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Process Unit Operations

Batch Process Manufacturing – Mixing & Blending

The quality of your final product has a direct correlation to how well it is mixed. Incorrectly selected mixing equipment causes inconsistencies in particle size, reactivity, texture, composition, etc.  In addition, optimized mixing process systems lead to less scrap product, shorter batch cycles and keep operational costs low.  EPIC has over 15 years of experience in line blend process manufacturing, including customizing mixing systems to combine different processing steps into the process blend skid (i.e. heat transfer, drying, coating, etc.) with lower power consumption and improved line blend performance.

Blending fluid can be achieved in either batch mixing systems or continuous mixing systems. Although the terms “blending” and “mixing” are often used interchangeably, they are slightly different processes. Mixing results in a uniform product, whereas products that are blended are truly homogeneous. When a process blend skid is used, two substances are infused  in equal parts to become indistinguishable from each other. In mixing, the contributing feeds may not make up the final product in equal parts.

Ready to talk to an EPIC engineer about your project? Call 314-845-0077 or contact us.

A batch chemical mixing module sits in front of other industrial skids

Line Blend System for 100+ Formulas Includes Continuous Process Mixing Systems and Various Batch SystemsManuafcturing Plant Design

An automotive parts client required a flexible chemical mixing system for 100+ formulas for treatment dips. EPIC integrated the chemical plant process mixing systems with intricate multi-stage batch control system, and a high level of communications, for real time changes and continual improvement.

 Read more about the industrial batch mixing system for 100+ formulas… 

Key Features: Chemical treatment dips, automated mixing system, batch mixing, Wonderware InBatch Software, Class 1, Group D, Division 1, hazardous area, line blend system

Blending System Design/Build Project Allows Client to Be First to Market with New Product

Client wanted newly designed process mixing system that blended 14 raw ingredients which required blending of aggregates, raw materials pre-mix skid, full blending system, and process/packaging integration. A condensed two-month project timeline was achieved through Front-End Engineering, modular process design/build and project collaboration.

Read more about this blending vessel here…

Key Features: Wonderware HMI and Controllogiz PLC integration, line blend, blending vessel, mix blend.

To get pricing information or discuss your mixing process project with an EPIC engineering specialist, please call 314-845-0077 or fill out the form below.

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The phases involved in the mixing process make a difference in equipment selection. Contact an engineer today to start designing your mixing system.

A classification of mixing processes is below:

Classification of Mixing Processes

After fully extracting your process needs and performing the necessary design calculations, EPIC’s engineers will help you select the best equipment for your process blend skid. Common mixing and blending systems & equipment include:

Types of Mixing Systems

    • Liquid Batch Mixing
      • Viscous
      • Single pot processing
      • Non-Newtonian
      • Micro-susceptible
      • Flammable liquids
      • Toxic fluids
    • Batch Mixing (Mass or Particle)
      • Powders
      • Granules
      • Pellets
    • Advanced Batch Mixing Techniques
      • Industrial in-tank agitators
      • High shear mixers
      • Scraped blade mixers
      • External re-circulation systems

Batch Mixer Equipment

  • Change-can mixers
  • Blend tank skid
  • Process blend tank
  • Helical blade mixers
  • Double-arm kneading mixers
  • Screw-discharge batch mixers
  • Banbury mixers
  • Blend tank system
  • Blended process
  • Suspension blending
  • High intensity mixers (intensive mixers)
  • Roll mills
  • Bulk blenders
  • Micro blender
  • Blending vessel
  • Ribbon blenders
  • Plow mixers
  • Cone and screw mixers
  • Pan muller mixers
  • Batch mullers

Continuous Mixers

    • Single-screw mixers
    • Rietz extruder
    • Twin-screw extruders
    • Inline shear mixer/inline shear mixing system
    • Farrel continuous mixers
    • Through-and-screw mixers
    • Blend tank skid
    • fmc blending
    • Process blend tank
    • Blend liquids
    • Holo-flite processor
    • Porcupine processor
    • Pug mills
    • Continuous muller
    • Kneadermaster
    • Static mixers
      • Kenics
      • Sulzer
    • Jet mixers
    • Agitated line mixers
    • Micro Blender
    • Blending fluid
    • Tumblers
    • Twin-shell mixers
    • Suspension blending
    • Process blend system
    • Double cone mixers
    • Horizontal drums
    • Ribbon mixers
    • Vertical screw mixers
    • Twin rotor
    • Turbine mixers
    • Tanks – various sizes
      • Unbaffled
      • Baffled
      • Agitated vessels
    •  Impellers
      • Close-clearance impellers
      • Radial-flow impellers
      • Top-entering impellers
      • Axial-flow fluidfoil impellers
    •  Stirrers
      • Close- clearance stirrers
    • Injectors
      • Mixing nozzles

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EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US
(314) 845-0077

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