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Principle, Construction, Working, Uses, Merits and Demerits of Double Cone Blender

Dry blending of free solids is the most frequent application for double cone blenders.

Double Cone Blender

Principle

Dry blending of free solids is the most frequent application for double cone blenders. These blenders can blend solids of different bulk densities and percentages in different ratios. During the rotation of the double cone, the matter is continuously intermixed. It normally takes 10 minutes to mix materials and may take longer or shorter depending on the complexity and size of the materials.

Construction

Two cylindrical cones are welded to a central cylindrical section to form the main body of this blender. During rotation, the axis passes through the cylindrical section and is parallel to the cone axis. The blender's motor is built into one of its two lateral supports. Stainless steel is used to construct the double cone blender. The blender is welded using argon arc welding. It is both mirrors polished from the inside and out. A mild steel or stainless-steel ball-bearing stand supports the device. There are capacities ranging from 20 L to 3000 L. Because both ends are conical, it facilitates easy mixing and dispensing. By statically balancing the cone, excessive load is protected from the motor and gearbox.

The cone has a butterfly valve at one end, a hole with an openable cover at the other end, and a butterfly valve at the other end for material discharge and cleaning. Within the blender are stainless steel baffles and a motor connected through a reduction gearbox. Variable speeds can be selected. Bigger models can be equipped with safety railings, limit switches, and platforms as options. An ancillary provision allows liquids to be introduced in spray form during the process through the inclusion of a liquid spray system. Using a vacuum unit with self-cleaning hoses, powders and granules can be loaded into the blender body through an automated loading system. There is also a self-cleaning automatic filter in the product receiving hopper; and a control panel for the unit. A retractable hermetic below can be used to load/discharge the material pneumatically.

Working

A vacuum intake system or manual feeding are used to feed powdery or granular materials into double cone containers. By rotating continuously, the material is continually moved in a complex and forceful manner to ensure uniform mixing. Both ends are conical, promoting uniform mixing and making discharge easier. It is possible to provide paddle-type baffles on the shaft, depending on the characteristics of the material, to help with mixing, uniform blending, and deagglomeration. Minimum dust handling is ensured with dust-free bin charging. Solid materials are loaded with the loading aperture into the blender. By moving through the various sections, the powder bed mixes axially. However, the speed at which it rotates affects how thorough the mixing is. Hermetic butterfly valves are used to discharge the mixture via either manual or automatic operation. A volume that promotes homogeneity should be between 35-70% of the gross volume.

Uses

  • DCBs can be used to mix dry powders or granules into tablets and capsule formulations.
  • It is used to mix dry granules sublots in bulk lubrication stages of tablet granules in order to increase the batch size.
  • Wet powder to dry powder mixing can be performed with this equipment.
  • The product can be used for pharmaceuticals, foods, chemicals, and cosmetic products, among others.
  • This mixer is well suited for mixing granular and powdery materials with excellent mixing quality.
  • The mixer can be used in chemical, plastic, rubber, food, essence, dye, and dyeing industries.
  • In general, it is used for medical intermediates, flavourings, graphite, coffee powder, iron powder with a specific gravity less than 7 grams per cubic centimeter that has some fluidity with no liquid content greater than 10%.

Merits

  • With a close-container design, the DCB mixer blender provides good product rolling and cross-mixing.
  • Conical shapes at both ends and the 'slant' design create uniform mixing and allow for easy discharge.
  • This device mixes, blends uniformly, and de-agglomerates materials.
  • By statically balancing the cone, any excessive load is prevented from damaging the gearbox or motor.
  • It is possible to provide paddle type baffles on the shaft for better mixing depending on the product's characteristics.
  • Corrosion and contamination are prevented by S.S.304 and S.S.316 being used in contact parts. It has an automatic dust-free system that ensures minimal handling of materials.

Demerits

  • Fine powders cannot be handled by DCB.
  • Due to the low shear exhibited by this equipment, fine and large particles cannot be effectively mixed together.
  • Rooms with low ceiling heights may not be suitable for installation since it requires more space.
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Ankur Choudhary is India's first professional pharmaceutical blogger, author and founder of Pharmaceutical Guidelines, a widely-read pharmaceutical blog since 2008. Sign-up for the free email updates for your daily dose of pharmaceutical tips.
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