Tripling The Output
A chemical packaging company needed to improve accuracy and reduce fines while speeding up mix times. Their old V-cone blenders were inefficient, unsafe, and unable to meet growing production demands.
Company Background
The client is a chemical packaging company under pressure to ensure that every package matches the labeled specification due to strict regulatory testing. They were also concerned about fines generation and long mixing times.
Issue
The company used V-cone tumbling blenders with mix times over 30 minutes. These units required large floor space, forced operators to leave the area during operation, and caused product degradation. The client wanted to explore new mixing technologies to maintain product integrity and improve safety.
Solution
We had previously met this client at a trade show where we demonstrated the ability of our mixers to blend minor ingredients homogeneously within 30 seconds. Invited to their facility, we tested their products with our mobile demonstration mixer.
The client selected our Single Rotor Mixers because they reduced residency time by 90%, minimizing product degradation and improving operator safety.
To validate, the customer produced twenty batches across two days with ~300 samples. All samples tested within 0.5–0.6% standard deviation.
We custom-designed a system including:
- Two single rotor mixers
- Mezzanine structure
- Bulk bag unloading system
- Load cell package
- Controls system
This new setup allowed them to produce in one single rotor mixer what previously required three V-cone blenders.
Results:
- Tripled output capacity
- Reduced product fines
- Increased safety for operators
- ROI in less than 6 months
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