How to Choose a Tilted High-Intensive Mixer? kontex Answers for You

I. Core Advantages and Typical Applications of Tilted Intensive Mixers

Before selection, first determine whether it suits your process.

Core Advantages:

• Three-Dimensional Chaotic Mixing: The mixing pan axis is tilted at a certain angle (typically 30°-60°) to the horizontal. Material is subjected to both the shear force from the high-speed rotor and the gravitational component due to the tilted pan, resulting in intense radial, axial, and tumbling motions, leading to very short mixing paths and extremely high efficiency.

• Exceptional Uniformity: This motion pattern eliminates dead zones completely, offering excellent dispersion of trace components (e.g., additives, pigments), and can achieve near-perfect mixing uniformity (very low CV values).

• Strong Process Adaptability: By adjusting speed, tilt angle (if adjustable), and process sequence, multiple unit operations such as dry mixing, wet mixing, granulation, coating, and reaction can be easily performed in a single machine.

Typical Applications (Consider this type when you have the following requirements):

• Extreme Demands for Uniformity: Such as high-end battery cathode/anode materials, MLCC electronic ceramic powders, Metal Injection Molding (MIM) feedstocks.

• Handling Highly Viscous or Paste-like Materials: Such as silicone sealants, paste explosives, polymer composites.

• Precision Granulation and Coating: For producing granules with high sphericity, narrow particle size distribution, and uniform coating, such as catalysts, functional fertilizers, pharmaceutical intermediates.

• Mixing Accompanied by Chemical Reactions: Processes requiring enhanced mass and heat transfer for solid-solid or solid-liquid reactions.

II. Five Steps for Systematic Selection

Step 1: Deeply Analyze Your Process Requirements (The Fundamental Starting Point)

1. Target Product Specifications: Final requirements for mixing uniformity, particle size and distribution, bulk density, granule strength, etc.

2. Process Route: Is it simple mixing, or a complete process like "dry mixing → spray liquid addition granulation → drying (optional)"? Is heating/cooling required?

3. Operation Mode: Is it single-batch production, or multi-product, small-batch R&D and production combined? This determines the requirements for equipment flexibility and ease of cleaning.

4. Capacity Requirements: Clear batch size (in liters or kilograms) and annual/daily capacity. Note the fill factor (typically 50%-70%) to determine the nominal volume of the equipment.

Step 2: Analyze Material Properties in Detail (The Decisive Factor)

1. Physical Properties: Initial particle size, density, flowability, viscosity, moisture content, abrasiveness, specific heat capacity.

2. Chemical Properties: pH, corrosiveness, sensitivity to oxygen/moisture, fire/explosion risk.
   These properties will directly determine equipment material, sealing class, explosion-proof requirements, and wear protection solutions.

Step 3: Examine Key Equipment Technologies and Configurations (The Core of Selection)

1. Mixing Pan and Drive System:

• Tilt Angle: Is it a fixed angle or variable angle? Variable angle offers unparalleled process flexibility, allowing optimization for different stages (e.g., large angle for dry mixing, small angle for wet mixing), a hallmark of high-end models.

• Drive Power and Stability: Motor power must provide sufficient torque to handle highly viscous materials. The drive system should operate smoothly and withstand full-load start-up.

2. Rotor System (The "Heart" of the Machine):

• Rotor Design and Speed: Single-shaft, dual-shaft, or multiple blades? Is the speed infinitely variable over a wide range? High speed (>1000 rpm) is for high-shear dispersion, low speed for gentle mixing and discharge.

• Blade Material and Wear Protection: Select from various materials and surface treatments, ranging from tool steel to hardfacing with hard alloys, based on material abrasiveness.

3. Liquid Addition System (Key for Granulation Processes):

• Addition Method: Must be an atomizing spray gun (not dripping), with precisely controllable spray pressure and flow rate.

• Spray Head Position and Quantity: Should cover the entire material flow field to ensure uniform contact between droplets and powder.

• Intelligent Control: Can it be linked to the main motor current/power for closed-loop addition based on real-time feedback? This is essential for achieving reproducible granules.

4. Process Monitoring and Intelligence:

• Power Monitoring (Essential): Real-time monitoring of motor load; its curve is the "fingerprint" for judging mixing/granulation progress and endpoint.

• Temperature Control: Does the mixing pan have a jacket? Can it be connected to cooling/heating sources? Are temperature sensors present?

• Control System: The PLC should be able to store process recipes and record key data (power, temperature, speed, liquid addition amount) for process optimization and quality traceability.

5. Discharge and Cleaning:

• Discharge Method: Bottom pneumatic large-opening door (fast and thorough) or pan tilting discharge? The impact on granule structure and cleanliness needs evaluation.

• Cleaning Design: Is a CIP cleaning ball or quick-open design equipped? This is crucial for R&D or production with frequent material changes.

Step 4: Request and Evaluate Tests from Professional Suppliers (An Indispensable Step)

• Provide Samples for Testing: This is the most reliable selection method. Pilot testing in the laboratory of a supplier like KONTEX allows you to:

• Visually verify mixing/granulation effects.

• Obtain critical process parameters (e.g., optimal speed, liquid addition time, power curve).

• Receive actual product samples for testing.

• Evaluate "Scale-up Capability": Inquire whether the supplier's laboratory-scale and production-scale machines have geometric and dynamic similarity in mixing principles and kinetics. This is the scientific basis for successfully scaling up laboratory results to industrial production.

Step 5: Comprehensive Evaluation and Decision
Comprehensively compare different proposals based on:

• Technical Match (Can it consistently produce qualified products?)

• Operational Economy (Energy consumption, spare part life, yield)

• Long-term Cost (After-sales service, technical support, upgrade potential)

• Supplier's Professional Competence and Industry Reputation

III. KONTEX's Summary and Recommendations

Choosing a Tilted Intensive Mixer essentially means selecting a long-term, reliable "technology partner" for your core process. It must not only meet current production needs but also possess sufficient advanced features and flexibility to adapt to future process upgrades.

Our core recommendation is: Avoid making decisions based solely on catalog specifications and price. Always return to the iron triangle relationship of "Process - Material - Equipment," and finalize the optimal solution through professional consultation and rigorous material testing.

KONTEX is committed to leveraging our profound technical knowledge and extensive application database to provide you with full-process support, from process feasibility analysis and customized solution design to test verification and production scale-up, helping you make a wise investment decision. We welcome the opportunity to discuss your specific needs in detail at any time.