Ginhong’s experience in supplying Industrial Planetary Disperser Mixers has paved vast opportunities for many cosmetic, chemical and pharmaceutical industries. Now, we are throwing some light on how you can wisely choose and buy your first Planetary Mixer.
One of the biggest roadblocks you may encounter in your manufacturing process is buying the wrong type of industrial mixer. This would obviously result in a huge financial slump. The apparent solution for saving you a lot of time and money is knowing which type of mixer is right for your application. Not all industrial mixers are created equal and there are different types of industrial mixers; each designed for different industrial mixing applications.
Planetary mixers, for one, have a more sophisticated gearing system and improved shafting operations Thus, more power and exceptional processing needs are delivered to efficiently disperse, mix and knead high viscosity materials. New and enhanced adhesives, epoxies, sealants, battery slurries and ceramic products are being supplied each day with utmost quality, thanks to planetary disperser mixers.
For many years, client demands have strengthened our skills in innovating our planetary disperser mixers to deliver their needs. We have enhanced our PLC system, blade design, drive power, pneumatic and hydraulic lift and powder induction system.
Ginhong is global supplier and exporter of planetary mixers and other types of industrial mixers specializing in the design and manufacture of new and revolutionary mixing technologies that have saved tons of mixing problems for many countries.
Our company is more than willing to share our collective technical experience with you to help you purchase your first Planetary Disperser Mixer.
We know that this can be a challenging task especially if you do not have much experience in dealing with equipment suppliers, so in this comprehensive guide, you will learn how to:
- test your materials and understand its mixing properties,
- select a planetary disperser mixer,
- specify specific needs with a manufacturer, and
- justify your capital expenditure.
Where are Planetary Disperser Mixers Today?
In the past, if you want to choose a mixer, you would simply look into a standardized chart where you will match up the mixer capacity, agitator power, disperser power and tip speed to the properties of your material.
Of course this method does not give a hundred percent solution for all mixer problems. Emerging mixer manufacturing companies have been in a tight competition on bringing the best mixers in the market to solve all mixing issues with lesser footprint.
Because of this, newer and more enhanced mixer designs have been released that gives the most accurate configuration, blading design and gearing system to produce the optimum product properties for the cosmetic, pharmaceutical and food industries.
Today, manufacturers can produce an industrial planetary disperser mixer that combines all the features you need. This has paved a way to an effective processing method that gives better flow, optimum shear and effective heat transfer.
Contents of this Guide:
[lwptoc]
Testing Your Materials and Being Accurate with Rheological Properties
Prior to purchasing a mixer, you must first know the characteristics of your materials and test it in the industrial mixer manufactufacturer’s lab scale mixers.
Typically, they will use a prototype or a lab mixer which is a representation of the industrial planetary disperser mixer. Under simulation, you and the manufacturer can be able to investigate if the mixer adapts to your materials’ requirements.
Furthermore, both sides can be able to determine the proper specifications of the planetary disperser mixer; What type of agitator blade does it need? Does it need hydraulics? Is vacuum needed?
Knowing the Capabilities of Planetary Disperser Mixers
Take this scenario:extremely viscous materials being processed using a multi-shaft agitator, or worse, a traditional agitator. While mixing, there comes a point where the ingredients no longer have the ability to flow. This can be attributed to the thickeners or additives or thick powders being mixed. The surface of the mixture would just be continuously carved by the impeller.
Meanwhile, heat builds up around the disperser and homogenizer assemblies. For this case, a planetary mixer may be more suitable for use.
The Solution:
In a Planetary Disperser Mixer, the impeller does not only move in one axis shaft, but rather, around the entire mixing vessel. The agitator built with rectangular blades passes in each part of the batch and not just around the periphery. This is an effective way of processing high viscous products, such as in processing gummy or sticky components.
Ginhong’s planetary disperser mixers provides powerful kneading and mixing action regardless of the product’s flow characteristics. Thus, a planetary mixer is the best solution for highly viscous products.
Specifying the Right Planetary Mixer for Your Application
To know which type of Planetary Mixer is the best for your application, you should be able to consider the following.
1. What is your material?
Planetary disperser mixers are used in mixing materials which are over 1,000,000 cps in viscosity. These products are especially thick and needs more advanced mixing blades and accessories. Large, viscous material batches can be processed at a lesser time and cost-effective way with planetary mixers.
Planetary Mixers are typically used for the production of:
|
|
Industries served by Ginhong Planetary Mixer includes:
- Paint and lacquer industry
- Adhesive and sealant industry
- Building chemicals industry
- Chemical industry
- Pharmaceutical industry
- Food industry
2. What is your production volume a day?
If you know your production volume a day, you would know the capacity of the mixing vessel you need for planetary disperser mixer. Furthermore, you can specify if you need one or more equipment for your manufacturing plant.
Again, take this example:
You need to produce 300,000 to 320,000 bottles of 300 mL Urethane sealants per day. Your plant would operate for 16 hours a day (2 shifts, 8 hours per shift).
- Mixing time + residence time for silicone sealant for this scenario is 10 min/batch.
Sizing your mixer capacity:
No. of bottles per hour =320,000 bottles/hr16 hours= 20,000 bottles/hr
Volume per hour = 20,000 bottles/hr x 0.3L/bottle = 6,000 L/hr = 100 L/min
Volume per batch = 100 L/min x 10 min/batch = 1,000 L/batch
Choosing a mixer:
- One (1) – 1000 L Planetary Disperser Mixer
Of course, you would have to consider other factors such as machine efficiency, probability of downtimes, duration of mixing and material transport and supply. We presented this scenario as an example but the whole process of sizing your planetary mixer depends on many factors.
3. Do you need a customized planetary mixer?
Ginhong is ready to customize your planetary mixer according to what your product needs. We have been dealing with multiple customization for customers for a long time. Determination of what needs to be done for your product can be determined by test results from our lab mixers.
Special installations can be accomodated to perform specific tasks such as extra heating, cooling or milling operations.
There are also cases that our clients requests for customized control panels. Other times, customers only want a heating phase tank without the water phase. We also get a lot of requests for size and shape customization.
4. Sealing the deal: How much would it cost you?
Planetary mixers are anywhere between 4-6 figures internationally speaking. When you deal with a China industrial mixer manufacturer, you can expect a lower investment without sacrificing the quality of the planetary mixer.
Planetary Mixer Configuration Options
One of the advantages of picking Ginhong as your Planetary Disperser Mixer supplier is you can choose from a variety of well-engineered and intricately designed mixer mounting assemblies and modules. Each of the mixing units are manufactured to cater varying mixing needs and processes.
Planetary Disperser Mixer
The Planetary disperser Mixer is a special type of planetary mixer combining an anchor blade and a shaft containing two disperser blades. Both rotate on separate axes while revolving around the tank.
The anchor blade continuously directs materials in the central area, where the high speed rotation of the disperser shears the materials. In effect, it completely mixes and homogenizes thick, viscous ingredients leaving no dead zones or unmixed portions. Thus, a Planetary Disperser Mixer eliminates multi-stage processes by combining two impellers in one equipment.
Double Planetary Mixer
A Double Planetary Mixer is a complete mixing equipment commonly used in manufacturing adhesives. Typical configuration consists of three mixing technologies: a rectangular blade, an HV blade or a finger blade and a two-blade disperser shaft.
The best part in using this enhanced planetary disperser mixer is it has a unique mixing movement that eliminates the climbing problem of materials, especially adhesives and extremely viscous pastes. Thanks to the sweeping spiral effect created by the HV blade, the material is conveyed effectively up and down the mixing vessel. The rectangular blade further cuts down agglomerates and blends the mixture, while the disperser facilitates easy dispersion and homogenization.
Discharge System
Hydraulic Ram discharge press are designed to remove non-flowable ingredients such as high viscosity materials from removable vessels of industrial planetary mixers and multi-shaft mixers. It is designed with a discharge pressure of 90 PSI up to 227 PSI depending on the difficulty of the material to be removed.
Hydraulic ram discharge press consist of a pressure plate mounted to a hydraulic ram, supported by a structural steel frame. The pressure plate closely fits the inner diameter of the mixing vessel, and, with the help of a special O-ring seal, forces the product through the discharge outlet in the bottom of the mixing vessel.
Thanks to this equipment, you can achieve a high product yield above 98%.
Construction of Planetary Mixers
What makes a well-engineered and high quality planetary disperser mixer and double planetary mixer?
Materials
The best planetary mixer comes with a stainless steel material and all the parts are compliant with cGMP regulations. Stainless steel has a high strength-to-weight ratio that makes it light for its strength capability. It’s also notable for being resistive to corrosion so highly acidic ingredients will not affect the properties of the metal.
Stainless steel planetary dispersers are recommended for clean operation. Other material options such as iron simply cannot compete with the overwhelming advantages of stainless steel. For highly abrasive ingredients, Ginhong adds a wear-protective coating on the tank and contact parts to further enhance its resistance.
Blade Options
Ginhong offers planetary anchor blade options, each manufactured for specific purposes.
RECTANGULAR BLADES
|
This type of mixer blade is used for suitable for dry and wet mixing for low to high viscosity products. |
HV – BLADES
|
The HV-Blade is for medium to high viscosity products (6 million cps).
This blade design has an angled helical configuration that yields down-thrust action. |
FINGER BLADES
|
Used for delicate products such as fibers. |
Fluid Viscosity
Abrasives and paper slurries are highly viscous products by nature and cannot be easily dispersed and homogenized. That is why fluid viscosity is an essential parameter to take note of when selecting the right type of mixer. Behavioral fluids perform differently when you mix it.
Some fluids would thicken as you mix, while others remain at the same viscosity. You need to determine the behavior of the fluid you will use.
Here are some of the most common kinds of liquids you may use with a planetary mixer.
Pseudoplastic Liquids: increase in shear rate, viscosity also increases. Some examples would include latex, paints and gels.
Dilatant Liquids: Increase in shear rate increases viscosity of dilatant liquids. Candies, slurries and clays are examples of dilatant liquids.
Thixotropic Liquids: This type of liquid decreases in viscosity as you agitate it. Some examples include peanut butter and tars.
Mixer Drive
A variety of drive systems are available for both the Double Planetary and the Planetary Disperser Mixer. Electric drives are standard. Electronic variable speed control is a popular option, because it enables you to start the mixer under heavy load and fine-tune the mixing process. Ginhong can also provide hydraulic drives for planetary mixers in any size.
Popular Planetary Mixer Option Packages
Vacuum and Heating and Cooling System
Vacuum construction and the jacketed mixing tank allows you to mix at the temperature you want and cool heat-sensitive products gently and quickly. The Double Planetary Mixer includes a heavy-duty frame, precision machined gears, extra durable bearings, and an all stainless steel gearbox.
Lifting System
The hydraulic lift system not only provides lifting ability to the planetary mixer but also provides compressing power to discharge the finished product from the portable mix tank.
Electrical Control Panel
Ginhong’s Mixers are all equipped with an electrical control panel which provides graphic man-machine interaction. They design and develop these panels using high-grade material in compliance with industry standards.
Ginhong offers a complete line of control systems that are pre-programmed/pre-wired for turn-key start-up and long-term flexibility. Our new streamlined, built-in designs reduce cabling while they simplify maintenance. Routine operation is also simplified. Intelligent menus reduce the risk of error while they help improve process consistency
Other Options
You can also request the manufacturer to custom-make your planetary disperser mixer according to what your product needs.
- Options for top-entry or bottom-entry mixer configuration.
- Options for heating and cooling system.
- Addition of extra load cells.
- Design for a specialized pressure vessel for varying steam pressures.
- Options for explosion proof motors and electrics.
PX Planetary Disperser Mixer
The PX Planetary Disperser Mixer is suitable for industrial applications such as in chemical, pharmaceutical, food and beverage, cosmetic factories and industries. For this type of machinery.
Ginhong offers working capacities from 15L-1500L with varying impeller rotations speeds (40 RPM to 95 RPM), agitator revolution speeds (25 RPM to 35 RPM), and Planetary agitator power (1.5 KW-55 KW).
PX Lab Planetary Disperser Mixer
PX Lab Planetary Disperser Mixer is a laboratory counterpart of the PX Planetary Disperser Mixer which is used for tests to yield new insights in mixer selection and application and to have the opportunity to refine mixing technique. This is often used before the product is subjected to the production line and for replicating process conditions.
Ginhong’s PX Lab Planetary Disperser Mixer is ideal equipment for setting up experiments for powder induction variation, shear rates variation, agitator combinations and speed variations, and vacuum variation to fine-tune operation and improve production yield.
For this type of equipment, Ginhong offers working capacities from 5L-10L with an impeller rotation speed of 160 and agitator revolution speed of 75 RPM and a planetary power ranging from 1.5 KW to 2.2 KW.
PX Double Planetary Mixer
PX Double Planetary Mixer is GInhong’s mixing equipment for mixing more than a billion cps of material viscosity. The agitator blades works at a low speed with thorough mixing action and thrust to effectively crush and melt solids, disperse powders and additives and knead viscous pastes. At the end of the process is a let-down procedure to achieve an optimum mixture rheology. This ultimately saves you a lot of money from buying separate mixing technologies for each process.
YJ Hydraulic Ram Discharge Press
In addition to the family of Planetary Mixers is Ginhong’s YJ Hydraulic Ram Discharge Press, which is used for special cases of discharging non-flowing, viscous products from a mixing tank of a Planetary Mixer or Multi-Shaft Mixer. This is very useful equipment to prolong the mixer’s life, enhance product quality, avoid microbial growth in the production line and prevent counter mixing.
Understanding the Difference Between Planetary Mixer Manufacturers
Asking for a quotation for your planetary disperser mixer is not simple and quick. Simply picking a mixer model in a catalogue is not a good way to purchase a mixer immediately. It is better to have a conversation with your Planetary Disperser Mixer Manufacturer to tailor the unique specifications that you need for your mixing process.
Therefore, you may expect the following questions from your planetary disperser mixer manufacturer before they hand you a proposal and suggestions.
GENERAL INFORMATION
- When do you need to be up and running with new planetary disperser mixer?
- Do you have an existing mixing equipment in your plant now?
- Do you have a budget in mind?
- Is your project approved and funded?
PRODUCT INFORMATION
- What is your product?
- POWDER PRODUCTS: What is the bulk density? LIQUID PRODUCTS: What is the fill temp and viscosity?
- Is your product dusty?
- Does your product needs to be cooled or heated?
FACILITY INFORMATION
- How many shifts are in production at your facility?
- What is the electrical availability in your plant?
- What is your plant ceiling height?
EQUIPMENT INFORMATION
- How do you wash down your equipment?
- Do you need equipment to feed and/or dose your product into the main mixing vessel?
Calculating ROI on CapEx– How long will it take for your planetary disperser mixer investment to pay for itself?
Calculating the Return on Investment from capital expenditure lets you forecast how long it’s going to take for your investment to pay off. Here are five steps to calculate your ROI.
- Ask the planetary mixer manufacturer for a quotation and add up equipment acquisition costs. Your list may include:
- Mixer price
- Freight costs
- Commissioning and installation costs
- Training costs
- Cost of financing
- Annual maintenance and parts expenses
- Think carefully and add miscellaneous fees and additional costs that you think would need to be regarded. You may involve your financial advisor in the matter. The cost may include tax incentives when you purchase your mixing equipment, etc.
- Include rental program fees if applicable when you rent the equipment for a month or two.
- Calculate ROI.
Calculate the Payback Period (PBB) Formula
This determines how much time it will take to recoup the initial investment.
Payback period=Total new equipment costTotal Periodic benefit realized from new equipment
For example, a planetary disperser mixer costs $3,000 and a cosmetic company has a net annual benefit of $2,500
Payback period=$3,000$2,500= 0.5 years or half a year
Calculate the Simple ROI
ROI is the ratio of a benefit or loss made in a fiscal year expressed in terms of an investment and shown as a percentage.
Return of Investment (ROI)=Net Benefit or loss generated by new mixer equipmentTotal new equipment cost
Using the same example as above, if you are purchasing a planetary mixer for $3,000 and forecast a net annual benefit of $2,500 (reduced energy consumption, eliminating additional deaeration units, shorter mixing cycle, heating time, or discharge time, smaller footprint, etc), your return on investment will be:
Return of Investment (ROI)=$2,500$3,000x 100 = 83.33%
Thorough understanding of all the financial and technical information to see your potential return on investment in a new industrial mixer will muster enough confidence in you to decide and take a course of action. It takes a lot of hard work but once you completely evaluate all your aspects, you can be able to capitalize smartly on your investment.
You can partner with Ginhong, and together, we can discuss and plan out the optimum planetary disperser mixer specifications and features you need that would bring your company manufacturing success.
Glossary of Terms
| AGITATE | A process to place a substance to motion with either stirring or shaking |
| CENTRIFUGAL FORCE | The force that acts on a substance in a direction away from the center of rotation |
| DIGITAL DISPLAY | A device or screen used to automatically show necessary information such as actual temperature, pressure, etc. |
| DISPERSER | A disperser is a mixer utilized to dissolve and break down solid substances to blend into a liquid substance. |
| EMULSIFIER | An emulsifier is a substance that acts as a stabilizer to prevent non-miscible liquids from separating. |
| HIGH SHEAR MIXER | A high-shear mixer uses a rotating impeller or high-speed rotor, or a series of such impellers or inline rotors, usually powered by an electric motor, to “work” the fluid |
| HOMOGENIZATION | Homogenization is a process used to make a mixture of insoluble liquids evenly blended together. |
| HOMOGENIZER | A homogenizer is a laboratory or industrial machine used to homogenize various types of material and mixtures. |
| HYDRAULIC SHEAR | Also called mechanical shear, is a phenomenon which takes place when ingredients are subjected to a high shear mixing effect where particle size reduction, emulsion, and homogenization occurs. |
| IMPELLER | An impeller is a rotating component of a centrifugal pump which transfers energy from the motor that drives the pump to the fluid being pumped by accelerating the fluid outwards from the center of rotation. |
| LAB SHAKER | A shaker is a piece of laboratory equipment used to mix, blend, or agitate substances in a tube or flask by shaking them. |
| MOTOR | A piece of equipment used to convert electricity into mechanical energy to generate force in the form of rotation. |
| OVERHEAD STIRRER | Another term for laboratory mixer. |
| PLANETARY MIXER | A type of industrial mixer that has the impeller rotate at a high speed while slowly revolving around the vessel. All parts of the mixing tank are reached by the impeller; used in processing high viscosity products such as gummy or sticky components. |
| PUMP | a mechanical device used to displace fluids with the use of pressure |
| ROTOR | the rotating assembly in a mechanical device, such as motors, and turbines. |
| ROTOR – STATOR MIXERS | A high shear mixer and disperser device or equipment that carries fluid towards a mixing head and where the intense action of the rotor breaks down materials into pieces. |
| RPM | Rotations per minute, or Revolutions per minute |
| SHAFT | A long and narrow part of equipment which rotates and transmits power from a source. |
| STATOR | the stationary portion of the motor. |
| VACUUM EMULSIFER HOMOGENIZER | a special vacuum-filled mixer equipped with an emulsifier and a homogenizer for manufacturing viscous emulsion, dispersion and suspension in either small-scale or large-scale cosmetic, pharmaceutical, food and chemical industries. |
| VORTEX | In fluid dynamics, a vortex is an area in a fluid that forms a twirling action around an axis and usually forms in fluids being stirred. |
| VORTEX MIXER | An equipment usually used in laboratories to mix small volumes of liquid. |
Your Next Steps
Purchasing a planetary disperser mixer is a daunting task as you would need to investigate every aspect from cost to quality and asses your material compatibility. We hope that this guide has helped you run-down the intricate process on how to choose and buy your first planetary mixer.
If you are finding it difficult to understand what steps to be done and need more assistance, do contact us. A conversation is more worthy than a product catalog and we believe that we can help you succeed in your business. Ginhong can also provide you with the latest technologies and trends on planetary disperser mixers.
