The Best Way to Mix Powder and Liquid
Creating a truly blended substance can be difficult without the right process engineering company. Viscosities, production output and many other factors must be considered from the very beginning of your project. EPIC’s engineers will augment your staff by partnering with you to address these factors and make sure that you end up with a homogenous blend that can scale up to your production needs. EPIC takes a turnkey approach to engineering, designing and fabricating powder-liquid mixing systems that incorporate powders and liquids into truly homogeneous mixtures.
Our process engineers have 20+ years of experience engineering turnkey powder-liquid mixing systems for products ranging from agrochemicals to powder-based food mix-ins. We serve a wide array of industries including:
- Specialty Chemicals
- Consumer Products
- Food & Beverage
- And more
Powder Liquid Mixing System Examples
Powder Blending System Brings New Detergent to Market
EPIC designed a skid for a Fortune 500 company that allows a powdered ingredient raw material to be added to the blending system and clearly separate the new detergent process from the liquids mixing operations within the manufacturing plant.
Key Features: Raw materials pre-mix skid, full blending system, and process/packaging integration, Condensed two-month timeline from first purchase order to completed commissioning, Wonderware HMI and ControlLogix PLC integration
Liquid Blending Systems for Edible Powder Mix
EPIC designed and fabricated a series of liquid blending systems for a biotechnology company that are used to constitute the proprietary edible powder to be applied to produce. The product is an organic, edible protective coating that slows the aging process of produce.
Key Features: 50-80 Gallon tank capacity, Dual-tank design, On-Demand Inline water heaters, Intuitive operator interface, Food-grade stainless steel sanitary materials of construction, Compact footprint, highly mobile
Batch Reactor System Automates Powder Additions
EPIC duplicated and added automation to the polymer making process to make various sized batches of polymers. The system included manual, vacuum assisted powder additions and automated mixing, batch reacting, and manual storage in 55-gallon drums.
Key Feature: Batch polymer reactor system, Dual reactors on a single skid design, Raw materials handling & ingredient additions, Hazardous material handlingRead Case Study
Powder Liquid Mixing System Services
EPIC specializes in delivering turnkey liquid-powder mixing systems. Our services include:
How to Mix Powder into Liquid
Which type of powder-liquid mixing system is most suitable for your mixing process? At EPIC, we use our in-plant experience to recommend a powder-liquid mixing solution that is right for you based on conversations with you throughout the front end loading process. There are two primary ways to mix powder with liquid.
Continuous Powder Liquid Mixing
Continuous powder-liquid mixing generates a continuous stream your final product. So rather than mixing one batch of liquid with one batch of solid, powder, or liquid, you have a continuous flow of components going into the system and a continuous stream of homogeneous mixture coming out the other end. These mixers may still use different mixing stages to ensure that you get a smooth, incorporated product.
Continuous liquid mixing systems can be helpful in situations where you need a completely identical product every time. The textile industry may use this technology to ensure that dye lots stay the same, and the food processing industry can use it to make sure they have evenly hydrated dough. In addition to improving product consistency, it can also up production since it enables you to produce more from one mixer.
Batch Powder Liquid Mixing
Batch liquid mixing systems, on the other hand, mix only one batch of your product at a time. Think of this like the process you use to make cookies in your home. All of the ingredients are carefully measured out and then they’re added to the mixer at the appropriate times in the process to make one batch of your product.
Batch liquid mixing systems can be very important for industries that are creating multiple different products. The paint and fragrance industries, for example, need to be able to produce different batches of different products. And with proper measuring practices, batch mixing can produce results nearly as uniform as continuous mixing.
Batch VS Continuous Mixing Comparison
There are tradeoffs to both batch and continuous mixing systems. Use the resource below to help inform which system type is right for your process or call 314-714-1580 for guidance from our process engineers.
|Equipment Requirements||Larger tanks are required for batch, and often finished product storage tanks are required for product variations||Best Choice|
|Space||Batching systems tend to have larger equipment (tanks) and can often take up more space than continuous mixing systems||Best Choice|
|Reaction involved||Best choice||Inline blending systems move quickly and do not have time to handle a reaction unless you use a special type of system called a CSTR – Continuous Stirred-Tank Reactor|
|Insoluble ingredients||Best Choice||Insolubles need more time to mix than a typical continuous mixing application allows|
|Flammable ingredients||Best Choice||Highly flammable or a large number of flammables are *usually* too volatile for an inline mixing system|
|Large ingredient viscosity range||Best Choice||Inline blending does not usually allow for enough time for ingredients of very vastly different viscosities to come together|
|Short blending times||You should consider continuous mixing applications for this if there are no other major inhibitors like flammables or dry ingredients. Continuous systems might allow greater flexibility for lower costs||Good Fit|
|Dry ingredients||Best Choice||In general, dry ingredients are harder to move through the piping and instrumentation that continuous inline systems rely on. Batch systems with solid solid mixing equipment is a better choice|
|High Mixing Energy Requirements||Best choice||A large amount of mixing energy is expensive or impossible to cram into the short mixing times typical of inline mixing systems|
|Large number of SKU’s||Requires holding tanks to store multiple variations of product instead of allowing for a quick rinse-out and recipe change like continuous mixing systems.||Best Choice|
|Accurate Ingredient Additions||Batch mix skids are designed to mix for appropriate time intervals that ensure accurate mixing.||Most continuous mixing systems can achieve accuracy within 1% deviation of the prescribed formulation. Continuous inline blending systems that are constantly running often achieve deviation rates that are less than a 1% average.|
|Cost||Typical batch applications require more material mixing equipment and storage the more recipe variations you want to run, so the costs can increase quickly compared to inline blending systems that offer flexible SKU’s with less capital investment and minimal storage requirements.||Best choice|