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Sigma Mixer Design-Construction-Applications Explained Sigma Mixer is highly popular equipment used for efficiently mixing and kneading high viscosity materials with utmost ease. Since, sigma… Sigma Mixer is highly popular equipment used for efficiently mixing and kneading high viscosity materials with utmost ease. Since, sigma mixer comes from the double arm kneader mixer family. So, let’s take a quick look at the design and construction of double arm kneader mixers. Design of Double Arm Sigma Mixer Kneader https://youtu.be/gBLJZTZnkF0?si=CNXUG_O2GUBx1PwF Send Inquiry Double arm Sigma Mixer kneader consist of two mixing blades which are positioned in a horizontal W shape. There is a wide array of blades made available such as masticator blade, sigma blade, spiral blade and nabbed blade to name a few. The gyratory motion of these blades takes place in two ways. One is peripheral motion to each other and the one other in which the blades inside the furrow can stretch outwards. The blades may operate at the same or different speeds while moving towards each other. The blades go over the container walls and each other at very close clearances of 2-3 mm which helps produce a homogenous mix. The biggest benefit of such close clearances is high shearing action which easily reduces every single large size particle. A consistent particle size distribution can be achieved within a very short span of time which is as less as just 10 to 30 minutes. High homogeneity levels can be expected while using these mixers. You can expect upto 99 percent of homogeneity which is amazing in itself. These mixers also come with their variants such as double arm kneader mixer extruders and they are very much capable of handling highly viscous materials. Even materials with 10 million centiposes viscosity can be managed. Energy Consumption You must know that double arm kneader mixer’s energy consumption is quite high as opposed to other mixer types. It could be in the range of 45 to 75 kw for per m3 of mixture. The most commonly used double arm kneader mixer is sigma blade mixer which is the most sought after on account of variegated reasons. Sigma Blade Mixer Supporting tangential and oblique movement is necessary for the chemical in mixers that manage acid based products. The geometry of sigma blade has been designed in such a way that it can draw, shear, knead, coarse as well as fold the glutinous mass of the material. It becomes capable of doing so because of the blade manipulate which is just next to the trough. It may interest you that the twist angle of the blade can be adjusted according to the kind of shear you are looking for. Operation of Sigma Blade Mixer Now, let’s take a quick look at how sigma blade mixer operates. Material is loaded from the top of the container, but it is mostly just about 40 to 65 percent of the total volumetric capacity of the mixer. Heavy duty drive systems are in place to facilitate the rotation of blades. These systems comprise a gearbox, motor, gears and couplings. Usually the tip speed of a sigma mixer is kept to 60 metres/minute. The mixing process may take place either at room temperate or controlled temperature conditions. Provision of jackets is there for the circulation of hot or cold media which comes in handy to maintain the required temperature. You can also equip the mixer with a discharge arrangement. The most commonly seen discharge arrangement is tilting discharge. Tilting arrangement of the container is designed for manual, motor or hydraulically operated arrangement. For materials containing lower viscosity, a bottom discharge valve can be facilitated on the trough. It is flush with a mixer trough to keep at bay any sort of dead or unmixed pockets of material. Applications of Sigma Mixer Frankly speaking the list is pretty long. This mixer is considered quite ideal for sticky, gritty, and pasty slurries with high viscosity quotient. Here is a list of some of the many products which can be mixed in sigma mixer. Biscuits Adhesives Ceramics Chemicals Chewing gum Butyl rubber Explosives Crayon and lead used in pencils Carbon pastes/sugar pastes Confectionary products and some foods Gaskets and gland packings Hot-melts Pharmaceuticals Mould preparations Erasers for pencils Mastics Fiberglass resin doughs Plastics Refractories Silicon rubber Soaps and detergents Rubber solutions Marzipan Hope you found the post useful. As a producer of high quality sigma mixer, we have an exclusive range for you. Check out our products section, now!
Different types of Blenders – Double Cone, Octagonal, V Cone Blender and Ribbon Blender Blenders are often used for mixing and emulsifying various food and other substances in various sectors like Chemical, food, Pharmaceutical,… Blenders are often used for mixing and emulsifying various food and other substances in various sectors like Chemical, food, Pharmaceutical, mineral and plastic industries. These Industrial Versions make excellent quality homogeneous mixture with desired speed, temperature and time. Let’s explore some of the Industrial Appliances below: Double Cone Blender Widely used in the Pharmaceutical and cosmetic industry, double cone Blender Versions are used for mixing of fragile homogeneous particles of dry powder and granules of different sizes and forms. The cone form of the Version enables uniform combination with automated ejection with higher efficiency and a stainless steel body. The best use of this machine is to mix fragile particles that has the risk of breakage and where generational dust must not exist. The mixer comes with an automated drum system, with one full revolution of the mixer; the entire content of the product can be transferred to the shaker and then back into the drums. The highly efficient machine comes with a special PLC programming which has high safety features and longer service life. With this Mixer, the normal cycle is reduced to 10 minutes with less risk of spillage. Octagonal Blender The name “Octagonal” is given because of its form and the ability to hold larger quantities of particles. Octagonal Blender might be similar to double cone or even “V” adjuster but occupies less space and power. Equipped with a shell of octagonal shape supported by both ends, the special thing about this machine is that even though it operates in low speed operation, it balances high proportion of material in a very convenient manner. Similar to double cone Version, it gently mixes dry particular and fine granules in a homogeneous mixture and has a vacuum charging system for dispatching. Octagonal Model is best for sectors such as pharmaceutical for better quality. V Cone Blender One of the most equipment in this category, V cone blender adjuster or twin shell adjuster comes with two hallow cylindrical shells wielded at an angle of 75 degree of 90 degree. The equipment is mostly used when there is a need of precise formulation of powder and granules mixing & lubricating. The containers having the “V” shape creates continuous split and recombines the materials creating minimal attrition. The equipment is mostly used in pharmaceutical, food, cosmetics, nutraceutical, plastic and other allied industries. Easy to clean and with an option of intensifier bar for special applications, V cone mixer is designed in a manner to give its customers a wear resistant discharge, minimal maintenance and zero contamination. Ribbon Blender Ribbon Blender consists of a “U” form or “W” shaped horizontal trough containing double helical ribbon agitator that rotates inside. This light duty model is well suited for solid materials such as powders and other fluids with low shear capacity. The appliance is designed in such a way that it achieves efficiency with triple mixing action. Although designed for handling solids, this model is versatile and can also handle liquids and gas streams. Ribbon Machines are one of the most efficient machines available for blending in the market. This technology is used in a variety of sectors such as pharmaceutical, food, chemical, plastic and other sectors. Despite these benefits, optimal usage depends on proper customization and depends from batch to batch. The ribbon mixer has a lot of advantages such as wear resistant, corrosion resistant, easy to dispatch, belt driven power transmission, and cooling jackets for a variety of applications.
Rapid Mixer Granulator, Tablet Press, Double Cone Blender in the Pharmaceutical Industry Curiosity is the key to the invention, this amazing adage has truly inspired every segment of our daily lives which… Curiosity is the key to the invention, this amazing adage has truly inspired every segment of our daily lives which have been made easy by millions of equipment that we use today. Every single penny spent on such inventions has proved its worth. Today, no one can imagine the world without machines and so do the industries. The pharmaceutical industry is one of the promising and flourishing industries of the world economy. It employs human effort as well as machines to yield its output and machines play a major role in this. Rapid mixer granulator Rapid Mixer Granulator is the multi-purpose processor device that is designed to work suitably for high speed dispersion of ingredients such as dry powders, aqueous or solvent granulation, effervescence products and melts pelletization. Granulation technique is the pillar for tablet formulation and holds the utmost importance. Wet granulation is one such common step in the production of solid dosage medicines. This technique can be accomplished in a mixer granulator. Tablet Press Machine Post granulation the process moves on to another level that is shaping up of tablets. This is where a tablet press machine plays an unequivocal role. The rotary tablet press machine is the best available equipment for bulk production tasks. Its punches and dies are positioned on a rotating turret and the number of functional stations positioned around the turret will determine the outcome and the yield. tablet press machine is indubitably the machine that is used to make tablets in various sizes as per the requirements. The powdered form of the ingredients can be transformed into a tablet form using this equipment. Such machines are mainly planted at pharmaceutical companies in order to produce medicine tablets. Tablet compression technique and thus this machine is crucial to Pharmaceutical companies. Double Cone Blender Another efficient and versatile machine used in pharma industry is the double Cone Blender used in the smooth mixing of dry powders and granules homogeneously. Made up of stainless steel throughout it offers an effective volume of around 35- 70% homogeneity for the gross volume. It plays a subtle role in the mixing of medicated granulated powders in pharma plants. It also ensures reduced retention and total discharge. Double cone blenders help to achieve high mixing efficiency through the help of multi shear deflector plates.
Vibro Sifter – Applicability And Usability in Pharmaceuticals Vibro sifter is one of the needed types of machinery in many laboratory and industrial processes. It is used for… Vibro sifter is one of the needed types of machinery in many laboratory and industrial processes. It is used for the gradation of raw materials by separating materials based on their particle size. Ideally, these are circular unitary gyratory screens which are also referred to as vibrating sifters, control sieves, vibro sieves or check screen. Vibro Sifter is available in many configurations, design, capability, etc. depending upon their requirement or application in specific activities. A Vibro sifter is not something unusual for the pharmaceutical or food processing industry and they are present in different categories depending upon size, the number of sieves, and specific application of equipment. Working Principle of Vibro Sifter Vibro Sifter works on the gyro principle. The word gyro here refers to Gyroscopic motion which is a tendency of a rotating object in order to maintain the orientation of its rotation. In machines, gyratory motion is obtained from specially designed gyro motor, which is fitted underneath the vibrating assembly. A specially designed rugged spring completely isolates this assembly from the base with the help of Gyro-motor. The motor is fitted with eccentric weights present at its as well as base to create centrifugal force. This whole assembly is covered by an SS plate. Assembling a Gyro Machine The deck hopper is also shielded from SS 316 sheet. A discharge port is provided on the hopper to collect the tangential discharge. A charging port is connected to the Conical shape top lid. There is a screen fitted in between the hopper & top lid. The machine’s inner & outer surfaces are mirror polished. How does Vibro Sifter Machine Work? Firstly the material which we wish to separate is fed into the machine. Hopper acts as feeding for the machine. Then it is assured that the rest components such as cover, screen structure, and the base frame are tightly clamped. Once the machine is given the power the vibrating motor will create a motion and screen or sieve will start moving in the motion. Material for separation now starts moving towards sieve depending on the size of the particle. They move in a continuous flow and are exited through the other end of the machine. Vibro Sifter Applications in Pharma Companies Vibro Sifter is one of the crucial components for the Pharmaceutical company as it is used in the end process. Vibro sifter ensures that there is no contamination and offers assured particles in the end product. We all know that preciseness is a must while we are manufacturing medicines as a slight increase or decrease in the quantity of the raw ingredient will alter the efficacy of the medicines. So, not only in end processes, but it can also be used while separating two or more ingredients from a mixture in order to weigh and create pellets. Thus, there is a need for such equipment in pharma companies. Besides Pharmaceuticals, the food and beverage industry also uses this machine. The Conclusion Lodha Pharma International is serving its pharma clients for a decade now. It is one of the respected names, well established brand in supplying the best packaging and process equipment for the Pharmaceutical industry. Based in Ahmedabad, it has not only tapped the domestic product, but has also explored the international markets and has been succeeding in both these markets.
Working Principle of Fluid Bed Dryer Fluid or Fluidised bed dryer is a kind of equipment used extensively in the pharmaceutical industries to reduce the moisture… Fluid or Fluidised bed dryer is a kind of equipment used extensively in the pharmaceutical industries to reduce the moisture content in raw ingredients like powder and granules. The working principle of this equipment includes fluidization of the fed materials. In this process, hot air at a high temperature and pressure is introduced in the system through a perforated bed of moist solid particulate. The solids are lifted from the bottom that are slightly wet in condition and are suspended in a stream of air (fluidized state). Heat transfer occurs as soon as there is a direct contact between the wet solid and hot gases. The dry gas takes away the vaporized liquid. The gas exiting is partially recycled, sometimes. Working Principle of Fluid Bed Dryer Fluid Bed Dryer is composed of a stainless steel chamber having a detachable bottom, which is often perforated and this is called the bowl. Through this perforated bottom, the air is introduced and with the help of heaters that increases the temperature of the air present inside. The heated air is then filtered and is allowed to pass through the bed of the material. Within the system, there is a provision for an attachment of a fan. The fan initiates and monitors the air flow direction. One can also regulate the air flow and the temperature at which the machine is working. The Fluid Bed Dryer bag expands with the flow of air and powder particles start a turbulent motion. The material gets dry inside due to perpetual exposure to dry air. The material thus exiting the system is once again filtered. Materials, after they are dried in a constant-rate drying, are processed via wet-bulb temperature. This process ensures that the ingredients dried through this process to low moisture content, under relatively low temperatures. One can achieve high drying results by installing the heat exchanging tubes or panels, which cover 80% of the heat exchange process. Due to the presence of a large heat exchange area inside the Fluidised Bed Dryer, the required gas amount is small. To check this issue, the sizes of each equipment of the system used in the system is minimized. Where is Fluidised Bed Dryer Used? A fluidized bed dryer is widely used in the granulation area of Pharmaceutical manufacturing. Granulation is a technique to dry the material in order to get the desired moisture content so that the manufactured medicines pellets are perfectly compressed. Fluid Bed Dryer has a high drying rate, therefore, the material gets dried very quickly. Because of this property, this machine proves very useful in giving out high output. Fluid Bed Dryer has been put in use to create synthetic resins. This machine can also be used in food, fertilizers, ceramics, Agrochemicals, etc. There is a machine type called B-FBD and this one is suitable for the material which requires drying in the decreasing-rate drying zone. Features of Fluid Bed Dryer The Fluid Bed Dryer is a versatile piece of equipment extensively used in the pharmaceutical industry to reduce moisture content in raw ingredients. It offers several features that make it an efficient and reliable choice for drying processes. Here are the key features of the Fluid Bed Dryer: Fluidization Principle: The equipment operates on the principle of fluidization, where hot air at high temperature and pressure is introduced into the system through a perforated bed of moist solid particulates. This fluidization process allows for efficient heat transfer and moisture removal. Stainless Steel Construction: The Fluid Bed Dryer is constructed with a stainless steel chamber, ensuring durability, resistance to corrosion, and easy cleaning. Perforated Bowl: The equipment includes a detachable bottom, often referred to as the bowl, which is perforated to allow the passage of air. This design promotes uniform airflow distribution and efficient drying. Controlled Airflow and Temperature: The Fluid Bed Dryer features an air intake system with heaters to increase the temperature of the air inside. The airflow direction, rate, and temperature can be controlled and regulated for optimal drying conditions. Turbulent Motion and Uniform Drying: As the air flows through the bed of material, the powder particles start a turbulent motion, ensuring uniform exposure to dry air and efficient drying of the material. High Drying Rate: The Fluid Bed Dryer offers a high drying rate, allowing for quick moisture removal and shorter drying cycles. This feature enhances productivity and output. Filtering System: The equipment is equipped with a filtering system to prevent the release of fine particles and ensure the quality of the dried material. Wide Range of Applications: Fluid Bed Dryers find applications not only in the pharmaceutical industry but also in other sectors such as food, fertilizers, ceramics, agrochemicals, and synthetic resin production. They are particularly effective in the granulation process for pharmaceutical manufacturing. Energy Efficiency: The design of the Fluid Bed Dryer includes heat exchanging tubes or panels, maximizing the heat exchange process and reducing the required gas amount. This promotes energy efficiency and cost savings. Compact Design: The equipment is designed with minimized equipment sizes, maximizing the heat exchange area within the dryer. This compact design ensures efficient and space-saving operation. The Fluid Bed Dryer offers reliable and efficient drying capabilities, enabling the production of high-quality materials with controlled moisture content. Its versatility, high drying rate, and energy efficiency make it a preferred choice in various industries, particularly in pharmaceutical manufacturing and granulation processes. The Concluding Line Abster Equipment, having a decade-old history and headquartered in Ahmedabad has been supplying automated, semi automated machines that help Pharma Companies to get their desired output. The company offers a complete range of packaging equipment from the pharma companies present in domestic as well as international markets.
Ribbon Blenders – Efficient and Versatile Mixing Solutions for Diverse Industries Ribbon blenders have emerged as one of the most efficient and versatile mixing solutions in various industries. Their unique design… Ribbon blenders have emerged as one of the most efficient and versatile mixing solutions in various industries. Their unique design and operational features make them an ideal choice for businesses that require consistent and homogeneous mixing of different ingredients. A ribbon blender, also known as a ribbon mixer, is a specialized mixing machine that utilizes a set of helical agitators, typically in the shape of ribbons, to blend materials. The ribbons rotate in opposite directions, creating a fluidizing and cascading motion that ensures thorough mixing. This design principle allows the ribbon blender to handle a wide range of materials, from powders to pastes and even viscous substances. Versatility of Ribbon Blenders One of the key advantages of a ribbon blender is its versatility. These mixers are capable of efficiently blending a diverse range of ingredients, including dry powders, granules, pastes, and more. Whether it’s mixing spices in the food industry, blending pharmaceutical powders, or combining chemicals in the production process, a ribbon blender can handle the task with precision and consistency. Furthermore, ribbon blenders are widely used in various industries such as food processing, pharmaceuticals, chemicals, and cosmetics. They can be found in bakeries, confectioneries, nutraceutical plants, and countless manufacturing facilities. This versatility stems from their ability to accommodate different capacities, construction materials, and customizable features to suit specific industry requirements. Benefits of Using a Ribbon Blender Efficient and Uniform Mixing The primary advantage of using a ribbon blender is its ability to deliver efficient and uniform mixing results. The rotating ribbon agitators create a continuous and fluid-like motion, ensuring that all ingredients are thoroughly blended. This eliminates the risk of ingredient separation or uneven distribution, resulting in consistent product quality Time and Cost Savings Ribbon blenders are designed to streamline the mixing process, leading to significant time and cost savings for businesses. The efficient blending action reduces mixing time, allowing for higher production rates. Additionally, uniform mixing ensures that every batch is homogeneous, eliminating the need for rework or waste due to poor mixing. Gentle Handling of Sensitive Materials Certain materials, such as fragile particles or heat-sensitive substances, require careful handling during the mixing process. Ribbon blenders excel in this regard, as their gentle blending action minimizes product degradation and preserves the integrity of sensitive materials. This is particularly crucial in industries like pharmaceuticals, where maintaining the potency and efficacy of active ingredients is paramount. Easy Operation and Maintenance Another benefit of ribbon blenders is their ease of operation and maintenance. These mixers feature a straightforward design with user-friendly controls, making them accessible even for operators with minimal training. Additionally, routine maintenance tasks, such as cleaning and inspections, are relatively simple. Regular servicing and lubrication of the agitators and bearings ensure optimal performance and longevity of the equipment. Customization Options Ribbon blenders offer customization options to meet specific mixing needs. Businesses can choose the capacity and size of the blender based on their production requirements. They can also select the construction material, such as stainless steel or carbon steel, depending on the type of ingredients being mixed. Furthermore, additional features like heating or cooling jackets, vacuum capabilities, and specialized discharge systems can be incorporated to enhance the functionality of the blender. Applications of Ribbon Blenders Ribbon blenders find applications across various industries due to their versatility and efficiency. Here are some examples: Food Industry In the food industry, ribbon blenders are widely used for mixing dry ingredients, such as spices, powders, and seasonings. They ensure consistent blending, which is crucial for achieving the desired flavor profiles and product quality. Ribbon blenders are also employed in the production of bakery goods, confectioneries, sauces, and dressings. Pharmaceutical Industry Pharmaceutical manufacturers rely on ribbon blenders for blending powders, granules, and other ingredients during the formulation of medications. The uniform mixing provided by ribbon blenders ensures accurate dosage and uniform distribution of active pharmaceutical ingredients (APIs). These mixers are also suitable for blending excipients, which are inactive substances used as fillers or binders in pharmaceutical formulations. Chemical Industry Ribbon blenders play a vital role in the chemical industry for mixing various chemicals, pigments, dyes, and additives. The uniform blending achieved by ribbon blenders ensures consistent product quality and eliminates the risk of segregation or uneven dispersion of ingredients. These mixers are employed in the production of paints, coatings, fertilizers, and specialty chemicals.
Ribbon Blender Maintenance Tips for Optimal Performance Ribbon blenders are widely used in various industries for mixing powders and granular materials. However, like any other machine, they… Ribbon blenders are widely used in various industries for mixing powders and granular materials. However, like any other machine, they require proper maintenance to ensure optimal performance and longevity. Neglecting routine maintenance can lead to costly repairs, downtime, and even safety hazards. Ribbon blenders are a well-proven technology for efficient powder mixing. They feature a U-shaped horizontal trough with a double helical ribbon agitator rotating within. The outer ribbon has a precise pitch that moves material radially, while the inner ribbon has an opposing movement ability that sends material towards the discharge opening. This alternating movement promotes thorough mixing and helps prevent product migration during changeovers. Importance of Regular Maintenance Regular maintenance is crucial for the smooth operation and long-term performance of ribbon blenders. Without proper maintenance, several problems can occur, such as material buildup, bearing failure, motor overload, and seal leakage. These issues can lead to reduced efficiency, increased energy consumption, and even safety hazards. Therefore, it’s essential to follow a maintenance schedule and perform routine inspections to identify and fix any potential problems before they escalate. Clean the Blender after Every Use Ribbon Blender (also called ribbon mixer) is a basic industrial mixing machine consisting of a trough-shaped shell, usually two to three times longer than it is wide. Cleaning the blender after every use is essential to prevent material build-up, contamination, and corrosion. Use a soft-bristle brush, a vacuum cleaner, or compressed air to remove any residual material from the trough, agitator, and discharge valve. Also, wipe the surfaces with a clean, dry cloth or a mild detergent solution. Avoid using abrasive materials or harsh chemicals that can damage the equipment. A horizontal agitator shaft runs through the center of the trough, and it is fitted with a pair of helical ribbons on either side. The outer ribbon has a pitch that moves material towards the discharge opening, and the inner ribbon has an opposing pitch that moves it away from it. Clean the Agitator of Ribbon Blender The agitator of a Ribbon Blender is the part that mixes the material inside the jar. Often, the agitator consists of metal ribbons that are twisted and balanced to continually transfer material inside the trough. A ribbon blender consists of a U-shaped horizontal trough and a specially fabricated agitator that contains inner and outer helical blades. These blades move the material axially, in opposite directions and radially to promote the thorough blending of materials in short cycle times. This combination is ideal for blending powdered and bulk solids, especially when the material has shear sensitivity. However, it is important to keep in mind that these mixers can only handle a certain amount of loading. Check the Seals of Ribbon Blender The seals prevent material leakage from the trough and protect the bearings and drive system from contamination. Inspect the seals regularly for signs of wear, cracks, or leaks. Replace any damaged or worn seals immediately to prevent material leakage and bearing failure. Also, make sure that the seals are correctly installed and aligned. When a ribbon blender is running, keeping the shaft inside the mixing tank sealed is important. This helps prevent contamination from the outside, prolongs the life of the blender’s bearings and avoids product leakage that can result in machine failure. A rotary shaft seal can be applied on one or both ends of the shaft depending on your specific ribbon blender. These specialized shaft seals can be installed easily and are designed to help prevent product leakage. A properly-maintained ribbon blender can ensure the efficiency and productivity of your operation. It also reduces downtime and increases your productivity while minimizing costs. These ribbon mixer maintenance tips are the best way to keep your ribbon blender performing at its peak. Monitor the Motor and Electrical Components The motor and electrical components of the ribbon blender are critical to its operation and require regular monitoring. Start by checking the motor for any signs of overheating or unusual noise. Inspect the electrical components, such as switches, fuses, and wiring, for signs of damage or wear. Ensure the wiring is properly grounded and all connections are tight and secure. If you notice any issues with the motor or electrical components, contact a qualified technician for further inspection and repairs. Neglecting these components can lead to costly repairs, downtime, and even safety hazards. Therefore, it’s essential to include them in your routine maintenance schedule and monitor them regularly to ensure optimal performance and longevity of your ribbon blender. Ribbon blenders are used for a wide range of industrial applications from food processing to making chemical mixtures and dry cleaning powders. The basic design consists of a horizontal trough with a shaft through the middle that contains mixing blades or “ribbons” that rotate inside. These ribbons transfer shear between the product and the agitator, which helps mix the ingredients. These ribbons can be agitated by paddles, blades or ploughs and come in different designs with variations in the number and type of blades or ribbons used. For optimum performance, ribbon blenders should be cleaned properly and regularly to prevent residue from building up and causing contamination issues in your production. For this reason, CIP (cleaning in place) cleaning of ribbon blenders can be done efficiently and thoroughly using either impingement or rotary jet head cleansers. Lubricate the Bearings Regularly Lubricating the bearings regularly is crucial to prevent premature wear and tear, overheating, and failure. Check the bearings every month and add lubricant as needed. Use a high-quality grease that is compatible with the bearing material and operating conditions. Over-lubrication can be as harmful as under-lubrication, so make sure to follow the recommended amount.
How They Work? – Vibro Sifter, Rapid Mixer Granulator, and Vaccum Tray Dryer Introduction- Granulation technologies help in the flow ability and processing properties of compounds needed in the pharmaceutical industries. These processes… Introduction- Granulation technologies help in the flow ability and processing properties of compounds needed in the pharmaceutical industries. These processes have improved dramatically with advanced technology and are one of the most important in the production line. A few cohesive machines and their way of working are described below- Vibro Sifter A Vibro Sifter is a piece of equipment that sieves materials in pharmaceutical and food manufacturing with different types of mesh. Sifting is done to remove lumps that might have formed after being stored for a long period. It is useful in removing unwanted foreign particles and separates the material according to size. The Vibro Sifter works on the principle of gyratory vibrations. The material is separated based on its particle size and the motor in the Vibro sifter gets energized inducing vibration in the screen or the sieve. This enables the material to travel across the sieve according to its particle size. The Vibro Sifters consist of a screen placed on the base plate attached centrally to the gyratory motor. The material to be sifted is placed through an inlet that is on top. When the same is dropped on the screen the particles that are smaller than the mesh size pass from the screen and the larger-sized particles are released through an outlet. There is a combination that ensures that through the weights placed on top and the arrangement of the bottom screen adequate filtration takes place and the desired separation of the material is achieved. The vibratory motor imparts a three-plane vibration to the screen owing to its revolving eccentric weight system. The entire mechanism is mounted on springs so that the vibration does not affect the other parts of the machinery. The vibratory motor imparts a three-plane vibration to the screen owing to its revolving eccentric weight system. The vibratory motor imparts a three-plane vibration to the screen owing to its revolving eccentric weight system. Rapid Mixer Granulator The rapid mixer granulator is a multi-processor processor suitable for high-speed dispersion of dry powders, aqueous or solvent granulation, and effervescent products and melts pelletization. In a rapid mixer granulator, the formation of granules occurs by rising, whirling, and tumbling motion of the material. Dry mixing is done by adding all ingredients into the RMG by the rotation of the impeller and chopper at high speed. When the binder solution is added to the powder the impeller and the chopper are operated at low speed. Once the wet mass is formulated then the impeller and chopper are operated at a high speed to form the granules of the required size. The Mixing time of the Rapid mixer Granulator depends on the ingredient quantity and the particle size in it. The rapid mixer and granulator are designed to achieve mixing and consistent granules at a much operating cost along with greater productivity. The working principle of the rapid mixer granulator is based on two decisive factors essential for the intimate mixing system Spinning close to the bottom of mixing bowl. The impeller sets the entire mixture in whirling rising and breaking the wet mass into small pieces and granules. Vacuum Tray Dryer Vacuum Tray DryerVibro Sifter – Applicability And Usability in Pharmaceuticals is the equipment that helps in vacuum drying and sustains pressure without the chance of any deformation. They are usually used for the drying of substances that are hygroscopic and heat sensitive. It is based on the principle of creating a vacuum to decrease the chamber pressure which is below the vapor pressure of the water, causing it to boil. The materials to be dried are kept on the trays inside the vacuum dryer and the pressure is reduced with the help of a vacuum pump. The reduced pressure increases the rate of evaporation and increases the drying rate of the product. The dryer door is tightly shut while the steam is passed through the space between trays and the jacket so that the heat transfer occurs by conduction. Vapours from the feed are sent into the condenser and once the drying pump is disconnected the dried product is obtained from the trays. Bottom Line The Vibro Sifter, Rapid Mixer Granulator, and the Vaccum Tray Dryer are types of machinery of proven reliability and with a wide variety of applications. These transformational machinery help in quick and efficient processing and offer an offer a scope, scale, and sorting process.
SOP for OPERATION OF DOUBLE CONE BLENDER 1.0 PurposeThe purpose of this SOP is to establish a standard procedure for operating the double cone mixer.2.0 ScopeThis SOP… 1.0 Purpose The purpose of this SOP is to establish a standard procedure for operating the double cone mixer. 2.0 Scope This SOP will be applicable for the double cone mixer in the granulation/Mixing area of the production section. 3.0 Responsibility 3.1 Machine Operator is responsible for operating the mixer. 3.2 Production Pharmacist is responsible for implementation of this SOP. 3.3 HOP is responsible to ensure the implementation of this SOP. 3.4 Quality Assurance Officer monitors the compliance of this SOP. 4.0 Procedure 4.1 Production Pharmacist will ensure that the double cone mixer and the area is properly cleaned. 4.2 Production Pharmacist will ensure that the double cone mixer and Area is labelled with Cleaned label status. 4.3 Before starting the operation of a double cone mixer, take line clearance from the QA officer and affix product related labels to the mixer and Area. 4.4 After line clearance, close the lower lid of the double cone mixer tightly. 4.5 Add materials to be mixed in a double cone mixer according to BMR. 4.6 After addition of material, close the upper lid tightly. 4.7 After ensuring that both lids are tightly closed, connect the electric wire of the double cone mixer to the power plug. 4.8 Set the time required for mixing according to BMR on the timer of the double mixer. 4.9 After setting the time,set the rpm for mixing according to BMR. 4.10 Press the start button to start the mixing process. 4.11 After completion of mixing time, the mixer will stop automatically,remove the wire from the plug. 4.12 Place a container below the lower lid of the double cone mixer and off load the mixed material in a polythene bag placed inside the container by opening the lower lid. 4.13 After complete removal of mixed material in containers, close the lid of the double cone mixer and affix it to be cleaned label. 4.14 Record the activity in the logbook of the double cone mixer and sign it. 5.0 Abbreviations 5.1 SOP: Standard Operating Procedure 5.2 rpm: Rounds per minute 5.3 BMR: Batch Manufacturing Record 5.4 QA: Quality Assurance 5.5HOP:Head Of Production
Sigma Mixer – Design, Construction, Operation, Applications Sigma Mixer – Design, Construction, Operation, Applications The sigma mixer is one of the most popular used for mixing and… Sigma Mixer – Design, Construction, Operation, Applications The sigma mixer is one of the most popular used for mixing and kneading high viscosity materials. It belongs to the family of double arm kneader mixers. Double Arm Kneader Mixers A ll double arm kneader mixers are equipped with two mixing blades placed in a W-shaped horizontal trough. Various blade profiles have evolved, each of which is best suited for a particular type of application. The commonly used blade types are the sigma blade, masticator blade, shredder blade, naben (aka fishtail) blade, and spiral blade. The rotation of the blades is either tangential to each other or the blades may overlap within the trough. The blades rotate toward each other at the same or differential speeds. The blades pass the container walls and each other at close clearances (2-3 mm) resulting in homogeneous mixing. The close clearances produce very high shearing action thereby reducing any large particles. These mixers produce a consistent particle size distribution without the need for additional high speed choppers. Homogeneous mixing is achieved within 10 to 30 minutes. Mixing homogeneity up to 99% and better can be achieved using the double arm kneader mixers. These mixers and their variants (double arm kneader mixer extruders) are capable of handling material with viscosity as high as 10 million centipoises. The power consumption in double arm kneader mixer is very high compared to other types of mixers and can range from 45 to 75 kW/m3 of mix material. The sigma blade mixer is the most commonly used type of double arm kneader mixer, and is best suited for all round use. Sigma Blade Mixer In mixers handling very viscous materials, it is necessary to promote both lateral and transverse motion of the material. The geometry and profile of the sigma blade is designed such that the viscous mass of material is pulled, sheared, compressed, kneaded, and folded by the action of the blades against the walls of the mixer trough. The extent to which this happens depends on the action of the blades – tangential or overlapping and the ratio of the speed of rotation of the blades.The helix angle of the blade can be modified depending on the required shearing. Tangential and Overlapping Blade Action Figure 2 – Tangential Blades In the tangential design, the blades rotate in the trough meeting tangentially as shown in figure 2. The front blade generally rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosity such as adhesives, rubber compounds, flush colors, dyes, and pigments. Double Arm Kneader Mixers All double arm kneader mixers are equipped with two mixing blades placed in a W-shaped horizontal trough. Various blade profiles have evolved, each of which is best suited for a particular type of application. The commonly used blade types are the sigma blade, masticator blade, shredder blade, naben (aka fishtail) blade, and spiral blade. The rotation of the blades is either tangential to each other or the blades may overlap within the trough. The blades rotate toward each other at the same or differential speeds. The blades pass the container walls and each other at close clearances (2-3 mm) resulting in homogeneous mixing. The close clearances produce very high shearing action thereby reducing any large particles. These mixers produce a consistent particle size distribution without the need for additional high speed choppers. Homogeneous mixing is achieved within 10 to 30 minutes. Mixing homogeneity upto 99% and better can be achieved using the double arm kneader mixers. These mixers and their variants (double arm kneader mixer extruders) are capable of handling material with viscosity as high as 10 million centipoises. The power consumption in double arm kneader mixer is very high compared to other types of mixers and can range from 45 to 75 kW/m3 of mix material. The sigma blade mixer is the most commonly used type of double arm kneader mixer, and is best suited for all round use. Sigma Blade Mixer The sigma blade profile is shown in figure 1. Figure 1 – Sigma Blade In mixers handling very viscous materials, it is necessary to promote both lateral and transverse motion of the material. The geometry and profile of the sigma blade is designed such that the viscous mass of material is pulled, sheared, compressed, kneaded, and folded by the action of the blades against the walls of the mixer trough. The extent to which this happens depends on the action of the blades – tangential or overlapping and the ratio of the speed of rotation of the blades.The helix angle of the blade can be modified depending on the required shearing. Tangential and Overlapping Blade Action Figure 2 – Tangential Blades In the tangential design, the blades rotate in the trough meeting tangentially as shown in figure 2. The front blade generally rotates faster than the rear blade usually in the ratio of 3:2. Tangential blades are generally used for material of higher viscosities such as adhesives, rubber compounds, flush colors, dyes, and pigments. Figure 3 – Overlapping Blades In the overlapping design, the blades overlap above the saddle of the container. The overlapping blade configuration is shown in figure 3. Due to the overlapping action it is necessary that the relative position of the two blades is unchanged, and as a result, both the blades rotate at the same speed. Materials that flow freely or creep down into the blades are mixed using the overlapping blade action. This design offers a faster interchange of material from one blade compartment of the mixer to the other. Overlapping blade action is used for materials of lighter viscosities such as carbon pastes, clay coating, creams, and ointments. The overlapping blade produces a lower kneading and shearing compared to the tangential blade action. Operation of Sigma Blade Mixer In operation,
