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Mixing Volume

Recommended mixing volumes of industrial bulk solids / powder batch mixers

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Section summary
1. Mixing volume ranges of common batch powder dry-mixers
2. Minimum and maximum mixing volume batch powder dry mixer

1. Mixing Volume ranges of common batch powder dry-mixers

Solids blenders can be ordered from manufacturers with quite a large range of sizes, from few liters to few or dozens of cubic meters. Solids blending is a volumetric process thus a volume should be specified when ordering a mixer, not a weight as the weight will vary with the bulk density of the solids. The table below shows the typical sizes of mixers that can be found on market.

Table 1 : Common solids mixers size range

Mixer Usual Sizes
Drum / Bin blenders
10 l in labs - 200 l industrial for drums
200 l - 2000 l for bins
Ribbon blenders 150 l - 5000 l
Bigger mixers are possible / special executions
Paddle mixers
100 l - 2000 l
Up to 5000 l for some manufacturers
Ploughshare type 100 l - 5000 l
Bigger mixers are possible / special executions

2. Minimum and Maximum mixing volume batch powder dry-mixers

It is very important to understand the difference in total volume and useful volume for dry mixers.

Mixer useful volume and total volume - how much can we fill a powder mixer ?

Figure 1 : Mixer total and useful volume

Most suppliers are giving a total volume, but one should not attempt to fill it 100% ! Indeed, in order to have a good mixing there should ALWAYS be a free space inside the mixer, so that the solids can move, rearrange and thus mix. The actual maximum volume that can be filled to get a good mix is actually the useful volume and represents only a certain percentage of the total volume. The useful volume is changing from one mixer type to another, and should also be adapted to the material being mixed. The table blow gives typical minimum and maximum - useful - mixing volume, it should be validated case by case by an homogeneity test.

Table 2 : Typical Min and Max mixing volume

Mixer Min mixing volume Max mixing volume
Drum / Bin blenders
Diffusive mixers
- 50-60%
Ribbon blenders 30% 70-80%
Up to 90% may be possible
Paddle mixers 30-40% 70-80%
Ploughshare mixers
Shear mixers
30-40% 70-80%


For mixers with agitators, a minimum volume is specified. Indeed, if the mixer is not enough filled, the agitator will not be able to pick up and move enough powder to have an efficient mixing.

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