Less equipment, lower cost and improved flexibility are a few of the many reasons inline blending systems and chemical injection skids are smart alternatives to batch manufacturing. EPIC has a team of process engineers with specific inline mixing experience. We leverage our process plant expertise in: flavor, fragrance and dye expansion to rapidly expand your processing capabilities at a minimal cost.
EPIC’s typical in-line blending systems include base/pre-mix dosing, major and/or minor ingredient dosing, liquid metering, in line blender, high shear mixing, in line mixer, in line dosing system, and finished product delivery. These fully assembled and tested systems can be used to create a wide range of finished products. Learn more about typical in-line blending systems designed/built by EPIC below.
Inline Blending FAQs
What types of inline mixer/ liquid metering systems do you design and build?
We build a variety of continuous blending modules that meet your blending, automation and budgetary specifications. All of these system continuously inject ingredients or chemicals for various mixing applications. Common types include:
- in line mixer systems
- Single pass mixing systems
- Inline blender systems
- inline dosing systems
- Liquid metering systems
- High sheer mixing systems
- Minor ingredient injection
- Major ingredient skids
- Base/premix dosing skids
- Finished product delivery
- Base product delivery
For more specific information on your particular application, please contact EPIC to discuss with one of mixing experts.
What products can be made with an inline mixer system?
Products that require considerable mixing energy or mixing that must occur over an extended time period may not lend themselves to inline blending. For example, flammables or mixtures with a wide range of viscosities are usually not suitable for in-line blending applications. There is not a clean cut way to say for sure whether or not your blending application will work as a continuous in-line blend system, but generally, the more of the following criteria that apply, the more likely it can be an in line blender:
- You are currently making the product using batch blending
- No reactions are involved in your blending
- There are no known solubility issues with your ingredients
- There are no or very few flammables involved
- Ingredients have a narrow range of viscosities
- Blending step time requirements are small
- None of your ingredients are dry materials
If you think your application would be a good fit for an in line blender or in line mixer application, checkout our inline blending checklist + planner or contact one of our blending experts: (314) 858-8839.
How much will an inline blending system cost?
This is a loaded question, which is difficult to answer without a significant engineering effort. Some consider in-line blending to be a “cheap alternative” to batching systems, but these systems still require a fair share of engineering and design and are much more than just some pipes flowing together.
There are a lot of factors that go into the cost associated with a chemical in line mixers such as; number of ingredients, number of recipes, accuracy and performance standards, degree of automation, liquid metering system use and required integration with existing equipment. In general, inline mixer systems are still less expensive than batching systems.
How do I know this type of system will mix my product accurately?
Most chemical blending systems can achieve accuracy within 1% deviation of the prescribed formulation. This can vary, and often depends on how a system is run. Continuous inline mixers that are constantly running and producing the same product often achieve deviation rates that are less than a 1% average. Batch in line mixer system that are regularly shut off and have many recipes changes tend to be less accurate.
To ensure a homogeneous mixture immediately after each ingredient addition point a static or high shear mixing additive is added as required. Agitation can also be provided in the finished product surge tank. Catch samples from the inline mix system can be taken to verify that finished product is indistinguishable from product made in a batch process.
All that is required to blend very large flow and small flows together is that measuring instruments and dosing equipment be properly sized for each individual flow stream in the continuous mixing system.
How do I get started designing an in line mixer system with EPIC?
- For a preliminary analysis of your project, please contact EPIC Systems at 314-200-0831 or fill out the fields below. Meeting your needs is our top priority. All project inquiries are evaluated by the Process & Mechanical Director of Engineering, Ken Sipes.We will follow up with you within 24 hours of your submission to discuss your project.Thank you for your interest in EPIC Systems.
In line Mixing Systems: Select Case Studies
An EPIC client required the addition of 20 flavors to their product mix with a limited budget and floor space. By using liquid blending ingredient trees instead of tanks, capitol costs were minimized. Pre-engineered, field-proven in blending systems from EPIC provided a fast, economic solution that allowed the client to drastically expand their product portfolio with minimal equipment additions. Read more about the liquid blending case study….
Key features: Pre-mix blend skid, in line liquid blending system, coupled blending and filler system, back pressure control, product-to-product washout, liquid metering system.
Dual Skid Continuous Chemical Blending System With Variable Flow Rates
A major ingredients module blended a pre-mix and several other ingredients into a base formula. This base mix was pumped to the second skid that added: dyes, ancillary chemicals and perfumes to manufacture a wide range of end-products. The second chemical injection skid was immediately upstream of the filler and both skids featured automated recipe inline mixing controls and variable flow rates.
Why EPIC Modular Process?
We are experienced at fully extracting your technical, operational and commercial specifications. We combine those with our knowledge of process capabilities, scale-up, and modular design/build to help you “Do It Better.” Our process for building complete modular process systems includes:
- Utilizing Front-End Engineering to ensure the proper steps are taken during project scope development
- Modular design/fabrication that reduces traditional downtime through parallel construction and results in cost-savings, increased safety and faster project delivery. Learn more about the benefits of modular…
- Maintaining an open door client policy to promote innovation and communicate. We invite clients to visit EPIC throughout projects
- Imparting a transfer of knowledge, not just basic training, for the chemical blending systems and equipment we provide
For a better solution, contact EPIC today.