High Shear Mixer: The Ultimate FAQ Guide

If you have any questions about high shear mixer, you will find the answer right here.

This is because this guide covers all information you need about high shear mixing machine – from features, classification, to working principle, just to mention a few.

Let’s dive right in.

What Is A High Shear Mixer?

This is a machine whose function is to disperse, grind, Homogenize, emulsify and dissolve unmixable mixtures. The mixtures can be of the same product or different.

Common characteristics of these machines are their high shear rates, high speed for the rotor tip, and high power consumption.

The rotating parts for these machines can either be one or more sets of screws, paddles, or impellers. Its stationary parts consist of the chamber walls, vanes, and baffles.

Lab high shear mixer

Lab high shear mixer

What Is The Function Of A High Shear Mixer?

The primary function of this machine is to grind, disperse, homogenize, emulsify and dissolve mixtures that are had to mix. Such mixtures can be of the same or different parts.

What Are The Benefits Of A High Shear Mixer?

There are several benefits you get by using this machine in your manufacturing processes. such benefits include:

Continuous Production Of Your Products

An effective high shear mixture can function at an optimum level without breaking down. Its easy operating principle and durable parts facilitate this production process.

The advantage here is it increases the production scale of your products, enabling you to maximize sales.

Quality Particle Production

A high shear mixer allows you to mix, shear, and emulsify particles with a high degree of accuracy. This is done by setting the correct operating parameters for the machine.

Accurate mixing and grinding are crucial in ensuring you have a quality particle production process.

The Short Drying Process For Products

This machine’s shearing and mixing process result in heat production due to the amount of force it uses. This heat contributes to the drying process of your products.

Once you remove your products from the machine, you don’t have to dry them for long again.

This is advantageous since it saves on the time and resources you need.

For instance, you won’t have to invest in drying machines. This allows you to save and invest in other processes that can enhance the quality of your production.

Less Environmental Pollution

A high-shear machine operates within an enclosed structure. It also ensures there is maximum shearing and mixing of your particles.

This results in a controlled production process with a less harmful impact on the environment. That includes less pollution and maximum utilization of the products.

Saves Resources

The simplification process of this machine allows you to save on resources such as time and cost. For instance, it is time and resource-consuming to mix two immiscible products.

However, a high sheer mixer facilitates this process, thereby saving you time and capital.

Are There Limitations To The Use Of A High Shear Mixer?

Yes. The use of a high shear mixer has the following limitations:

Degradation Of Powder Products

Using a high-shear mixer on fine and fragile powder can degrade the final quality of your product.

This is due to the sheer amount of force that the machine uses to mix its product.

The solution for this is to ensure you use the recommended materials that a specific high-shear mixer allows.

Poor Quality Products

Operating a high shear mixer requires a high level of accuracy in mixing and controlling the temperature. For instance, over wetting the products during the mixing process results in lump formation.

This lowers the quality of your final products.

Limits The Type Of Materials You Can Use

The use of this machine has a limit as to the type of materials you can use. This also limits the type of product you can manufacture using this machine.

The solution for this is to purchase different machines for specific functions which are relatively expensive.

What Is The Difference Between A High Shear Mixer And A Low Shear Mixer?

The main difference between a high shear mixer and a low shear mixer is their operation and materials. A high-shear mixer is ideal for mixing immiscible materials.

Such materials can be of the same part or different parts. For instance, they can be liquids, semi-solids, or solids. A high shear mixer usually operates using high force compared to a low shear mixer.

The use of a low-shear mixer is in mixing mixable products. Such products usually have the same viscosity.

The materials you use in a low-shear mixer do not necessarily require further breaking. This makes the shearing rate for these mixers below.

The use of a low shear mixer is common in materials that are heat-sensitive and fragile.

What Are The Parts Of A High Shear Mixer?

The main parts that you can find in an effective high shear mixer are:

Parts of high shear mixer

Parts of high shear mixer

External Frame

This is the outer part of your high shear mixer, which is mainly of stainless steel. Stainless steel is preferred due to its unique properties, such as ease of cleaning and durability.

However, you can have different materials depending on the type o your mixer and manufacturer. The outer frame helps in housing the internal parts of your machine.

It also provides a conducive environment for the functioning of your machine since production takes place within it.

Motor

A motor offers the mechanical energy that your high-shear mixer needs to function. This energy is vital in the mixing and shearing processes of your machine.

You can have different motors depending on their energy capacity and the size of your machine.

Feeder And A Discharge Port

The feeder is where you introduce your materials into the machine. They are available in different shapes, such as a funnel or cylindrical, depending on the design of your machine.

It is the feeder that determines the rate of introducing particles into the machine. The larger the feeder, the higher the feeding rate.

After production, you have to discharge the finished products via the discharge port. It is also available in different types and sizes.

Spray Nozzle

The function of the spray nozzle is to spray liquid to your particles during the shearing and mixing process. The rate of spraying depends on the quality of your final products.

Spraying helps in the emulsification and shearing process.

Choppers

Choppers facilitate the breaking of the particles into smaller sizes. The choppers are available in different configurations and sizes depending on the requirements of your final products.

You can have different choppers for the same machines since they are easy to detach and attach.

Control System

The control system is a vital part of your machine where you set the parameters for the functioning of your high-shear machine. The control system consists of various controls like the power, temperature, and mixing button.

Before you start operating your machine, you need to set the correct parameters via the control system. This allows your machine to produce the desired output.

Mixing Rotor

The mixing rotor ensures there is adequate mixing of your particles to bring out the desired output. The mixing rotor is available in different designs depending on the type and design of your high shear mixer.

Can You Replace High Shear Mixer Parts?

Some replacement parts for high shear mixer

Some replacement parts for high shear mixer

Yes. You can replace worn-out or broken parts of your high-shear mixer. However, such replacement should only take place with original spares, preferably from your manufacturer.

Original spares allow for the smooth functioning of your machine. You can achieve this by engaging your manufacturer or a reliable spare dealer.

How Does A High Shear Mixer Work?

The effective operation of a high shear mixer relies on the working of its different components. The starting point is the feeding stage.

This involves introducing your materials into the feeder. The introduction rate depends on various factors, such as the size of the feeder and mixer.

You can introduce as many materials as to how you want for the final appearance of your product. These materials then flow into the mixing component of your machine.

This part has several choppers which cut the particles into smaller sizes. The cutting ensures that the particles are of the right size for further processing.

You can change the size of choppers depending on the design of your machine. Some mixers allow you to remove the chopper and replace it with the one you desire.

In other cases, you can reduce the size of the choppers by adjusting them at the control panel. The chopper usually rotates at a speed of between 100 RPM and 500RPm.

The difference between the liquid outside the rotor diameter and that at the center creates the shearing necessary. The high chopper speed is responsible for forming powdered particles, which are seamless and have density.

The presence of an electric-powered reamer helps in regulating adhesive solubility. After completing the mixing process, the powder discharges from the machine through the discharging unit.

This is mainly by the force which originates from the revolving shear.

How Do You Install A High Shear Mixer?

High shear mixer

High shear mixer

There are several aspects of your high-shear mixer that you must install appropriately for your machine to work effectively. The starting point is installing the electrical element of your machine.

When installing this part is vital that you be careful to avoid installing the cable in the wrong place. Check to ensure the switch on the high shear mixer functions properly.

A reliable manufacturer usually offers an electrical shield for shielding the electrical cables.

This minimizes damage or interference, ensuring that your machine works effectively.

Check that the power source is efficient to warrant the proper functioning of your machine.

This prevents under-functioning or electrical disruption due to low voltage.

The next step involves assembling the various parts. Proper assembling ensures that your machine functions accordingly.

You need to tighten any loose bolts and parts before commissioning your machine. You should also check with the motors and choppers to ensure they are in a proper position.

The motor should be tight since it is responsible for providing the necessary force that the machine needs to function.

Ground installation is also critical. The installation process should be on a flat and stable surface.

If you are placing your machine on the ground, you have to tighten it firmly with bolts.

This is to prevent the machine from shaking during operation as that can affect its efficiency.

After installing your machine, you must test it before commissioning. Testing indicates where the machine is not functioning properly, and it helps you rectify it early enough.

How Does Fluid Flow In A High Shear Mixer?

There are two types of fluid flow in a high shear mixer that is laminar and turbulent flow. Laminar flow is one in which the particles and fluid flow in the same direction.

This type of fluid flow is helpful for fluids that are not thick and results in smooth particles. It is an efficient method to use on fluids that are heat sensitive.

A turbulent flow is one in which the fluid flow is opposite to that of the particles. Such a flow results in heat production as the particles slide against each other.

It is an essential flow if you are using thick fluids.

What Are The Types Of High Shear Mixers?

The main types of high shear mixers available are:

Batch High Shear Mixers

A batch high shear mixer features a rotating shaft at the bottom of the tank and a feeder on the top part of the tank.  You, therefore, have to feed your materials from the top part of the machine.

The advantage of this type is it has a processing capacity that is twice that of an inline high shear mixer. A batch high shear mixer is common in an application where there is a high production demand.

However, you need considerable space for installation due to its large size, which can be a limitation where such space is unavailable.

Sticky products tend to stick within your batch high shear mixer, necessitating frequent cleaning and maintenance. This has the effect of increasing the operating cost.

Batch high shear mixer

Batch high shear mixer

Inline High Shear Mixers

This type of high shear mixer features a rotor-stator array within a housing with an inlet and an outlet on opposite ends. The rotor part protrudes through the seal.

Introducing your materials to the mixer is through a generator through a continuous stream. The advantage of this type is its controlled environment which allows you to get the desired mixing.

You can achieve equilibrium mixing using this machine, bypassing your materials through it severally. Its relatively small size makes it ideal for installation where space is an issue.

Inline high shear mixer

Inline high shear mixer

Powder Induction High Shear Mixer

A powder induction high shear mixer is common in the production of powder products. Its functioning involves the reliance on a vacuum system when drawing powder materials from the feeder to the mixing head.

There is an accumulation of the powder and the liquid in the mixing chamber, resulting in lump formation.

The advantage of this type is its relatively low price compared to an inline high shear mixer. It also does not consume space, making it an ideal where space is an issue.

The main limitation is sticking the powder in the mixing chamber. Poor cleaning can lead to contamination of the product.

Powder indusction high shear mixer

Powder induction high shear mixer

How Do You Select The Best High Shear Mixer?

The following factors are crucial when selecting an ideal high shear mixer for your use:

Type Of High Shear Mixer

The different type of high shear mixers offers different product results and are suitable for different applications. For instance, batch high shear mixers are not ideal for the pharmaceutical industry, where an inline high shear mixer functions best.

Material To Process Using High Shear Mixer

Understanding the products that you want to manufacture is key to selecting the best high-shear mixer.  Several factors can affect the type of product that you want to manufacture.

For instance, the market demands raw materials and government regulations. You, therefore, have to consider these actors before deciding the product you want to manufacture.

All the types of your high shear mixers are suitable for different products and desired output. Powder induction high shear mixer is ideal for manufacturing powder-related products.

Batch high shear mixer works well with high volume products and those that require granules.

Price Of High Shear Mixer

The right high shear you select should meet your financial capabilities. This means you have to consider the different types, different manufacturers, and the different incentives available.

However, you should not compromise the quality of your high-shear mixer for price. Aside from choosing the best price, it would help if you considered the quality standards available.

The best high shear mixer should be of ideal price and meets all the quality standards necessary.

Flexibility Of Particular High Shear Mixer

It is best to select a high-shear machine that you can use to manufacture more than one product. This helps in reducing costs in terms of purchasing other mixers while giving you value for your money.

Flexibility can be in terms of what the machine can perform and the size of granulation it can manufacture.

Technological Compatibility Of High Shear Mixer

Technological compatibility allows for the integration of your high shear machine with other production processes. This facilitates manufacturing while reducing your overall cost.

You can also consider technology in terms of the ease of operation of your machine. Selecting such a machine reduces the overall operating cost while enhancing production.

Production Capacity Of High Shear Mixer

You have to select a high-shear mixer that meets your production capacity. Such a capacity should include any future expansion of your production.

Is There A Difference Between An Inline High Shear Mixer And A Batch High Shear Mixer?

Yes. There are several differences between an inline high shear mixer and a batch high shear mixer.

The purchasing cost of an inline high shear mixer is higher than that of a batch high shear mixer. This is due to the functional capability of an inline high shear mixture that lacks in a batch high shear mixer.

The operation principle of an inline high shear mixer involves the production of particles in a continuous process. This maximizes the production output.

A batch high shear mixer involves the production of particles in batches. It, therefore, has a lower production output than an inline high shear mixer.

The quality of particles in an inline high shear mixer is high than that of a batch high shear mixer. This is because an inline shear mixer is absent in a batch high shear mixer due to the high aeration process.

The mixing process in a batch mixer is longer than that of an inline mixer. This is because the particle sizes you can use in an inline mixer are smaller than those in a batch mixer.

The unique characteristics of an inline mixer make it ideal for use in a wide range of applications compared to a batch mixer.

Where Can You Use A High Shear Mixer?

A high shear mixer is used in the manufacturing industry where mixing different raw materials is vital. You can use different high shear mixers depending on the type of high shear mixer.

Some of these industries are:

Food Manufacturing Industry

Different food manufacturing industries use a high-shear mixer in their processes. The purpose here is to create suspension, granules, powder, or emulsions.

Food products that you need to use this machine include sauces, pastes, and dressers. For instance, in the manufacturing of Ketchup, doughs, and mayonnaise.

The raw materials for these products can either be solids, semi-solids, or liquids that require mixing.

Cosmetics And Pharmaceutical Industry

Common products that you need to use a high-shear mixer in this industry include syrups, tablets, ointments, and gels. Other products are suspensions, injection solutions, and creams.

The raw products you need to manufacture these products require shearing and mixing. This is possible through the use of a high-shear mixer.

Coating And Paints

Shearing is a critical aspect in the paint manufacturing industry due to the non-Newtonian nature of paints. The shearing process depends on the final thickness that you want for your paint.

Toner And Ink Manufacturing

The shearing and mixing process of a high shear mixer facilitates the thickening process. This is due to the rheopectic nature of toners and inks.

You have to control the shearing and mixing process in the manufacture of these products to prevent their solidification.

Petrochemicals

The use of a high shear mixer here is in injection molding and casting. You can also use the machine in oil viscosity modification, asphalt production, and wax emulsification.

Paper Industry

A high shear mixer in the paper industry helps in the production of pulp which is helpful in the manufacturing of paper and related products.

The mixer shreds the raw materials before mixing them with chemicals and fluids to form a pulp.

What Is The Cost Of A High Shear Mixer?

The actual pricing of your high shear mixer depends on a combination of factors which include:

Type Of High Shear Mixer

The different types of high shear mixers have different functional capabilities and different characteristics. The differences allow for use in different applications resulting in unique products.

These are the differences that affect the final pricing of these machines. You must understand the type of machine you want to purchase before checking for the price.

Manufacturer Of High Shear Mixer

Difference manufacturers quote different prizes for their high-shear mixers. This is due to different factors such as profit margin and market demands.

When selecting the best manufacturer, you need to have one whose machines adhere to available quality standards.

Technological Advancement In High Shear Mixer

Technological advancement gives a particular machine an edge over those which lack the technology. Such technology can allow for efficient production and compatibility with other machines.

However, this technology increases the price of such a machine compared to those whose machines lack it.

What Does Equilibrium Mixing Mean In A High Shear Mixer?

Equilibrium mixing refers to the point that your mixture has the characteristics you need. Such characteristics include particle size, particle density, and mixture viscosity.

Equilibrium mixing is vital in controlling the volume of the rotor-stator head. Getting the right equilibrium involves setting suitable parameters on the control panel before production starts.

How Difference Is Acoustic Mixing From High Shear Mixing?

In acoustic mixing involves the use of sound waves originating from a vessel base to function. A high shear mixing involves the use of choppers and impellers to work effectively.

There is shearing and mixing in a high shear mixing which is absent in acoustic mixing. An acoustic mixer uses less energy compared to a high shear mixer.

A high shear mixer has diverse usage due to the materials it can utilize. An acoustic mixer is limited to materials that sound waves can penetrate and break down quickly.

How Do You Optimize A High Shear Mixer?

The main aim of optimizing a high-shear mixer is to get the most of your products from the process. You can achieve this by considering several factors of the machine and your products.

You need to use the right product and product size. This ensures that the machine functions according to the manufacturer’s guidelines.

Always ensure you have the suitable parameters before you start operating the machine. You can set these parameters from the setting panel.

Maintaining proper conditions of your high shear mixer ensures it functions at an optimum level. This involves tightening any loose parts or replacing any worn-out parts.

When replacing worn-out parts, you must do so with the original spare parts from your manufacturer. You can also purchase these parts from a reliable dealer recommended by your manufacturer.

What Is Shear Rate In A High Shear Mixer?

The shear rate in a high shear mixer refers to the rate at which the choppers tear down the raw materials into particular sizes.

The shear rate determines the functional capacity of your machine and the type of products you get.

How Do You Maintain A High Shear Mixer?

Maintaining a high-shear mixer prolongs its shelf life while functioning at an optimum level. Proper maintenance involves ensuring all the parts are in proper condition.

You have to frequently change the choppers to ensure they cut particles to suitable sizes. You have to cover the motor when not in use.

This is to prevent particles from entering it, which can result in malfunctioning. It would help if you frequently cleaned your high-shear mixer to prevent contamination.

Cleaning removes dirt and debris from the previous process, giving you a clean machine for use. Always ensure that you are using the proper cleaning process that your manufacturer details for you.

You have to replace worn-out parts using those you purchase from your manufacturer or a reliable dealer. This ensures the machine functions efficiently.

How Do You Determine The Degree OF mixing In A High Shear Mixer?

Different factors determine the degree of mixing for your high shear mixer. You have to consider the state of the final product that you want.

Suspensions usually take a high degree of mixing compared to granulation. The physical state of the raw materials also affects the degree of mixing.

You can easily mix liquid products easier than mixing semi-solid or solid products.

Which Materials Can You Use On A High Shear Mixer?

You can use different materials depending on the type of high-shear mixer you are using. These materials include solids, liquids, and semi-solids.

Does A High Shear Mixer Come With A Warranty?

Yes. You get a warranty when you purchase your high-shear mixer from a reputable manufacturer. The terms and conditions of the warranty may vary from one manufacturer to another.

The general principle is that the warranty is valid for issues in which the manufacturer is the cause f the problem.

How Do You Integrate A High Shear Mixer In Your Production Line?

The process of integration is to facilitate the production process and give you quality products. This is possible if the other machines in your production line are compatible with your high-shear mixer.

Integration of a high shear mixer is common in industries such as the food and pharmaceutical industries. They help prepare the raw materials for further processing.

At SaintyCo, we have a range of processing machines such as Tablet press machines, capsule filling machine, and candy making machines, amongst others.

Contact us today for all your high shear mixer machines.

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