Bin Blender

Do you have any questions about IBC blenders? Take a look at some of these frequently asked questions about this equipment. Probably yours is among them.

What is the bin blender used for?

The primary function of the bin blender is to mix grains and granules.  It is also used for mixing powdery materials.

When it comes to real-world applications, bin blenders are used for mixing filling materials for the capsules. In the process of mixing, it creates a homogenous mixture. This simply means that the resultant product from the blending process will have the power of each ingredient.

What is blend uniformity and how can I achieve it?

Blend uniformity is a key parameter that is used for measuring the effectiveness of a bin blender. It gauges how uniform the materials of the IBC bin mixer will be mixed and blended.

It is important to verify the uniformity of the materials after each blending process. Also, when buying your bin blender, find out how its operations will affect its uniformity.

cGMP requires that pharma manufacturers test each batch of the products to test various parameters, among them is the uniformity and homogeneity of the blended materials.

Various factors affect the uniformity of blended material. They include;

Particle size

Since blending may involve the mixing of different ingredients, in most cases, the sizes of their particles are also different. Some ingredients have large particle sizes while others have small.

This can end up affecting the uniformity of the materials even after the blending process.  This is usually the case when there is a big difference, otherwise, it is easy to minimize the impact when the difference in size is small.

Non-optimum blending

This is a problem when the bin blender is not programmed to operate to the optimum levels. In such cases, you are likely to record underperformance from the blender.

Weight difference

The varying weight of the different ingredients can also have a direct impact on the uniformity of the blended materials. Just like the size issue, you need to consolidate if the weight difference is big. You should probably put in place an effective weight control measure.

Density difference

A significant difference in density is also likely to affect the uniformity of the materials. This is likely to happen because the materials of higher density will be segregated from those of lower density.

Inadequate particle distribution

If the particles are not well distributed during the blending process, there will be a high chance of failing to achieve the desired uniformity. Here you should analyze the effectiveness of the bin blender to ensure even distribution of the materials.

Sampling and analytical errors

This mistake is likely to occur during the process of sampling the materials for the blending process. A mistake made at this stage is likely to affect the uniformity of the final blended materials.

How do I improve the uniformity of the bin blender?

There are various techniques that you can use to keep the blended materials uniform.

The first step to ensure that you minimize the analytical and sampling errors.  Follow all the required procedures that should be performed at this stage.

It will better to observe proper timing for the blending process. Ensure that adequate time is accorded to the process so that all the ingredients and particles mix thoroughly to the required levels.

Choosing the best industrial bin blender can help you achieve the desired uniformity. It will be easy to optimize the blending process when you have the best equipment for doing the job.

Why is the mixing time of the bin blender important?

Mixing time is one of the key parameters that affect the operations of the IBC bin blender. This is the duration taken for the materials to be blended.

 As an operator, you are required to strictly observe the mixing time. Under timing can result in partially blended materials.

 On the other hand, blending beyond the required time can lead to segregation and disintegration of the materials. This can lead to the unequal distribution of the ingredients.

Take time to study the requirements of the materials and choose the ideal mixing time. A well-timed mixing process will result in quality end-products.

Also, mixing time can affect the uniformity of the material. Since the blending process involves mixing different ingredients, the structural and chemical differences between these ingredients could prevent the final mixture from being uniform or homogeneous.

What is segregation in blending?

Segregation, which is commonly known as demixing is another issue that you are likely to encounter when using a bin blender.

The problem can occur when blending either powder, grain, and granule materials. Segregation is likely to result in undesirable outcomes from the blending process.

Demixing inside the blender

Various scenarios can lead to the occurrence of segregation. It can occur inside the blender, in the bin orb during the process of discharging materials from the blender to the bin.

The nature of segregation inside the blender may depend on the type of blender that you are using. For the v-blender, segregation is likely to occur when the blender is rotated on one axis at slow speeds.

The tumbling of powder can easily cause the materials to segregate on the axis of rotation. At the end of the blending process, you may notice that the materials have different axial bands and different particle sizes.

Connective bin blender has a reputation of minimizing the intensity of segregation unless the materials accumulate on the dead spot of the blender.

The discharge stage is another scenario that can cause segregation of the blended materials. This happens when the materials flow downstream to the blender bin.

This segregation is known as sifting segregation as the smaller accumulate to form heaps. Larger particles will form in the middle of heaps instead of rolling down the heap.

You will notice segregation further when transferring the materials from the bin mixer to another container for further processing.

Segregation during the sampling process

In this scenario, a piece of equipment known as a thief sampler is used for extracting a sample of the material from the blender. The equipment is designed to obtain materials from the bin blender without interfering with the structural features of the powder.

However, the process of dragging the sampler from the blender can easily lead to segregation or demixing.

How to minimize demixing in blending?

Whether you are blending for pharmaceutical, food, chemical, or any other industry, it is vital to put adequate measures to minimize the effects of segregation. Here are some effective tips that you can use to reduce the segregation of the materials in the bin blender;

Find out the cause

The surest way of dealing with a problem is finding out its primary cause. As we have explained, different factors can cause demixing.

Find out whether the problem is caused by different particle size, density, or the type of bin blender.  You can do the diagnosis by testing a small sample of the material to be blended.

Examine the bin blender

Another solution is to carefully examine the working and operation of the bin blender. Find out any mechanical and electrical issues that may be affecting the normal operations of the bin blender.

The bin blender should be in perfect working condition.

What is a V-type Bin Blender?

While looking for an industrial bin blender, you are likely to encounter one unique blender; V blender.

As the name suggests, this is a V-shaped blender that blends products through the rotation mode. As the blending container rotates, all the materials are evenly mixed. This blender also takes a significantly short time to mix the material.

The body of this bin blender comprises of two cylinders that are inclined next to each other to form a V-shape. The inclination is at a special angle, and in most cases is between 70 to 100 degrees.

However, the accuracy of a V-shape bin blender heavily depends on the volume of the material in it. It is not advisable to fill up this IBC bin blender to the brim. Instead, you should only have it 60% full.

Despite having a unique shape and design, V-shape bin blenders are easy to use. Once you have loaded the materials in the blender, you simply need to set it and it will start the mixing process. Once the blending period is over, you will easily discharge the material.

They are also easy to clean. As all the components are easily accessible.