Batch and continuous mixing.pdf

BATCH AND CONTINUOUS MIXING,
RAPID MIXING GRANULATOR
SUBMITTED BY: SUBMITTED TO:
NAME – SACHIN DR. SUSHAMA TALEGAONKAR
ENROLLMENT NO. – 24/MIP/SPS/22

INTRODUCTION
 Mixing is a process in which two or more ingredients are treated so that each
particle of any one ingredient is as nearly as possible adjacent to a particle of
each of the other ingredients.
 Mixing results in a randomization of dissimilar particles within a system.
2

WHY MIXING?
 To secure uniformity of composition so that small samples withdrawn from a bulk
material represent the overall composition of the mixture.
 To improve single phase and multi-phase systems.
 To control heat and mass transfer.
 To promote physical and chemical reactions.
3
Khar R.K.,Vyas S.P., Ahmad F.J., Jain G.K.,“The Theory and Practice of Industrial Pharmacy”, Fourth edition, Published by CBS publishers.

CLASSIFICATION OF MIXERS
Mixers
Liquid
mixers
Batch
Impellers
Propellers
Turbines
paddles
Jet mixers
Air jet
Fluid jet
Continuous
Baffled
pipe
Mixing
chamber
Semi-solid
mixers
Batch
Kneaders
Sigma-blade
Planetary
Muller
Continuous
Mills
Roller
Colloid
Solid
mixers
Batch
Tumblers
Twin-shell
Double cone
Drum
Cube
Slant double
cone
Agitator mixers
Ribbon
Planetary
Nauta
Fluidized
Processors
Lodige
Diosna
Gral
Continuous
Barrel
Zig-zag
4

Mixer
classification
Batch type
Rotation of
the entire
mixer body
with no
agitator or
mixing blade
1.Barrel
2.Cube
3.V-shaped
4.Double cone
5.Slant
double cone
Rotation of
the entire
mixer body
with a
rotating high
shear agitator
blade
V-shaped
processor
Double cone
formulator
Slant double
cone
formulator
Stationary
body with a
rotating
mixing blade
Ribbon
Sigma blade
Planetary
Conical screw
High-speed
granulations
(stationary body
with a rotating
mixing blade
and high speed
agitator blade)
Barrel
Bowl
Air mixer
stationary
body using
moving air as
agitator
Fluid bed
granulator
Fluid bed
drier
Continuous
type
Zig zag
5
CLASSIFICATION OF MIXERS BASED ON MIXER ASSEMBLY
Lachman L., Lieberman H.A., et al, “Pharmaceutical dosage forms: Tablets”, Volume 2, Second edition, Published by Marcel Dekker, Inc New York.

BATCH MIXING
IMPELLERS
 Liquids are most commonly mixed by impellers rotating in tanks.
 Types of impellers:
i. Propellers
ii. Turbines
iii. Paddles
 These types of impellers are made on the basis of the type of flow pattern they
produce on the basis of the shape and pitch of the blades.
6

PROPELLERS
Principle
 Shearing force is the main principle behind the propeller mixer.
Construction
 The vessel has a propeller attached to it.
 Angular blades enable fluid to flow in both axial and radial directions.
 Propeller size can be increased up to 0.5m depending on the size of the tank.
 The propeller rotates at higher speed generally in the range of 2000 to 8000 RPM.
7

Advantages
 Propellers are used when high
mixing capability is required.
 Effective for mixing liquids
having viscosity in range of 2
Pa.s or slurry with up to 10%
solids of fine particle size.
 Propellers increases the
homogeneity of materials.
Disadvantages
 Propellers are not effective with
liquids of viscosity greater than
5 Pa.s. e.g., Glycerin and castor
oil.
 Vortex causes frothing.
8

APPLICATIONS
 Propellers are used when huge quantities of liquids and dispersions are to be mixed.
 Used for mixing liquids having a viscosity of about 2 Pa.s.
 Propellers can handle corrosive materials with a glass lining.
 Propellers are employed in the production of emulsions.
9

TURBINES
Principle
 Turbine mixer agitators can create a turbulent movement of the fluids due to the
combination of centrifugal and rotational motion.
Construction
 A turbine consists of a circular disc to which a number of short blades are attached.
 The blades may be straight, pitched, curved, or disk type.
 The turbines rotates at a slower speed usually 50-200 RPM than the propellers.
10

Advantages
 Effective in mixing high viscous
solutions (up to 7 Pa.s) e.g.,
Liquid paraffin, glycerin etc.
 Highly suitable for making
dispersion containing 60% solids.
 Generate higher shearing
forces than propellers.
Disadvantages
 Possibility of air entrapment that
may cause oxidation of material
being mixed.
 Limited flexibility.
11

APPLICATIONS
 Turbines are used in preparing emulsions, suspensions and syrups.
 Highly used in chemical reactions and extraction operations. For example, liquid and
gas reactions.
12
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PADDLES
Principle
 Paddle work with producing a uniform laminar flow of liquids. Paddles push the
liquid radially and tangentially with almost no axial action unless blades are
pitched.
Construction
 A paddle consists of a central hub with long flat blades attached to it vertically.
 Two blades or four blades are very common.
 A paddle rotates at a low speed of 50 RPM.
13

Advantages
 As paddle-impellers mix liquids
with low speed the possibility of
vortex formation is least.
 These are heavy-duty mixers
suitable for slow operation.
 They can mix systems effectively
with 2 or 4 blades.
Disadvantages
 Mixing of the suspensions is poor,
thus, baffled tanks are required.
 They are not efficient for mixing a
variety of materials with different
consistencies.
14

APPLICATIONS
 Manufacturing of antacid suspensions (Aluminium hydroxide gel and magnesium
hydroxide).
 Preparation of antidiarrheal mixtures such as bismuth-kaolin mixture.
 Paddle mixers are used in dissolution testing, a critical process in pharmaceutical
development and quality control.
15

JET MIXERS
1. Air jets
Principle
 Compressed air is allowed to pass at high
pressure from the bottom of a vessel which
creates turbulence, air bubbles are formed in
the liquid phase.
 The buoyancy of the bubbles lifts the liquid from
the bottom to the top of the vessel.
16

Advantages
 Liquids of low viscosity, non-
foaming, non-reactive with the
gas employed are mixed
effectively.
 Intense turbulence generated by
the jet produces intimate mixing.
Disadvantages
 Liquids of high viscosity cannot
be mixed with air jet mixer.
17

APPLICATIONS
 Air jet mixers are employed to create stable emulsions by dispersing immiscible
liquids.
 Air jet mixers are utilized in wastewater treatment plants.
 Air jet mixers are used for the removal of entrapped air or gas bubbles from
liquids.
18

2. Fluid jets
Principle
 Pressurized liquid is pumped through the jet nozzle into the tank for mixing.
 The change from the pressure energy to kinetic energy creates a region of low
pressure that entrains liquid from within the tank via open suction ports.
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Advantages
 No moving parts inside the tank.
 Quick mixing time.
 Suitable for mixing sludges.
 Multiple mixers can be installed.
Disadvantages
 Susceptible to clogging if the
tank contains solids.
 High maintenance costs.
20
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APPLICATIONS
 Liquid jet mixers are used for mixing and blending liquids of different viscosities
and densities.
 Mixing and blending of petroleum products.
 Liquid jet mixers can be used for heat transfer and cooling applications.
 Liquid jet mixers are utilized for efficient mixing of gases and liquids.
21

CONTINUOUS OR IN-LINE MIXER
1. Baffled pipe
Principle
 Baffled pipe mixing involves disrupting
the flow pattern, generating
turbulence, increasing surface area,
extending residence time, and
promoting mixing through the use of
internal baffles.
22

Advantages
 Enhanced mixing efficiency by
promoting turbulence and
disrupting laminar flow.
 Reduction of dead zones or
stagnant regions.
 Increased surface area.
Disadvantages
 Pressure drop in the system due
to the presence of obstacles
(baffles) within the flow path.
 Maintenance and cleaning
problems.
 Risk of blockage.
23

APPLICATIONS
 Baffled pipes are extensively used in chemical processing industries for mixing
different chemicals, reagents, or reactants.
 In biopharmaceutical manufacturing processes, baffled pipes are used for the
mixing of cell cultures, media, and bioreactor contents.
 Used in chemical reactors to enhance mixing and reaction kinetics.
24

SEMI-SOLID MIXERS
 The mechanism involved in mixing semisolids depends on the characteristic of the
material which may show a considerable variation.
Powder
state
Pellet
state
Plastic
state
Sticky
state
Liquid
state
Mixing of the plastic
material is facilitated by the
application of shear forces.
25

BATCH MIXING
1. SIGMA BLADE MIXER
Principle
 Sigma blade mixer involved shearing which is produced by inter-meshing sigma
shaped blades which promotes both lateral and transverse motion of the
material.
 The geometry and profile of the sigma blade are 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.
26

WORKING OF SIGMA BLADE MIXER
 Materials are loaded through the top of the trough to typically 40 to 65
% of the mixer’s total volumetric capacity.
 The blades move at a different speed using the drive system.
 The material moves up, down and shears between the blades and the
wall of the trough.
 The equipment is also attached to the perforated blades to break lumps
and aggregates.
 The discharge of the material is either by tilting the mixing vessel,
through the bottom discharge valve, or through a discharge screw.
 The homogeneous mixture is obtained within 10 to 30 min with a mixing
homogeneity of up to 99%.
27

Advantages
 The sigma blade mixer leaves
fewer dead spots during mixing
operations.
 It is ideal for mixing and
kneading highly viscous mass
and sticky products.
Disadvantages
 Power consumption is very high
compared to other types of
mixers.
 Requires more space for
installation.
 Requires proper blade speed
adjustments.
28

APPLICATIONS
 The sigma blade mixer is a commonly used mixer for high viscosity materials in
preparing emulsions, syrups, and ointments.
 Sigma blade mixers are used for the wet granulation process in the manufacture
of tablets.
 It is used for solid-liquid mixing as well as for solid-solid mixing.
29

2. PLANETARY MIXER
Principle
 The principle is based on the rotation of
planetary blades on their own axis while they
travel around the center of the mixing bowl
which ensures complete and effective mixing.
 The mixing blades revolve in opposite
direction to sweep the entire circumference of
the vessel as well as rotate around its own axis.
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WORKING OF PLANETARY MIXER
 The material to be mixed is loaded in to the bowl.
 The planetary motion of the beater enables faster and
better mixing of material in a considerably short time.
 The operation at slow speed is suitable for dry mixing
with less dust generation and faster speed for kneading
operation during wet granulation.
 After the mixing is completed, the bowl is lowered and can
be easily detached and removed from the mixer assembly.
 The mixed contents are discharged either by hand
scooping or through a bottom discharge valve.
31

Advantages
 There are virtually no dead
spaces in the mixing bowl.
 Homogenous mixing with
uniform consistency.
 By the operation of Planetary
mixer the wastage of particles
is minimum.
Disadvantages
 It generates heat which may be
unsuitable for proper mixing.
 When handling high viscosity materials
the energy required is more.
 High maintenance due to moving
part.
32

APPLICATIONS
 Planetary mixers are used for wet/dry solid-solid materials mixing.
 It is used for the dry powder to wet phase mixing for wet granulation.
 In pharmaceutical and chemical industries the function of planetary mixer is the
mixing of various ingredients to form lotions, creams, emulsion, paste and semisolid
mixture.
33

CONTINUOUS MIXING
1. ROLLER MILL
Principle
 The principle of the roller mill is breaking and
crushing actions are achieved mechanically with the
application of pressure.
 Stress is applied by rotating heavy corrugated
wheels (mullers or rollers).
34

Working
 The material passes from the hopper A,
between rolls B and C, and is reduced in size
in the process.
 The gap between rolls C and D, which is
usually less than that between B and C,
further crushes and smoothens the mixture,
which adheres to the roll C.
 A scraper E, is arranged so as to continuously
remove the mixed material from the roller D.
35

Advantages
 Produce more uniform, fewer
fines, and oversized particles
when it comes to product quality.
 Generates less heat.
 Less moisture loss.
 Low machine noises level.
Disadvantages
 Additional operator inputs are
required since the rolls need to
be adjusted to suit grind
requirements.
36

APPLICATIONS
 Used in the pharmaceutical industry for size reduction of active pharmaceutical
ingredients (APIs) and excipients.
 Roller mills are used for grinding rubber compounds, plastics, and polymers into
fine powders or pellets.
 Roller mills are utilized in the chemical industry for grinding and pulverizing various
chemicals, minerals, and pigments.
37

2. COLLOID MILL
Principle
 The colloidal mill works on Shearing by using a rotor/
stator.
Construction
 To feed the material hopper is used, which is
attached to the rotor and Stator assembly.
 Rotors and Stators used for Shearing the mixture.
 Motor assembly to rotate.
 A discharge point for outlets the mixture.
38

Working
 The liquid containing solid particles is put into the hopper.
 A suspension or liquid passes through the moving part (Rotor)
and Non-Moving (Stator), which causes a high shearing force
between the two narrow gaps.
 Shear stress force can be reduced or increased by changing the
gap (50 to 1000 mm) and by changing rotor speed (1000 to
25000 rpm), but in most cases the speed is 2000 to 18000 rpm.
 The liquid mixture continuously flows through these two-part and
makes it homogeneous, then finally drains out through the outlet.
39

Advantages
 The machine is self-draining.
 High capacity and minimal
requirements.
 Low machine noise level.
Disadvantages
 It has no wide application in
solids.
 Wear of the rotating plates.
 No fine grinding.
 Consumes energy though still
dependent on some factors.
40

APPLICATIONS
 It is used for the formation of homogeneous mixtures, suspensions, and emulsions
in pharmaceuticals, especially for tablet coating solutions.
 Its capabilities to produce a high suspension by reduced Particle size up to 3
microns.
 Colloid mills are employed in the chemical industry for the dispersion and size
reduction of various materials, including pigments, dyes and resins.
41

SOLID MIXERS
Mechanisms of
solid mixing
Convective mixing
The movement of groups of
adjacent particles from one
place to another within the
mixture.
Shear mixing
The change in the
configuration of ingredients
through the formation of slip
planes in the mixture.
Diffusive mixing
The redistribution of particles
by the random movement of
particles relative one to the
other.
42

BATCH MIXING
1. TUMBLERS
A tumbling mixer consists of a container of the one of several geometric forms, which
is mounted so that it can be rotated about an axis to cause movement of the material
in all planes, which is necessary for rapid overall mixing.
Various types of tumblers with different geometric shapes such as:
a) Twin-shell
b) Double-cone
c) Drum
d) Cube
e) Slant double cone 43

44
GRADES OF STEEL USED IN MANUFACTURING OF EQUIPMENT
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a). Twin shell V-blender
Principle
 The working principle involved in twin shell blender is tumbling and cascade
action.
Working
 V-blenders should be filled to a volume between 50 and 60% of their
entire capacity.
 Tumbling occurs when the blender is rotated. The V-blender continuously
separates and recombines the material as it tumbles.
 Continual convergence and divergence between the material and the
blender results in homogenous mixing.
 A blend is usually completed in between 5 and 15 minutes depending on
the properties of a material being blended.
45

APPLICATIONS
 V blenders used in dry mixing of
solids, delivering efficient blending
in a short span of time.
 V blenders are widely used in the
food industry for products such as
dry flavors, spices, and baby foods.
46
Paul E.L., Kresta S.M., et al., “Handbook of Industrial mixing”, Published by John Wiley & sons, Hoboken, New Jersey.

b). Double cone blender
Principle
 The working principle involved in Double cone blender is also
tumbling and cascade action.
Working
 The powder is filled up to two third of volume of blender to ensure
proper mixing.
 The rate of rotation should be 30-100 revolutions per minute.
 On rotation mixing occurs due to tumbling motion. The product can be
discharged from the bottom of the equipment.
 The mixing tank can be slanted freely at the angle of 0° to 360°
degrees for discharging and cleaning purposes.
47

APPLICATIONS
 For mixing dry powder and granules for
tablets and capsules formulations.
 In the cosmetic industry it is used for blending
powders, pigments, fragrances, and other
cosmetic ingredients.
 It can also be used for pharmaceutical industry,
food industry, chemical process industry etc.
48

c). Slant double cone blender
Principle
 The working principle involved in slant double cone
blender is tumbling and cascade action.
Working
 Its working is similar to the double cone mixer only
difference is the slant design.
 The slant double cone design eliminates dead spots which
occasionally occur in conventional double cone mixer.
49

Advantages
 Minimal attrition when blending
fragile granules.
 Large capacity equipment
available.
 Easy to load and unload.
 Minimal maintenance.
Disadvantages
 High head space needed for installation
(particularly with V-shaped mixers).
 Tumbling type blenders not suitable for
fine particulate system.
Advantages and disadvantages of V-shaped, Double cone and slant double
cone mixers.
50

2. AGITATOR MIXERS
 Agitator mixers employ a stationary container to hold the material and bring about mixing
by means of moving screws, paddles, or blades.
 These mixers do not depend entirely on gravity.
 The high shear forces that are set up are effective in breaking up lumps or aggregates.
 Well-known mixers of this type include the following:
a) Ribbon mixer
b) Planetary mixer
c) Nauta mixer
d) Fluidized mixer
51

a). Ribbon blender
Principle
 The principle involved in ribbon blender is shear, which is supplied to the material (powder bed) by the
rotating blades.
 Along with shear, convective mixing also occurs.
 High shear forces are developed which break the lumps and aggregates.
52

Working
 The feed material is charged in the blender through nozzles or feed-
hoppers mounted on the top cover of the blender.
 The material is loaded by typically filling 40 and 70 % of the total
volume of the container.
 The ribbon agitator is designed to operate at a peripheral speed
(also known as tip speed) of approximately 100 m/min.
 As a result of the radial and the counter-current axial movement,
homogenous blending is achieved within 15 – 20 min of start-up
with a 90 – 95 % or better homogeneity.
 After blending, the material is discharged from a discharge valve
located at the bottom of the trough.
53
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Advantages
 The rate of shear can be
increased with the help of
perforated blades.
 Require less space.
 Low mixing time.
Disadvantages
 Formation of dead spots
(unmixed areas) may occur.
 Produces less shearing force
compared to planetary mixer.
 It has fixed speed drive.
54

APPLICATIONS
 Ribbon blender is used for mixing solids containing fine particles, wet masses,
plastic solids, fibrous and sticky material.
 It is also used for mixing solids having uniform density and particle size.
55

b). Nauta mixer
Principle
 The principle involved in nauta mixer is convective mixing.
Working
 The nauta mixer consists of the vertical cone shape of the vessel
inside which the screw is mounted upon the central arm.
 The screw rotates at very high speed around 70 to 80 RPM and
rotates inside the periphery of the vessel, while the central arm
rotates at a very low speed around 1 to 2 RPM.
 This rotation creates the convective action of mixing of raw materials
inside the cone shape mixing vessel.
56

Advantages
 Require less floor space.
 Fast mixing time.
 Minimum heat generation.
 Self emptying with minimum
product retention.
Disadvantages
 High maintenance.
 Require computational demand.
57

APPLICATIONS
 Mixing and homogenization of powders, pastes and slurries.
 Vacuum drying of pastes and slurries.
 Granulation or agglomeration of powders by the addition of a binder liquid.
 Reaction under vacuum or pressure conditions.
58

c). Fluidized mixer
Principle
 The air movement is used for mixing powders. Air is
admitted at its base at an angle which gives tumbling
action and spiral movements to the powder.
Construction
 It consists of stationary vessel which may be horizontal
or vertical which is made up of stainless steel.
 A wire mesh is placed at the bottom of the vessel which
acts as support for placing the materials.
 Air is allowed from beneath the mesh and circulated by
using a fan.
59

Advantages
 Reduced mixing time.
 Mixing is efficient.
 Useful for drying.
 Also useful for coating with some
modifications.
Disadvantages
 Noise and vibration.
 Limited power range.
 Dependence on Compressed Air
Supply.
60

APPLICATIONS
 Used in the chemical industry for blending and mixing chemicals, including
powders, dyes, pigments, and additives.
 Fluidized mixers find application in the blending and granulation of nutraceuticals,
herbal extracts, and dietary supplements.
 In blending and coating of fertilizers, pesticides, and agricultural additives.
61

3. Processors or Rapid mixer granulator
 Rapid mixture granulator (RMG) is used in
agitation, and shear mixing (to break internal
molecular force).
 The components of RMG are highly responsible
for the wet granulation process are:
1. Cylindrical or conical mixing bowl
2. Three-bladed impeller
3. Chopper
62
Litster J., Ennis B., “The Science and engineering of granulation process”, Chapter 10, Volume 15, Published by Springer.

 The impeller blade rotates at speeds ranging from 60 RPM to 800 RPM in anti-
clockwise direction.
 Most designs incorporate an off center chopper rotating at very high speed (500 to
3500 RPM).
 These mixer granulators range in scale from 10 litres to 1200 litres and typical batch
time are of the order of 5 minutes.
 Batch high shear mixers can be further divided into two categories:
i. Vertical shaft: Diosna, Gral
ii. Horizontal shaft: Lodige
63

i. Vertical shaft
Diosna mixer granulator
 It is type of high-speed powder mixer and
processor.
 The mixer utilizes a bowl mounted in the vertical
position, a highspeed mixer blade that revolves
around the bottom of the bowl and a high-speed
chopper blade, which functions as a lump and
agglomerate breaker.
64

Gral mixer granulator
 This equipment is a modification of the industrial
planetary mixers.
 The difference between them is the new unit contains two
mixing devices (larger mixing blade & chopper blade
system).
 A large mixing arm is shaped to the rounded configuration
of the bowl and provides the large-scale mixing motion to
the powder.
 A smaller chopper blade enters off-center from the mixing
arm and is located above it.
65

ii. Horizontal shaft
Lodige mixer granulator
 Lodige mixer consists of a horizontal cylindrical shell
equipped with a series of plow-shaped mixing
tools and high-speed blending chopper(s)
assemblies mounted at the rear of the mixer.
 In operation, the plow-shaped mixing tools revolved
at variable speeds to maintain the contents of the
mixer in an essentially fluidized condition.
 Provide a high-volume rate of transfer of material
back and forth across the blender.
66

 The Lodige mixer was one of the first high-shear powder blender capable of rapidly
blending pharmaceutical powders and wet massing within the same equipment.
 With some formulations, the equipment may also be capable of producing
agglomerated granular particles that are ready for fluidized bed or other drying
methods without further processing.
67
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Advantages
 Requires less binder solution.
 Faster granulation.
 Production of less friable
granulation.
 Uniform particle size distribution.
 Reduce dust generation.
Disadvantages
 High maintenance and operating costs.
 Granules are less spherical than
tumbling granulators.
 Difficult to scale and maintain product
attributes.
Advantages and disadvantages of mixer granulators
68

APPLICATIONS
 Used in the pharmaceutical manufacturing industry for mixing different ingredients
for making tablets, and granules.
 Mixing and manufacture of different chemical ingredients in chemical industries.
 Mixing equipment for the manufacturing of different cosmetic products.
 Rapid mixer granulator is used for mixing and blending different food products in
food industries.
69

CONTINUOUS MIXING
Barrel type continuous mixer
 Barrel type continuous mixer is based on the principle
of tumbling motion.
 The presence of baffles further enhances the
mixing.
 When the material approaches the midpoint of the
shell, a set of baffles causes a part of the material
to move inlet end, allowing remaining part to move
forward.
70

Zig-zag continuous blender
 It consists of several “V”-shaped blenders
connected in series.
 When the blender is inverted, the material
splits into two portions, one-half of the
material moves backwards, while the other
moves forward.
 In each rotation, a part of the material
moves towards the discharge end.
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REFERENCES
 Khar R.K., Vyas S.P., Ahmad F.J., Jain G.K., “The Theory and Practice of Industrial
Pharmacy”, Fourth edition, Published by CBS publishers.
 Lachman L., Lieberman H.A., et al, “Pharmaceutical dosage forms: Tablets”, Volume
2, Second edition, Published by Marcel Dekker, Inc New York.
 Paul E.L., Kresta S.M., et al., “Handbook of Industrial mixing”, Published by John
Wiley & sons, Hoboken, New Jersey.
 Litster J., Ennis B., “The Science and engineering of granulation process”, Chapter
10, Volume 15, Published by Springer.
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