low turbulence, and is excellent for shear sensitive applications.

 The hydrofoil is a 3 bladed high efficiency impeller. ... It is known for its
high efficiency because it is able to produce the greatest amount of flow per
horsepower in the spectrum of Mixer Direct's line of mixing blades.

 Radial Flow Impellers:  having the working fluid flowing

mainly along the radii of rotation

 The impeller blade in radial flow impellers is parallel to the axis of the
impeller. As a result, the radial-flow impeller discharges flow along the
impeller radius in distinct patterns.

e.g.: Flat Blade Turbine,paddle &anchor

Flat Blade Turbine

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Paddle- a short pole with a broad blade at one or both ends

Anchor- something that provides strength and support

RADIAL FLOW PATTERNS

Radial flow impellers generate a side to side flow pattern. Like the axial flow impellers,
adding baffles reduces the swirling and vortexing motion in the vessel therefore
increasing the level of agitation inside. 

For more details visit

INTRODUCTION TO MIXER IMPELLERS &FLOW PATTERN –SARA PETERS

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What is the difference between radial flow and axial flow?

Axial flow impellers cause the tank fluid to flow parallel to the impeller's axis of
rotation while radial flow impellers cause the tank fluid to flow perpendicular to
the impeller's axis of rotation.
What is radial flow and axial flow?

“Axial” refers to the direction of flow produced by the impeller. ...

Similar to the axial flow turbine, the term “radial” describes the flow
of liquid resulting from the impeller. The radial turbine blades are
welded to the hub with the blade surfaces parallel to the shaft.

3. Heavy Duty Mixers: Mixers for Viscous, Pasty Materials

For high-viscosity materials, the mixing regime changes from one in which
turbulence dominates (as in liquid agitators) to one in which viscous drag forces
dominate. Moreover, some materials exhibit Non-Newtonian behavior. A non-
Newtonian fluid is a fluid whose flow properties are not described by a single
constant value of viscosity. Therefore mixing of such material requires special
heavy duty mixers. These include:

· Double Arm Mixers,· Planetary Mixers&· Dual and Triple Shaft Mixers

Mixing Equipment

Radial-flow impeller
· Radial Flow Impellers: The impeller blade in radial flow impellers is parallel to
the axis of the impeller. As a result, the radial-flow impeller discharges flow along
the impeller radius in distinct patterns.

e.g.: Flat Blade Turbine, Paddle, Anchor,propeller,&helical screw

A)Propeller-(consisting of a revolving shaft with two or more broad, angled

blades attached to it.)

It is axial flow ,high speed impeller for liquids of low viscosity&effective in large
vessels.
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B)Paddles-( a short pole with a broad blade at one end) .

It is axial flow, at low speed gives mild agitation.

c)Turbines-( A turbine mixer is a mechanical device which is used in the mixing of the

different types of liquids by using different types of blades and impellers)

high speed impellers&are effective for over wide range of viscosities..

Fig. impeller designs- Typical configuration of a

stirred tank
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Fig. 6.2 Typical configuration of a stirred tank

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Fig. A standard tank with a working volume of

100 M3 and used for penicillin production
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Unbafled vessel

Flow Patterns Developed in Agitated Tanks

(Circular flow in a unbaffled stirred tank)

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Radial-flow impeller

Flow pattern produced by a radial-flow impeller in a baffled

tank
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Axial-flow impeller-: The impeller blade makes

an angle of less than 90° with the plane of
impeller rotation. As a result the locus of flow
occurs along the axis of the impeller (parallel to the
impeller shaft)
e.g.: Marine Propellers, Pitched Blade Turbine

Fig.Pitched-blade turbine
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Fig . Flow pattern produced by an axial-flow impeller in a

baffled tank
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Solid-solid mixing:: 

Solid-solid mixing: This is the process in which two or more than two solid
substance are mixed in a mixer by continuous movement of the particle.
Mechanism of mixing in solids: 1- convective mixing (macro mixing) In the case
of convective mixing material in the mixer is transported from one location to
another. This type of mixing process will lead to a less ordered state inside the
mixer, the components which have to be mixed will be distributed over the other
components
Convective mixing is the mixing of solid particles in which groups of particles are
moved from one position to another.

Liquid-liquid mixing:: 

Liquid-liquid mixing is the formation Of homogenous system by the application

of shear.

Mixing of immiscible Liquids: (emulsifier OR homogenizer.)

Mixing of immiscible Liquids Carried mainly in the manufacture of

emulsions,& the equipment used for the preparation of an emulsion is known
as emulsifier . Also known as homogenizer as it results in fine emulsion. Fine
emulsion is prepared in 2 stages. 1 st stage -coarse emulsion is prepared by
using one of the :- Wedge wood Mechanical blender, Hand homogenizer
,Porcelain mortar and pestl . 2 nd stage- Silverson emulsifier Colloidal mill
,Rapisonic homogenizer.

Silverson mixer -Emulsifier: 

Silverson mixer -Emulsifier Principle: It produces intense shearing forces and

turbulence by use of high speed rotors. Circulation of the material ensures rapid
breakdown of the dispersed liquid into smaller globules(a small ball of something,
especially a drop of liquid: ). Blades are surrounded by a mesh,
Uses: Used for the preparation of emulsions and creams of fine particle size
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Flow in agitated batch

a – axial-flow pattern, baffled vessel, b – radial-flow pattern, baffled vessel, c – tangential-flow pattern,
unbaffled vessel

VORTEX
 a mass of air or water that spins aroundveryfast and pulls objects into its empty 
centre &is a dangerous or bad situation in whichparticle become more and
more involved and from which particle cannot escape:
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Figure. Agitation in an unbaffled vessel (left) leads to swirling flow

with surface vortex formation and poor solids distribution, while
standard baffling (right) with a pitched-blade turbine promotes axial flow
that results in good solids distribution

Method of mixing fluids

mechanical mixing (rotating, vibrating)
hydraulic mixing
pneumatic mixing
pipeline mixing(turbulent flow, static mixer)
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A–mechanical mixing using turbines

B–mechanical mixing using blade impellers
C–hydraulic mixing
D–pneumatic mixing with stationary inputs
E–pneumatic mixing with automatic regulation
F–hydraulic mixing with antifoaming shower
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Assessing Mixing Effectiveness

Mixing time is a useful parameter for assessing mixing
efficiency and is applied to characterize bulk flow in fermenters.
The mixing time( tm) is the time required to achieve a given
degree of homogeneity starting from the completely segregated
state.
It canbe measured by injecting a tracer into the vessel and
following itsconcentration at a fixed point in the tank. Tracers in
common use include acids, bases and concentrated salt
solutions;corresponding detectors are pH probes and
conductivity cells.
Mixing time can also be determined by measuring the
temperatureresponse after addition of a small quantity of heated
liquid.
: What is MIXING INDEX?

Definition of MIXING INDEX-

Measure of quality of mixing process, ratio of surface areas of
particles after and before mixing, esp when mixing fillers into
polymers,
Summary
After the study of this chapter, you should be:
a)familiar with equipment used for mixing in stirred tanks;

b)able to describe the mechanisms of mixing and their effect on mixing time;

c)able to understand the effects of scale-up on mixing

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Screw Mixers
Working principle
First step is charging of mixer from the top, manually or vide pneumatic or mechanical conveying.
After the mixer is charged the mixing process starts. The mixing is carried by means of 3 distinct
intermixing actions:

1) The screw agitator, turning on its axis, produces a lifting action as it spirals the materials in
an upward flow.

2) At the same time, orbiting the tank, the screw removes material away from the wall and
deflects it into the centre of the tank.

3) Material lifted by the screw gravitates downward, thoroughly intermixing with material being
spiraled upwards.

The typical speed of the central screw is 70 to 80 Rpm. The Tip speed can fluctuate from 1 to 3 m/s.
The result is most intimate intermingling of all ingredients. The mixing time is depending on product
characteristics, mixing accuracy and batch size.

Applications
Vertical ribbon blenders are generally used in case of applications that require gentle mixing action
and minimal heat generation at the same time these mixers can also be used for applications that
requires high shear mixing this is accomplished using lump breakers, which is driven separately.

 Mixing of free flowing powders

 Moistening of powders
 Coating
 Granulation Mixing of slurries & Drying of powders
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Tumble blender-
A tumble blender is available in a variety of geometries, the most common being the V-shaped or double-
cone configurations. The vessel is partially loaded with product and rotated at operating speeds in the
range of 5 to 25 revolutions per minute. Diffusion is the main mechanism for mixing: batch materials
cascade down, distributing particles over a freshly exposed surface as the vessel rotates on a horizontal
axis.
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V-shaped blender
In a V-shaped blender, the batch is continuously being split and recombined. In order to take advantage
of this mixing and flow pattern, raw materials are generally loaded to the vessel in layers rather than side
by side. Tumble blending is very low-impact and appropriate for processing abrasive solids. It is also
commonly used in making precise blends containing trace components (<1%) or ingredients that are
vastly dissimilar in size and density.

The geometry of the V-shaped and double-cone vessels allows complete discharge of the blended
material. Both designs however require a large footprint to accommodate the mixer base, as well as
ample overhead space for the vessel to rotate. In certain installations, this type of equipment is operated
from within a dedicated room to ensure safety.

A few examples of typical end products include: 

Metal powders 
Cereal 
Face powders 
Detergents 
Bakery mixes 
Ceramic powders 
Plastics 
Milk powders 
Fertilizers

Ribbon BLENDERS(RADIAL&COUNTERCURRENT AXIAL MOVEMENT)

DIGARAM

CONSTRUCTION

WORKING PRINCIPLE

APPLICATIONS
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Sigma Mixer
The sigma blade mixer is a commonly used mixer for high viscosity materials. This article details the construction of the sigma
mixer, design and operational features, and its applications. The different variants of the sigma mixer design are discussed.

 The sigma mixer is one of the most popular used for mixing and kneading high viscosity materials. It belongs to the
family of double arm kneader mixers.

Double Arm Kneader Mixers

All double arm kneader mixers are equipped with two mixing blades placed in a W-shaped horizontal trough. Various blade
profiles have evolved, each of which is best suited for a particular type of application. The commonly used blade types are the
sigma blade, masticator blade, shredder blade, naben (aka fishtail) blade, and spiral blade. The rotation of the blades is either
tangential to each other or the blades may overlap within the trough. The blades rotate toward each other at the same or
differential speeds. The blades pass the container walls and each other at close clearances (2-3 mm) resulting in homogenous
mixing. The close clearances produce very high shearing action thereby reducing any large particles. These mixers produce a
consistent particle size distribution without the need for additional high speed choppers. Homogenous mixing is achieved within
10 to 30 minutes. Mixing homogeneity upto 99% and better can be achieved using the double arm kneader mixers. These mixers
and their variants (double arm kneader mixer extruders) are capable of handling material with viscosities as high as 10 million
centipoises. The power consumption in double arm kneader mixer is very high compared to other types of mixers and can range
from 45 to 75 kW/m3 of mix material. The sigma blade mixer is the most commonly used type of double arm kneader mixer, and
is best suited for all round use.

Sigma Blade Mixer

The sigma blade profile is shown in figure 1.

In mixers handling very viscous materials, it is necessary to promote both lateral and transverse motion of the material. The
geometry and profile of the sigma blade is designed such that the viscous mass of material is pulled, sheared, compressed,
kneaded, and folded by the action of the blades against the walls of the mixer trough. The extent to which this happens depends
on the action of the blades - tangential or overlapping and the ratio of the speed of rotation of the blades.The helix angle of the
blade can be modified depending on the required shearing.
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

 angential and Overlapping Blade Action

In the tangential design, the blades rotate in the trough meeting tangentially as shown in figure 2. The front blade generally
rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosities
such as adhesives, rubber compounds, flush colors, dyes, and pigments.

In the overlapping design, the blades overlap above the saddle of the container. The overlapping
blade configuration is shown in figure 3. Due to the overlapping action it is necessary that the relative position of the two blades
is unchanged, and as a result, both the blades rotate at the same speed. Materials that flow freely or creep down into the blades are
mixed using the overlapping blade action. This design offers a faster interchange of material from one blade compartment of the
mixer to the other. Overlapping blade action is used for materials of lighter viscosities such as carbon pastes, clay coating,
creams, and ointments. The overlapping blade produces a lower kneading and shearing compared to the tangential blade action.

 Operation of Sigma Blade Mixer

In operation, material is loaded through the top of the container to typically 40 to 65 percent of the mixer's total volumetric
capacity. The rotation of the blades is through heavy duty drive systems typically consisting of a motor, gearbox, couplings, and
gears. The tip speed of the sigma mixer is generally limited to 60 metres per minute. Mixing may be carried out at ambient
temperature or under controlled temperature conditions. The mixer troughs can be provided with jackets for circulation of hot or
cold media to maintain the required temperature conditions within the mixer. The discharge of the material from the mixer
container is either by tilting of the mixer container (see figure 4), bottom discharge valve (see figure 5), or through an extruder /
screw located in the lower portion between the two trough compartments (see figure 6).The mixer may be equipped with any one
of these discharge arrangements.

The tilting discharge arrangement is most common. The tilting arrangement of the container may be designed for manual
operation or may be mechanized using motorized or hydraulic arrangement.
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For materials of lower viscosity, the bottom discharge valve may be provided on the mixer trough.
The design profile of the valve should be flush with the mixer trough to avoid any dead or unmixed pockets of material).

The extruder/screw discharge has an advantage that materials can be directly discharged,
extruded, in the required shape or size for further processing. In addition, the screw design eliminates operator exposure to hot
materials if the mixing processes are carried out at high temperatures and/or with materials that are toxic in nature.

 Applications of the Sigma Mixer

The sigma mixer is the best suited mixer for pasty, sticky, and gritty slurries with high viscosities. The following are some of the
commonly used products that are mixed in the sigma mixer.

o Adhesives
o Biscuit dough
o Butyl rubber
o Carbon pastes
o Ceramics
o Chemicals
o Chewing gum
o Crayon and pencil lead
o Explosives
o Fiberglass resin doughs
o Food and confectionery products


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 angential and Overlapping Blade Action

In the tangential design, the blades rotate in the trough meeting tangentially as shown in figure 2. The front blade generally
rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosities
such as adhesives, rubber compounds, flush colors, dyes, and pigments.

In the overlapping design, the blades overlap above the saddle of the container. The overlapping
blade configuration is shown in figure 3. Due to the overlapping action it is necessary that the relative position of the two blades
is unchanged, and as a result, both the blades rotate at the same speed. Materials that flow freely or creep down into the blades are
mixed using the overlapping blade action. This design offers a faster interchange of material from one blade compartment of the
mixer to the other. Overlapping blade action is used for materials of lighter viscosities such as carbon pastes, clay coating,
creams, and ointments. The overlapping blade produces a lower kneading and shearing compared to the tangential blade action.

 Operation of Sigma Blade Mixer

In operation, material is loaded through the top of the container to typically 40 to 65 percent of the mixer's total volumetric
capacity. The rotation of the blades is through heavy duty drive systems typically consisting of a motor, gearbox, couplings, and
gears. The tip speed of the sigma mixer is generally limited to 60 metres per minute. Mixing may be carried out at ambient
temperature or under controlled temperature conditions. The mixer troughs can be provided with jackets for circulation of hot or
cold media to maintain the required temperature conditions within the mixer. The discharge of the material from the mixer
container is either by tilting of the mixer container (see figure 4), bottom discharge valve (see figure 5), or through an extruder /
screw located in the lower portion between the two trough compartments (see figure 6).The mixer may be equipped with any one
of these discharge arrangements.

The tilting discharge arrangement is most common. The tilting arrangement of the container may be designed for manual
operation or may be mechanized using motorized or hydraulic arrangement.
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For materials of lower viscosity, the bottom discharge valve may be provided on the mixer trough.
The design profile of the valve should be flush with the mixer trough to avoid any dead or unmixed pockets of material).

The extruder/screw discharge has an advantage that materials can be directly discharged,
extruded, in the required shape or size for further processing. In addition, the screw design eliminates operator exposure to hot
materials if the mixing processes are carried out at high temperatures and/or with materials that are toxic in nature.

 Applications of the Sigma Mixer

The sigma mixer is the best suited mixer for pasty, sticky, and gritty slurries with high viscosities. The following are some of the
commonly used products that are mixed in the sigma mixer.

 Adhesives
 Biscuit dough
 Butyl rubber
 Carbon pastes
 Ceramics
 Chemicals
 Chewing gum
 Crayon and pencil lead
 Explosives
 Fiberglass resin doughs
 Food and confectionery products
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 angential and Overlapping Blade Action

In the tangential design, the blades rotate in the trough meeting tangentially as shown in figure 2. The front blade generally
rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosities
such as adhesives, rubber compounds, flush colors, dyes, and pigments.

In the overlapping design, the blades overlap above the saddle of the container. The overlapping
blade configuration is shown in figure 3. Due to the overlapping action it is necessary that the relative position of the two blades
is unchanged, and as a result, both the blades rotate at the same speed. Materials that flow freely or creep down into the blades are
mixed using the overlapping blade action. This design offers a faster interchange of material from one blade compartment of the
mixer to the other. Overlapping blade action is used for materials of lighter viscosities such as carbon pastes, clay coating,
creams, and ointments. The overlapping blade produces a lower kneading and shearing compared to the tangential blade action.

 Operation of Sigma Blade Mixer

In operation, material is loaded through the top of the container to typically 40 to 65 percent of the mixer's total volumetric
capacity. The rotation of the blades is through heavy duty drive systems typically consisting of a motor, gearbox, couplings, and
gears. The tip speed of the sigma mixer is generally limited to 60 metres per minute. Mixing may be carried out at ambient
temperature or under controlled temperature conditions. The mixer troughs can be provided with jackets for circulation of hot or
cold media to maintain the required temperature conditions within the mixer. The discharge of the material from the mixer
container is either by tilting of the mixer container (see figure 4), bottom discharge valve (see figure 5), or through an extruder /
screw located in the lower portion between the two trough compartments (see figure 6).The mixer may be equipped with any one
of these discharge arrangements.

The tilting discharge arrangement is most common. The tilting arrangement of the container may be designed for manual
operation or may be mechanized using motorized or hydraulic arrangement.
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For materials of lower viscosity, the bottom discharge valve may be provided on the mixer trough.
The design profile of the valve should be flush with the mixer trough to avoid any dead or unmixed pockets of material).

The extruder/screw discharge has an advantage that materials can be directly discharged,
extruded, in the required shape or size for further processing. In addition, the screw design eliminates operator exposure to hot
materials if the mixing processes are carried out at high temperatures and/or with materials that are toxic in nature.

 Applications of the Sigma Mixer

The sigma mixer is the best suited mixer for pasty, sticky, and gritty slurries with high viscosities. The following are some of the
commonly used products that are mixed in the sigma mixer.

 Adhesives
 Biscuit dough
 Butyl rubber
 Carbon pastes
 Ceramics
 Chemicals
 Chewing gum
 Crayon and pencil lead
 Explosives
 Fiberglass resin doughs
 Food and confectionery products
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