Conical Mixer - High-Quality Mixing with PerMix Conical Mixers

Working Principle of PerMix Conical Mixers & Vacuum Conical Mixers/Dryers

PerMix Conical Mixers and Vacuum Conical Mixers/Dryers are engineered for precision mixing and efficient drying, combining gentle tumbling motion with advanced axial-radial mixing. Their unique conical vessel design optimizes material flow, eliminates dead zones, and minimizes heat generation, making them perfect for heat-sensitive, fragile, and segregative materials.

With customizable features such as vacuum integration, heating & cooling jackets, and high-speed choppers, PerMix offers versatile solutions tailored to a wide range of industries, including pharmaceuticals, food, chemicals, nutraceuticals, and cosmetics.

🔹 Key Components & Their Roles

1️⃣ Conical Vessel for Optimal Mixing & Flow

🔹 The conical shape naturally guides materials downward, ensuring a continuous and uniform mixing process.
🔹 Prevents material stagnation and dead zones, making it highly efficient for batch sizes ranging from small to large volumes.
🔹 Provides complete product discharge, minimizing material retention and waste.

✅ Why It Matters: Ensures gentle, efficient, and homogeneous mixing without overheating or product degradation.

2️⃣ Agitator Screw with Planetary Motion

🔹 The central screw rotates along its axis while simultaneously orbiting the inner walls of the cone (planetary motion).
🔹 Moves materials both vertically and radially, achieving homogeneous mixing without material segregation.
🔹 Handles powders, granules, pastes, and liquids, ensuring even distribution of all components.

✅ Why It Matters: The axial-radial mixing action ensures every particle is evenly blended, eliminating hot spots or unmixed areas.

3️⃣ Vacuum System for Low-Temperature Drying (Vacuum Models)

🔹 The vacuum environment lowers the boiling point of moisture, allowing for fast, efficient drying at lower temperatures.
🔹 Ideal for heat-sensitive materials such as pharmaceutical powders, nutraceuticals, and specialty chemicals.
🔹 Eliminates trapped air, improving product density, texture, and quality.

✅ Why It Matters: Reduces drying time, enhances product stability, and prevents oxidation or degradation.

4️⃣ Heating & Cooling Jackets for Precise Thermal Control

🔹 An optional heating & cooling jacket surrounds the conical vessel, allowing precise temperature management.
🔹 Steam, water, or thermal oil circulates through the jacket to heat or cool the product as needed.
🔹 Supports thermal-sensitive mixing, drying, and crystallization applications.

✅ Why It Matters: Prevents overheating, improves moisture evaporation efficiency, and stabilizes temperature-sensitive formulations.

5️⃣ High-Speed Chopper Blades (Optional for Breaking Lumps & Agglomerates)

🔹 Choppers break down lumps and agglomerates during mixing to ensure a smooth, uniform final product.
🔹 Essential for granulation, wet coating, and dispersing sticky materials.
🔹 Customizable blade speed & configuration for specific process requirements.

✅ Why It Matters: Ensures consistent particle distribution, improves flowability, and enhances powder homogeneity.

🔹 Step-by-Step Mixing & Drying Process

1️⃣ Loading the Vessel

🔹 Materials are loaded into the conical vessel, ensuring efficient space utilization with no risk of material loss.

✅ Why It Matters: Prevents dust formation, improves ingredient dispersion, and supports batch integrity.

2️⃣ Agitation & Mixing Phase

🔹 The central screw lifts materials from the bottom of the vessel while gravity pulls them back down, creating a continuous mixing loop.
🔹 The axial-radial motion ensures complete and uniform blending without excessive shear stress.

✅ Why It Matters: Prevents ingredient segregation, ensuring a fully homogeneous mixture.

3️⃣ Vacuum Drying Process (If Applicable)

🔹 Vacuum is applied, lowering the boiling point of moisture, which accelerates drying without heat damage.
🔹 The heating jacket provides controlled thermal energy, further enhancing moisture removal efficiency.
🔹 Vapors are extracted via the vacuum system, allowing for solvent recovery (if needed).

✅ Why It Matters: Preserves product integrity, shortens drying times, and ensures high-purity formulations.

4️⃣ Final Discharge of Product

🔹 After mixing or drying, the conical shape naturally directs materials to the discharge outlet, ensuring complete product removal.
🔹 Zero product retention, reducing waste and cleaning time.

✅ Why It Matters: Improves batch yield, reduces cross-contamination risk, and enhances process efficiency.

🔹 Advantages of PerMix’s Conical Mixer Working Principle

✔ Gentle, Efficient Mixing: Perfect for fragile powders, heat-sensitive materials, and delicate granules.
✔ Uniform Homogeneous Blending: Prevents segregation and uneven ingredient distribution.
✔ Fast, Low-Temperature Drying: Vacuum-assisted drying reduces processing time while protecting product integrity.
✔ Customizable Process Control: Options for heating, cooling, vacuum drying, and high-speed choppers.
✔ Hygienic & Easy-to-Clean Design: Meets FDA, GMP, and food-grade sanitary standards.

✅ PerMix Conical Mixers are designed for industries demanding the highest level of precision, efficiency, and reliability.

🔹 Industries Benefiting from PerMix Conical Mixers & Vacuum Conical Mixers/Dryers

✔ Pharmaceuticals: Mixing & drying API powders, excipients, and sensitive drug formulations.
✔ Food & Beverage: Processing spices, dairy powders, baking ingredients, and flavorings.
✔ Chemicals: Handling corrosive powders, catalysts, and specialty materials.
✔ Cosmetics & Nutraceuticals: Producing herbal extracts, powders, and active ingredient formulations.
✔ Powder Coatings & Advanced Materials: Ensuring homogeneous blending of specialty powders.

🔹 Why Choose PerMix for Conical Mixing & Drying?

At PerMix, we offer industry-leading conical mixing and drying technology, ensuring unparalleled efficiency, performance, and customization.

✅ Advanced Engineering: Cutting-edge design & manufacturing expertise.
✅ Customizable Solutions: Fully tailored features & process automation.
✅ Superior Efficiency: Optimized for low energy consumption & high throughput.
✅ Durable Construction: Built with 316 stainless steel, Hastelloy, Hardox, or titanium.
✅ Industry Compliance: Meets FDA, GMP, ATEX, and sanitary food processing standards.
✅ Turn-Key Installation & Support: Full setup, automation, and training available.

🔹 Get the Perfect Conical Mixer for Your Process

Looking for a high-performance Conical Mixer or Vacuum Conical Mixer/Dryer? PerMix has the perfect solution for your production needs.

📩 Contact us today to request a customized system and expert consultation! 🚀

Difference Between Single Screw and Double Screw in Conical Mixers

When selecting a PerMix Conical Mixer, understanding the difference between single screw and double screw configurations is essential to optimize performance based on your application needs. Here’s a detailed breakdown:

Single Screw Conical Mixer

Overview:
A single screw conical mixer features one vertical screw agitator that rotates on its axis while orbiting along the conical vessel wall. This design is highly efficient for most applications and provides consistent, homogeneous mixing.

Advantages of Single Screw:

1. Simplicity in Design:
   • Fewer moving parts result in lower maintenance requirements.
   • Easy to operate and clean.
2. Cost-Effective:
   • More affordable due to reduced manufacturing complexity.
3. Sufficient for Standard Applications:
   • Handles a wide range of mixing tasks effectively, including powders, granules, and liquids.
4. Compact Footprint:
   • Requires less energy and space compared to double screw models.

Limitations of Single Screw:

• Slower Mixing for Large Volumes:
  • May take longer to achieve homogeneity in large batches.
• Less Efficient with Low-Density or Light Powders:
  • Mixing may require more time to ensure consistency with materials prone to floating or segregation.

Double Screw Conical Mixer

Overview:
A double screw conical mixer includes two vertical screw agitators that rotate and orbit the vessel simultaneously. This design significantly enhances the mixing action by handling more material in less time.

Advantages of Double Screw:

1. Faster Mixing:
   • Dual screws increase mixing efficiency by simultaneously moving materials through the mixing zone.
   • Ideal for large batch sizes or high-throughput requirements.
2. Enhanced Homogeneity:
   • Better suited for materials with varying densities or challenging flow properties.
   • Minimizes segregation of light or fragile particles.
3. Improved Handling of Low-Density Materials:
   • Provides better control and mixing of materials prone to floating or clumping.
4. Versatility:
   • Excels in complex applications such as coating powders with liquids or mixing highly viscous substances.

Limitations of Double Screw:

• Higher Cost:
  • More components and complexity result in a higher initial investment.
• Increased Maintenance:
  • Additional screws and mechanisms may require more frequent maintenance.
• Larger Energy Requirements:
  • May consume more power compared to single screw mixers.

When to Choose Each Configuration

Conclusion: Tailored Solutions with PerMix

At PerMix, we offer both single and double screw conical mixers, ensuring you get the perfect solution for your specific process requirements. Whether your focus is on cost-effectiveness and simplicity or enhanced efficiency and versatility, our mixers deliver unmatched performance and reliability.

1. Available Options for PerMix Conical Mixers & Vacuum Conical Mixers/Dryers

   PerMix conical mixers and vacuum conical mixers/dryers are designed with versatility and customization in mind. Below is a comprehensive list of options available to enhance the performance, adaptability, and efficiency of our mixers:

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   Material of Construction

   1. 304 Stainless Steel – Standard for most applications, offering corrosion resistance and durability.
   2. 316/316L Stainless Steel – Ideal for pharmaceutical, food, and chemical applications requiring higher corrosion resistance.
   3. Hastelloy – Suitable for handling highly corrosive materials.
   4. Hardox – Perfect for abrasive materials to ensure long equipment life.
   5. Titanium – For ultra-corrosive or specialty applications.
   6. Carbon Steel – Cost-effective option for less demanding applications.

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   Agitator Options

   1. Single Screw – Efficient for standard mixing needs.
   2. Double Screw – Enhanced mixing for complex materials or larger batch sizes.
   3. High-Speed Chopper Blades – To break down lumps, agglomerates, or sticky materials.
   4. Liquid Additive Nozzles – For precise liquid injection during mixing.

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   Thermal Control

   1. Heating & Cooling Jackets – Steam, water, or oil-based jackets for controlled thermal processes.
   2. Cryogenic Cooling Options – For applications requiring extremely low temperatures.

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   Vacuum System Options

   1. Mild Vacuum – Suitable for standard drying processes.
   2. High Vacuum – For highly sensitive materials or applications requiring extremely low pressure.
   3. Condensate Recovery System – Collect and recycle vapors during vacuum drying.

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   Loading & Discharge

   1. Vacuum Loading System – Eliminates the need for additional loaders, simplifying material handling.
   2. Load Cells – For precise weighing and batch control.
   3. Pneumatic Discharge System – For automatic material removal.
   4. Butterfly Valves – Durable and efficient for controlled discharge.
   5. Sanitary Valves – For food-grade or pharmaceutical applications.

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   Automation & Controls

   1. PLC/HMI Controls – Fully automated control systems with recipe management.
   2. Remote Monitoring – Enable remote operation and monitoring for efficiency.
   3. Explosion-Proof Controls – For hazardous environments or processes.

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   Hygienic & Sanitary Design

   1. CIP (Clean-In-Place) Systems – Integrated systems for efficient cleaning.
   2. Polished Surfaces – Mirror-polished finishes for easy cleaning and reduced contamination risk.
   3. Sanitary Seals – Prevent material leakage and maintain hygiene.

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   Gas Purge Systems

   1. Inert Gas Purge – For handling reactive or sensitive materials.
   2. Nitrogen Purging – Prevent oxidation during mixing or drying.

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   Additional Customizations

   1. Explosion-Proof Design – For processes involving flammable materials.
   2. Insulated Jackets – Reduce energy loss during thermal processes.
   3. Mobile Skid Mounting – Portable design for flexibility in multi-location use.
   4. Vibration Isolation Mounts – Reduce noise and vibration during operation.

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   Why Choose PerMix?

   Our wide range of options ensures that your PerMix conical mixer or vacuum conical mixer/dryer is tailored to your exact application requirements. Whether you need enhanced durability, precision thermal control, or advanced automation, PerMix delivers solutions that exceed expectations.

   Contact us today to configure your ideal mixer!