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PerMix Sigma Mixers & Sigma Mixers & Extruders

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PerMix Sigma Mixers & Sigma Mixers & Extruders

The PerMix PSG series Sigma Mixer, which is also known as the Double Sigma Mixer, or Double Z Blade Mixer, is used for the mixing-kneading of materials with very high viscosity (over 500,000 cps).

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PerMix Sigma Mixers: Engineered for Performance Across All Industries

At PerMix, we take pride in manufacturing the most versatile and reliable sigma mixers and sigma mixer/extruders on the market today. Our advanced designs and custom construction options allow us to serve industries ranging from pharmaceuticals and food processing to hazardous chemical environments and heavy-duty applications handling abrasive and corrosive materials.

With decades of engineering expertise, innovative design, and turn-key installation capabilities, PerMix Sigma Mixers are the ideal solution for precision mixing, kneading, and extrusion applications.

🔹 Custom-Engineered Sigma Mixers for Every Industry

At PerMix, we understand that different industries require specialized mixing solutions. That’s why we offer fully customizable sigma mixers built to meet the exact requirements of your production process.

✔️ Sanitary Sigma Mixers for Pharmaceuticals & Nutraceuticals

🔹 cGMP-Compliant & Hygienic Design: Meets FDA, GMP, and global pharmaceutical safety standards.
🔹 Polished 316L Stainless Steel Contact Surfaces: Ensures easy cleaning and contamination-free processing.
🔹 Crevice-Free Interior & FDA-Approved Seals: Prevents product buildup and enhances sterilization.
🔹 CIP (Clean-In-Place) & SIP (Sterilize-In-Place) Capabilities: Automated cleaning for fast, residue-free sanitation.

✅ Ideal for: Mixing ointments, creams, pastes, active pharmaceutical ingredients (APIs), and nutraceutical formulations.

✔️ Explosion-Proof (EXP) & ATEX-Certified Sigma Mixers for Hazardous Environments

🔹 ATEX & Explosion-Proof Motors & Controls: Ensures safe operation in volatile chemical and energy sector applications.
🔹 Fully Sealed Enclosures: Prevents flammable gas or dust ignition risks.
🔹 Anti-Static & Intrinsically Safe Construction: Reduces electrostatic buildup, making it safe for highly reactive environments.

✅ Ideal for: Chemical manufacturing, adhesives, sealants, polymers, battery production, and reactive compounds.

✔️ Heavy-Duty Sigma Mixers for Abrasive & Corrosive Applications

🔹 Hardox Construction: Withstands highly abrasive powders and slurries, ensuring extended equipment life.
🔹 Hastelloy & Titanium Options: Provides superior corrosion resistance against acidic, caustic, or reactive chemicals.
🔹 Specialty Coatings for Maximum Durability: Designed for high-wear industrial mixing applications.

✅ Ideal for: Mining, construction materials, specialty chemicals, and industrial adhesives.

🔹 Advanced Features for Maximum Efficiency

At PerMix, we go beyond standard designs by offering custom-engineered features to enhance your process efficiency and product quality.

✔ Vacuum Mixing & Drying Capabilities: Enables moisture removal, solvent recovery, and temperature-sensitive processing.
✔ Heating & Cooling Jackets: Provides precise thermal control for uniform heating and cooling.
✔ Dual-Zone Jacketed Design: Allows for independent heating and cooling zones within a single batch.
✔ Integrated Extruder Options: Streamlines product discharge, shaping, and continuous processing.

🔹 Industry Applications for PerMix Sigma Mixers

PerMix Sigma Mixers serve a wide range of applications, ensuring consistent mixing, kneading, and extrusion performance across various industries.

✔️ Pharmaceutical & Nutraceutical Industry

🔹 Mixing Active Pharmaceutical Ingredients (APIs) into pastes and ointments.
🔹 Blending and granulating nutraceutical formulations.
🔹 Vacuum drying of semi-solids and heat-sensitive ingredients.

✔️ Food Processing & Confectionery Industry

🔹 Dough kneading for bakery products.
🔹 Mixing candy fillings, chocolates, and fudge.
🔹 Blending nut butters, pastes, and thick emulsions.

✔️ Chemical & Polymer Industry

🔹 Formulating adhesives, sealants, and polymer-based compounds.
🔹 Mixing resins, pastes, and synthetic materials.
🔹 Processing hazardous, solvent-based, or reactive chemicals.

✔️ Mining, Construction & Industrial Applications

🔹 Mixing abrasive slurries, cements, and refractory materials.
🔹 Processing high-wear composites and synthetic rubbers.
🔹 Blending high-density powders used in heavy-duty applications.

🔹 Why Choose PerMix Sigma Mixers?

At PerMix, we don’t just manufacture mixers—we provide turn-key process solutions that ensure efficiency, safety, and performance.

✅ Industry-Leading Engineering: Decades of expertise in high-performance mixing technology.
✅ Fully Customizable Designs: Available in sanitary, explosion-proof, and heavy-duty configurations.
✅ Automation & Process Control Integration: Featuring PLC/HMI control systems for real-time monitoring and automation.
✅ Scalable Solutions: From small R&D lab units to full-scale industrial production systems.
✅ Built for Longevity: Constructed from premium materials like stainless steel, Hardox, Hastelloy, and titanium.
✅ Comprehensive Installation & Support: Includes on-site setup, process optimization, and training.

🔹 Get the Perfect Mixer for Your Needs

When you choose PerMix Sigma Mixers, you’re investing in cutting-edge engineering, superior durability, and turn-key solutions that outlast and outperform the competition. Whether you need a sanitary mixer for pharmaceutical applications, an explosion-proof system for hazardous materials, or a high-performance mixer for industrial-grade slurries, PerMix has the perfect solution for you.

📩 Contact us today for expert guidance and a customized solution tailored to your specific mixing needs

Working Principle of PerMix Sigma Mixers & Sigma Mixer Extruders

At PerMix, our Sigma Mixers and Sigma Mixer Extruders are engineered to deliver exceptional mixing, kneading, and extrusion performance, making them the preferred choice for processing high-viscosity materials. Designed for industries such as pharmaceuticals, food, adhesives, sealants, rubber, and specialty chemicals, these mixers offer unmatched precision, efficiency, and reliability.

With customizable features, including vacuum integration, heating & cooling jackets, explosion-proof construction, and abrasion-resistant materials, PerMix Sigma Mixers set a new industry standard for high-performance processing solutions.

🔹 How a PerMix Sigma Mixer Works

The Sigma Mixer is a specialized high-viscosity batch mixer that utilizes two Z-shaped blades rotating inside a horizontal mixing chamber. These counter-rotating blades create an intense kneading and shearing action, ensuring uniform blending of even the most challenging materials.

1️⃣ Shearing & Kneading Action for Optimal Mixing

🔹 The Z-shaped blades rotate at different speeds, creating a high-shear zone where materials are stretched, folded, and compressed.
🔹 This powerful kneading motion evenly distributes ingredients, ensuring homogeneity for high-viscosity pastes, rubber compounds, and polymer-based materials.

2️⃣ Adjustable Speed & Precision Mixing Control

🔹 The blade speed and direction can be fine-tuned based on the specific rheology of the material being processed.
🔹 Variable-speed motors allow gentle mixing for sensitive materials or high-intensity kneading for thick, heavy compositions.

3️⃣ Vacuum Capability for Air-Free Processing

🔹 When equipped with a vacuum system, the mixer removes trapped air, eliminating voids and bubbles in pharmaceutical creams, food pastes, adhesives, and polymer compounds.
🔹 Vacuum mixing also enhances product consistency, adhesion strength, and overall material quality.

4️⃣ Temperature Control with Heating & Cooling Jackets

🔹 The mixing chamber can be equipped with heating or cooling jackets for precise temperature regulation.
🔹 Applications include:
✔ Polymerization & Vulcanization – Controlling heat during polymer formation.
✔ Food & Pharmaceutical Processing – Preventing overheating of heat-sensitive ingredients.
✔ Solvent Recovery & Evaporation – Assisting in moisture and solvent removal.

✅ Ideal for: Adhesives, rubber, silicone pastes, chemical reactions, and dough-based materials.

🔹 How a PerMix Sigma Mixer Extruder Works

The Sigma Mixer Extruder integrates the kneading and blending power of a Sigma Mixer with an extrusion system, allowing for continuous material processing and direct discharge. This dual-function system eliminates manual handling, enhances process efficiency, and improves final product consistency.

1️⃣ Mixing & Kneading Process

🔹 The mixing chamber functions identically to a standard Sigma Mixer, ensuring thorough kneading and material uniformity.

2️⃣ Integrated Extrusion for Streamlined Processing

🔹 After mixing, the material is pushed towards an extrusion screw or die, where it is shaped, compacted, or transferred to the next stage of production.
🔹 The extrusion system applies controlled pressure, ensuring consistent discharge, reduced handling, and optimized output.

3️⃣ Precision & Efficiency in Every Batch

🔹 The automated extrusion system ensures uniformity in product shape, density, and texture.
🔹 Customizable die plates allow manufacturers to tailor product dimensions and forms.

✅ Ideal for: High-viscosity materials such as sealants, putties, rubber compounds, polymer-based adhesives, and specialty resins.

🔹 Advantages of PerMix Sigma Mixers & Sigma Mixer Extruders

At PerMix, we engineer Sigma Mixers to offer the most efficient and versatile processing solutions available today.

✅ Powerful Z-Blade Mixing for Faster Processing:
✔ Deep kneading action ensures complete material dispersion.
✔ Reduces batch processing time while improving consistency.

✅ Versatility Across Multiple Industries:
✔ Suitable for pharmaceuticals, food, adhesives, chemicals, and high-viscosity compounds.
✔ Handles both small-scale and large-scale production needs.

✅ Customizable Features for Every Process:
✔ Vacuum integration for bubble-free mixing.
✔ Heating & cooling jackets for thermal-sensitive materials.
✔ ATEX-certified explosion-proof construction for hazardous environments.
✔ Abrasion-resistant Hardox and Hastelloy options for tough applications.

✅ Streamlined Production with Sigma Mixer Extruders:
✔ Eliminates manual handling, improving efficiency and consistency.
✔ Continuous extrusion reduces labor and minimizes waste.
✔ Precision die shaping ensures accurate product dimensions.

🔹 Why Choose PerMix for Sigma Mixers & Sigma Mixer Extruders?

At PerMix, we combine decades of engineering expertise with cutting-edge mixing technology to manufacture the highest-performing Sigma Mixers and Sigma Mixer Extruders on the market. Our commitment to innovation, efficiency, and customer satisfaction ensures that you receive a customized mixing solution that outperforms the competition.

✅ Industry-Leading Engineering & Innovation:
✔ State-of-the-art blade design for maximum mixing efficiency.
✔ Automated process control with PLC/HMI integration.

✅ Custom-Designed to Meet Your Exact Process Needs:
✔ Available in stainless steel (304/316L), Hardox, Hastelloy, and titanium.
✔ Explosion-proof, sanitary, and corrosion-resistant options available.

✅ Turn-Key Installation & Global Support:
✔ Includes on-site setup, commissioning, training, and maintenance support.

✅ Best-in-Class Performance & Value:
✔ Unmatched durability, efficiency, and long-term reliability.
✔ Industry-leading warranty and lifetime customer support.

🔹 Get the Perfect Sigma Mixer for Your Production Needs

Whether you need a high-performance Sigma Mixer for batch mixing or a Sigma Mixer Extruder for seamless continuous processing, PerMix has the perfect solution for you.

📩 Contact us today for expert advice and a customized solution tailored to your specific mixing and extrusion needs!

A Comprehensive Guide to Sigma Mixer Installation & Setup for Optimal Performance

Installing a PerMix Sigma Mixer correctly is essential to maximize efficiency, ensure longevity, and maintain consistent product quality. A properly installed sigma mixer reduces downtime, enhances safety, and optimizes mixing performance across pharmaceutical, food, chemical, and industrial applications.

At PerMix, we provide turn-key installation services along with comprehensive setup support to ensure that your sigma mixer is fully operational from day one. This guide outlines the step-by-step process to install and set up a sigma mixer for optimal performance and reliability.

🔹 Step-by-Step Sigma Mixer Installation Guide

1️⃣ Choose the Right Location

Selecting the correct installation site is crucial for optimal operation and maintenance accessibility.

🔹 Well-Ventilated & Clean Area: Helps prevent dust buildup and ensures safe working conditions.
🔹 Adequate Space for Access & Maintenance: Ensure sufficient clearance around the mixer for routine inspections and servicing.
🔹 Proximity to Power & Raw Materials: Reduces energy consumption and material transfer time.
🔹 Safe Flooring: Install the mixer on a non-slip, reinforced surface to prevent vibrations or shifting.

2️⃣ Verify Power Requirements

Before installation, confirm that the electrical supply meets the manufacturer’s specifications.

🔹 Correct Voltage & Frequency: Ensures consistent performance and avoids electrical failures.
🔹 Professional Electrical Inspection: If necessary, consult a certified electrician to ensure proper wiring and grounding.
🔹 Explosion-Proof Units: If operating in hazardous environments, confirm that ATEX or EXP-rated electrical connections are installed.

3️⃣ Unpacking & Inspection

Before assembly, conduct a thorough inspection of the unit to ensure that all components are intact and undamaged.

🔹 Check for Transit Damage: Inspect housing, blades, control panels, and electrical connections.
🔹 Verify All Components: Ensure that seals, lubrication points, and safety features are in place.
🔹 Cross-Check Against Packing List: Confirm that all accessories and tools are included.

✅ Report any shipping damage immediately to PerMix or your freight carrier.

4️⃣ Foundation & Leveling

A stable, level foundation is essential for minimizing vibrations, reducing wear, and ensuring efficient mixing.

🔹 Install on a Solid Foundation: Preferably on a concrete floor or vibration-resistant surface.
🔹 Use a Spirit Level: Adjust the mixer’s feet or base to ensure precise leveling.
🔹 Anchor Bolts (Optional): For heavy-duty applications, secure the mixer with anchor bolts to prevent movement.

✅ Proper leveling is critical for the longevity of the drive system and blade operation.

5️⃣ Drive System Assembly

The drive system is pre-assembled at the factory but requires lubrication before startup.

🔹 Fill with Oil: PerMix ships units dry to avoid HAZMAT classification during transit. Ensure the correct lubricant type and fill level before operation.
🔹 Inspect Gearbox & Motor Connections: Confirm secure attachment and alignment of drive components.

✅ Refer to the manufacturer’s lubrication chart for recommended oil type and change intervals.

6️⃣ Blade & Trough Installation

PerMix ships sigma mixers fully assembled, ensuring that blades, troughs, and mechanical components are pre-fitted for seamless integration.

🔹 Double-Check Blade Alignment: Ensure that the Z-shaped blades are correctly positioned and rotate freely.
🔹 Inspect Scrapers & Edge Seals: Verify that material clearance is optimized for thorough mixing.

✅ No further mechanical assembly is required—your mixer arrives ready for operation!

7️⃣ Sealing & Lubrication for Smooth Operation

Proper sealing and lubrication prevent leaks, wear, and premature component failure.

🔹 Check Shaft Seals: Ensure that all sealing components are tight and properly seated.
🔹 Lubricate Bearings & Moving Parts: Use manufacturer-recommended lubricants to reduce friction.
🔹 Inspect Safety Seals for Vacuum Models: If operating a vacuum sigma mixer, verify airtight seals to prevent leaks.

✅ Regular lubrication extends the lifespan of critical moving parts.

8️⃣ Electrical Connections & Safety Testing

Proper electrical connections ensure safe operation and compliance with industry standards.

🔹 Follow the Manufacturer’s Wiring Diagram: Connect power, control panels, and safety interlocks.
🔹 Double-Check Grounding & Circuit Protection: Reduces electrical hazards and surge damage.
🔹 Test Emergency Stops & Overload Protection: Ensure that all safety systems function properly before startup.

✅ For explosion-proof (EXP/ATEX) models, use certified electrical enclosures and connections.

9️⃣ Perform a Test Batch Before Full-Scale Production

A test batch ensures that your sigma mixer is operating correctly before production.

🔹 Run the Mixer Without Load: Verify blade rotation, speed, and direction.
🔹 Test a Small Batch: Confirm mixing time, shear intensity, and product consistency.
🔹 Adjust Speed & Temperature Settings: Optimize parameters for your specific application.
🔹 Monitor for Unusual Noises or Vibrations: Indicates potential misalignment or lubrication issues.

✅ Make any final adjustments before moving into full-scale production.

🔹 Regular Maintenance for Long-Term Reliability

Following manufacturer-recommended maintenance schedules will extend the life of your sigma mixer and ensure consistent performance.

✔ Lubricate Bearings & Seals: Prevents excessive wear and overheating.
✔ Inspect Blades & Drive System: Check for misalignment, excessive wear, or residue buildup.
✔ Monitor Electrical Components: Ensure that wiring and control panels remain in top condition.
✔ Clean Mixing Chamber After Each Use: Prevents cross-contamination in sanitary applications.

✅ Routine servicing keeps your sigma mixer running at peak efficiency for years to come.

🔹 Why Choose PerMix for Your Sigma Mixer Installation?

At PerMix, we provide more than just high-quality mixers—we offer comprehensive turn-key solutions, including installation support, automation integration, and maintenance training.

✅ Industry-Leading Engineering: Designed for efficiency, durability, and precision mixing.
✅ Custom Installation Support: We offer on-site setup, commissioning, and operator training.
✅ Advanced Process Control: PLC/HMI automation options for seamless production integration.
✅ Comprehensive Service & Support: Global technical assistance and spare parts availability.

🔹 Get Expert Assistance for Your Sigma Mixer Setup

Following these installation and setup steps will ensure that your PerMix Sigma Mixer is operating at maximum efficiency from day one. If you need professional installation, training, or process optimization, our expert team is here to help.

📩 Contact PerMix today for technical support, custom installation services, or a consultation on optimizing your mixing process! 

Sigma Mixer Specifications

  • Customizable Options for PerMix Sigma Mixers and Sigma Mixer Extruders

    PerMix offers a wide range of customizable options for our sigma mixers and sigma mixer extruders, allowing you to tailor each unit to meet the unique demands of your industry and application. From advanced temperature control to precise ingredient loading systems, we ensure your mixer is optimized for efficiency, safety, and performance.

    1. Heating & Cooling Jackets

    Our sigma mixers can be equipped with heating and cooling jackets to maintain precise temperature control during the mixing process.

    • Applications:
      • Heating: Ideal for processes like polymerization, vulcanization, or cooking food products.
      • Cooling: Essential for controlling heat-sensitive materials or solidifying mixtures.
    • Features:
      • Available in single or dual-zone designs for maximum flexibility.
      • Compatible with steam, hot oil, water, or glycol systems for efficient heat transfer.

    2. Heating & Cooling Arms

    For applications requiring even more precise temperature control, PerMix offers heating and cooling arms.

    • These arms directly transfer heat or cooling to the product inside the chamber, providing faster and more uniform temperature adjustments.
    • Perfect for high-viscosity products where thorough heat distribution is critical.

    3. Vacuum Capabilities

    Vacuum functionality enhances product quality by:

    • Removing trapped air, resulting in a denser, more homogeneous product.
    • Enabling vacuum drying for industries like pharmaceuticals, adhesives, and food.

    Vacuum sigma mixers/dryers can also integrate with condensers for vapor recovery, improving efficiency and sustainability.

    4. ATEX & Explosion-Proof (ExP) Construction

    For hazardous environments, PerMix sigma mixers can be built to meet ATEX and ExP standards.

    • Safety Features:
      • Explosion-proof motors and controls.
      • Anti-static construction to prevent ignition risks.
      • Fully sealed designs for handling volatile or flammable substances.

    These mixers are ideal for chemical, pharmaceutical, and coatings industries.

    5. Materials of Construction

    We offer a variety of materials to suit your specific product requirements:

    • 304 and 316 Stainless Steel: Ideal for sanitary applications in food and pharmaceuticals.
    • Hastelloy and Titanium: Best for highly corrosive substances.
    • Hardox Steel: Exceptional durability for abrasive materials.
    • Carbon Steel: A cost-effective option for less demanding applications.

    Each construction option is tailored to balance performance, longevity, and budget.

    6. Ingredient Loading Options

    Efficient ingredient loading is key to streamlining production. PerMix offers:

    1. Manual Loading
      • Simple and cost-effective for small batches or low-viscosity materials.
    2. Automatic Dosing Systems
      • Precision dosing via load cells ensures accurate ingredient addition for consistent product quality.
      • Compatible with powders, liquids, and bulk materials.
    3. Vacuum Loading
      • Uses vacuum to draw ingredients into the chamber, eliminating the need for separate loaders.
      • Reduces dust, contamination, and manual handling.
    4. Integrated Bulk Bag Unloaders
      • Designed for high-volume production, enabling seamless ingredient transfer from bulk bags to the mixer.

    Tailored Solutions for Every Application

    With these customizable options, PerMix sigma mixers and sigma mixer extruders are versatile enough to handle:

    • High-viscosity pastes and doughs.
    • Heat- or cold-sensitive materials.
    • Hazardous or volatile environments.
    • Abrasive or corrosive products.

    Why PerMix?

    PerMix leads the industry with:

    • Innovative engineering to optimize performance.
    • Flexibility to meet diverse application needs.
    • Competitive pricing without compromising quality.

 

Unveiling the Benefits of Sigma Mixer with Vacuum: Elevate Your Mixing Experience

In the dynamic world of industrial mixing, the Sigma Mixer with Vacuum stands out as a revolutionary solution, combining cutting-edge technology with unparalleled efficiency. This article explores the myriad advantages that this sophisticated equipment brings to the table, making it an indispensable asset for various industries.

  1. Precision Mixing: The Sigma Mixer with Vacuum excels in achieving precision mixing results. Its dual blades, sigma and extruder, work in tandem to ensure uniform blending of diverse materials, from powders to pastes. This precision is crucial in industries like pharmaceuticals, cosmetics, and food processing, where consistency is paramount.
  2. Enhanced Homogeneity: The vacuum feature adds a new dimension to the mixing process by removing unwanted air and gases. This not only prevents oxidation and preserves product quality but also enhances homogeneity. The result is a thoroughly mixed and degassed product, meeting the highest quality standards.
  3. Reduced Processing Time: Time is money in the industrial landscape, and the Sigma Mixer with Vacuum proves its worth by significantly reducing processing time. The vacuum expedites the removal of entrapped air, expelling it from the mixture efficiently. This accelerated process ensures quicker production cycles, boosting overall operational efficiency.
  4. Energy Efficiency: With an eye on sustainability, the Sigma Mixer with Vacuum is designed for energy efficiency. The vacuum function contributes to reducing the energy required for mixing, making it an eco-friendly choice. This aligns with the global trend towards environmentally conscious manufacturing practices.
  5. Versatility Across Industries: One of the standout features of the Sigma Mixer with Vacuum is its versatility. From rubber and plastics to adhesives and ceramics, this mixer adapts seamlessly to various industries. Its ability to handle a diverse range of materials makes it a go-to choice for manufacturers with multifaceted production needs.
  6. Minimized Material Waste: Achieving precision in mixing translates to minimized material waste. The Sigma Mixer with Vacuum ensures that each batch is thoroughly blended, leaving little room for inconsistencies or rejected products. This not only saves resources but also contributes to cost-effectiveness.
  7. Easy Maintenance and Cleaning: The design of the Sigma Mixer with Vacuum prioritizes user convenience. Its straightforward structure allows for easy maintenance, and the vacuum feature facilitates quick and efficient cleaning between batches. This ease of maintenance translates to increased uptime and a hassle-free production process.

The Sigma Mixer with Vacuum emerges as a game-changer in the realm of industrial mixing. Its ability to deliver precise, homogeneous mixtures, coupled with time and energy efficiency, positions it as an invaluable asset for a wide range of industries. As manufacturers seek to elevate their production processes, this advanced mixing solution proves to be a strategic investment, promising enhanced quality, reduced waste, and heightened operational efficiency.

Need Help Selecting Your Equipment?

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PerMix is here to listen to your needs and provide sustainable solutions. Contact us to discover more.

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