To optimize mixing equipment, it is essential to consider the following parameters:
- Characteristics of the products to be mixed (viscosity, density, etc.)
- Function to be performed (homogenization, heat exchange, suspension maintenance, dissolution, dispersion, emulsification, etc.)
- Batch volume (depending on the volume, different solutions may be chosen, such as agitator only or agitator + in-line mixer)
- Optimized production times
A proper definition of the agitator or mixing system is key to achieving optimal performance. The aim is to minimize production times, maximize raw material efficiency, and ensure consistent product quality across all batches.
- Optimization example: high-viscosity resins
The client entrusted us with the task of optimizing and improving a mixing process for high-viscosity resins.
How critical is the definition of the impeller diameter in optimizing the process?
CFD (Computational Fluid Dynamics) simulations allow us to visualize the agitator’s performance inside the tank.
Can you see the dead zones with no movement?
The customer’s previous agitator was unable to move the entire volume of fluid inside the tank, resulting in excessively long processing times. By increasing the impeller-to-tank diameter ratio we exponentially improved fluid movement, generating flow between the different layers and promoting an overall axial flow throughout the tank.
What we achieved: a higher pumping rate from the impellers at a lower rotational speed, leading to reduced energy consumption, a lower carbon footprint and optimized mixing in this reactor.
It is important to evaluate whether your agitators:
- Have the appropriate diameter ratio for your product’s viscosity
- Generate sufficient flow to ensure global movement within the tank
- Meet the process times required by your production
This type of analysis allows you to detect the need to optimize your mixing processes.
The secret to optimization lies in having access to:
- Experience
- Calculation software
- CFD simulation tools
- Pilot plant for testing all types of agitation and mixing scenarios
- A team of skilled and experienced technicians capable of understanding the complexity of your process and proposing the most suitable solution
Do you need to add this value to your mixing equipment by optimizing agitator power, reducing plant consumption, and improving your carbon footprint?
Our Process Engineering department offers you the possibility to optimize your new processes, study and optimize the agitators and mixers in your factory, giving a new dimension to your facilities at the production level.
We conduct training courses on mixing technology that will allow you to rationalize and visualize whether the agitators and mixers you have in your factory meet your expectations and needs.
Yours is the product, ours is the mixing.
