5 Key Benefits of Using Ribbon Mixers in Your Industrial Processes
Ribbon mixers are a type of powder blending machine. Often used for solids-on-solids mixing (coating a dry ingredient onto another), they can also be used for liquid absorption or particle suspension mixes. Their simple construction and low maintenance requirements make them an excellent choice for any facility. They can be customized with various materials, finishes, and paints to suit your needs.
High Mixing Efficiency
Ribbon mixers are practical when mixing various materials with differing shapes, sizes, and densities. One example is trail mix, which includes nuts, seeds, chocolate pieces, pretzels, and granola. In this case, a thorough mix must also be accomplished without damaging the more delicate ingredients. A suitable ribbon mixer for your application helps minimize upfront investment and maintenance costs while maximizing production. To ensure this, work with a supplier who can customize your ribbon mixer to your specific material and application. They can even help with testing to verify that the agitator design is right for your needs. This way, your ribbon mixer will achieve the best possible results. A full-welded construction ensures no gaps are present, which could contaminate fresh powder or cause equipment wear and tear.
Ribbon mixers are designed to perfectly blend up and mix the most dried granules, powders, solids, and light pastes. These machines are lightweight and considered the most versatile, sturdy, and efficient in the pharmaceutical, agricultural, and food manufacturing industries. Ribbon agitators feature two sets of helical metal ribbons – outer and inner. They are welded to the ends of the agitator shaft and sealed to prevent leakage of materials outside the machine. A drive mechanism with a shaft speed and torque suitable for the specific material type powers them. These can also be equipped with PLC recipe controls for enhanced batch-to-batch consistency and data logging. These features allow for minimal maintenance, saving you time and money over the life of the equipment.
Low Energy Consumption
Ribbon mixers can handle various applications, including coating dry ingredients with liquid components or spraying a lubricant onto dry granules. Their versatile nature makes them a good choice for food and beverage processing, pharmaceutical manufacturing, chemical production, and more. Choosing the suitable ribbon mixer for your facility is crucial to ensure it will work with your materials without overheating or damaging them. A ribbon blender with the appropriate size agitator will allow you to process your ingredients thoroughly and efficiently without overworking or straining the mixer’s motor. A variable frequency drive will reduce energy consumption and wear and tear on the mixer motor and drive mechanisms. This is especially important when working with delicate or abrasive ingredients.
Ribbon mixers are used in the pharmaceutical industry to blend powder ingredients such as binders and fillers for tablet production or nutritional products to combine vitamins and flavorings. Proper blending ensures the drugs work as they should. Ribbon agitators can mix materials that other types of industrial mixers would not. This is particularly true regarding powders that are abrasive or sensitive to shear. They also feature a strategically positioned spray system, adding liquid quickly without over-flooding the batch. This allows maximum contact between the agitator and the batch material to prevent the formation of damp clumps. Ribbon mixers can be made with either mild or stainless steel to suit the specific needs of your facility and ingredients. Non-contact areas of the equipment can be lined with other materials to enhance the mixing performance and protect the interior parts from premature wear.
Ribbon mixers can be customized to fit your specific mixing needs. This includes the overall design, drive mechanism, and power consumption. It also includes the powder valve you need on your discharge port and how much volume your mixer can handle. Many ribbon mixers can be modified to meet cGMP standards, which require a Ra0.4 finish on any material-contact parts inside the mixer. Stainless steel is often used for this, as it can be cleaned thoroughly. Other customization options include a variety of materials and finishes for non-contact surfaces. For example, if your facility is working with corrosive chemicals, you may require a different type of coating. This helps minimize upfront costs and maintenance while maximizing production and quality. Customizing a ribbon mixer can also make it easier for employees to work with.