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The PerMix Fluidized Bed Mixer / Twin Shaft Paddle Mixer is a fast mixer with high efficiency, which can also be known as Fluidizing Mixer, Fluidized Zone Mixer, Non-gravity Mixer or Zero-gravity Mixer.
A fluidized zone mixer is a high-efficiency batch mixer designed to create a controlled, partially fluidized mixing environment that combines intense mixing performance with reduced mechanical stress.
Unlike conventional ribbon, paddle, or plow mixers that rely primarily on bulk movement or mechanical impact, fluidized zone mixers use high-velocity paddles or mixing tools to suspend and mobilize particles within a defined mixing zone. This creates a state where material behaves more like a fluid than a solid—without the need for air fluidization.
The result is:
Extremely fast mixing
Excellent homogeneity
Efficient dispersion of liquids
Reduced dead zones
Lower energy use compared to fully fluidized systems
As the mixing shaft rotates:
Specially designed mixing tools accelerate material upward
Particles are lifted and separated from one another
A dynamic “fluidized” mixing zone is formed
Material continuously circulates through this zone
This action allows particles to move independently rather than in clumps, dramatically improving mixing efficiency and liquid distribution.
Fluidized zone mixers are engineered to sit between low-shear and high-energy mixing technologies.
They offer:
Faster mixing than ribbon or paddle mixers
Lower mechanical stress than plow mixers
Excellent performance for powders with challenging flow behavior
Superior liquid dispersion without excessive shear
They are especially effective when traditional mixers struggle with:
Segregation
Poor liquid distribution
Long mixing times
Inconsistent batch quality
Fluidized zone mixers are commonly used for:
Protein powders and nutritional blends
Functional food ingredients
Fine chemical powders
Battery materials
Detergents and specialty additives
They perform exceptionally well with powders that are difficult to blend uniformly using conventional mixers.
At a high level:
Ribbon mixers rely on bulk circulation
Paddle mixers rely on gentle folding
Plow mixers rely on mechanical impact
Fluidized zone mixers rely on particle suspension and separation
This makes fluidized zone mixers uniquely capable of achieving high uniformity in very short cycle times.
Understanding the fluidized zone mixing principle explains why these mixers:
Achieve faster homogeneity
Improve liquid coating efficiency
Reduce segregation
Scale more predictably
They are often selected as an upgrade to older ribbon or paddle mixers without increasing footprint.
Fluidized zone mixers are selected when mixing speed, uniformity, and liquid dispersion must be achieved without the drawbacks of excessive shear, long cycle times, or large equipment footprints. Understanding when this technology is appropriate—and when it is not—ensures optimal performance and cost-effective processing.
A fluidized zone mixer is typically the best solution when one or more of the following conditions apply:
Fast, High-Uniformity Mixing Is Required
Fluidized zone mixers achieve homogeneity in significantly shorter cycle times than ribbon or paddle mixers by suspending and separating particles in the mixing zone.
Powders Are Prone to Segregation
Materials with different particle sizes, densities, or shapes benefit from the particle-level mobility created within the fluidized zone.
Efficient Liquid Addition Is Critical
Liquids added to powders are dispersed rapidly and uniformly due to continuous particle separation, reducing the risk of lumping or over-wetting.
Upgrading an Existing Mixer Without Increasing Footprint
Fluidized zone mixers are often selected as a drop-in performance upgrade to replace outdated ribbon mixers while maintaining similar vessel size and layout.
Energy Efficiency Matters
Compared to high-impact mixers, fluidized zone mixers deliver excellent results with lower mechanical stress and optimized power usage.
Fluidized zone mixers are commonly chosen for:
Protein powders and sports nutrition blends
Nutraceutical and functional food ingredients
Fine chemical powders
Battery and advanced materials
Detergents and specialty additives
These applications demand fast, repeatable mixing with precise liquid dispersion.
While highly versatile, fluidized zone mixers are not ideal for every process.
A fluidized zone mixer may be unnecessary or unsuitable when:
Materials Are Extremely Sticky or Paste-Like
Very high viscosity materials may require different mixing technologies designed for paste handling.
Agglomeration or Wet Granulation Is Required
Processes that intentionally form granules typically require plow mixers or granulators rather than fluidized zone mixers.
Very Gentle Mixing Is Required
Extremely fragile materials may be better served by low-shear paddle mixers.
Particle Size Is Poorly Controlled Upstream
Wide particle size variation may require milling before fluidized zone mixing to achieve consistent results.
At a high level:
Choose a ribbon mixer for conventional blending of free-flowing powders
Choose a fluidized zone mixer when faster mixing, better liquid dispersion, and reduced segregation are required
Fluidized zone mixers are often selected as a performance upgrade without increasing mixer size.
Choose a fluidized zone mixer for fast, efficient blending with moderate energy input
Choose a plow mixer for aggressive mixing, granulation, or cohesive materials
Each technology serves a distinct role.
Selecting the correct mixer technology:
Reduces mixing time
Improves batch uniformity
Prevents unnecessary shear or heat generation
Simplifies scale-up
Lowers operating costs
Misapplication often leads to longer cycles, inconsistent product quality, and underutilized equipment.
Fluidized zone mixers are available in single shaft and dual shaft configurations. While both operate on the same core principle of particle suspension and separation, the number of shafts directly affects mixing intensity, control, and scalability.
Choosing the correct configuration ensures optimal performance without unnecessary complexity or cost.
Single shaft fluidized zone mixers use one centrally mounted shaft fitted with specially designed mixing tools that create a defined fluidized mixing zone.
Key characteristics:
Simplified mechanical design
Lower installed power compared to dual shaft designs
Highly efficient particle suspension for most powder blends
Excellent liquid dispersion performance
Reduced maintenance due to fewer moving components
Best suited for:
Free-flowing to moderately cohesive powders
Protein powders and nutritional blends
Fine chemical powders
Detergents and specialty additives
Applications upgrading from traditional ribbon mixers
Single shaft designs often provide the best balance of performance, efficiency, and cost.
Dual shaft fluidized zone mixers use two counter-rotating shafts, dramatically increasing particle interaction and mixing control.
Key characteristics:
Two synchronized shafts creating overlapping fluidized zones
Increased mixing intensity without excessive shear
Superior performance for larger batch sizes
Enhanced handling of more difficult or segregative materials
Greater control over liquid dispersion and coating
Best suited for:
Large production batches
Powders with wide particle size or density differences
Formulations requiring extremely tight homogeneity
High-throughput operations
Applications where cycle time must be minimized
Dual shaft designs are selected when maximum performance is required.
At a process level:
Single shaft mixers provide efficient fluidization with lower energy input
Dual shaft mixers provide greater particle interaction and tighter control
The decision is driven by material behavior, batch size, and uniformity requirements—not simply production volume.
Single shaft mixers generally consume less power and experience lower mechanical load
Dual shaft mixers distribute load across two shafts, allowing higher throughput while maintaining stability
Both designs are engineered for long service life when properly applied.
During scale-up:
Single shaft mixers scale well for most powder blending applications
Dual shaft mixers are often preferred for very large vessels where uniform fluidization must be maintained across a wider mixing zone
PerMix evaluates scale-up based on mixing behavior, not just vessel size.
In most cases:
Start with a single shaft fluidized zone mixer
Move to a dual shaft design when material complexity, batch size, or homogeneity requirements demand it
This approach ensures optimal performance without overengineering.
PerMix fluidized zone mixers are engineered to create a stable, controlled fluidized mixing environment while maintaining mechanical durability, efficiency, and long service life. Every component—from mixing tools to vessel geometry—is designed to support high-speed particle suspension without excessive shear or wear.
At the core of the fluidized zone mixer are specially engineered mixing tools mounted on one or two horizontal shafts.
Key design features include:
Optimized tool geometry to accelerate and suspend particles
Controlled tool spacing to maintain a consistent fluidized zone
High-strength shafts designed to resist torsional and bending loads
Dynamically balanced assemblies for smooth, vibration-free operation
The goal is to separate particles efficiently so they behave as an active, mobile mass rather than a compacted bulk solid.
Single shaft designs focus on efficiency and simplicity:
Fewer moving components
Lower mechanical complexity
Reduced maintenance requirements
Dual shaft designs focus on enhanced performance:
Overlapping fluidized zones for increased particle interaction
Improved uniformity in larger vessels
Distributed mechanical load across two shafts
Both designs are engineered to deliver consistent fluidization across the entire batch volume.
The vessel geometry plays a critical role in maintaining stable fluidization.
Design considerations include:
Precisely contoured internal surfaces to support particle circulation
Elimination of dead zones and material hang-up
Reinforced vessel shells to handle dynamic loads
Optimized aspect ratios to maintain uniform mixing at scale
The vessel is engineered to work with the mixing tools—not against them.
Fluidized zone mixers are used across food, chemical, nutraceutical, and industrial applications, requiring flexible material options.
Available materials include:
Carbon steel for general industrial use
304 stainless steel for food and non-corrosive applications
316 / 316L stainless steel for hygienic or corrosive environments
Wear-resistant steels or specialty alloys for demanding conditions
Material selection directly impacts cleanliness, durability, and lifecycle cost.
Reliable sealing and bearing systems are essential due to high shaft speeds and continuous operation.
PerMix fluidized zone mixers can be equipped with:
Packed gland seals
Mechanical seals
Air purge seals for dust containment
Gas purge seals for inert or controlled atmospheres
Bearings are mounted externally, outside the product zone, to:
Reduce contamination risk
Simplify inspection and maintenance
Extend bearing service life
Fluidized zone mixers require precise speed control to maintain stable particle suspension.
PerMix designs drive systems with:
Heavy-duty gear motors matched to process requirements
Direct-drive or guarded transmission systems
Variable frequency drives (VFDs) for speed optimization
Speed control allows operators to fine-tune fluidization intensity for different materials and batch sizes.
Discharge systems are designed to empty the vessel efficiently without collapsing product uniformity.
Common discharge options include:
Large bottom discharge valves
Full-length discharge doors
Assisted discharge for difficult materials
Proper discharge design minimizes product hold-up and supports fast batch changeover.
For food, nutraceutical, and pharmaceutical applications, PerMix offers hygienic fluidized zone mixer designs.
Available features include:
Polished internal finishes
Smooth, continuous welds
CIP-ready configurations
FDA-compliant seals and elastomers
These features support cleanability and regulatory compliance.
Every structural and mechanical element of a PerMix fluidized zone mixer is designed to support:
High rotational speeds
Continuous particle suspension
Consistent batch performance
Long-term mechanical reliability
This engineering focus ensures stable operation across a wide range of materials and operating conditions.
PerMix fluidized zone mixers are configured to support high-speed, high-uniformity mixing while remaining adaptable to a wide range of materials, formulations, and production environments. All options are engineered as part of the system—not added later—ensuring stability, safety, and repeatable performance.
Fluidized zone mixers excel at liquid dispersion due to continuous particle separation within the mixing zone.
Available liquid addition options include:
High-precision spray nozzles positioned directly in the fluidized zone
Metered dosing pumps for controlled liquid delivery
Multiple injection points for staged or multi-component addition
Heated liquid delivery for viscous oils, syrups, or binders
These systems ensure rapid wetting without lumping, pooling, or over-saturation.
Thermal control can be integrated when temperature affects flowability, stability, or downstream processing.
Available options include:
Full welded heating or cooling jackets
Dimple jackets for improved heat transfer efficiency
Hot water, steam, thermal oil, or chilled water service
Single-zone or multi-zone temperature control
Temperature control allows fluidized zone mixers to handle heat-sensitive or temperature-dependent formulations with precision.
Fluidized zone mixers can be configured for vacuum operation when oxidation control or gentle drying is required.
Vacuum options include:
Vacuum-rated vessel construction
Condensing columns and vapor recovery systems
Inert gas purge capability
Oxygen-reduced or oxygen-free processing environments
Vacuum operation enhances drying efficiency and protects sensitive materials.
Discharge design is critical for preserving batch uniformity and minimizing product loss.
Common discharge configurations include:
Large bottom discharge valves
Full-length discharge doors
Assisted discharge systems for difficult-flowing materials
These options ensure complete, fast emptying while maintaining product consistency.
Fluidized zone mixers are available in materials selected to match wear, corrosion, and regulatory requirements.
Available materials include:
Carbon steel
304 stainless steel
316 / 316L stainless steel
Wear-resistant steels
Specialty alloys for corrosive or high-purity applications
Material selection impacts cleanliness, durability, and total cost of ownership.
Seal systems are selected based on product sensitivity and operating conditions.
Available options include:
Packed gland seals
Mechanical seals
Air purge seals for dust control
Gas purge seals for inert or hazardous atmospheres
Atmosphere control improves safety and protects oxidation-sensitive materials.
Fluidized zone mixers can be supplied with automation systems tailored to production needs.
Control options include:
Local operator control panels
PLC and HMI systems
Recipe management and batch sequencing
Data logging and traceability
Integration with upstream and downstream equipment
Automation improves repeatability and supports scale-up.
PerMix offers customization to simplify installation and plant integration.
Available options include:
Integrated support frames and access platforms
Load cells for batch weighing
Skid-mounted designs
Custom inlet and outlet configurations
These features improve ergonomics, safety, and overall process efficiency.
Every option is engineered to preserve the stability of the fluidized mixing zone while expanding process flexibility.
Fluidized zone mixers are chosen for their ability to deliver exceptionally fast, uniform mixing while maintaining controlled energy input. Preserving this performance during scale-up requires careful management of fluidization dynamics, tool geometry, and operating parameters.
PerMix fluidized zone mixers are engineered to scale predictably and repeatably from lab and pilot units through full-scale production systems.
Performance in a fluidized zone mixer is defined by the stability of the particle suspension.
Key performance drivers include:
Mixing tool geometry and spacing
Shaft speed and tip velocity
Batch fill level
Particle size, density, and cohesiveness
When properly engineered, particles remain separated and mobile, allowing rapid redistribution and uniform blending throughout the batch.
Fluidized zone mixers typically achieve homogeneity in seconds to minutes, rather than extended mixing cycles.
Performance benefits include:
Extremely short mixing times
Rapid liquid dispersion
Reduced risk of segregation
High throughput per batch
This makes fluidized zone mixers ideal for high-output operations where consistency cannot be compromised.
Scale-up focuses on maintaining similar fluidization behavior, not simply increasing vessel volume.
PerMix scale-up methodology emphasizes:
Preserving tool tip speed and energy density
Maintaining consistent batch fill ratios
Adjusting tool configuration for vessel diameter
Ensuring uniform fluidization across the full mixing zone
This approach ensures formulations developed in R&D behave consistently at production scale.
As batch size increases, liquid addition must remain synchronized with particle suspension.
PerMix addresses this by:
Scaling spray patterns and nozzle placement
Matching liquid flow rate to fluidization intensity
Coordinating liquid addition with mixer speed
This prevents localized wetting and ensures uniform coating across all particles.
Fluidized zone mixers operate efficiently, but high mixing speeds can generate heat if not controlled.
Thermal management strategies include:
Optimized shaft speeds
Integrated heating or cooling jackets
Vacuum operation for temperature-sensitive materials
Proper thermal control protects product quality and process stability.
Vacuum fluidized zone mixers combine particle suspension with reduced pressure to enhance drying efficiency.
Performance benefits include:
Lower drying temperatures
Improved mass transfer
Uniform moisture removal
Reduced oxidation
Drying performance scales reliably when vessel geometry and agitation are correctly matched.
Repeatable performance is achieved through:
Rigid mechanical design
Stable drive systems
Controlled energy input
Optional automation and recipe control
These features minimize operator variability and support validated processes.
Poor scale-up can lead to:
Loss of fluidization stability
Uneven liquid distribution
Inconsistent batch quality
Increased energy consumption
PerMix fluidized zone mixers are engineered to minimize these risks by applying proven scale-up principles from the earliest stages of process development.
Fluidized zone mixers are selected when speed, uniformity, and liquid dispersion must be achieved consistently across challenging powder systems. Their ability to suspend and separate particles makes them ideal for applications where conventional mixers struggle with segregation, long cycle times, or inconsistent coating.
Below are common single shaft and dual shaft fluidized zone mixer workflows across industries.
Primary challenges:
Segregation due to density differences
Poor liquid distribution
Long mixing times
Dusting and fines
Typical workflow:
Ingredient Conditioning or Light Milling
Raw ingredients are screened or lightly milled to standardize particle size.
Fluidized Zone Mixing
Powders are rapidly suspended and blended to achieve uniformity.
Liquid Addition (Optional)
Lecithin, oils, or flow aids are sprayed evenly into the fluidized zone.
Discharge & Packaging
Product exits with improved flowability and consistency.
Why it works:
Particle suspension eliminates segregation and enables fast, repeatable blending.
Primary challenges:
Uniform distribution of actives
Heat sensitivity
Oxidation risk
Cleaning and validation
Typical workflow:
Precision Size Conditioning
Actives and carriers are prepared to consistent particle size.
Fluidized Zone or Vacuum Fluidized Mixing
Ingredients are blended under controlled energy.
Optional Vacuum or Inert Processing
Oxygen exposure is minimized for sensitive compounds.
Downstream Processing
Blends move to encapsulation, sacheting, or tableting.
Why it works:
Fast mixing with controlled energy preserves potency and product integrity.
Primary challenges:
Poor flowability
Agglomeration
Uneven liquid coating
Throughput demands
Typical workflow:
Pre-Milling or Classification
Raw materials are conditioned for uniform feedstock.
Fluidized Zone Mixing
Powders are suspended and blended efficiently.
Liquid Injection or Conditioning
Binders, coatings, or reactants are dispersed evenly.
Optional Thermal Conditioning
Heating or cooling stabilizes product properties.
Why it works:
Fluidization improves dispersion and reduces cycle times.
Primary challenges:
Fine powders prone to agglomeration
Tight homogeneity requirements
Dust control
Scale-up repeatability
Typical workflow:
Micronization or Fine Milling
Materials are reduced to precise size targets.
Dual Shaft Fluidized Zone Mixing
Powders are blended with enhanced particle interaction.
Vacuum or Inert Processing (Optional)
Sensitive materials are protected during mixing.
Discharge to Downstream Processes
Why it works:
Overlapping fluidized zones ensure consistent particle interaction and uniformity.
Primary challenges:
Rapid blending requirements
Liquid surfactant addition
Uniform appearance
High throughput
Typical workflow:
Ingredient Preparation
Powders are conditioned for flow.
Fluidized Zone Mixing
Dry components are blended rapidly.
Liquid Surfactant Addition
Liquids are evenly sprayed into the fluidized zone.
Cooling & Discharge
Why it works:
High-speed mixing supports short cycle times without sacrificing quality.
Primary challenges:
Long cycle times
Segregation
Inconsistent liquid distribution
Typical workflow:
Direct Equipment Upgrade
Existing mixer is replaced with a fluidized zone mixer of similar footprint.
Process Optimization
Mixing time is reduced and uniformity improved.
Optional Liquid Addition Enhancement
Why it works:
Fluidized zone mixers often provide a performance upgrade without increasing space requirements.
Engineering the process around material behavior and performance goals delivers:
Shorter mixing cycles
Improved homogeneity
Better liquid distribution
Reduced segregation
More predictable scale-up
Fluidized zone mixers perform best when they are part of a coordinated, application-driven workflow.
Fluidized zone mixers are exceptionally efficient at blending powders, but like all mixers, their performance depends heavily on particle size consistency upstream. Understanding when milling, mixing, or a combined approach is required is essential to achieving the speed, uniformity, and repeatability fluidized zone mixers are known for.
Milling, or size reduction, is used to prepare materials for stable fluidization.
Milling is typically required to:
Reduce oversized particles that disrupt fluidization
Narrow particle size distribution
Improve flowability and bulk density consistency
Minimize segregation during high-speed mixing
Wide particle size variation prevents particles from suspending uniformly, reducing the effectiveness of the fluidized zone.
Fluidized zone mixing focuses on rapid, particle-level distribution, not size reduction.
Fluidized zone mixers are used to:
Achieve fast, uniform blending
Disperse liquids evenly into powders
Prevent segregation during mixing
Reduce overall batch cycle time
They perform best once particle size is already within a workable range.
Milling alone may be sufficient when:
A single material is being processed
Particle size is the final product specification
No blending or coating is required
Examples include:
Producing a uniform powder for packaging
Conditioning raw materials for downstream processing
Preparing feedstock for later mixing steps
In these cases, a mixer may not be required.
Fluidized zone mixing alone is appropriate when:
Incoming materials already have consistent particle size
Ingredients fluidize easily
The process requires fast blending rather than size reduction
Examples include:
Blending pre-milled powders
Mixing dry formulations with similar density and size
Rapid dispersion of small amounts of liquid additives
Here, the fluidized zone mixer delivers maximum efficiency.
Many high-performance processes require both milling and fluidized zone mixing.
A combined approach is recommended when:
Raw materials arrive with inconsistent particle size
Fine and coarse materials must be blended together
Liquid coating or conditioning must be precise
Scale-up repeatability is critical
In these cases:
Milling prepares the material for stable suspension
Fluidized zone mixing delivers fast, uniform blending
Each step reinforces the other.
Integrating milling upstream provides:
More stable fluidization
Faster mixing cycles
Improved liquid dispersion
Reduced energy consumption during mixing
Easier scale-up from lab to production
Rather than forcing the mixer to compensate for poor feedstock, the process is engineered correctly from the start.
PerMix works closely with DP Pulverizers to provide complete milling and fluidized zone mixing systems.
DP Pulverizers offers industrial size-reduction technologies including:
Hammer mills
Pin mills
Turbo mills
Air classifier mills
Jet mills
Fine grinding and conditioning systems
These mills prepare materials for optimal downstream fluidized zone mixing performance.
Learn more about industrial milling solutions here:
👉 https://www.dpmills.com
Understanding when to mill, when to mix, and when to do both:
Improves batch uniformity
Shortens cycle times
Reduces process variability
Protects capital investment
Simplifies scale-up
Fluidized zone mixers deliver their best performance when they are part of a properly engineered powder processing workflow.
PerMix fluidized zone mixers are engineered with one clear objective: deliver faster, more uniform mixing without the penalties of excessive shear, long cycle times, or oversized equipment. The difference between PerMix and other manufacturers lies in how the fluidized zone is created, controlled, and sustained across batch sizes and applications.
Many mixers marketed as “high-efficiency” simply increase shaft speed or power. This often leads to heat generation, wear, and inconsistent results.
PerMix fluidized zone mixers are:
Engineered to create controlled particle suspension
Designed to separate particles rather than force them together
Optimized to maintain a stable fluidized zone across the entire batch
This approach delivers uniformity through physics, not brute force.
PerMix offers both single and dual shaft configurations because one size does not fit all.
PerMix advantages include:
Single shaft designs optimized for efficiency, simplicity, and lower power draw
Dual shaft designs engineered for large batches, difficult materials, and tighter homogeneity
Purpose-built geometry rather than repurposed mixer platforms
This flexibility allows the mixer to match the process, not the other way around.
Compared to traditional ribbon or paddle mixers, PerMix fluidized zone mixers:
Reduce mixing times dramatically
Improve liquid dispersion and coating efficiency
Minimize segregation during blending
Reduce batch-to-batch variability
Unlike aggressive mixers, this performance is achieved without damaging fragile ingredients.
High-speed mixing demands robust engineering.
PerMix fluidized zone mixers feature:
Rigid, balanced shafts designed for continuous operation
Heavy-duty bearings mounted outside the product zone
Conservative drive sizing to handle startup and full-load conditions
Long service intervals with predictable maintenance
This ensures stable performance over the life of the equipment.
Many manufacturers treat options as bolt-ons. PerMix integrates customization into the core engineering.
PerMix fluidized zone mixers support:
Precision liquid addition systems
Heating, cooling, and vacuum configurations
Sanitary and hygienic designs
Automation, recipe control, and data logging
These features are engineered to preserve fluidization stability—not disrupt it.
PerMix approaches fluidized zone mixers as process solutions.
Support includes:
Material behavior evaluation
Mixer selection between single and dual shaft designs
Scale-up guidance from lab to production
Integration with upstream milling and downstream processing
This reduces risk, shortens commissioning time, and improves long-term results.
Lower purchase price often leads to:
Longer mixing times
Inconsistent product quality
Higher energy consumption
More frequent maintenance
PerMix fluidized zone mixers are designed to deliver:
Higher throughput per batch
Reduced operating costs
Long-term reliability
Upgrade flexibility as processes evolve
The result is superior total cost of ownership.
Fluidized zone mixers are chosen when performance matters.
PerMix single and dual shaft fluidized zone mixers deliver:
Faster, more uniform mixing
Superior liquid dispersion
Predictable scale-up
Engineering support that extends beyond installation
That is why manufacturers choose PerMix when conventional mixers reach their limits.
PerMix is here to listen to your needs and provide sustainable solutions. Contact us to discover more.