How Double Planetary Mixers Reduce Time and Cost in Mixing High Viscosity Materials

To manufacturers in the fine chemicals, adhesives, composites, as well as new energy industries, the process of working with high viscosity materials can frequently be a matter of tradeoffs between mixing quality and production efficiency - slow batch times, material waste, and expensive reworks may take a supply of profit margins and add to delivery times. Vacuum Double Planetary Mixers have been designed to deal directly with these inefficiencies, and the precision design features that reduce processing time, minimize waste and reduced long-term operating costs and provide the homogeneous, defect-free mixing needed by high viscosity formulations. Since our double planetary mixers are used in both lab-scale research and design and industrial 5000L-scale production, each step of the mixing process is simplified and an affordable solution to process high viscosity materials. We discuss below the main ways this technology can result in savings of time and money to your production line.

Single Process Mixing Removes Multiple Processing Phases

One of the main benefits of us double planetary mixers is that all mixing work is accomplished in one vessel thus the numerous articles of equipment and hand transfer of stuff between steps are not required. In high viscosity traditional mixing procedures, blending, degassing and dispersing are usually done in different steps, each of which consumes more time, labor, and poses the risk of material loss or contamination. Our mixers combine comprehensive blending of planetary agitation with an inbuilt vacuum system to provide in-situ degassing, and high-torque motors to provide efficient solid wetting and dispersing of particles. This single step operation cuts the batch cycle time by minimizing equipment changeover, minimizing equipment transfer time as well as lessening the labor expenses on manual handling of materials. This continuous flow may result in a large amount of time saved when processing the material when dealing with extremely high viscosity materials such as epoxy resin and silicone sealant, in comparison to regular mixing systems.

Precision Design Reduces wastage and rework of materials

Unmixed material waste, wall build-up and non-conformance batches is a significant cost contributor in high viscosity mixing- and the double planetary mixers of Rumi are designed to remove these problems. Our mixers are agitated using agitator blades that have little clearance with the stainless steel (SUS304/SUS316L) vessel walls and bottom thus no material is left unexploited or unprocessed. The 360 agitation of dual agitators also provides pan mixing throughout the entire batch to rid any inconsistencies in formulations that result in costly rework or scrapped products. Moreover, the sealed vacuum system does not allow the formation of air bubbles, which is a typical flaw of high viscosity materials that would typically need reprocessing as a remedy. Our mixers save a lot of material waste and save a lot of labor and time that would have to be spent on correcting faulty products in a second run by mixing perfect and homogenous batches.

Long-lasting Construction and Scalable Design Reduce Long-term Operational Costs

The purpose of the double planetary mixers is to provide an industrial longevity and scalable production to promote long-term cost savings and lower overall cost of ownership (TCO). Our mixers are built using heavy-duty planetary gear drives with high-torque three-phase asynchronous motors to provide a reliable mixer with a low maintenance requirement, reducing downtime and maintenance expenses throughout the life of the mixers. Corrosion-resistant stainless steel is used in all parts of the product that come in contact with the product, making them easy to clean and conform to the industry hygiene requirements, which minimize cleaning time and the expense of cleaning chemicals. There is also a continuous growth in size of our mixer line that can fulfill the needs of small-scale R&D in Laboratory Vacuum Double Planetary Mixers to large-scale production of large-scale manufacturing with the same core technology. This scalability implies that the same mixing technology can be used to test the formulation and produce it fully, this means that manufacturers do not have to have different R&D equipment and production equipment, and it lowers the capital investment. Better still, our mixers can easily be used with all the production line solutions offered by Rumi like hydraulic discharging systems and PLC touch screen control, which further simplifies the operations and reduce the cost of operations in the long term.

Supported by ISO9001 and CE certification, the Double Planetary Mixers of Rumi are engineered with precision and economical design to provide concrete time and cost benefits to a high-viscosity material processing. The mixers will enable manufacturers to achieve high levels of productivity, improve profitability and reduce long term maintenance and capital expenses by simplifying batch processing and reducing wastage, as well as allowing them to satisfy the production needs of consumers with high quality and consistent outputs. Rumi being a major manufacturer of fine chemical processing equipment can also be fully customized and has EPC construction and consummate after sales services, which ensure that your mixer is designed to meet your particular production requirements and will run at full efficiency long into the future..