Compile a list of ingredients
Numerous ribbon stand mixer design features will be influenced by your ingredient characteristics, and beginning with this knowledge will assist your equipment maker in optimising the design. This way, you’ll get the size and functionality you require without having to pay for unnecessary extras. Which features you include will depend on the state of the materials, whether they are solid, powder, liquid, or paste. For solids, it’s advantageous to be familiar with any of the following:
No. of ingredients
Density of matter
Weight Variation in particle size
Sensitivity to the extreme
Create a system that is optimal for your ingredients. Download the Weighing and Batching Engineer’s Guide >
Requirements for Recording Facilities, stand mixer
Space may be an issue in some buildings. This has an effect on your mixer’s footprint and profile, which in turn has an effect on volume and production. If a large 8 or 10 tonne ribbon mixer is required to satisfy production requirements, ensure that it does not obstruct other equipment or create worker risks.
Calculate Total Manufacturing Production
The amount of material to be mixed will help you establish the size and profile of the ribbon mixer design, as well as the number of mixers you may require. This manner, you avoid investing in a mixer that is larger than necessary or that is incompatible with your entire cycle duration.
Calculate the Mixing Time with stand mixer
Generally, your ingredients must pass through the mixer three times entirely to be adequately blended. How long this takes varies according on the dimensions of the ribbon mixer and the qualities of the ingredients. To be deemed sufficiently mixed, the coefficient of variation must be less than ten. Prior to using your ingredients, test the mixer and system to ensure that there is no excessive variance and that the cycle time is optimal.
Time Stamp for Weighing
While reducing mixing time can result in increased efficiency, this is not the case if the mixer is idle while ingredients are measured. The time required to weigh and discharge ingredients will provide you with an indication of the optimal mixing time. If the times for weighing and mixing are nearly same, you can minimise idle time for each process.
Accurate Design of Agitator Profiles
To obtain an adequate mix, you must completely fill the ribbon mixer to its swept volume. This means that the agitator profile contributes to the amount of material that the machine can mix in a single cycle. The mixer profile should not be greater than 2.5 times the agitator’s diameter. The agitator’s design, particularly the ribbon thickness and shaft, may also be an influence, as a heavier agitator requires more energy to move and produces greater shear. If the agitator design is adequate for the ingredients and facility, a simpler agitator design can lower the initial outlay.
Determine the profile of the ribbon mixer
You can establish the best ribbon mixer profile using the preceding information. Longer mixers will be able to mix a greater volume, but at a slower rate, which will not be an issue provided the cycle time matches the weighing time. To achieve a shorter mixing time and more volume, you must proportionately scale up the ribbon mixer profile.
The quantity of ribbon mixers , stand mixer
In some circumstances, it may be more cost effective to employ two ribbon mixers rather than a larger one. This way, if a mixer fails, production will be reduced rather than halted.
Considerations for Liquid Coating
If you require a liquid coating for your ingredients, you may decide to apply it during the mixing stage. Bear in mind that some liquid coatings may not be applied uniformly or may not be suited for spray nozzles at this stage. If the liquid coating can be applied during the mixer cycle, be sure to account for any additional adherence. If the materials adhere to one another or to the mixer, additional maintenance may be necessary, reducing the ROI.
While ribbon mixers are generally mild and impose little shear on ingredients, this can be a critical factor when working with some shear-sensitive compounds. Consider both solid and liquid elements; are they prone to break apart or separate? Is further shear required to break up clumps in the ingredients? The majority of mixer manufacturers are willing to do testing to discover the optimal setup for your product.
The majority of ribbon mixers work at roughly 20 revolutions per minute, while the horsepower required varies according on the mixer’s size and the qualities of the ingredients. Ascertain that you do not overestimate your motor and thus incur additional costs, or that you do not underestimate your motor and thus lower the power available to your ribbon mixer.
Install a Sufficient Discharge Gate
The discharge gate on your ribbon mixer(s) will be determined by the cycle time, downstream process, and material composition. While drop bottom discharge gates provide rapid discharge, they can be more difficult to shut, allowing particles to escape. This can be difficult with extremely fine components. The discharge rate of slide gates will be slower, but they will seal more tightly. Multiple slide gates can be used to create a tight seal while allowing for a faster discharge.
The type of gear reducer employed in your ribbon mixer motor can result in additional maintenance expenditures. In lieu of a jack shaft or foot mount, a shaft reducer avoids the need for an oil bath on the sprocket.
Certain ribbon mixers are easy, and mixer design has remained relatively consistent over time and across the industry. Others are more intricate, and taking into account all of the components might help you improve the design. With the proper ribbon mixer design from the start, your mixer will continue to operate silently and efficiently in the background, with no complications.