Continuous Mixing

In continuous mixing, the weighing, feeding, mixing and discharge steps occur continuously and simultaneously.
The materials to be mixed flow continuously into the mixer at a measured flow rate.
Materials are mixed as they travel from the feeding point to the discharge point.
The time of travel from the feeding point to the discharge point is termed as the retention time of the material in the mixer.
The discharge rate from the continuous mixer is measured in ‘kg / hr’.
Continuous mixing system are used when:
- High volumes are to be mixed.
- The pre-mixing and post-mixing equipment are operated continuously
The advantages of the continuous mixing operation are as follows:
- Continuous mixers of lower volumes and power produce large quantities of mix, when compared to batch mixers.
- Using online monitoring and measuring instruments, continuous mixers can be operated in an automated mode.
The disadvantages of the continuous mixing operation are as follows:
- Continuous mixers lack of operational flexibility as compared to batch mixers.
- Continuous mixers are not suited for mixing large number of ingredients with high variations in charging quantities.
- Continuous mixers are expensive to maintain.
- Continuous mixers are not suited for applications where product formulations need to be precise.

Segregation of material during discharge can be minimized by locating the mixer discharge near the packing units.
For best results from a continuous mixer, a well defined sampling and material testing procedure should be followed.
The material feeding devices should be carefully calibrated and frequently checked for accuracy.

Related terms- Batch mixers, Batch mixing, Continuous mixers