Mixing is an essential process where many industries are involved in pharmaceuticals, chemical industry, food processing, building material and agriculture. Among the two most frequently deployed mixing machines to powder and granules, there are namely the Ribbon Blender Mixer and the Plough Shear Mixer. The two are high-performance mixing systems that are supplied by INCMachine with individual capabilities and areas of application.

The following is a general guide that gives the comparisons between the two commonly used mixers in industrial plants; the Ribbon Blender Mixer and the Plough Shear Mixer to enable business and plant engineers make the correct mixer selection based on the type of process that they are dealing with.

What is Ribbon Blender Mixer?

Ribbon Blender Mixer is a horizontal mixer, which basically comprises the U-shaped trough with the inner and outer helical ribbons fixed or fitted in a shaft positioned horizontally. The ribbon rotates such that this is used to ensure that a counter-current flow of materials is realized facilitating blending of uniform blend.

Key Features

• U shaped trough with horizontal design
• Twin ribbon agitators ( inner and outer spirals )
• Delicate blending that is not intensive
• Cleaning and maintenance is easy
• Very suitable with powders, granules and light pastes

Applications

The ribbon blenders are often found in the industries with application where accurate testing of dry powders, granular or lesser liquids addition is required. The common ones are:

• Food and beverage (spice mix, baking mix)
• Drugs (drugs in powder form)
• Drugs (laundry powders, dye, condiments, preservatives)
• Cosmetics (products based on powder)

Advantages

• Use of low energy costs
• Consistency of and reproducibility of mixing
• Simple way of loading and discharge
• It is economical at large volume batches
• Appropriate in heat sensitive materials since the amount of shear is minimal

Ribbon blenders however are not suitable with very sticky, cohesive or lumpy products. The mild agitation caused may fail to dissolve agglomerates or hydrate the materials.

What is Plough Shear mixer?

The Plough Shear mixer is an intensive mixer and it has a cylindrical horizontal grain with plow-shaped mixing tools that are mounted in a central shaft. It normally contains high velocity choppers that add to dissipation of the particles and increase dispersion thus limiting agglomeration.

Key Features

• Importance to mixing in the cylindrical mixing chamber
• Agitators shaped like a plough and at a pre-determined angle
• High-speed optional choppers on the mixer to help in dispersion
• High shear mixing effect

Applications

The mixer is suitable where high speed of homogeneous mixing is required such as:

• Powders and compounds Chemical
• Pigments and dyes
• Drugs that need active dispensing
• Sticky Or moist mixtures
• slurries and paste-like material

Advantages

• Mingier mixing at shorter cycles times
• Able to run agglomerates to pieces
• Effective in dry and semi wet materials
• Extremely proficient in coating, granulating and mixing

The plough shear mixer is also energy intensive and therefore not recommended in handling fragile or highly sensitive materials owing to its violent nature of mixing.

Table of technical comparison

Selecting the Appropriate Mixer – What Mixers Are Appropriate to Your Process

Choose a Ribbon Blender Mixer When:

• It is a combination of powders or bulk solids of dry substances
• Your contents are not sticky and they are free-flowing
• Your process has low requirements of harsh blending to prevent the wear of particles
• Energy efficiency is among the priorities
• You should have an affordable option when it comes to bulk together with high volumes

Choose a Plough Shear Mixer When:

• You are dealing with solid, tacky or wet substances
• In your mixing process dispersion is necessary as well as de-agglomeration of your materials.
• There is need to have faster batch processing
• The mixture contains liquid, colorant or any other additive
• Your product should be highly sheared to become homogenous

Operational Considerations

Cleaning and Hygiene

Since they are open and have less parts, ribbon blenders are easier to clean. They suit well to such industries as food where active control of contamination is important.

The complicated inner structure of plough shear mixers and the optional choppers applied demand even more cautious cleaning procedures (in case they work between batches of products).

Maintenance

Ribbon blenders are less complex regarding structures thus easy to maintain. They also have fewer parts that move which decreases the replacement of the parts.

Plough shear mixers are also associated with increased wear and tear parts because they run at high speed. They require timely maintenance and a regular inspection in order to perform optimally.

Conclusion

Both Ribbon Blender Mixer and Plough Shear Mixer are capable devices in the manufacturing scene of mixing. It is largely dependent on the kind of materials you have, a required throughput, and the objectives of the process that will prove the best choice between them.

The Ribbon Blender Mixer is a cost effective, efficient and consistent mixing set up that works well with businesses that deal with dry free flowing powder products. Alternatively, in case your application is with moister and sticky mix, or complex mix that needs vigorous mixing and can also use quick dispersion, Plough Shear Mixer could be the best alternative.

The appropriate use of mixing technology, which includes investing in a credible partner such as INCMachine, can help increase product quality and efficiency of the process as well as provide consistency to its operations.