RB Ribbon Mixer

Ribbon Mixer: The Ultimate FAQ Guide

Let’s take a look at some of the vital aspects of ribbon mixer such as features, parts, working principle, technical specification, and uses among other vital aspects.

So, if you want to be an expert in ribbon mixer machine, read this guide.

What is a Ribbon Mixer?

A ribbon mixer is a machine that achieves a consistent and homogeneous mixture of granules or powders.

It comes with a shell that has a U shape with an agitator that rotates.

The agitator has several helical ribbons that achieve a convective mixture of the materials.

They can achieve a gentle to high-intensity mixing parameter.

It can handle a large number of powders and solids.

Ribbon mixer

What should you Consider While Selecting and Customizing a Ribbon Mixer?

The ribbon mixer you should consider will influence how fast and efficient it can mix your products.

Customizing a ribbon mixing machine can happen in a variety of ways but it may be difficult when choosing the best model.

Some of the factors you ought to consider while choosing and customizing a ribbon mixer include:

Type of Agitator or Ribbon

A corkscrew-like type of metal blade assists the ribbon mixer to achieve the mixing of products.

The agitator comes with an outer and inner helix.

The inner and outer helix move in opposing directions to achieve the best mixture.

If you need to change the characteristics of the products, you can run the mixer at a higher speed.

Also, you can add high-speed choppers to achieve this effect.

This is applicable for products that contain liquids or those sensitive to the shear.

The products, mixing time, and size will influence the type of agitator you require in the ribbon mixer.

Factors that can assist in choosing the best agitator are:

1. Friability

It is advisable to use a paddle when the products you are mixing might break during the mixing process.

Also, you can conduct the mixing process at a moderate speed to minimize the chances of the product breaking.

2. Shear

An agitator with a high degree of shear is suitable when dealing with dense or viscous products.

When increasing the shear, you also need to increase the horsepower.

The amount of energy going into the mixer is dependent on:

• The speed of the agitator and
• Tolerance between the agitator and the body of the mixer.

3. Single or Twin Ribbons

Double sets of agitators will achieve the mixing process in a short time.

The ribbon mixer will use paddles, ribbons, or a combination of these two.

Twin agitators will increase the horsepower you need.

4. Shape and Size

It is vital to consider the volume and shape of the ribbon mixer before purchasing one.

These two will influence the number of products you can mix as well as the speed of mixing.

There are instances a large ribbon mixture might be suitable for your production needs.

Also, some scenarios are better at employing one or several small ribbon mixers to optimize your production needs.

When using several mixers, when one of them shuts down, you can continue using the other mixers.

Besides, they will also speed up the mixing process of various products.

Achieving an efficient mixture requires you to fill the mixer to its swept volume.

Swept volume is the area that the agitator in the mixer occupies.

The length, volume, breadth, and size of the agitator are worth considering while customizing your ribbon mixer.

5. Ribbon Mixers’ Horsepower

The common ribbon mixers available operate at around 20 rotations per minute.

Ribbon mixers that have two agitators or broader ribbons will need more power.

It is advisable to use a single-agitator ribbon mixer with 10 horsepower for every ton of product you are mixing.

This is preferable when mixing medium-density products.

A motor with an appropriate motor will influence how efficient and effective a ribbon mixer will be.

Besides, a powerful motor is costly.

6. Discharge Gate

It is important to understand how products will leave the ribbon mixer.

Some factors that partially influence the quality of a ribbon mixer are the cycle time and the downstream process.

Some procedures need you to immediately discharge products after the mixing process.

In this scenario, it is suitable to use a full-length discharge gate.

Some processes may need progressive discharge hence, a slide gate is suitable.

Examples of discharge gates include:

1. Multiple Slide Gates

These gates will help you achieve a rapid discharge rate while maintaining a tight seal.

2. Pneumatic slide gate

This will allow the products to exit gradually, thus assisting in measuring, batching, or packaging.

They also contain tight seals that minimize fine products from escaping into the environment.

3. Drop bottom

This discharge gate will immediately release products from the ribbon mixer.

The gates work rapidly, and it might be hard to achieve a tight seal when dealing with fine products like powder.

This fine powder may escape in the environment, meaning you require the best ventilation system.

Material and Body Finishing

The main material that makes the body of a ribbon mixer is mild and stainless steel.

Construction material is dependent on the products you are mixing and how their usage.

For instance, stainless steel is suitable for foodstuff as one can easily clean and sanitize it after use.

Special finishes in stainless steel might not be necessary when dealing with products not prone to food-borne illnesses.

Since the exterior does not come into contact with products, it can have a mild steel body and paint.

The interior needs no paint as it can contaminate the products.

There are some interiors with liners that enhance the performance of the mixer.

They will prevent abrasive materials from corroding the mixer.

Popular materials and finishes include:

1. Food grade stainless steel.
2. Epoxy paint or industry enamel paint.
3. Ceramics or UHMW plastic are abrasive resistant linings.
4. Standard and sanitary weld finishes.

How do you use a Ribbon Mixer to achieve a Good Homogeneous Mixture?

Ribbon mixer system

The mixing time for a ribbon mixer ranges from 3 to 5 minutes.

Some have a reputation of having a long mixing duration.

Hence, operators use it for 10 to 15 minutes.

If the products have no liquid, a long mixing time should alert the operators that the mixing process is not ideal.

The following factors influence the performance of the ribbon mixer to achieve a homogeneous mixture:

Size of the Mixing Batch

The top part of the agitators needs to be visible from the height of the products.

Also, there needs to be some headroom from the cover of the ribbon mixer.

Overloading a ribbon mixer will lower its performance level.

Besides, it is not advisable to under-fill the mixer as this will not achieve a good mixture.

Mixing Speed

It is advisable to use the manufacturers mixing speed to achieve a good mixture.

The speed for medium-sized ribbon mixers is around 50 rotations per minute.

Use appropriate speeds to minimize the chance of products breaking fur to the thrust of the agitators.

Additional Ingredients

Always add additional ingredients at the center of the batch to ensure uniformity of the mixture.

What are the Common Problems that a Ribbon Mixer may Encounter?

Some problems might occur with a ribbon mixer despite being reliable equipment.

They include:

Blockage of the Ribbon

This can be due to the high density of the powder.

Solve this by lowering the density of the batch size in the ribbon mixer.

Also, start the mixing process at low speeds during the filling stage and stop it after finishing discharging all products.

An Extended Mixing Duration

One issue might be overfilling the products in the mixer which you solve by reducing the batch size.

Also, the mixing speed might be low hence you can increase the speed.

The filling sequence might be incorrect thus solve this by loading additional ingredients at the center of the batch.

Product is Breaking

This is due to using a long mixing duration and too much speed.

Solve this by lowering the mixing time and speed.

How do you Choose a Ribbon Mixer?

Choosing a suitable ribbon mixer will ensure that you meet your production needs.

The factors to consider while choosing a ribbon mixer are:

Quality Standards

Choose ribbon mixers that meet international standards to ensure the safety of your staff and quality mixing.

This ensures the reliability, effectiveness, and acceptability of the machine in the market.

Maintenance

Choose a mixer that is easy to maintain, repair, or replace components.

Besides, ensure the spare parts of the mixer are readily available in the market.

Budget

The amount you have influences the type of ribbon mixer you can purchase.

It is always better to purchase a mixer that will meet your production needs.

Age of Mixer

There are instances you can find second-hand ribbon mixers.

These come at a lower price than brand new ones.

Always ensure that they are in good working condition before choosing to go this route.

Besides, test the machine to the maximum to ensure it works as it should.

Level of Technology

As the world advances, many machines are employing some level of technology in them.

Ribbon mixers with the latest technology allow you to achieve quality and reliable mixtures.

Efficiency of the Mixer

Choose a ribbon mixer that will ensure quality mixing procedures with minimal to no room for errors.

Size of Machine

These mixers come in various sizes and shapes.

Select a mixer that will fit the work area in your production plant.

Commercial industries go for large machines, while mid-sized companies go for medium-sized to small mixers.

What are Some Detailed Specifications of a Ribbon Mixer?

Some of these specifications include:

Mixer Access

Accessing the inside of ribbon mixers may be difficult since the agitator occupies a lot of space and is complex.

Hatches at the top of the mixer or a cover that you can remove will improve the accessibility of the mixer.

The cover can either slide or tilt to allow access.

There are instances the manufacturer may propose the use of an extraction system.

This allows the operator to remove the entire ribbon, but it adds extra cost and makes the machine complex.

Sensors are suitable in such instances where it will stop the mixer from operating when accessing the inside part.

These will provide safety to the operators.

Accessing the inside to clean will inhibit cross-contamination of products.

Plow and Paddle Layout

Some manufacturers are using paddles and plows to change the agitator.

These designs are different from shear mixers or twin shaft paddle mixers.

The advantages of using a single shaft paddle construction are:

1. Suitable for products that have a poor flow rate.
2. Delicate materials
3. When the batch size is lower as 15 to 20% of the average batch size.

Using plows make it possible to have better mixing even on the walls of the ribbon mixer.

Besides, use high centrifugal forces when using shear or ploughshare mixers.

This is because they have a cylindrical body design and not a U-shaped basin.

Outlet Valves

There are three types of discharge valves available in the market:

Bomb Doors Discharge Valves

These allow the bottom part of the ribbon mixer to open up completely with the help of flaps.

It is advantageous since it has a low mixing duration, and a minimal amount of products remain in the mixer.

Close the doors tightly during the mixing process.

These doors also allow the cleaning of the ribbon mixer.

Simple Flap Discharge Valves

It is the most common, and it has a rectangular shape design.

Round Hygienic Discharge Valves

These valves come with a round shape and will limit the chances of products escaping during the mixing process.

The valves are small increase the discharge time hence lowering the capacity of the mixer.

ATmospheres EXplosible [ATEX] – Dust Explosion Risks in Ribbon Mixers

Here are some instances that will prevent the risk of dust explosion from occurring:

1. Pressurize the bearing seals.
2. The tip speed of the paddle has to be < 1 m/s when loading and discharging products.
3. Enough clearance between the tip of paddles and the body of the ribbon mixer to avoid contact housing.

Instrumentation

Here are some instruments that can find in a ribbon mixer:

1. Safety Latches

These latches will inhibit operators from accessing the mixer while the machine is on.

Also, it ensures the safety of the operators and the mixer.

2. Speed Sensors

It will confirm the speed and rotation of the agitators.

3. Flowmeter

It is between the compressed air supply system and the bearing seal flush.

The bearing seal flush prevents products from contacting the bearings.

When products enter the bearings, it may cause damages and increase the chances of a dust explosion due to ignition.

4. Valve Position Sensors

It ensures that the operator has closed the discharge valves.

5. Temperature sensors

These will identify irregular heating that may occur due to faulty bearings.

What are the Components of a Ribbon Mixer?

Several components make up a ribbon mixer, and they are:

Parts of ribbon mixer

Electrical Cabinet

It houses all the electrical parts that will draw and power the mixer.

Mixing Chamber

It is in this part that all the mixing happens and comes in a U shape design.

Stainless steel makes up the bulk of the ribbon mixer’s body design.

The agitator is found inside this mixing chamber.

This chamber is capable of mixing:

1. Solids
2. Powder
3. Liquids
4. A combination of powder, granules, and liquids

Motors

It allows the machine to operate smoothly.

They will convert electrical energy to mechanical energy allowing the ribbons to rotate.

Outlet Valve

This component allows the products to exit the mixing chamber after the mixing process.

It provides a reliable seal to prevent leakages during the process.

Also, the operator can control it manually, electrically, or with pneumatic systems.

The outlet valve comes in a variety such as:

1. Butterfly discharge valves
2. Knife gate discharge valves
3. Spherical discharge valves
4. Rotary ball discharge valves
5. Plum-blossom discharge valves

Top Cover

It functions by covering the mixing chamber during the mixing process.

Also, you can open it to load products and clean the mixer.

Stainless steel is the main material for this component.

Ball Bearings

They allow the smooth rotation of the ribbon within the mixing chamber.

Lubrication makes them able to minimize friction during the mixing process.

Agitators

These can come as dual helical agitators with an outer and inner ribbon.

They move in opposite directions to ensure a homogeneous mixture.

Control Panel

This component allows the operator to control and monitor the mixing process.

It comes with buttons that are easy to operate.

Rotating Element

This part rotates to ensure a consistent and reliable mixing process.

Its rotational pace depends on the size of the outer ribbon.

What is the Mixing Mechanism of a Ribbon Mixer?

Here are the steps on how a ribbon mixer operates:

Preparation Stage

First, ensure that you connect the mixer to the power source and that it is in good working condition.

Next, open the top cover and load the products in the mixing chamber, then seal it.

Mixing State

Turn the machine on to start the mixing process.

The operator can control the mixing speed and duration on the control panel.

This will allow the products to mix efficiently minimizing breakages.

Mixing duration varies from product to product hence ensure the speed and time will efficiently mix them.

Discharge Stage

Once the mixing is complete, the operator will open the discharge valves.

This allows the products to exit the mixing chamber.

All this happens from the control panel.

What are the Various Types of Industrial Mixers available in the Market?

There are several types of industrial mixers in the market.

It is vital to understand how each of them operates before purchasing one.

Here are a few mixers that you can find:

• Cone mixers
• High shear mixer granulator
• Fluidizing mixers
• Multi directional mixer
• V mixer and blender

What are Some Technical Specifications of a Ribbon Mixer?

Since there are a variety of ribbon mixers, they come with varying technical specifications.

They include:

Ribbon mixer system

• Barrel volume of between 100 and 10000 liters.
• Loading volume ranging between 30 and 6000 liters.
• Mixing duration between 0 and 99 minutes.
• Machine weight of between 320 and 8000 kg.
• Stainless steel body design.
• Various power voltage: 110V to 480 V.
• Power Frequency of 50HZ or 60HZ
• Rotating speed between 10 and 60 revolutions per minute.
• Total power consumption ranging between 4 KW and 22 KW.

What are the Applications of Ribbon Mixer?

Several industries use a ribbon mixer to achieve quality mixing solutions.

They include:

• Pharmaceutic industries
• Food industries
• Chemical industries
• Cosmetic industries
• Agricultural industries

Mixing powder

What Industrial Materials can you Mix with a Ribbon Mixer?

A ribbon mixer can mix a variety of materials such as:

• Baby food
• Salt
• Milk powder
• Animal feed
• Laundry detergents
• Chemicals
• Dry food products
• Pet foods
• Spice blends
• Dietary supplements
• Bakery premixes
• Epoxy resins
• Abrasives
• Bird seeds
• Gypsum
• Fertilizers
• PVC compounding
• Fire retardants
• Talcum powders
• Pharmaceuticals
• Instant drink blends
• Herbicides and pesticides
• Plastic powders
• Polyethylene
• Cereals
• Carbon black
• Eye shadow
• Face powders
• Instant drink blends
• Plastic resins
• Polymer additives
• Cleaning compounds
• Pigment cake mixers

What are some of the Design Features of a Ribbon Mixer?

Here are some design features of a ribbon mixer:

• Pollution-free design.
• It has a center discharge valve.
• The triple mixing process for fast and efficient mixing.
• Mount support to provide a large discharge clearance.
• Working capacities of between 5 liters and 25000 liters.
• The Pitch of the outer ribbon directs products to the discharge valve.
• Countercurrent motion of the agitators to give a homogenous mixture.
• They can come in standard steel, carbon steel, or allow steel body designs.
• Automotive paint will cover the exterior of the mixer.
• Interiors are polished stainless steel.

How do you Maintain a Ribbon Mixer?

Maintaining a ribbon mixer will allow the machine to operate optimally and be durable.

Clean the machine after each use to eliminate cross-contamination and mold from growing.

Lubricate the bearings to minimize tear and wear due to friction.

Ensure the top cover and discharge valves form a complete seal during operation to avoid spillages.

Use genuine parts to replace broken or worn out parts to eliminate breakdowns.

Replace faulty electrical components to eliminate electric shock or combustion within the mixer.

Replace worn out agitators to ensure efficient and reliable mixing processes.

Replace loose locks to ensure the top cover does not vibrate and open during operation.

Clean the pneumatic valves to ensure the opening of the discharge area is consistent.

Replace worn out bearings to ensure the agitator and ribbon rotate efficiently.

Ribbon mixer machine

What Types of Agitators can you use with a Ribbon Mixer?

There are different agitators you can find in a ribbon mixer and they include:

Hi-shear Paddle agitator

They are smaller than paddle agitators.

The front paddles have notches that minimize pinching from occurring between the paddle and the mixing tank.

These notches minimize strain on the tank and agitators as it can happen on non-free-flowing products.

Center Discharge Ribbon Agitator

This exclusively mixes free-flowing products like:

1. Colorings
2. Fire retardants
3. Plastics
4. Chemicals
5. Lubricants
6. Fine powders

It is also good for mixing food products in the food industries.

The agitator is suitable when mixing products for food consumption because it is accurate and efficient.

Double Helical Ribbon Agitator

It is more efficient and works well when adding small amounts of ingredients to the main batch.

The products will circulate from one end of the mixing chamber to the other.

Outer ribbons move products towards the discharge area while inner ribbons move in the opposite direction.

Plough Shear Blade

They are suitable for mixing:

1. Cement
2. Chemicals
3. Adhesives
4. Paints
5. Fertilizers
6. Pesticides
7. Pharmaceuticals
8. Dyes
9. Confectionery, etc.

Paddle Agitator

It is suitable for mixing highly viscous or free-flowing materials.

They also have a low degree of particle shear.

Why is it Important to Use a Ribbon Mixer?

The reasons why a ribbon mixer is important is because:

Variety

A ribbon mixer can blend products such as powders, liquids, solids, and paste.

Sealing

The mixer has superior sealing to eliminate leakages during the blending process.

Loading Rate

It has a high loading capacity of about 70%.

Uniform Mixtures

The twin ribbon agitators allow the ribbon mixer to form a uniform blend.

Countercurrent movement of agitators enhances this capability.

Efficiency

The mixer can achieve a homogenous mixture within a short period.

This allows you to have a large production capacity.

Capacity

A ribbon mixer has a capacity ranging from 5 to 25000 liters.

Sizeable

The mixer comes in different shape and size configurations.

It can fit a small work area in your production plant.

What Types of Shaft Seals can you find on a Ribbon Mixer?

The available shafts you can find are:

Mechanical Seal

It has a rotating seal that produces low friction.

Also, it will attach to the shaft and the stationary seal face.

Besides, it is suitable for various materials, even those with fine powder sizes.

Single Lip Seal

A mechanical action will compress the seal product to the shaft on one point using a spring action.

It is suitable for granular products with low to minimal head pressure of fine materials.

Double Lip Seal

A mechanical spring will maintain contact between the seal and the shaft.

It is also suitable for granular powders.

Standard Packing Gland

Several kinds of strands press against the shaft and the solid plates.

It seals even the finest powders.

How does a vertical and horizontal ribbon mixers compare?

A vertical ribbon mixer is suitable for small farms.

It has vertical screws that transport products to the top, and then they fall.

This process repeats itself.

A horizontal ribbon mixer has paddles or blades on a horizontal shaft.

They can achieve homogenous mixtures within short periods.

How does a Paddle Mixer and Ribbon Mixer compare?

Here are some comparisons between the two:

Ribbon Mixer

Ribbon mixer equipment

They are suitable for materials with the same size, density, and shape.

The rubbing between the inner and outer ribbon will produce heat, which can be good when coating products.

Also, you can use choppers when adding paste and liquids.

Besides, they are common in food industries where the need to mix bulk products is high.

Paddle Mixer

Paddle mixer

They are suitable for mixing products whose size, shape, and density differ.

The paddle will scoop products and lift them upwards.

Also, you can add choppers to lower the size of products and when adding colorants and ingredients.

It is easy to clean and sanitize sanitary paddle mixers.

One can use paddle mixers for batch and continuous mixers.

What are the Advantages of a Ribbon Mixer?

Here are the advantages of a ribbon mixer:

• It is possible to repeat the process by using the control panel.
• It has a low mixing time.
• The working liquid will not spill when you overload it.
• It produces low noise.
• Ease of operation.
• Twin agitators allow for efficient and smooth mixing processes.
• Maintenance is easy.
• Good sealing eliminates products from leaking.
• Triple mixing allows for a fast and efficient mixing process.

What are the Disadvantages of a Ribbon Mixer?

Some of the disadvantages include;

• It might be expensive to purchase.
• It consumes a lot of power.
• Erosion of particles may happen at the walls due to high forces.
• It is susceptible to dead spots near the discharge area and the central axis.
• The mixer has a set drive speed.
• Great mixing at the surface of the mixer causes a variation in the composition of products.
• When operational, it is impossible to click the ribbon mixer.
• Two-dimensional mixing may result in poor mixing.
• The difficulty comes when cleaning the mixing chamber as you cannot remove the agitators.

What are Common Ribbon Mixer Processes?

They include:

Powder Mixing

Examples include baking mixtures, powdered flavors, chemical additives, supplements, and tablet formulations.

Mixing Various Solids

Include mixing various components with varying shapes and sizes.

Minor Coating of Particles

This includes coating particles with small components.

These include fine powder lubricants or spray flavorings oils.

Vacuum Drying

It is suitable when eliminating volatile compounds from:

1. Pharmaceutical granulation
2. Plastics
3. Ceramics
4. Metals
5. Chemicals

Paste and Slurry Mixing

This happens when you mix a range of viscous materials like cake batter, egg salads, plaster slurries, etc.

Preparation of Solid-liquid Mixtures

It involves mixing low viscous liquids with solid pieces.

What is the Cost of a Ribbon Mixer?

Various factors will influence the price of a ribbon mixer.

They include:

1. Manufacturer
2. Discounts and offers
3. Customization
4. Amount of units you are purchasing
5. The technology of the mixer
6. Age of the mixer, etc.

Considering all these, a ribbon mixer will cost between 500 US dollars to 50000 US dollars.

Depending on your unique requirements and specification, SaintyCo offers a range of ribbon mixer machines.

Contact us today for all your ribbon mixer needs.