Mixing

 Intermingling of two or more separate components to form

more or less uniform product.

 Some other terms are

 Agitation

 Blending

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 Agitation Mixing Blending

Agitation refers Blending is the

Mixing is the
to the induced mixing of two
random
motion of the components to form a
distribution, into
material in a homogenous mixture.
and through one
circulatory
another, of two or
pattern in some Sometimes, blending
more initially
type of is the term used for
separate phases.
container. mixing of liquids.

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 Mixing of solids

Solid – no such currents

Liquids – currents are
so mixing is done by
generated
other means
Liquid – well-mixed
Solids – identifiable
product (homogeneous)
phases

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 Types of mixture

 Perfect mixture / Solution

 Segregated mixture / Suspension

 Random mixture / Colloidal Dispersion

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Perfect mixture / Solution

 Solutions are mixtures made by mixing a solute and a solvent.

The solute is the substance that dissolves. The solvent is the

substance that does the dissolving. Solutions are
homogeneous

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Suspension / Segregated mixture

 Suspensions are heterogeneous mixtures of a solid and a

liquid in which the solid does not dissolve. Particles of one

component have a greater probability of being found in
greater amount in one part of the mixture than the other.

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Random mixture / Colloidal Dispersion

 Colloidal Dispersions are mixtures with characteristics part

way between a solution and a suspension. Colloidal

dispersions may appear homogeneous but are actually
heterogeneous.

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 Types of mixers

 Mixing is by slow speed agitation of the mass with an

impeller
 By tumbling

 By Centrifuging smearing and impact

 For cohesive solids – powerful and heavier machines

 For free flowing solids – light in construction

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 Mixers for non cohesive solids

 Mixer for dry and free flowing solids are

 Light in construction

 Moderate power consumption

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 Mixers for cohesive solids

 Appropriate contact

 Mixing elements cannot generate flow currents

 High viscosity

 Mixing is by combination of low speed

 Shear
 Smearing
 Wiping
 Folding
 Stretching
 compressing

 Mixer have

 high power consumption

 Cooling is required 11
 Mixers for Cohesive solids

 Different types of mixers are:

1. Change-Can mixer
2. Kneaders
3. Dispersers
4. Masticators
5. Continuous kneaders
6. Mixer extruders
7. Mixing rolls
8. Muller and pan mixers
9. Pug mills

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1. Change-Can Mixers

 For viscous liquids and light pastes as:

 Food processing

 Paint manufacturing

 5 to 100 gal. in size

 Change-Can mixer are:

1. Pony mixer

2. Beater mixer

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 1. Pony mixers

 Agitator consist of vertical blades held on rotating head

positioned near the wall of the can

 Blades are slightly twisted

 Agitator is mounted eccentrically

 Can rest on a turn table driven in direction opposite to that of

agitator
 All the material in the can is brought to the blade to be mixed

 When mixing is completed –blades are cleaned and can is

replaced

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Change Can Mixer (Pony Mixer)
 2. Beater mixers

 Can or vessel is stationary

 Agitator has a planetary motion

 Visits all parts of vessel

 Beaters are shaped to pass with close clearance over the side &

bottom of mixing vessel

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Change Can Mixer (Beater)
 Kneaders, Dispersers and Masticators

 Kneading – “squashing the mass flat, folding it over on itself

and squashing it once more”

 Also tear the mass apart and shear it between a moving blade

& a stationary surface.

 For deformable & plastic solids

 Large energy requirements

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 Kneaders, Dispersers and Masticators

 Mixing is done by two heavy blades on horizontal shaft in a

short trough with a saddle shaped bottom

 Blades turn towards each other at top, drawing mass
downward over the point of the saddle, then shearing it
between the blades and wall
 They turn at different speeds usually 1.5 : 1 or 2 : 1

 Mixing time – 5 to 20 min or longer then trough is tilted for

discharging or can be unloaded through an opening

 Cooling is provided commonly

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 Banbury mixer

 Heavy duty two-arm mixer

 30 to 40 rpm

 Solids enter from top and discharge from bottom

 Applications:
 Compound rubber and plastic solids
 Masticate crude rubber
 Devulcanize rubber scrap
 Make water dispersion and rubber solution

 Shorter time and small batches

 Cooling is done by:

 Water spraying on walls
 Circulating through hollow agitator shaft

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Banbury Mixer
Banbury Mixer
 Design of Blades

 Sigma blade:

 Used for general purpose kneading

 Edges are serrated to give a shredding action

 S-type Double-naben (fish-tail blade):

 Effective with heavy plastic materials

 develop high shear force

 Z-type Disperser blade:

 Heavier and develop high shearing forces

 Disperse powders or liquids into rubbery masses.

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 Kneader
(Sigma Blades)
 Kneader
(Sigma Blades)
Double Naben Blades Z-type Disperser blade
Continuous Kneaders

 Continuous operation

 deals light to fairly heavy materials (heavy, stiff, or gummy

materials)

 consist of
 Single horizontal shaft
 Slow in motion
 Rows of teeth on shaft arranged in spiral pattern
 Stationary teeth on the wall of casing
 Close clearance between dynamic and stationary teeth

 Shaft turns and also reciprocates in the axial direction

 Smearing action b/w teeth in axial or longitudinal direction as

well as radial shear

 Several tons per hour
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 Mixer Extruders

 The discharge of continuous kneader is restricted by covering

it with an extrusion die

 Pitched blades of the rotor build up considerable pressure in

the material
 Material is cut and folded and subjected to additional shear

 Contain one or two horizontal shafts, rotating but not

reciprocating , carrying blades set in a helical pattern.

 Pressure is built by reducing the pitch of helix or by reducing

the diameter of chamber or both

 Continuously mix, compound, and work thermoplastics, clays,

and other hard-to-mix materials.

 Heating jacket is provided. 29
Mixer Extruder
 Mixing Rolls

 Smooth metal rolls at variable speeds

 For pastes & deformable solids to intense shear

 3 to 5 horizontal rolls in vertical stack

 Material moves from slower to faster ones

 Batch roll mills has two rolls set in horizontal plane and

require long mixing time and attention

 Used for dispersing solids in rubber and plastic materials

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Mixing Rolls