The process with accurate mixing technology is essential when developing a new product because quality, economic, and safety issues depend on it.
The 5 steps to follow for a successful mixing
To obtain a good agitation, laboratories or industries must take different parameters into account:
· Step #1: identify the type of mixture to be made.
· Step #2: characterization of the ingredients mixed. It is necessary to know the characteristics and rheology of the ingredients used: density, solubility, granulometry, viscosity, crystals, gas, etc.
· Step #3: characterization of the mixing tools. Good knowledge of the product’s nature makes it possible to determine the flow required for optimal mixing.
· Step #4: definition of the tools in a tank. The tool(s) location in the agitated tank affects the pumping and shear rate.
· Step #5: calculation of mixing parameters: rotation speed, peripheral speed, circulation rate in the tank, mixing time.
Choosing the right mixing tool according to the application and mixing process
The determination of the tool will depend on the type of mixture. There are four main types of mixing familiar to any application sector.
Tools for a liquid/liquid mixture with miscible liquids
Axial flow propellers promote circulation in the medium. To homogenize the liquids and the temperature (heating/cooling), our experts recommend using turbines such as the four-blade, profiled three-blade, and marine propeller.
Tools for a liquid/liquid mixture with non-miscible liquids
The mixing mobile must allow shearing to disperse one phase into another. The emulsion is used to manufacture cosmetic creams, toothpaste, and balms.
Radial flow turbines are ideal for emulsions, as well as rotor-stators emulsifier.
Tools for a liquid/solid mixture
Requirements vary according to the characteristics of the particles. Soluble powders need circulation to dissolve the particles in the liquid. Non-soluble powders need circulation to suspend the powders in the medium (pigments, for example). Or need a shearing effect to disperse the particles.
Axial flow propellers generate circulation. Radial flow turbines generate more shear to favor the dispersion and transformation of the particles.
Tools for a viscous/slurry mixture
The viscous mixing process is more complex to implement. The Trimix triple agitation mobile integrates an emulsifier for agitation at the bottom of the tank, three-bladed propellers on three levels in the tank’s center, and a scraper.
After obtaining the emulsion, air can be incorporated to get a foaming aspect, a lighter and airier product. The circulation movement allows air integration, and the shearing action reduces the size of the air bubbles.
Would you like to know more about choosing a mixing unit? Watch our webinar “The key criteria for a successful mixing process”.