Do you want a mixer or grinder that could deal with your bulk material in the manufacturing process? If yes, you can choose high shear mixer granulator.
To get further knowledge about high shear mixer granulator, read this guide. We have elaborated complete information about it. Let’s move onto it.
What is High Shear Mixer Granulator
High shear mixer also called as rotor stator mixer. It’s a machine which is used to mix, grid and dissolve various materials. This machine operates on strong forces, therefore the substances could break and mix properly. These mixers are important in many manufacturing processes. You can use them to produce consistent and high quality products because of their ability to create a uniform mixture.
Parts of High Shear Mixer Granulator
Here are the main components of this machine which you have to tackle while using this machine for multiple functions.
- Cylindrical or Conical Mixing Drum: The mixing drum can be cylindrical or conical. This part is the chamber where the mixing and granulation process takes place. The conical shape facilitates better discharge of the granulated product. This also ensures that minimum residual material is left in the back.
- Impeller with Trio Blade System: The impeller is a part of that machine which affects the mixing and granulation procedure. This part consists of a trio configuration blade. You can set the rotational speed of the impeller, which optimizes the shear forces applied to the substances.
- Primary Chopper and Supplementary Chopper: Choppers are integrated into the granulator to enhance reduction of granule size . The primary chopper operates at a higher speed, and the supplementary chopper operates at an exceptional speed or configuration for further disintegration of the product.
- Motor:The motor provides power to propell the impeller and chopper.
- Discharge Pot: The discharge pot is the component from where you removed the final granulated product.
The Working Principle of High Shear Mixer Granulator
The high shear mixer granulator operates through a series of key techniques:
- Mixing: When the granulator is turned on, it starts mixing the dry powder well.
- Binder Addition: In this step, a liquid binder also known as granulation liquid is added to the powder.
- Wetting: When the powder absorbs the binder, it becomes moist.
- Nucleation: Small powder crystals begin to form.
- Densification: The powder becomes denser because the granulation procedure continues.
- Granule Formation: The granules undergo attrition and breakage, which leads to the formation of round and strong granules.
Factors Affect the High Shear Mixer Granulator Working
Physical Properties of Materials: The particle length, shape, density, and moisture content of the substances have a greater effect on granulation process regulation and final product.
Excipients: The type and amount of excipients, which includes fillers, lubricants, and disintegrants, play an important role in the formation and stability of granules. It affects the flowability and compressibility.
Binder Solutions: The type and quantity of binder solutions also affect the granulation process. This solution determines the power and efficiency of the granules. Some binders can also have an effect on drying time of granules and its shape.
Process Variables: Some important parameters may include granulator bowl load, impeller speed, granular design and wet massing time.
- Optimal granulator bowl loading ensures powerful mixing and granulation.
- Higher impeller speed can boost the granulation system.
- Granular design features of the granulator have an impact on mixing efficiency and consistency.
- Duration of the wet massing phase influences granule size.
Technology and Manufacturer Insights: Selecting a high shear mixer granulator requires many technologies and their processes for specific formulations.
Equipment Features: Evaluating the components of the machine is essential, which includes high-speed mixing and granulation, fitting discharge plug, precision mixing machine and mixing impeller and blade angle.
Different Types of High Shear Mixer Granulator
Batch High Shear Mixers
A batch high shear mixer processes all the elements together in a huge box or tank. This type of high shear mixers is used to mix big volume formulations easily and instantly.
- The components are added from top, and the mixer uses a rotor to stir and shear material.
- These batch mixers can integrate components faster than in-line mixers.
- After mixing a batch, cleanliness of the system is important to save from contamination.
In-line High Shear Mixers
In-line mixers continuously mix ingredients as they flow through the mixer.
- In this mixer the components are added in the mixer through an inlet, float beyond a rotor-stator assembly, and exit through an outlet.
- The rotor-stator arrangement creates high shear forces that mix the ingredients very well.
- This result is crucial for the product quality.
Powder Induction High Shear Mixers
This machine uses a vacuum for adding powdered material of desired product in the specific place of the machine.
- As the rotor of the mixer spins, it generates a vacuum that pulls powders from a hopper into the liquid mixture.
- This method avoids the clumping that may appear while powders are brought to liquids. Hence we can say, this mixer offers an efficient product.
- These require proper care to control the mixing speed and time to protect from overheating, which could alter viscosity and have an effect on product integrity.
High Shear Granulators
These mixers turn powders into larger granules, which are greatly usable in tablet manufacturing.
- In these machines, a binding liquid is blended with the powder which forms a wet aggregate.
- The process includes the wetting of the powder, then allowing it to develop large aggregates, and breaking down excess granules to get the favored size.
- It produces homogenous granules that improve its drift and usability for further process.
Ultra-High Shear Mixers
These mixers perform at extraordinarily high speeds to create excellent particle sizes and efficient blending.
- Ultra-high shear mixers use a specialized designed rotor which creates powerful pumping action and severe shear forces, mixing solids and liquids quickly.
- The ultra high speed ensures that substances are homogenized.
- These mixers are extremely good for ensuring a clean output.
Bottom Entry High Shear Mixers
These mixers are used along slower mixers.The shear mixer pulls substances down into the combination sector and utilizes centrifugal force to combine them thoroughly.The high shear mixer handles extreme blending, the slower mixers ensure that every material in the machine is blended well.
What Are the Applications of High Shear Mixer Granulator?
High shear mixer granulators are flexible machines used throughout various industries due to their efficient blending and granulation abilities. Here are some prominent sectors which uses this machine:
Pharmaceutical Industry: In pharmaceuticals, high shear mixer granulators are used for the manufacturing of drugs and tablets. They ensure uniform blending of pharmaceutical components (APIs) with excipients, leading to satisfactory final product. The granulation process helps in improving flowability and compressibility of powders that are difficult to attain in tablet formulation.
Food Industry: Manufacturers also use these machines to mix different ingredients in food while processing. They could prepare instant meals, powdered beverages, and seasonings. High shear granulation helps in attaining uniformity between distribution of flavors and vitamins, which ultimately improve the stability of the last product.
Cosmetics and Personal Care: In the cosmetics industry, high shear mixer granulators are employed to create homogeneous combinations of powders and liquids, which is important for products like lotions, and powders. The ability to granulate helps in generating optimized particle size that improve the properties of personal care items.
Chemical Industry: High shear granulators are used to mix and granulate various chemical formulations, including fertilizers and other chemical substances. These machines deal with highly cohesive substances and improve the granule , which are crucial for better performance.
Mining and Minerals: In mining, these machines are beneficial for granulating mineral powders. These ensure consistent particle sizes for better processing. They enhance the drifting traits of substances, which facilitates managing and shipping.
Plastics and Polymers: High shear mixer granulators are worried within the manufacturing of polymer blends and compounding substances. They ensure blending of various plastic resins and components, which is vital for production of superplastic materials.
Conclusion
High shear granulator’s all types are idealy used for mixing purposes in different companies from pharmaceutical to plastic and polymer. Their unqiue advantage is, you can use them in minning processes as well.
If you want any type of high shear mixer granulator, contact now!
