Powder processing industry entails machineries that are highly performing, repeatable and less degrading to the materials. The Double Cone Blender is one of such machines that can withstand the expectations expected of it in a variety of industries. The blender is designed to get a homogeneous blend of free-flowing dry powders and granules and can be found on incmachine.com.

The Double Cone Blender has also won the attention of various companies in the field of drugs, nutraceuticals, chemical industries, cosmetics and food processing as these companies found it extremely useful because it can make uniform blends using minimal amount of energy and they also do not have a heavy maintenance requirement.

What is Double Cone Blender?

The Double Cone Blender is a batch mixer with a symmetrical shell with two cones shaped like cones which rotate about a horizontal axis. The inside materials are rocked and mixed up as it rotates but the mixing kept at a consistency point and does not provide hard high impact shear.

Important characteristics of the Double Cone Blender

• Conical twin-shell construction, to give blend uniformity
• Soft mixing motion retaining the integrity of the particles
• Thumb screw end plates (optional) to enhance efficiency of mixing
• Stainless steel made design hospitable and strong
• OPUSH features and optional vacuum or nitrogen purging characteristics

The mixing happens in this blender on the principle of the tumbling movement when the powders drop and cascade into each other. Its geometric shape does not allow it to have dead-spots and ensures an even dispersion of materials.

Functions of Double Cone Blender

It is loaded with materials and when turned on, the Double Cone Blender rotates with a regulated speed. The mixing mechanism of rolling in the double-conical vessel enhances diffusion mixing that depends on gravity and movement of particles but not when it comes to stiff shear.

With this mild mixing effect, the Double Cone Blender is perfect in processes where the product integrity is important and where the particle size is essential to be maintained. Optional internal baffles can be fitted to improve the mixing efficiency, particularly where slightly cohesive powders are being used.

Usages of the Double Cone Blender

The Double Cone Blender is very common and applied in all types of industry that deal with materials that have been finely dry and free flowing. It is simple and effective enough to be chosen with reliability by such sectors:

Pharmaceutical Industry

• Mixing active pharmaceutical ingredients to excipients
• Equilibrium mixing up of the powders prior to tablet compression
• Clean tags on batch to batch consistency

Chemical Industry

• Blending of colorants, detergents and catalysts
• Process of making powdered raw materials ready to set a reaction in place

Food Processing

• Mixing of flour, spices, flavorings and additives
• Ensuring stability of powder based nutritive supplements

Personal care and Cosmetics

• Homogenization of cosmetics powders and skin-care base
• Compact powder products dry blending preparation

The benefits of the Double Cone Blender

1. Gentle Blending

Another outstanding advantage of the Double Cone Blender, is its gentle tumbling. Since this is a low impact process, materials are not disrupted in terms of shape and size hence suitable in handling delicate substances.

2. Homogenous Mixing

The symmetric shape and regular rotation schedule provide the even combination of materials without separation. This produces high quality of products and uniformity of batches.

3. Discharging and loading are easy.

The ports used in providing easy entry and exit of material are commonly wide in Double Cone Blenders. This eases material transportation and lowers wastage of product.

4. Sanitary Construction

These machines are made of polished stainless steel, which is easy to clean and of GMP compliancy. This qualifies them to work well in the pharmaceutical and food industries.

5. Energy Efficiency

The process incorporates the use of gravity that is less power intense than high-shear mixers. This assists to cut down the operating cost in the long run.

6. Customization Options

Depending on processing requirements, Vacuum options, liquid addition connections and internal baffles can be fitted in Double Cone Blenders.

Technical Specifications

Although certain final configurations might be different, a common Double Cone Blender consists of:

• The working range of 5-10000 liters
• Speed of rotation: 5 to 25 RPM
• Solid material contacts of SS304 or SS316L
• Manual or automatic discharging valve
• Accessible optional control panel and timers that can be programmed

To see more specifications, go to the product page at incmachine.com.

Constraints and Factors

Notwithstanding all its strong points, the Double Cone Blender is more recommended to be used with particular types of materials and processes. In this regard, considerations are as follows:

Unsuitable:

• Tremendously cohesive or sticky materials
• Liquid based mixing or slurry formulations
• High-shear processes, or size reduction processes

Other mixers such as Plough Shear Mixer or Ribbon Blender can be better suited in this case and are also available on INCMachine.

Comparison with other Industrial Blenders and Producers  

In comparison to any other blenders like the V-Type Blender or Ribbon Blender, the Double Cone Blender possess special benefits of being simple, very gentle and quite efficient. The shape of the V-type blenders gives the same tumbling action as compared to a double cone; however, the shape of a double cone gives a better axial mixing that enhances uniformity.

The Ribbon Blender, however, is more vigorous similar to ribbon agitators, and thus it is more suitable to blend slightly damp or cohesive powders. Ribbon Blender might not however be used to work on fragile materials which would break under shear.

Why Choose INCMachine?

INCMachine offers high quality Double Hydra Cone Blenders with functions: high efficiency, sanitary and high durability. The main advantages:

• Foundational production to suit your volume and manufacturing needs
• Entire stainless steel construction that makes it resistant to corrosion
• Use optional automation and control systems
• Installation advice and on site assistance

Whether you need to scale your batch processing or need to add more capacity to current production lines, Double Cone Blender by INCMachine provides reliable service with a long-term cost advantage.

Final Thoughts

The Double Cone Blender is a tested solution under the circumstances where companies desired to have consistent and gentle blend of powdered and granular materials. It has the advantages of being simple, being low-energy consuming and has high mixing uniformity; therefore, a perfect combination in a firm where the production of a product is not negotiable.

Offering customizable features and durable material and structure, the Double Cone Blender gives standard size as well as large-scale manufacturers an effective cost-effective mixing tool. The blender can be customized specifically to fit your process requirements whether you blend pharmaceuticals, chemicals, food or cosmetics.