Continuous Mixing

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.
  • Mixing Expert Tips
  • 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

Related Articles: Batch Mixing

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