Choosing a Continuous Mixer Manufacturer

This article was co-authored by:

Chris Kozicki
Agglomeration Expert

Carrie Carlson
Technical Writer

Continuous mixers play a vital role in a wide array of industrial process settings, de-dusting materials, promoting product uniformity, streamlining downstream processes, and so much more. And while the capabilities of a continuous mixer are many, so too are the number of manufacturers offering these diverse machines, making the selection process overwhelming and ripe for confusion. 

Below are the most important aspects to consider when choosing a continuous mixer manufacturer. 

Process Development & Testing Capabilities

Continuous mixers such as pin mixers and pugmill mixers can serve a number of purposes throughout the industrial sector. Manufacturers offering process development services and comprehensive testing capabilities provide added value in selecting the best mixer configuration for the application at hand.

Such capabilities are particularly important when switching from a batch to a continuous operation, as many interrelated variables must be worked out. 

Whether switching from a batch to a continuous mixer, or developing a new process altogether, testing provides the opportunity to work out process variables and circumvent potential issues early so they can be addressed during the design stages. It can also validate proof of concept, proof of product, and proof of process, reducing the opportunity for surprises after scale-up. 

FEECO continuous mixers are backed by our state-of-the-art Innovation Center, where we can run both initial feasibility tests and pilot-scale tests to determine process variables and scale up mixer design. Retention time can also be gathered through testing, as well as a number of other process variables.

Pugmill Mixer (Pug Mill, Paddle Mixer) Testing, Batch Pugmill Mixer

Pugmill mixer testing in the FEECO Innovation Center

Flexibility & Customization

In addition to testing and process development services, the manufacturer must also be able to tailor the mixer to the intended application. All materials respond differently to the mixing process, and while testing determines the process variables necessary to meet the process goals, the manufacturer must be able to address these unique requirements through the mixer’s design. 

As a key component in most processes, customizing the chosen mixer for optimal performance is crucial to maximizing efficiency and minimizing downtime and lost product. Further, since the effectiveness of the mixer often impacts every subsequent processing step, achieving optimal performance is essential to overall process fluidity and product quality, particularly when it comes to agglomeration/granulation operations.

Customization might come in terms of sizing, speed, materials of construction, feed mechanisms, and various add-ons to tailor the machine to the job at hand. 

Continuous Custom Pugmill Mixer (aka., Pug Mill, Paddle Mixer)
FEECO Continuous Pugmill Mixer with custom access/inspection doors

Experience and Knowledge

While it might seem obvious, selecting a manufacturer with adequate background and expertise goes a long way in ensuring an optimal continuous mixing solution; manufacturers taking a one-size-fits-all approach should raise a red flag. 

In addition to the mixer design, several factors will impact mixer performance and product quality, including binder type, concentration, and formulation, as well as several feedstock and process flow parameters. While these can often be worked out during testing, manufacturers must recognize these factors and be adequately prepared to address them.

Batch Pin Mixer for Testing

Batch Pin Mixer used for testing in the FEECO Innovation Center

Proven Design

Not all continuous mixers are created equal, and investing in an under-performing mixer can have costly consequences. In selecting a continuous mixer manufacturer, be sure to validate manufacturer claims by asking for references and project profiles. 

Additionally, buyers should look for manufacturers with a service department. Not only does this add a layer of security in the event that something goes wrong, but it also means that the company has been around long enough to require servicing and replacing their equipment after many years of duty. 

High-Quality Fabrication

High-quality fabrication is a necessity with any equipment, but it is especially important when it comes to continuous mixers. The constant shear action requires that mixers be fabricated with top quality materials in order to withstand the rigors of daily operation, especially when working with corrosive or abrasive materials. 

Pugmill mixers for copper concentrates, for example, must perform reliably under continuously harsh and corrosive conditions. As such, though pugmill mixers already boast a robust design, they must be further reinforced to withstand such demanding conditions in this application. 

Inferior materials of construction and a lack of observing best practices in fabrication can quickly result in a high-maintenance, low-reliability machine that causes excessive downtime. 

Pugmill Mixer in Fabrication

FEECO Pugmill Mixer in fabrication

Ongoing Support

As mentioned, the presence of a service department provides peace of mind should something go wrong, but a service department is much more than that. 

OEM service providers are a valuable asset in streamlining troubleshooting and issue resolution, as well as providing spare parts; no one knows the equipment better than the original manufacturer. Choosing a manufacturer that can service and provide parts for their equipment is an excellent step in prolonging the life of the equipment and minimizing downtime and maintenance costs. 

Conclusion

Continuous mixers are a critical tool in de-dusting, achieving adequate end product characteristics, and streamlining production for a variety of industrial processes. The selection of a manufacturer that can provide an optimal continuous mixing solution can be made easier by considering factors such as the manufacturer’s ability to run process development tests, customize the equipment, and provide ongoing support. Additionally, manufacturers should always follow best practices in fabrication and be able to illustrate their proven experience through project profiles and other resources. 

With more than 70 years of experience, FEECO is the leading provider of continuous pin mixers and pugmill mixers. Our custom equipment is backed by our Innovation Center and our highly trained customer service team. For more information on our continuous mixers, contact us today!

About the Authors . . .


Chris Kozicki is a Process Sales Engineer and agglomeration expert.

More About Chris

More About Chris

Carrie Carlson is a technical writer and visual designer.

More About Carrie