IBC Blending System: The Ultimate FAQ Guide
Why Choose IBC Blending System?
A good blender or blending system is known by the quality of its blending.
It should enable you to homogenously blend various ingredients.
The IBC blending system stands out since you do not need to transfer the substance between different machines to achieve homogenous blending.
Another outstanding aspect of the IBC blender is the user-friendly control system.
The control system is easy to understand and does not require extensive training.
With this system, you are able to accurately set and manage the blending process to ensure you get the best results.
The blender is also built with a stable structure that ensures it remains firm throughout the blending process.
This leads to a smooth, undisturbed process, and also ensures a longer machine lifespan.
The machine is also electricity-powered, which ensures smoother operation, and reduces maintenance costs as compared to the hydraulic or pneumatically-powered machines.
Is there a Difference between Industrial Mixer and IBC Blending System?
Ideally, the two perform the same function, so that the IBC blender is considered as one of the industrial mixers.
These two, however, differ with regards to the level of efficiency and output quality.
The IBC blender performs faster and with more precision compared to an ordinary industrial mixer.
This is mainly owing to the use of container blending, which enables faster loading and unloading, and improved containment.
IBC blender has, therefore, become the technology of choice in most industries when it comes to mixing and blending products.
What are the Advantages of IBC Blending System?
Complete IBC Bin Blender
Intermediate Bulk Container (IBC) blending has many benefits that have helped in tackling many problems in the chemical and pharmaceutical industries.
With IBC blending, chances of cross-contamination, blend quality problems, and clean-up and batch integrity issues have reduced a great deal.
The use of IBC blending has led to faster loading and unloading by enabling complete product containment.
Also, the IBC blender is, therefore, a stand-alone unit, meaning it can simply be loaded using a forklift.
Besides, the IBC blender, unlike the conventional blenders, does not require clean-up, leading to the reduced machine and room cleaning times.
This blender also ensures less blend time.
This, in turn, translates to increased productivity.
The IBC blending system also enhances batch integrity.
There is no need to remove the batch from the blending container.
Contamination and spillage are almost entirely curtailed.
That the product never comes into contact with the container means that cross-contamination is totally prevented.
What are the Disadvantages of IBC Blenders?
Just like every other machine, the IBC blender also has its weaknesses.
One outstanding drawback of these machines is the requirement for high power input.
Also, the IBC blender has a size limitation because it has to remain easily transportable using a pallet track.
The technology, especially the control panel, may sometimes be a little complex.
However, with some training, operating the system becomes easy.
Despite these few shortcomings, the IBC blender has become the top choice for blending companies today.
What is IBC Blending System Used For?
The IBC blending system has quite a number of uses.
Many factories, for example, use the bin blender to blend different food, pharmaceutical or cosmetic products.
The machine also helps to thoroughly mix different contents to achieve a perfect mixture.
One thing that makes the IBC blending system to stand out is the ability to prevent product contamination.
If you are dealing with sensitive products that require zero-contamination, the IBC blending system will help you achieve just that.
This is a huge advantage over the V-blender, which allows for certain levels of product contamination.
IBC Tumbler Blender and Ribbon Blenders; How do They Compare?
IBC tumbler blender is mostly used in mixing free-flowing powders and solids.
It is the best guarantee for immediate product turnover and total product containment.
This equipment is ideal for companies that produce multiple products.
Ribbon blender, on the other hand, comes with ribbon-shaped blades which move throughout a U-shaped trough in an axial direction.
They are most commonly used in the food industry to mix different types of ingredients.
This blender offers very fast, high-quality blending.
Whenever the vessel is inverted, the products are split.
You can adjust the speed of rotation to make sure that the contents get to the lower part of the vessel, thus enabling the splitting.
What are the IBC Blender Considerations for Powder Mixing?
There are many factors you will have to consider in powder mixing.
The first decision, however, is whether to go for batch or continuous manufacture.
If you will be producing the same product throughout, then continuous production is the best.
Batch production works where you intend to change the recipes quite regularly.
Although continuous production seems to be the cheaper option, most manufacturers still go for the batch.
This is mostly in an attempt to try and meet the customers’ craving for varieties.
For this reason, other factors such as the powder characteristics and batch size will always be of great influence.
Other critical factors to consider include the mixing time, the change over time, and ease of cleaning.
The risk of contamination is another factor that you cannot overlook, as it affects the suitability of the final product.
Similarly, also ensure that you take keen consideration of the after mixing segregation risk.
You are not set until you have assessed and ascertained the amount of factory space required.
This goes beyond just the machine size.
You will have to factor in the area needed for cleaning, loading, and offloading the machine.
If you will make the best decisions on these aspects and choose the best blender, you are sure to get a high production capacity at lower costs.
More importantly, you will end up with superior product quality.
Is there a Difference Between Blending and Mixing?
Although most people use the two words interchangeably, there is a slight difference between them.
The two processes both involve mixing two or more products, but blending is usually a relatively more gentle process.
In blending also, the result is a homogenous product that is inseparable.
Mixing, on the other hand, is more aggressive and mostly involves beating the products being mixed.
What is Double Cone Blender?
The double cone blender is essential equipment in the chemical, pharmaceutical, and nutraceutical industries.
Double cone blender
Its design has just one access cover.
This makes the processes of inspection and cleaning much easier.
The double cone blender is most suited for mixing between 2-5 ingredients.
This blender works using a free-flow principle.
It is, therefore, mainly used for blending free-flowing granules and powders.
Also, compared to the v-blender, the double cone blender requires less headroom.
What is V Blender?
As the name suggests, the V blenders are v-shaped.
Same to the double cone blender, this blender is used in the nutraceutical, pharmaceutical and food industries.
It is also widely used in the cosmetic industry.
The V blender is more efficient, with shorter blending times compared to the double cone blender.
Two connected cylinders divide and intermesh the particles of the products.
Each of the cylinders has its own access cover.
These are used for loading the material, and for cleaning and inspection.
These blenders can mix between 2-10 different ingredients.
What are the Components of the IBC Blending System?
The IBC blending system is made up of many components, each of which performs a specific role.
These components include:
- The blending container: This is where the actual blending and mixing happens. They come in different designs and specifications.
- Rotation counter: This part ensures the thorough mixing of the ingredients or materials in the container.
- Charging and discharging pots: these parts allow entry into and exit from the blending container. They usually have valve sealing to prevent the powder and granules from escaping.
- Control panel: The IBC blending system has a touchscreen control panel where parameters such as the rotating speed and mixing time are preset. The control panel is well-labeled to enable ease of use.
Clamping bars: They are used to clamp and fasten the blender to ensure it remains stable in the vibration that accompanies the process.
How Does IBC Blending Systems Work?
The IBC blending system has a simple working principle.
The process begins when you insert the bins into the lifting arm.
This arm then lifts the bin off the ground.
Then, the driving system rotates the rotary frame.
The rotary frame then rotates the bin in set cycles and at a preset speed while it is lifted off the ground by the lifting arm.
This process enables the blending action to take place.
All these processes are guided by entering commands such as rotation speed and the number of cycles in the control system.
These commands can be entered or changed at any time to control the blending action.
Although there are different bin blenders in the market, they usually have the same working principle, and it is that simple.
Which Industries use IBC Bin Blender?
The main industries that use the IBC blending system are the pharmaceutical and food industries.
Pharmaceutical Industry: It is used to blend active ingredients of drugs with excipients such as starch, lactose, or cellulose.
Food industry: used in preparing spices, flavors, and cake mix.
Chemical Process Industry: Used to mix specialty chemicals, fertilizers, explosives, dry powdered detergents, rubber compounds, and glass or ceramics.
The metal powder, chemical, and plastics industries also use this technology.
The IBC blending system in these industries was, for a long time restricted to dry powders and granules.
However, recent technology has enabled the handling of shear or liquid additions.
Some blenders are made with attachments to enable the addition of liquids in the course of the blending process.
IBC blenders have become vital in multi-product environments because they are able to mix many different products within a short period.
The machines are also able to blend lubricants into powder mixtures.
How Does IBC Blending System Structural Design Compare?
Different types of blender systems
The structural design characteristics of the IBC blenders are mostly similar.
The blenders always have a cone shape, with the cone facing downwards.
It has two openings, the charge hole on the bottom, narrower side, and the manhole on the broader top.
Some manufacturers will, however, design their blenders with slight differences in shape.
Still, whether it comes with a round or even square shape, the concept and design remain mostly similar.
Clamping Bar or Cage Mechanism:
Which the Best for Holding IBC Blender?
Clamping bar and cage
The clamping bar or the cage mechanisms play an important role in ensuring the stability of the IBC during operation.
You can always opt for either of the two, depending on the size of the machine you are using.
For smaller blenders like most benchtop blenders, the clamping bar is better.
The cage mechanism, on the other hand, is preferable where you are dealing with larger bin blenders.
cGMP Design Critical in IBC Blending System?
The current Good Manufacturing Practices (cGMPs) are very critical in ensuring both the functionality and market performance of the blending system.
Normally, the key reason why it is important to comply with these standards is that it boosts customers’ trust in the machines.
This will, in turn, lead to a high ROI.
The cGMP aims to ensure that the blending system that your company manufactures meets the required standards.
An IBC system that is compliant with these standards, for example, is easy to clean and maintain.
cGMP standards also require that the right materials are used to make the blender.
These materials should be strong, hygienic and rustproof.
Failure to observe these standards usually leads to warnings and sometimes penalties.
How Does Liquid Addition Improve IBC Blending Process?
Liquid addition enables the IBC blending system to effectively add liquids into powder recipe mixes.
This is achieved when the system automatically adds a controlled shot of liquid into the powder mix in the IBC blender.
The liquid, therefore, ends up evenly dispersed throughout the powder recipe-thus preventing the formation of lumps.
Because there is no need to open the blender when adding the liquid, manual handling is reduced.
This enhances containment, and also makes the whole process more hygienic and flexible.
What is the Best IBC Blender Material?
The best material for making the IBC blender is stainless steel.
The AISI 316 is the best for the parts that come into contact with the material.
The other sections can be made of AISI 304.
Stainless steel is preferred for the following reasons:
- Stainless steel bins are non-reactive. This ensures that you get pure, uncontaminated products, which is vital for the health of the users.
- Stainless steel bins are not affected by dust and rust. They are therefore more durable than the other metals, thus saving you from buying new equipment every often.
- They are also easy to clean and maintain.
Which IBC Blender Design Features Guarantee Homogenous Blending?
For optimal and homogenous blending, the IBC blending system is designed with the following features:
Your blending system will need to remain stable throughout the blending process if you are to get good and timely results.
To achieve this, the IBC system designed should be stable, and will not need maintenance every often.
A good system is designed with clamping cages that connect the top and bottom. This feature will also increase the lifespan of your blending system.
- Control System
These IBC blending systems come with a user-friendly control system that does not need much expertise.
The system is automatic, meaning that it will require minimum attention once the required parameters are entered.
Most IBC blenders come with smooth mirror-like finishing on both the inside and outside.
The smooth inner finishing is particularly important as it enables easy cleaning of the machine.
Loading and offloading of the materials is also easy.
How Does Rotating Angle Affect IBC Blender Efficiency?
The rotating angle for most IBC blenders ranges between 200 and 300.
When the IBC in the blender is offset at this angle, it helps the powder to changes the direction of flow for every rotation.
This, in turn, helps to improve the blending time and consistency.
Choosing the correct rotating angle is therefore vital in ensuring the best results within the shortest time possible.
Which IBC Blending Systems Does SaintyCo Manufacture?
SaintyCo designs and manufacturer cGMP complainant IBC blending systems.
Some of our blending systems include:
- HYD Series Holder Type Bin Blender
- Pharma IBC Blending System
- Post Bin Blender
- Bench To Blender
Can SaintyCo Custom IBC Blending Systems?
Yes, we do.
Our IBC blending equipment come in a range of designs with varying capacities.
Talk to us today, for all your custom IBC bin blending needs.