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Process Unit Operations

Batch Process Manufacturing – Mixing & Blending

Modular Mixing SystemThe 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 batch process manufacturing, including customizing mixing systems to combine different processing steps into the mixer (i.e. heat transfer, drying, coating, etc.) with lower power consumption and improved mixing performance.

Mixing and blending 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 homogenous. When blending 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.

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

Mixing Systems Equipment

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. Common mixing and blending equipment includes:

Batch Mixers

  • Change-can mixers
  • Helical blade mixers
  • Double-arm kneading mixers
  • Screw-discharge batch mixers
  • Banbury mixers
  • High intensity mixers (intensive mixers)
  • Roll mills
  • Bulk blenders
  • Ribbon blenders
  • Plow mixers
  • Cone and screw mixers
  • Pan Muller mixers
  • Batch muller

Continuous Mixers

  • Single-screw mixers
  • Rietz extruder
  • Twin-screw extruders
  • Inline shear mixer/inline shear mixing system
  • Farrel continuous mixers
  • Through-and-screw mixers
  • Holo-flite processor
  • Porcupine processor
  • Pug mills
  • Continuous muller
  • Kneadermaster
  • Static mixers
    • Kenics
    • Sulzer
  • Jet mixers
  • Agitated line mixers
  • Tumblers
  • Twin-shell mixers
  • 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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