Different industries have different requirements for mixing uniformity, heat transfer efficiency and process adaptability, making it difficult for standardized equipment to meet complex working conditions. For complex mixing scenarios such as high-viscosity pastes, multi-component powders, and corrosive materials, we provide Customized ribbon mixer solutions , which can customize suitable mixing equipment for you according to your on-site working conditions, mixed materials and material ratios.
Customized ribbon mixers can adapt to material characteristics on demand, with high efficiency of three-dimensional mixing of double-ribbons, support for 500L-20m³ volume customization, and optional wear-resistant and corrosion-resistant materials.
Excellent performance: Customized ribbon mixers are closely designed around material characteristics and production requirements, and can achieve higher mixing uniformity. In the chemical industry, for some reaction raw materials that require extremely high mixing uniformity, customized mixers can increase the uniformity to more than 99%, ensuring the consistency and stability of chemical reactions.
Cost-effectiveness: In the long run, although the initial investment of customized ribbon mixers is relatively high, it can effectively reduce energy consumption, reduce equipment maintenance costs, and improve product qualification rate because it can accurately adapt to production needs.
Flexibility and adaptability: With the changes in market demand and the adjustment of enterprise product structure, customized ribbon mixers can quickly adapt to new material mixing needs by replacing some components and adjusting control system parameters.
In many industries, conventional ribbon mixers cannot meet production needs. When facing high-viscosity materials and uniformity, it is difficult to meet the standards; when the material properties are very different, it is easy to have special requirements such as stratification, and customized solutions are needed to resolve them.
High-viscosity material mixing problem: polymer solutions, colloids and paste materials have a viscosity of more than 10,000 mPa·s, and traditional paddle stirring is prone to laminar dead zones, resulting in a mixing time extension of more than 30%. For example, in paint production, if the color paste is unevenly dispersed, it will cause the color difference between batches to exceed the standard.
Heat transfer efficiency bottleneck: The heat transfer coefficient of materials in the reactor is often lower than 200 W/(m²·K), which restricts the temperature control accuracy of the exothermic reaction. A case study of the synthesis of a pharmaceutical intermediate showed that insufficient heat transfer resulted in a 40% increase in reaction time and a 15% increase in by-products.
Anti-adhesion and cleaning challenges: In processes such as starch saccharification and resin polymerization, the thickness of material adhesion to the wall can reach 5-10 mm, which not only causes a waste of raw materials, but is also likely to cause local overheating and lead to product degradation.
As a source manufacturer, we can recommend customized mixers for you according to your needs and make suitable mixing equipment.
Screw ribbon design: In addition to conventional double-layer screw ribbons, for special mixing needs, it can be designed as multi-layer screw ribbons, intermittent screw ribbons or variable diameter screw ribbons. Multi-layer screw ribbons can further enhance the convection and shear of materials at different levels; intermittent screw ribbons can form more irregular vortices during the flow of materials; variable diameter screw ribbons can optimize the stirring intensity according to the flow characteristics of materials at different positions of the barrel.
Cylinder structure: According to the material characteristics and mixing process, the cylinder can be of different shapes and sizes. For high-viscosity materials, it can be designed as an inverted cone cylinder to reduce the residual material at the bottom; for materials that need to be heated or cooled, the cylinder can be equipped with a jacket structure.
Basic material: According to whether the material is corrosive, hygiene requirements, etc., choose from common materials such as carbon steel, 304 stainless steel, 316L stainless steel, etc. Carbon steel has a low cost and is suitable for mixing ordinary materials that are non-corrosive and have low hygiene requirements; 304 stainless steel has a certain corrosion resistance and can meet the needs of general industrial production; 316L stainless steel has excellent performance in resistance to chloride ion corrosion and is often used in food, medicine, marine environment and other fields with extremely high requirements for corrosion resistance.
Drive configuration: According to the power demand, speed requirements and operating stability of the mixer, select the appropriate drive motor and reducer. For the mixing of high-viscosity and large-capacity materials, high-torque motors and high-power reducers are required to ensure that the equipment can operate stably; for mixing processes that require precise speed control, variable frequency motors can be used to achieve stepless speed regulation.
Automatic control: To improve production efficiency, reduce labor costs, and ensure the stability of mixing quality, customized ribbon mixers can be integrated with automatic control systems. Through the PLC controller, parameters such as mixing time, speed, temperature, etc. can be preset to achieve full-process automation of automatic loading, mixing, unloading, etc.
Our mixers can customize solutions for different customers, provide customized ribbon structure, material, and drive system, and are suitable for chemical, food and other industries.
High-viscosity resin mixing solution for the chemical industry: In response to the challenge of a specialty chemical manufacturer to deal with ultra-high viscosity epoxy resin, we have developed a dedicated double-ribbon mixing system. Through the 5mm precision gap design, hydraulic lifting cover and 316L stainless steel polishing, the mixing dead corner and cleaning problems are solved, and the temperature control jacket and automatic metering system are integrated.
Smart production line for aseptic sauces in the food industry: In order to meet the dual needs of food groups for aseptic production and capacity improvement, we have created a fully enclosed solution that meets the standards. The innovative use of magnetic drive and wide ribbon blade design, combined with online viscosity monitoring and electrolytic polishing surface treatment, achieves zero leakage while adapting to viscosity fluctuations.
Breakthrough in new energy battery material mixing system: In response to the special requirements of lithium battery positive electrode material production, we have developed a revolutionary non-metallic contact mixing system. Through the combination of ceramic lining and PTFE coating, multi-stage ribbon layering control, as well as vacuum degassing and explosion-proof design, metal pollution is effectively controlled at the PPB level.
Dahan Machinery has been focusing on customizing ribbon mixers for many years and has rich experience. The technical team is professional and innovative, and can deeply analyze customer needs and customize exclusive solutions based on material characteristics, production capacity scale and production environment. The processing equipment is advanced, and high-quality carbon steel, stainless steel and other materials are selected to strictly control quality. From design to after-sales, one-stop service is provided to help many companies improve the efficiency and quality of mixing processes.
As an efficient mixing equipment, the ribbon mixer plays an important role in many industries such as chemical, food, pharmaceutical, and building materials. Its unique structural design enables it to perform well in handling high-viscosity materials, slurries, and materials that require uniform mixing.
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