Conical Mixer - High-Quality Mixing with PerMix Conical Mixers

Working Principle of PerMix Conical Mixers & Vacuum Conical Mixers/Dryers

Overview of the Mixing Action

PerMix Conical Mixers and Vacuum Conical Mixers/Dryers operate based on a combination of gentle tumbling and efficient axial-radial mixing, ensuring a homogeneous mix of powders, granules, or liquids. Their unique conical vessel design ensures optimal material flow while minimizing heat generation, making them ideal for processing heat-sensitive or fragile materials.

Key Components & Their Roles

1. Conical Vessel
   • The conical shape promotes a natural flow of materials due to gravity, enabling a consistent mixing process without dead zones.
   • The design is highly efficient for batch sizes ranging from small to large volumes.
2. Agitator Screw
   • A centrally positioned screw rotates along its axis while orbiting the inner surface of the cone (planetary motion), moving materials vertically and radially.
   • This motion ensures uniform mixing of all particles, preventing segregation or uneven blending.
3. Vacuum System (for Vacuum Conical Mixers/Dryers)
   • When vacuum is applied, it enables low-temperature drying by reducing the boiling point of moisture, which is particularly useful for heat-sensitive products.
   • The vacuum system also removes trapped air, improving the density and quality of the final product.
4. Heating & Cooling Jackets (Optional)
   • A jacket surrounding the conical vessel allows for precise thermal control, enabling efficient heating or cooling during mixing or drying processes.
   • Steam, water, or oil can circulate through the jacket depending on the required process temperature.
5. Chopper Blades (Optional)
   • High-speed choppers can be integrated for breaking down lumps or agglomerates during mixing, ensuring a smooth and consistent final product.

Mixing Process

1. Filling the Vessel
   • The materials are loaded into the conical vessel. The efficient design ensures no risk of product loss or spillage during loading.
2. Agitation & Mixing
   • The central screw rotates and conveys materials upward from the bottom of the cone.
   • As materials reach the top, gravity pulls them back down, creating a continuous mixing loop.
3. Vacuum & Drying (if applicable)
   • For drying applications, vacuum is applied to remove moisture from the material.
   • The heating jacket provides the necessary thermal energy to accelerate moisture evaporation. The resulting vapor is evacuated via the vacuum system.
4. Discharge
   • After mixing or drying is complete, the conical shape ensures easy and complete discharge of materials, minimizing product retention.

Advantages of PerMix’s Working Principle

• Gentle Mixing: Ideal for fragile or sensitive materials, preventing degradation or heat damage.
• Efficient Drying: Combines vacuum and thermal energy for low-temperature, high-efficiency drying.
• Uniform Mixing: Prevents segregation with consistent axial-radial material movement.
• Customizable Processes: Heating, cooling, vacuum, and high-speed choppers allow for versatility across industries.
• Hygienic Design: The conical vessel is easy to clean, ensuring compliance with food and pharmaceutical standards.

Difference Between Single Screw and Double Screw in Conical Mixers

When selecting a PerMix Conical Mixer, understanding the difference between single screw and double screw configurations is essential to optimize performance based on your application needs. Here’s a detailed breakdown:

Single Screw Conical Mixer

Overview:
A single screw conical mixer features one vertical screw agitator that rotates on its axis while orbiting along the conical vessel wall. This design is highly efficient for most applications and provides consistent, homogeneous mixing.

Advantages of Single Screw:

1. Simplicity in Design:
   • Fewer moving parts result in lower maintenance requirements.
   • Easy to operate and clean.
2. Cost-Effective:
   • More affordable due to reduced manufacturing complexity.
3. Sufficient for Standard Applications:
   • Handles a wide range of mixing tasks effectively, including powders, granules, and liquids.
4. Compact Footprint:
   • Requires less energy and space compared to double screw models.

Limitations of Single Screw:

• Slower Mixing for Large Volumes:
  • May take longer to achieve homogeneity in large batches.
• Less Efficient with Low-Density or Light Powders:
  • Mixing may require more time to ensure consistency with materials prone to floating or segregation.

Double Screw Conical Mixer

Overview:
A double screw conical mixer includes two vertical screw agitators that rotate and orbit the vessel simultaneously. This design significantly enhances the mixing action by handling more material in less time.

Advantages of Double Screw:

1. Faster Mixing:
   • Dual screws increase mixing efficiency by simultaneously moving materials through the mixing zone.
   • Ideal for large batch sizes or high-throughput requirements.
2. Enhanced Homogeneity:
   • Better suited for materials with varying densities or challenging flow properties.
   • Minimizes segregation of light or fragile particles.
3. Improved Handling of Low-Density Materials:
   • Provides better control and mixing of materials prone to floating or clumping.
4. Versatility:
   • Excels in complex applications such as coating powders with liquids or mixing highly viscous substances.

Limitations of Double Screw:

• Higher Cost:
  • More components and complexity result in a higher initial investment.
• Increased Maintenance:
  • Additional screws and mechanisms may require more frequent maintenance.
• Larger Energy Requirements:
  • May consume more power compared to single screw mixers.

When to Choose Each Configuration

Conclusion: Tailored Solutions with PerMix

At PerMix, we offer both single and double screw conical mixers, ensuring you get the perfect solution for your specific process requirements. Whether your focus is on cost-effectiveness and simplicity or enhanced efficiency and versatility, our mixers deliver unmatched performance and reliability.

1. Available Options for PerMix Conical Mixers & Vacuum Conical Mixers/Dryers

   PerMix conical mixers and vacuum conical mixers/dryers are designed with versatility and customization in mind. Below is a comprehensive list of options available to enhance the performance, adaptability, and efficiency of our mixers:

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   Material of Construction

   1. 304 Stainless Steel – Standard for most applications, offering corrosion resistance and durability.
   2. 316/316L Stainless Steel – Ideal for pharmaceutical, food, and chemical applications requiring higher corrosion resistance.
   3. Hastelloy – Suitable for handling highly corrosive materials.
   4. Hardox – Perfect for abrasive materials to ensure long equipment life.
   5. Titanium – For ultra-corrosive or specialty applications.
   6. Carbon Steel – Cost-effective option for less demanding applications.

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   Agitator Options

   1. Single Screw – Efficient for standard mixing needs.
   2. Double Screw – Enhanced mixing for complex materials or larger batch sizes.
   3. High-Speed Chopper Blades – To break down lumps, agglomerates, or sticky materials.
   4. Liquid Additive Nozzles – For precise liquid injection during mixing.

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   Thermal Control

   1. Heating & Cooling Jackets – Steam, water, or oil-based jackets for controlled thermal processes.
   2. Cryogenic Cooling Options – For applications requiring extremely low temperatures.

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   Vacuum System Options

   1. Mild Vacuum – Suitable for standard drying processes.
   2. High Vacuum – For highly sensitive materials or applications requiring extremely low pressure.
   3. Condensate Recovery System – Collect and recycle vapors during vacuum drying.

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   Loading & Discharge

   1. Vacuum Loading System – Eliminates the need for additional loaders, simplifying material handling.
   2. Load Cells – For precise weighing and batch control.
   3. Pneumatic Discharge System – For automatic material removal.
   4. Butterfly Valves – Durable and efficient for controlled discharge.
   5. Sanitary Valves – For food-grade or pharmaceutical applications.

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   Automation & Controls

   1. PLC/HMI Controls – Fully automated control systems with recipe management.
   2. Remote Monitoring – Enable remote operation and monitoring for efficiency.
   3. Explosion-Proof Controls – For hazardous environments or processes.

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   Hygienic & Sanitary Design

   1. CIP (Clean-In-Place) Systems – Integrated systems for efficient cleaning.
   2. Polished Surfaces – Mirror-polished finishes for easy cleaning and reduced contamination risk.
   3. Sanitary Seals – Prevent material leakage and maintain hygiene.

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   Gas Purge Systems

   1. Inert Gas Purge – For handling reactive or sensitive materials.
   2. Nitrogen Purging – Prevent oxidation during mixing or drying.

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   Additional Customizations

   1. Explosion-Proof Design – For processes involving flammable materials.
   2. Insulated Jackets – Reduce energy loss during thermal processes.
   3. Mobile Skid Mounting – Portable design for flexibility in multi-location use.
   4. Vibration Isolation Mounts – Reduce noise and vibration during operation.

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   Why Choose PerMix?

   Our wide range of options ensures that your PerMix conical mixer or vacuum conical mixer/dryer is tailored to your exact application requirements. Whether you need enhanced durability, precision thermal control, or advanced automation, PerMix delivers solutions that exceed expectations.

   Contact us today to configure your ideal mixer!