200L hydraulic tilt z arm machine with vacuum/jacket heating kneader
Multi-Function Vacuum Kneader Machine
In the past, plasticine manufacturers need different dough mixer for different material’s production. When they were intended to expand the range of product varieties, they need to buy another mixer which they thought it’s not so economical. In a view of this fact, we have researched and developed a new dough kneader that can be used for various Plasticine products’ manufacturing. Besides, it’s suitable to other industry too.
Kneader is widely used in high viscosity and high elastic-plastic material such as chewing gum, bubble gum, toothpaste, plastic, rubber, silicone rubber, dyes, pigments, inks, food gum base, pharmaceutical agents, architectural coatings, carbon, fiber, high viscosity sealant, neutral glass glue, aluminum silver paste, Pulp, cellulose, battery paste, silicone resin, cosmetics, neutral or acid glass cement, paper pulp, medicine, resin, plasticine, BMC/CMC and others industries.
Model
Vacuum Kneader
Full volume
200L
Brim trough size(L*W*H)
650*650*600mm
Trough material
Inner shell: Stainless steel#304 & 8 mm steel plate
Jacket: Carbon steel Q235 coated with heat resistant paint & 6 mm steel plate
Outer shell: Stainless steel & 1 mm steel plate
Heating method
Electric heating
Agitator shape
Sigma type
Agitator quantity
2
Agitator rotating direction
Opposite direction
Agitator Rev
45/33rpm
Radial clearance between agitator and hopper inner surface
2±0.5mm
Axial clearance between agitator and hopper wallboard
1.5±0.5mm
Discharge way
Hydraulic tilt
Main motor power
11KW
Overall size(L*W*H)
2100*1250*1350mm
Vacuum kneader preparation before operation
1. Check whether the fasteners are loose, whether the steam pipeline is leaking, and whether the circuit and electrical equipment are safe. The electric heating type kneader must have a grounding device. 2. Clean the kneading chamber before the test machine. Do 10-15 minutes of dry run, confirm that the machine is running normally, and then put it into production. Generally, the gears (including the reducer) of the new machine are noisy when they are used in the initial stage, and they will naturally decrease after some time. 3. After the machine is installed, first clean, decontaminate and wipe the anti-rust grease. Check each lubricating point and inject lubricating oil (grease). 4. Check the tension of the V-belt before driving, and move the motor to an appropriate position by adjusting the bolt. 5. When steam is used for heating, a safety valve and a pressure gauge should be installed at the steam inlet pipe, and the steam pressure must not exceed the working pressure requirement of the mixing tank indicated on the label. 6. The use of inversion should be reduced when kneading with the paddle.
Precautions for vacuum kneader
1. When stirring, the lid should be covered and the bolts should be tightened. The shaft end is equipped with an adjustable sealing sleeve, which can be adjusted when the material is leaking. Do not put your hands on the cylinder mouth when the cylinder head is lowered to avoid crushing your fingers. 2. Pay attention to the rotation range of the cylinder when lifting and lowering the cylinder of the vacuum kneader, so as not to hurt the human body. Stirring should be stopped when discharging. 3. If any abnormal phenomenon is found when the vacuum kneader is working, it should be stopped immediately, and measures should be taken to eliminate the fault. It is strictly forbidden for the machine to work under abnormal conditions. 4. The vacuum kneader adopts electric heating, steam, oil heating, water cooling, and other methods for temperature adjustment, and adopts hydraulic cylinder turning and covers the opening. The discharge methods include hydraulic pressure, cylinder dumping, ball valve discharge, screw extrusion, etc.
The purpose of flaking is to cool and solidify fusion liquid. The solidified product is shaped thin flake. The flake is capable of conveyance, safekeeping, transportation, and discharging.
Fusion liquid Flake Handling
There is a possibility that the product hardens in the pipe.○It’s possible to carry that by an ordinary conveyor. Safe Keeping×The fusion liquid is easy to oxidize.○Because it’s a solid,it’s difficult to deteriorate compared with liquid.Transportation×Fusion liquid hardens by heat-radiation. Re-heating. It’s possible to put the flake in a flexible container bag.Discharging×Heat-resistance is requested ofthe filling machine.○Because a handling is easy to do, the flake is easy to discharge.
Summary about Drum Flaker The Dip feed type can’t dispose of high viscosity liquid. When viscosity liquid is inserted between the drum and the roll, the high viscosity liquid is stuck in drum. An adjustment in a clearance of the drum and the roll takes time and effort.There are 2 ways of supplying system of melting liquid. We recommend easy “Dip feed” of operation control.It’s possible to put the roll for “Top feed” as an option for high viscosity liquid.Dip feed typeTop feed type Leveling Roll Melting liquid is poured into the pan.This is standard way and operation control is easy compared with the Top feed type. You can put a liquid level sensor on the pan and adjust the provision.Melting liquid Leveling Roll Melting liquid３-２、Supply system of melting liquid
Cooling water is supplied inside the drum.Melting liquid is stuck in the surface of the drum,is cooled and solidify. The production thing which isSolidified is scratched with a scraper and it is taken
Various designs for different operating principles
In view of the large variety of products in the chemical and food industries, it will come as no surprise that also supplies an extremely varied range of machines. This variation is not only in design and operating principle, but also in materials used. PRODUCTS WITH POOR SOLIDIFYING PROPERTIES There are products that do not match the operating principles described on this page, such as products with neither good nor poor adhesion properties, but with poor solidifying properties instead. For those situations, . The surface can also be furnished with special
(dovetail-sectioned) grooves for products with poor adhesion properties.THE DRUMS MATERIAL The drums are mostly made of stainless steel. Besides the choice of many types of stainless steel, chromium-plated, Hastelloy, or cast iron drums are also possible. The exact choice will depend on your product, the work site environment, available space, and the process to be performed. The result is a durable drum with high dimensional stability and uniform heat distribution over its entire surface.
DIP FEED products with low viscosity and good adhesion properties. The rotating drum dips directly into the melt contained in a heated pan under the drum. A film of product solidifies immediately on the drum surface during its contact with the melt. In addition, a thin layer of liquid adheres to the solid layer, passes out of the pan and solidifies during completion of the drum revolution. Among the products processed on this type of drum flaker are phtalic anhydride, caprolactam, fatty acids, bisphenol, naphthalene and DMT.
BOTTOM DIP ROLL A heated applicator roll is located under the drum and dips into the melt. The film of liquid melt that sticks to the applicator roll is transferred to the cooling drum and solidifies. For products with good adhesion to metal surfaces and low to moderate viscosities, flake thickness may be controlled between certain limits. Applications are flaking of va
OVERHEAD APPLICATOR ROLLS For accurate control of end product thickness and shape, an internally heated applicator roll is located above the cooling drum. The melt is fed into the nip between the applicator roll and the drum. Contact with the heated roll ensures that the product remains liquid in the feeding system. Heated endplates prevent leakage of the melt to the sides both during applicator roll gap setting and thermal expansion. A film of melt passes through the gap between the roll and the drum, sticks to the cold drum, and solidifies. For products showing poor adhesion to metals and moderate to high viscosities, flake thickness may be controlled accurately through the gap setting mechanism of the applicator roll. Applications can be found for example in processing of soaps, stearates, and fatty acids
Fine chemicals applications Fine chemicals are complex, single, pure chemical substances, produced in limited quantities in multipurpose plants in multi step batch chemical or biotechnological processes.
The main demands set by the chemical industry to suppliers of equipment are a high safety standard, maximum plant operating time, the economic use of energy, and competence in problem solving. drum flaker can be used for solidification and flaking of various fine chemicals. For industrial implementation, some product properties must be investigated under real process conditions. This can be arranged in our pilot plant.
Essential Oil Distillers is suitable for the extraction of various flowers and leaves which contain essential oil. It adopts water vapor distillation apparatus for water distillation method and water proof distillation method, so the extraction of plant volatile component is effectively, this equipment is suitable for enterprises to set up production near the plant origin place.
The equipment is new, multi functional and multipurpose plant essential oil extraction unit. the equipment can collect the plant essential oil, aromatic plants, and other effective ingredients efficiently.
Features and advantage: Oil extraction rate is very high Adapt to various heating methods Machine structure can be done according to customer requirements This equipment is made of SUS304 stainless steel with special frame. It has Special condenser design which can extract the oil efficiently.
Essential oil distiller working process and working principle:
(a) water vapor water distillation 1) of the material into the extracting tank distillation in the basket, basket distillation for orifice plate structure, distillation blue can be on-demand materials, such as fresh flowers and plants is placed at the bottom of the retort to join a certain percentage of pure water, water not overflow the distillation blue lowest place.General material liquid ratio of 1:3 is best.(can also add a moderate amount of additives according to the technical requirement).
2) open the extraction distillation tank heating system, make the distilled water heated to set temperature (generally for water boiling temperature of 100 degrees Celsius), extract the normal start.When distilled water temperature reached 70 degrees Celsius, open condensate valve. If equipped with ice water unit need to be water temperature reached 50 degrees Celsius is open cold water unit, and maintain stability of the condenser water flow rate.
4) distillation extraction began, condenser condensate must be open.General plant essential oil extraction time is longer, mezzanine boiler temperature can be set to 120 ~ 130 degrees Celsius, distillation tank temperature setting to 102 ~ 105 degrees.To keep the distillation tank water boiling.Ensure that the steam is enough. Operation experience: before distillation temperature reach the set value, can be set higher interlayer boiler temperature, such as 150 degrees, let the temperature rise more quickly, when the temperature difference 10 degrees or so close to the set value, the temperature of interlining boiler to normal, such as 115 degrees.
5) general distillation extraction time is 3 ~ 5 hours, (according to the roses, for example, 3 hours yield efficiency 84.783%, yield efficiency 95.652%) 5 hours after the distillation extraction, shut off the distillation extraction tank heating system, etc. After 20 minutes in the closed cooling water.
6) condenser opens in the extraction tank temperature to 80 ° C, while ensuring the condenser top open open.
7) condenser in normal work, the upper openings with water vapor.If there are any vapor emitted that condensed water temperature too high or low condensed water.If there are any conditions, can use cold water cycle refrigeration unit.It can better improve the effect of the extraction of volatile oil. (note: if the API to powder or tiny particles that can use API into the first fine stainless steel wire mesh paved distillation in the blue, after extraction is advantageous for the liquid out.) (2) water vapor distilled water 1) the flowers and plants such as the material directly into the distillation extraction tank, the bottom of the retort adding suitable amount of pure water, half of the volume of water not overflow the retort, generally for 1/3 of the tanks as well.(can also add a moderate amount of additives according to process requirements, generally increase the concentration of 2.5% concentration of sodium chloride aqueous solution to distillation, obvious effect). 2) open the extraction distillation tank heating system, make the distilled water heated to set temperature (generally for water boiling temperature of 100 degrees Celsius), extract the normal start.When distilled water boiling on condensed water device, guide the steam entering the condenser, cooler, oil water separator.Condensate can be opened in advance Behind (like water distillation operation.)
We are selling below models:
Models
Description
Price
ABFEO100
100L
ABFEO200
200L
ABFEO300
300L
ABFEO400
400L
ABFEO500
500L
ABFEO1000
It can put 120kg flower into the EO1000 Leaves 150kg into EO 1000, L W H : 6000X2300X 3700 MM
ABFEO2000
it can put 240kg flower into EO2000, 300kg leaves into EO 2000, L W H : 5800X2400X3700MM
ABFEO3000
It can put 360kg flower into EO 3000, 450kg leaves into EO3000, L W H :6200X2600X5200MM
Distillation is the art of removing these precious chemicals via high pressure steam or mix of steam and boiling water. To begin distillation, the appropriate amount of plant material is packed into a hopper. The canister is sealed to create atmospheric pressure. The correct amount of water is added for that batch and then heated. Steam is created by either boiling the water in the hopper or injecting steam and forced through the pressurized hopper or vessel containing the plants. The heat of the steam ruptures the molecules in the plant and carries the particles of essential oil and other constituents through a cooling system into another container. When the steam passes through the cooling unit, it reverts back to water, where it separates from the essential oil because of their different densities. Essential oils are lighter than water and will therefore float on top. Water soluble chemicals will stay mixed with water creating extracts or hydrosols. Following is a brief description of three basic methods.
Water Distillation For this method, the plant material is submerged in water. The water is then heated to boiling point During this process, there is direct contact between boiling water and plant material. All parts of the plant material must be kept moving by the motion of boiling water. This method is used with plant material that can’t be easily be broken down with steam or water and steam distillation such as cinnamon bark.
Water and Steam Distillation Water and steam distillation methods employ the same basic equipment as water distillers. The fundamental difference is the plant material is set on a perforated grill above the water as opposed to being immersed in the water. This method is more energy efficient as the essential oil is produced at a much faster rate with higher yields. Thermal degradation is reduced as well. Many oils which contain significant aldehydes such as lemongrass are still produced this way.
Direct Steam Distillation
This type of distiller is designed quite differently than water and water steam distillers. There is no water in the hopper with the plant material. Steam is generated in a separate boiler chamber and then injected into the plant material from outside the still. The plant material is placed on a perforated grid above the steam inlet. A real advantage of steam generation is that the amount of steam can be readily controlled. Because steam is generated in a satellite boiler, the plant material can be heated at lower temperatures of 90- 100° C reducing thermal degradation. A drawback to steam distillation is the much higher capital expenditure on such equipment. Many mass produced essential oils such as rosemary, lavender and eucalyptus, are produced this way
Do All Plants Produce Essential Oils?
No they don’t. In fact of the hundreds of thousands of plant species, only a few thousand may be capable of producing an essential oil. Therefore, when companies state that essential oils are the “life blood of a plant” this is not true.
Can Any Plant be Distilled?
Theoretically, you can distill any plant material, however, you may not like the results. Distillation is reserved for plants which are capable of producing an essential oil and not easily damaged by heat. Jasmine is one of the most coveted aromatic oils in the world but it can’t be distilled without serious thermal degradation which destroys the aromatic properties that make it so precious.
Given that it takes thousands of pounds of petals harvested during a few weeks of the year and a few hours of those days to produce even a few ounces of oil through other effective methods of extraction, it make no economical sense to waste any petals on distillation to produce an inferior product.
Are Plants Which Do Not Produce Essential Oil Distilled?
Some plants such as witch hazel or sweetgrass which don’t produce an essential oil are distilled because their water is coveted for aromatic, spiritual and medicinal properties. Others can be concentrated to create water soluble extracts such as cucumber or green tea.
Are all Plants Distilled in the Same Amount of Time?
The amount of time for distillation per batch of plant material has a vast range dependent on the quality of oil required and the plant material itself. This is where expertise of specific plants is necessary to produce a quality oil or one to specific industry standards. For example, lavender can be distilled in one to two hours depending on batch size, whereas clove or cinnamon take much longer.
Different distillation times of a particular plant will create different grades. Ylang Ylang, a prized aromatic oil, has several grades (extra, 1 , 2, 3 and dark). The grades are indicative of distillation time with “extra” and 1 being the shortest time, which produces the lowest yield, best aromatic properties and highest price. The perfume industry purchases most of these grades leaving very little for public consumption. Grade 3 and dark, produce more oil because of longer distillation time, but is not considered fragrantly appealing so the price is dramatically reduced. These grades are usually destined for industrial purpose.
There is also no such thing as 2nd or 3rd distillation. A batch of plant material is distilled once and then discarded. Most often the plant material is spread back in the fields to provide nutrients and act as ground cover to reduce weeds.
Can an Essential Oil or Liquid Plant Extract be Distilled?
Yes it can. This is most often done to further process an oil to remove impurities or reduce high amounts of hazardous chemicals. Peppermint which may contain 50-80% menthol on initial distillation can be re distilled to reduce levels under 40% content, making the oil more aromatic and safer to use. The menthol crystals that are removed are usually sold to pharmaceutical companies. Bitter orange which is initially expeller pressed, is then distilled to remove water and other impurities. many citrus oils are extracted via cold pressing but then distilled to remove photo sensitizing chemicals or isolate other aroma chemicals. This process is called “Folding”
A ribbon blender gets its name because the blades are angled in different ways from a central shaft so that it looks like ribbons of metal. The varied direction of the blades allows the blender to move parts of a mixture in different directions at the same time. The mixer often has a closed container, often in the shape of a trough. The shaft and blades are located inside the container. A ribbon blender can be either horizontal or vertical.
Uses for a Ribbon Blender
Ribbon blenders are often used for food and medicine manufacturing as those industries often must mix substances with a lot of particles. Because it is critical that the particles be mixed evenly, a ribbon blender provides the best opportunity to achieve that result. Ribbon blenders are also used in heavy industry.
Types of Ribbon Blenders
There are different types of ribbon blenders available. A ribbon blender with a u-shaped shell is the most traditional version. These have a full, open top with a flanges, filtered cover. Cylindrical shell ribbon blenders are used where vacuum, pressure or heating and cooling is required. Access is limited to small doors on top or on the sides of the blender. Semi-cylindrical shells are often used for cooking and cooling application where high levels of heat transfer are required. A double ribbon blender provides a more thorough mixing as it has an inner and outer ribbon that provides counter-directional flow so that the product remains in constant motion. A paddle-ribbon combination blender has inner ribbons with an outer paddle that works well with fragile, heat-sensitive materials.
A ribbon blender is the perfect choice for manufacturers that need rapid blending of materials. With a variety of styles to choose from, manufacturers are able to select the one that works best for their needs.
Why do You Need a Ribbon Blender and Mixer?
Well, if you are into blending business, then definitely you need to acquire this machine as opposed to other machines.
Efficient and top quality ribbon blenders have securely controlled clearances between surfaces and agitator tips.
In addition to that, they are quick, effective and capable of systematic mixing of powders.
Below are special features of Ribbon blender and mixer that no other mixer boasts of.
I. Varying Applications and Very Few Crushes
Unlike other machines, the ribbon mixer has a double ribbon agitator that makes the machine multipurpose and suitable for mixing:
Powder- powder
Powder- liquid,
Paste and highly viscous material such as putty etc.
The radial speed of the ribbon is also flexible to ensure little or no material destructiveness.
Other than that, this blender doesn’t easily break down, unlike others.
II. It Possesses a Triple Ace Mixing Capability
This triple action is the key to unlocking the high speed and efficient blending ability.
The double helical agitators of the machine rotate thereby tumbling on the material inside the blender.
As a result, the pitch of the exterior ribbon transfers the material towards the discharge door.
However, the interior ribbon which possesses an opposing pitch moves the material further from the discharge door.
III. Superior Loading Rate and Enhanced Sealing
The mixing cylinders are inclined at an angle ranging from 180˚ – 300˚ and it comes with the largest loading capacity of about 70%.
Apart from that, a variety of sealing methods are incorporated for you to choose from and select a suitable one for your product.
For superfine powder product, pneumatic together with packing seal is used while for materials with relatively good fluidity mechanical seals are used.
IV. Produces a Super Uniformity and Homogeneous Blend and Mixture
Unlike other blenders, the Ribbon mixer has got a double ribbon agitator.
They move in a counter current motion displacing the materials from one end through the center to the other opposite end of the mixer.
Thus resulting in the production of a homogeneous mixture.
V. It Avails Thorough, Gentle and Super Blends within a Very Short Time
The ribbons of the machine, rotate at a super fast speed approximately, 70 – 100 meters per minute
In the process, they move the material both radially and laterally within short cycle duration.
Usually, it takes just about 15 – 20 minutes for complete blending.
VI. Available in Different Working Capacities
These machines come in different sizes and capacities ranging from 5litres to 25000 liters blenders.
Remember, the minimum working capacity for ribbon blender is approximately 30 – 40% of the overall capacity.
VII. Suitable for Use in a Limited Overhead Space
Is your working space limited?
Do you have a limited overhead space?
If so.
Then it is time to upgrade.
This is a user-friendly machine and can fully fit in a limited overhead space.
Applications of Ribbon Bin Blenders
This blender is trusted by many due to its ability to mix powders.
Section of Ribbon Mixer
Below are the main applications of the ribbon blender and mixer:
Blending of a largenumber of dry solids.
Drying of powdered materials suitable for wet phase mixing.
Mixing of drugs, cosmetics, and various chemicals.
Dry blending of capsule ingredients.
Lubrications of dry granules and pellets in large quantity.
Coating of solid particles with liquids to produce a suitable formulation.
In Pharmacology, ribbon blenders are used in the manufacturing of polymer blends, pharmaceutical powders, and composite fillers.
In Food and beverage processing industries, ribbon blenders are used to produce infant food, flavorings, seasonings, dried food products, breakfast cereals, cake mixes, dietary supplements, instant drink blends etc.
Some other industrial materials usually blended in the Ribbon mixer include the following:
Animal Feeds
Pet feeds
Bird seeds
Cosmetics
Abrasives
Pesticides and herbicides
Plastic powders
Laundry detergents
Fertilizers
Plastic powders
Fire retardants
Gypsum
Cleaning compounds
Apart from that, did you know that these mixers are multipurpose?
Well, they also serve the following purposes apart from blending:
Vacuum drying.
Granulation
Coating of solid particles with a little liquid component or a very fine and smooth powder.
Having discussed that, it’s time we concentrate on parts of the equipment.
Parts of a Ribbon Blender
Just like other technical machines, a ribbon blender is a versatile machine that has several.
These parts work together to ensure a smooth working mechanism and production of a uniform blend.
It parts, therefore include:
Mixing vessel
Flat top cover
Discharge valve
Rotating shaft
Agitator element
Control systems
Drive mechanism
I will guide you through the parts, one at a time:
a) Mixing Vessel
This is the chamber of the Ribbon mixer where the mingling and blending of the materials take place.
This chamber is usually designed in a U- shaped manner.
It is this chamber that mixing takes place.
Depending on the nature of your application, you can mix:
Solid or powdered materials
Liquids with liquids
Mixture of liquids, powders and granules
U-shaped mixing vessel
The mixing vessels occupy the largest space of the machine.
It is in this part that the main shaft agitator is located.
The inner and outer ribbons do their famous countercurrent motion from here.
b) Strong Top Flat Cover
Depending on the size of the trough, a tight-fitting top flat cover is available to optionally cover the container during operation.
The top cover is an entirely opened lid that gives you room for easy cleaning and loading of the raw material.
Lid or cover
The cover is usually made of strong stainless steel and doesn’t bend from little strain.
c) Superb Discharge Division
The discharging division is professionally fitted with efficient valves that promptly control the discharge.
Discharge
Normally, the valves provide a fine seal to eradicate material wastage through spillage.
Also, they uphold a tidier and safer working surrounding for the operator.
The drive mechanisms of the valves could be:
Manual
Pneumatic – this kind of operation ensures more precise control of the discharge process.
Electric
The good news?
You are able to select the valves from a variety.
Depending on the type of the raw material you can pick:
Spherical valves – suitable for sensitive products that require no dead spots once discharged.
Knife gate valves – they are usually dusted tight and ideal for powders and other dry materials.
Rotatory ball valves – these are liquid tight valves appropriate for wet materials.
Butterfly valves
Plum- blossom dislocation valves
From the discharge vent, the product flows out and you can collect it in the stuffing boxes.
Thereafter, it could be packed according to your preference.
d) Rotating Shaft
This is the horizontal tunnel that rotates at an immensely high velocity to ensure the efficient and rapid movement of the agitator.
Rotating shaft
The agitator rotation subsequently makes the material to be tumbled upon and radially carried inside the blender.
In most cases, the pace of the shaft varies.
It depends on the circumference of the outer ribbon.
The optimal speed of the shaft is about 80 – 100 meters per minute.
This high speed is essential in offering exhaustive and uniform blends within a short duration.
e) Agitator Element
This could be two helical agitators just like the ABSTER Ribbon Blender with inner and outer ribbons.
Helical Agitator
This is ideal for both dry and wet applications including slurry, thickened or diluted slurry can be mixed and blended sufficiently.
f) Control System
The interesting part is that the blender comes with a per-loaded and wired control panel.
Do you have a fixed budget or schedule?
A preinstalled program is important because it:
Saves you the task and expenses of seeking services from a local installer.
Makes the machine automatically ready for use immediately after setup.
The control panel is essential to the overall operations of the mixer.
It comprises of:
Main power switch.
Safety limit switches.
Fuse especially for the motors.
Emergency stop button.
All these parts shall be completely tested and guaranteed during the purchase to certify their working conditions and suitability.
g) Drive Mechanism
This part is responsible for ensuring the smooth operational basis for the machine.
However, the driver unit, the power consumption and the output speed can be altered in accordance with:
The kind of material to be blended.
Starting method.
Processing
The drive unit comprises of motors from which you have a wide range of options to pick from.
They may include general motors, variable frequency motors, high efficiency and energy saving motor, explosion resistant motors.
Motor unit
The motor connections are diverse and may include the following kinds of connection:
Direct connection
Pulley connection
Hydraulic coupler connection
The regularly used reducers are K, R, and F – series gearbox, cycloidal reducer; cycloidal reducer, planetary gear reducer and universal gear reducer.
Ribbon Blender Design and Construction
The blender comprises of:
U – Shaped horizontal container
Agitator comprising of two helical ribbon agitators i.e. inner and outer ribbons that rotate.
The agitator’s vessel is positioned within the center of the container.
As you’ll see from the images below, the agitator construction provides a three-way mixing action that ensures prompt and efficient blending.
Technical drawing of ribbon mixer
The ribbon blender is carefully designed, constructed and fabricated to ensure rapid, efficient and exhaustive mixing of powdered materials.
Both the dimensions and configurations of the machines are precisely designed and balanced.
It is to enhance smooth movement of materials within the container.
Of course, this ensures dead spots are avoided and to avail speedy product discharge.
Alternatively, the paddle agitator can be incorporated.
These paddles are stationed to move the materials mixed in counter lateral and radial directions.
However, the paddle design is mostly used in the following cases:
When friable materials are to be blended
In circumstances when the batch capacity to be mixed in the blender is limited usually as little as 15% of the overall capacity.
Some common aspects of blender constructions and design are based upon the following:
Construction Materials
The machine body is made of varied materials that are carefully chosen depending on if the parts are to be in contact with the raw material or not.
Again, the materials for other auxiliary machine parts such as the driving unit are different.
Quite a number of ribbon blender and mixer machines feature stainless steel (304 and 316L).
The steel is usually made to undergo suitable surface treatment modes such as;
Polishing
Mirror polishing
Sandblasting
Wiredrawing
Thereafter the metals are riveted and used in the construction of different parts of the mixer.
Internal section of ribbon mixer
Wear and tear resistant liner sheets may also be used when abrasive products are involved.
Unlike the interior parts, all the exterior stainless surfaces are painted with automotive paints such as enamel paints.
The ribbon blender is riveted and welded into a single unit.
Bulky and stable gauge walls are also used.
The end panels are fully reinforced.
All these measures make the vessel extremely rigid and stable to keep in control of the agitator vibrations and movement.
The machine has got strong and firm stands that support it and keep it in position eliminating any chances of the blender collapsing.
The components and devices used together in the ribbon blender are internationally famous certified products with superior quality and highly durable.
All these parts are approved in accordance with the Good Manufacturing Practice (GMP) models.
The entire construction of the blender is suited for coping up and withstanding the atmospheric pressure imbalance during the operation.
The mixing capacity of the machine is also sufficiently large covering approximately 70% to 80% of the general vessel volume. This provides:
Adequate and optimal space for material flow on the sides of the agitator.
Maximum contact between the agitator and the batch material. It ensures the product mixture produced is of top quality and homogeneous (no matter the quantity of the raw material).
Strategically positioned spray system, making it easy to introduce liquid into the system. Adding liquid is important when you want to produce homogeneous powders against liquid dissemination.
This ribbon blender not only works alone, but it is driven by a combination of some mechanical parts such as motors, couplings, and gearbox.
The motors usually generate a power of about 10 HP to 15 HP for blending of one thousand kilogram product mass.
For a large number of masses, a versatile power may be used.
In addition, the mixer has got a centrally situated flush discharge valve at the bottom section of the machine.
The mixer also comes with a tight-fitting top cover.
The top cover size would entirely depend on the dimensions of the blender.
The following features may be customized depending on the customer’s needs and operational demands:
A variety of discharging valves may be used as per the needs and preference of the customer. They include either manually or pneumatically operated valves such as slide gate, butterfly, diaphragm etc.
Powerful choppers may also be fixed on the sides. The high-speed choppers help in breaking down the agglomerates or lumps in the process of mixing. Also, they help in blending raw materials that are prone to forming agglomerates.
A sizeable window opening suitable for carrying out an inspection of the blender and cleaning the trough.
Numerous discharge locations depending on the blender capacity.
A specially designed jacket to assist in heating and cooling down the machine during operation.
Non- explosive motors, speed varying drives together with the digital control panel.
Now, with all these, it is important to look into the working mechanism of the blender.
For more information, please look at the table below.
Technical specifications of ribbon mixer
Ribbon Blender Working Principle – Here’s the Secret to Achieving Homogeneous Mixture
Ribbon blenders are efficient at mixing powders with powders as well as powders with liquids.
During the blending operation, both the sets of inner and outer helical agitators play a major role.
The outer ribbon conveys the materials from one end to the midsection of the mixing vessel.
At the same time, the inner ribbon transmits the raw materials from the mid-section to the opposite ends.
Essentially, they operate in a counter direction.
You can see that in the video below:
The ribbons move in a rotational motion at a very high speed, thereby achieving a radial movement.
A combination of radial and counter current motion occur repeatedly to ensure highly homogeneous mixing and blending is achieved within a very little time.
These fast rotating and high impact ribbons also eradicate lumps hence availing blends free from lumps.
It usually takes about 15 – 20 minutes from the start up to attain a blend when working with the machine.
The quality of the resultant product obtained is approximately 90 to 95 percent standardized.
Please note:
The size of the particles and the substance density of the raw materials have a direct impact on the resultant mixing capabilities of the ribbon blender.
These two elements subsequently affect the quality of the blend produced.
Therefore, it is only constituents with relatively related particle sizes and densities.
These would usually mix more rapidly as opposed to those constituents with variation in these properties.
Once the blending process is completed, the rotation of the ribbon agitator triggers the product discharge.
Of course, this occurs from the discharge valve situated at the bottom part of the trough.
As I had mentioned, the valves operate either manually or pneumatically.
The material could be discharged nearly entirely with no or little dead zones.
Technical Specification of Ribbon Blender and Mixer
The ultimate choice of ribbon blender and mixer completely depend on your set objectives and mission.
Sigma blade mixer is a kind of mixer which is specialized in using mixing high viscous material .
sigma blade mixer advantages
Sigma blade mixer is used for chewing gum, bubble gum, toothpaste, plastic, rubber, silicone rubber, dyes, pigments, inks, food base, pharmaceuticals, architectural coatings, carbon, fiber, high viscosity sealant, neutral glass glue, aluminum silver Pulp, silica gel, pulp, cellulose, battery paste, dyes, silicone resins, cosmetics and other industries.
The sigma mixer machine is a special mixing and mixing device. The most common one is to use two squeegee blades, which are arranged in a side-by-side differential speed type, that is, the speed of one stirring paddle is fast, and the speed of one stirring paddle is slow, so as to produce high Shear force, different paddle speeds enable the material to be quickly sheared so that the material can be totally mixed
