This document summarizes different types of mixers used for cohesive solids. It describes change-can mixers, kneaders, dispersers, masticators, continuous kneaders, mixer extruders, mixing rolls, muller and pan mixers, and pug mills. It provides details on their applications, components, operation, and advantages for various mixing applications involving viscous liquids, plastic and rubber solids, and other deformable materials.

1. MIXERS
FOR
COHESIVE
SOLIDS

2. 2
 Appropriate contact
 High viscosity
 Mixing is by combination of low speed
 Shear
 Smearing
 Wiping
 Folding
 Stretching
 compressing
 Mixer have
 high power consumption
 Cooling is required
Mixers for cohesive solids

3. DIFFERENT TYPES OF
MIXERS

4. 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

5. 5
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

6. 6
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
 BATIDORA_PONY_MIXER_500.mp4

7. Change Can Mixer (Pony Mixer)

8. 8
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

9. Change Can Mixer (Beater)

10. 10
Kneaders
 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
 Kneading_Mixing_Machine.pdf
 KNEADER.mp4

11.  It is heavier in construction and draws more power than a
kneader it works on additives & coloring agent into split
material.
 25_hp_Cowles_High_Speed_Disperser_#3497.mp4
 dispersion-kneader-machinery.pdf
Disperser

12.  A masticator is still heavier & draw even more power it can
distigrate scrap rubber & compound the toughest plastic
masses.
 Masticators are often called intensive mixer.
• Masticator Mixer with Screw Discharge.mp4
Masticators

13. 13
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
 Make water dispersion and rubber solution
 Shorter time and small batches
 Cooling is done by:
 Water spraying on walls
 Circulating through hollow agitator shaft

14. Banbury Mixer
Bainite_Automated_Turnkey_Mixin
g_Line_-_Saves_Labor.mp4

15. 15
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.

16. Kneader
(Sigma Blades)

17. Kneader
(Sigma Blades)

18. Double Naben Blades Z-type Disperser blade

19. 19
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
 Several tons per hour

20. 20

21. 21
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.

22. Mixer Extruder

23. 23
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
Mixing Rolls

24. Mixing Rolls

25.  Medium-speed
 Muller-types mixer for batch operation.
 Small-to medium sized sand partical
 Most difficult mixing
 Features:
1. Good mixer for batch of heavy solids.
2. Energy efficiency.
 muller mixer pan type.mp4
Muller Mixer

26. QUESTIONS???