Mixers & Blenders

What are mixers & blenders and how do they operate?

Industrial Mixers and Blenders are used in the process of combining different materials to produce a desired product and quality. Blenders & mixers typically operate, by either a high speed blade which provides a high shear to disperse and dissolve materials or a low speed blade, which folds and blends the materials to improve and achieve blend uniformity.

It is imperative that this process runs efficiently because uniformity or lack of, can have a significant effect upon the reaction, durability, performance and quality of the resultant product.


What are the most common mixer and blender issues?

Blend Uniformity

As mentioned above, if materials are mixed and blended unevenly, even the smallest inconsistency could lead to a significant decrease in a materials quality, potentially affecting the size, colour and even taste of the finished product. This could result in complaints from your customers, products being rejected and ultimately costing you precious time and money

Material Segregation

Aeration is the circulation and dissolving of air into the materials which the blenders and mixers contain, which can result in the segregation of particles with different weights, densities and shapes. Whilst light particles in aerated materials will move towards the top of a the mixer of blender, larger and heavier particles will locate and settle at the bottom. Material segregation can therefore exacerbate blend uniformity issues, as well as leading to material buildup and possible blockages.

Discharge Cross Contamination

Discharge cross contamination is an issue which can occur in mixers and blenders when fresh material is mixed with older materials. This can occur when stagnant material builds up on mixer and blender side walls due to friction and as a result restrict material from flowing and thus blending evenly. Stagnant material is effectively wasted material and will result in a loss of money and time, due to the downtime needed on site to manually clean the mixers and blenders.

To avoid costly production delays, mixer and blending issues must be dealt with immediately.

How do Acoustic Cleaners solve Mixer and Blending issues?

Many mixers and blenders are situated in remote locations, meaning that manual cleaning often proves difficult and costly. Acoustic cleaners, however provide both an efficient and cost effective mixer and blender maintenance investment. Unlike other mixer and blending cleaning solutions, Acoustic Cleaners not only deal with mixer and blender issues at present but prevent other issues from occurring again.

Primasonics Acoustic cleaners create a series of high energy- low frequency sound waves, which penetrate materials with rapid pressure fluctuations. By using alternating frequencies, acoustic cleaners are able to target particles that have different masses and which therefore travel at different speeds.

As a result, the compacted materials will vibrate at different rates to their surrounding environment, causing them to debond from each other and dislodge from surfaces. This will eradicate issues concerned with mass flow, and ensure materials are dispensed efficiently.

Unlike traditional mixer and blender cleaning solutions, acoustic cleaners can tailor their frequency to deal appropriately with different with mixers and blenders. The appropriate frequency is determined by the amount of material build up, the viscosity of materials and the natural vibration frequency of the material which the mixers and blenders contain.

Primasonics Acoustic Cleaning technology

What are the benefits of using Acoustic Cleaners in this field?

Non Intrusive– Acoustic Cleaners are designed to reflect sound from solid surfaces. Therefore, the powerful sound waves that they transmit will only penetrate targeted materials and not the structure of mixers and blenders. Unlike other mixers and blender cleaning methods, this will prevent the propagation of wear due to intense vibrations and the therefore the possibility of structural damage.

Prevention– Rather than dealing with specific and localised issues, Acoustic Cleaners are designed to take a holistic and long-term approach to combatting mixer and blender issues. By consistently disbanding the presence of any compacted materials, Acoustic Material provide a preventative solution to not just one but all of mixer and blender issues listed above.

Efficiency– Acoustic Cleaners ensure that the mass flow of material is maintained at all time and the production and dispensing rate is achieved at maximum efficiency. This eradicates any issues that can arise from handling hard-to-flow materials, for example those with a high viscosity, which are more likely to cake and clump together.

Minimal Sound Pollution– The sound waves created by acoustic cleaners only penetrate the targeted material. This means that sound is only increased within the vessel, where cleaning is required and therefore prevents sound pollution in the local area.

Health & Safety– In addition to the elimination of costly manual work and cleaning regimes, acoustic cleaners also eliminate the danger of sparking, as they are powered by compressed air rather than electricity.