MIXING PROCESSES

A Variety of Processes Based on Mixing Technology

MAP mixers are highly versatile and suitable for a wide range of processes in solids mixing technology. They effectively mix dry powdery materials, incorporate small amounts of liquids, and facilitate the agglomeration or granulation of powders with the addition of liquids. Additionally, MAP mixers are used for drying moist media and coating materials. They are also used for thorough homogenisation in resting chambers as well as for crumbling lumpy substances. Their adaptability makes them ideal for various applications across industries where precision, consistency, and efficiency in processing solids and powders are essential.

Powder mixing

MAP mixers are engineered for efficiently mixing a variety of solids. Depending on the task, up to 20 different individual components may need to be mixed together. The design of the MAP mixer ensures that the entire product chamber is involved in the mixing process, facilitating cavity-free homogenisation. Depending on the configuration of the mixing tools or the speed of the mixer, agitation can range from gentle to high turbulence. For solid mixtures or solid-liquid combinations, the achieved mixing quality can reach ±1% in relation to the added components, depending on the specific characteristics of the products.

Powder Mixing with liquid addition

Numerous applications focus on converting powdery, dusty bulk materials into a dust-free form through the addition of small amounts of liquids. In the MAP mixer, these bulk materials are thoroughly mixed with the liquid component, resulting in a dust-free bulk material that can be efficiently fed into open loading and transport systems. MAP’s batch and continuous mixers are particularly well-suited for this application, providing very short retention time on compact machines. Existing installations have achieved throughputs exceeding 1,000 m³/h, demonstrating the efficiency and effectiveness of MAP mixing technology in handling large volumes of material.

Agglomerating / Granulating

In MAP mixing machines, the powdery solid component is brought into intensive contact with a suitable liquid binding agent. This process facilitates the interconnection of solid particles through agglomeration, resulting in the formation of spherical or crumb-like granules. By carefully controlling the mixing intensity and the generated shear forces, various sizes of agglomerates can be produced. The stability of the resulting granules can range from low to medium, depending on the strength of the binding agent used. If further drying of the granules is necessary, it should be conducted gently through convective drying methods to preserve the integrity of the product.

Schematic representation of dry mixing technology

Drying

MAP dryers excel in contact drying, transferring energy through heated surfaces in direct contact with the product. Thermal oil, hot water, or steam circulate through a chamber jacket to heat the product, raising its temperature to the boiling point of liquid components. As evaporation occurs, the product dries to the desired residual moisture level. The mixing tools ensure continuous homogenisation for uniform results. For high-temperature applications, MAP provides advanced solutions, including steam, oil, or electrical heating units. Drying efficiency is further enhanced under vacuum conditions, ensuring optimal performance and consistent outcomes across various applications.

coating

In various industries, a wide range of products is coated to meet specific market demands. Our specially developed mixing technology facilitates the introduction and homogeneous distribution of even the smallest quantities of liquids for dust binding or taste adaptation, tailored to the customer's specific application. Expertise in understanding the various product characteristics and associated production processes is crucial to achieving optimal results. By providing this knowledge, we ensure that the final coated product can fully realise its market potential across all desired characteristics.

Resting and Homogenisation mixing process.

Resting & Homogenising

MAP offers a comprehensive range of homogenising mixers or resting chambers designed for different uses, whether to keep products in motion before transitioning to another process or for products that should not be de-agglomerated or compacted. MAP homogenisers can also feature thermal exchange capabilities, allowing them to maintain products at the desired temperature, whether hot or cold. This versatility ensures optimal handling and processing of the materials throughout the production cycle.

Crumbling

Crumbling with a single-shaft MAP mixer involves the thorough blending of materials, ensuring consistent particle size and texture. The mixer’s single shaft agitates the components, gradually breaking them down into finer particles, resulting in an even, high-quality crumble for various industrial applications.

Heating / Cooling

The MAP mixer range supports continuous and batch heating and cooling processes, including post-drying cooling within the MAP dryer or a jacketed heating or cooling mixer. Custom-designed mixing shafts enhance cooling efficiency, while direct methods like liquid injection enable evaporative cooling. Vacuum conditions ensure low product temperatures, delivering optimal results across applications.

Froude number and physical effect

The horizontal MAP single-shaft mixer, utilising ploughshare-type mixing tools and the fluidised bed principle, epitomises efficient industrial mixing technology. Within fractions of a second, it achieves significant intermixing of dry components. Key to its operation is the Froude number, determining forces within the mixing process. With adaptable configurations, it balances mixing time and quality across various industrial applications, showcasing MAP's innovation and excellence.

Click the video on the right showing the computer simulation of mixing two components in a WBH batch mixer with ploughshare tools.

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