AIPAK V Mixer

1.What is meant by V mixer?

V Mixer

A V mixer is an industrial mixing machine, different from other mixers because of its unique construction. Yes, it is named after its V-shape design. You surely would have seen or heard another term- twin shell mixer- for it.

It is assembled by two shells that are joined together at the end to create a V-shaped structure. V mixer is a typical tumbling mixer that performs granules and powders by rotation of its V-shell.

The materials in the V mixer are constantly separating and agglomerating. This helps in a homogenous mixture without the use of extreme shearing forces or heat.

2.Why is V mixer crucial in various production sectors?

A V mixer is the heart of the mixing process, yet its significance is usually overlooked by many manufacturers. It is a secret behind the art of blending materials. Interested in the fundamental advantages of this industrial mixture, then read the next section to discover some important ones.

Uniform Distribution of Materials in Mixture

Uniform Distribution of Materials

A mixture is usually identified by an even distribution of particles. It doesn’t have any visible lumps or agglomerates. A slanting design of a V mixer is highly favored because it assists in uniform and consistent mixing.

Indeed, its rotation is essential in minimizing the separation of varyingly sized particles. In this way, you’ll have a smooth mixture in your productions.

Gentle Movement for Fragile Materials

Gentle Movement for Fragile- Picture Courtesy: Farmako

Wondered how delicate materials are blended without having any particle degradation? The simple answer is by V mixer. It features a gentle tumbling of the vessel, which doesn’t generate high shear forces and heat.

Also, there are no blades or agitators in the V mixer, thus you can easily use this machine without worrying about any type of damage to your delicate and precious feed.

Low Utility of Power

Low Utility of Power- Picture courtesy: Wikipedia

Manufacturers across the globe are trying to cut down their utility bills by consuming less electricity in their facilities. Therefore, you will be happy to learn that a V mixer is quite an efficient tool in terms of energy consumption. V mixer is furbished with light-duty motors that don’t require much energy for running, unlike other high-shear agitating mixers.

Its operation is based on gravity-led tumbling, which uses little energy and allows you to ease up on utility bills.

Convenient Product Unloading

Convenient Product Unloading- Picture courtesy: Sofraden

Material retention is a prevalent problem in industries, often resulting in the loss of valuable products. However, there is a way out of this issue and it is to have a V mixer installed in your production.

This machine comes with a stainless-steel interior that prevents the sticking of the mixture to its nooks and crannies. That’s why, you have convenient discharging without losing any of your product. Moreover, some of its models also have quick-release offloading valves, which make discharge steps even quicker and easier.

Simple Maintenance

Simple Maintenance- Picture courtesy: Asia mixer machine

Hard-to-maintain and clean machines are one of the biggest issues for manufacturers. But you would be surprised to read that a V mixer is very easy to maintain and clean. It features a straightforward design without any moving blades, so you can easily perform maintenance and cleaning without any fuss.

3.What do you know about the working stages of a V mixer?

The working stages for V mixer and their illustration are discussed in this section:

Stage 1: Charging of Dry Powders

Materials charging

Material such as powders, granules, or dried pallets are added to the machine feeding valves. Using an interlock valve, tight-close the machine to avoid material wastage during the mixing process. The material addition must be decided and followed depending on protocol therefore avoid overloading to get proper mixing.

Stage 2: Mixing

Mixing in Different Direction

This phase begins with locking the valves and commanding the machine to start rotating. The mixing drum starts revolving all around the safety guards to ensure deep mixing and the gentle tumbling induces the breaking down of powders and makes amazing mixing effects. Plus, the intensifying bar also aids generous mixing with particle size reduction. The material now uplifts and moves downward by the force of gravity.  After passing a certain period, the machine stops as directed by the operator.

Stage 3: Powder Offloading

Powder Offloading

Mixed powder is now removed from the machine by manually opening of discharging port. You can torque the lever and release the existing section. The powders start to evacuate the machine by transferring them to packaging containers such as drums, or bags, or you can connect the evacuating pipe to avoid dust formation.

4.In which sectors is a V mixer typically employed?

After gaining an insight into the advantages of a V mixer, you’ll now certainly be thinking about its usage. Perhaps it a one of the most common machines across every industry because it can handle diverse sets of ingredients. Now let’s have a look at some potential sectors where a V mixer is typically found:

Pharmaceutical Industry

Pharmaceutical Industry- Picture courtesy: Nutrivital

You can’t have even the tiniest bit of inaccuracy in pharmaceutical preparation. Thus, pharmaceutical machines must yield precise and unvarying outcomes every time. A V mixer is an engineering marvel that is designed to handle pharmaceutical ingredients with extreme fragility and precision to generate smooth mixtures.

Furthermore, its easy-to-clean surfaces and nonporous quality makeup allow you to safely blend your materials without stressing about contamination.

Food Industry

Food industry- Picture courtesy: Fullmoon global

You can’t find even one industrial food product that doesn’t involve mixing. Hence, you can safely say a V mixer is a central part of the food industry. Whether blending spices, mixing milk powders, formulating cereals, creating bakery mixes, or producing coffee and tea products, a V mixer is essential in all.

It is ideal for every mixing job in this sector because it is highly hygienic and anti-corrosive in nature, and it maintains flavor consistency in the final mix.

Chemical Industry

Chemical Industry- Picture courtesy: Steelfabricservice

A V mixer is an indispensable piece of equipment in the chemical industry. Are you curious why? It is capable of handling highly fine and free-flowing powders without affecting their structural composition.

This equipment is the first choice of chemical businesses to blend chemicals because numerous chemicals- catalysts, pesticides, fertilizers, detergents, dyes, and additives- have fine particles.

Nutraceutical Industry

Nutraceutical Industry

Nowadays, you’ll see nutraceutical products everywhere. They are in demand because of their health-boosting effects. For the blending of nutraceutical powders, herbal supplements, vitamins, minerals, and other key nutrients, a V mixer is mostly utilized in the nutraceutical industry.

Its gentle and fine mixing is a major reason why this machine is a perfect fit for this job.

Cosmetic & Personal-care Industry

Cosmetic & Personal-care Industry

The importance of a V mixer can’t be denied in the cosmetic industry. Often, cosmetic powders, for instance, talcum powders, beauty blushes, eye shadows, and, nail powders carry a hint of delicacy, consequently, a V mixer is utilized for creating cosmetic blends with smooth and easy-to-apply textures.

Plastic Industry

Plastic industry

Prepared to be surprised because a V mixer has also a special place in the polymer industry. You will find it incredible that it is a key machine in blending additives, coloring agents, stabilizers, as well as resins. With this machine, you can obtain an even dispersion of various plasticizers in plastic products.

5.What are the main structure and components of the V mixer?

Parts of V mixer

V mixer itself is comprised of some essential parts and every designed structure has its own importance. We have described each operative responsibility belonging to the V mixer composition. If you see the above image, the labeling would definitely assist you with the exact location. Come on have a look at the explanation.

Feeding Valve

The feeding valve is the major opening of the V mixer that allows you to put the mixing material. The machine is designed with two feeding valves. The purpose behind this is to facilitate fast operation and keep a balanced proportion of the raw ingredients. You can incorporate the mixing material either using the feeding pipes or directly subjecting ingredients manually inside the mixer.

Discharge Port

After the mixing process, the combined formulation of the ingredients is now released out of the unit with the help of a discharge port. This is located at the bottom of the machine. So, it supports easy discharging of the powdery material upon cycle completion. Once the material is unloaded you can firmly close them. Moreover, it is facilitated with a hook that supports easy opening and closing of the component.

Control Panel

How to operate the machine? It is mainly performed by a control panel. As its name shows, the entire procedure is controlled by loading the protocol using this part. This is included with, speed of mixing, time of run, rpm, switching ON, OFF, etc. Today, you can find a control panel with more advanced options. Yes, you can operate by using the digital screen, it also enables you to watch the process, recall memory, store memory, etc.

Intensifying Bars

These are inside designs presented in the mixing drum that help in offering escalation forces to break the clumpiness or agglomerative particles. So, you can get smooth mixed powders when these bars rotate around the fixed axis. Inside the drum, the mixing is accelerated by two means, one is the rotation of the drum and the second is of course intensifying bars. Moreover, their numbers also vary, some machines have few intensifying bars while some units are composed of more. It's all about your requirements and models of the machine.

Machine Safety Guards

The V mixer is mainly supported by the supporters with the help of safety guards. This is the strong bar that firmly holds the machine and allows its rotational movement all around it.

Mixing Drum

This is the leading compartment of the machine. Here you can incorporate the mixing ingredients. The design of the mixing drum is based on three significant openings. Two are feeding valves and one is a discharging port.

The entire structure is represented with a V shape frame. Therefore, you can enjoy the tumbling effect when it moves all around to offer diffusive mixing to powders. This unit is capable of inducing the subtle force and produces uniformity in the mixing ingredients without chances of particle separation.

6.How is a V mixer different from a ribbon mixer?

V mixer VS Ribbon mixer

Since a V mixer and a ribbon mixer belong to different categories of mixing/blending machines, hence, there are significant variations between both of them. Now, let’s take a look at some of their differences:

Feature	V Mixer	Ribbon Mixer
Design	As it is inferred from its shape, it is composed of two shell cylinders joining together to create a V-shaped assembly.	In most cases, the ribbon mixer is a horizontal U-shaped vessel.
Blades or Agitator	It is without any sort of mixing blades or agitators.	It has an internal shaft or agitator and outer helical screws. The latter are also called ribbons. And it is where this machine gets its name.
Mixing Approach	This machine has a tumbling movement for mixing materials.	It involves a connective mixing in which ribbon helical structures mainly disperse materials in opposing directions to blend them.
Shearing Forces	Involves low-shear force and has gentle blending.	Typically encompasses high shear forces and is mostly used for breaking down massive lumps.
Mixing Efficiency	It has a more uniform mixing but takes more time to mix materials.	It has rapid and aggressive blending action.
Material Filling and Discharge	In a V mixer, you load materials from the top vent, and the products get offloaded from the bottom vent.	Usually, you place feed in the ribbon mixer from the side opening while products are unloaded through the vent present at the bottom or side.
Cleaning	It is quite easy to clean due to its simpler structure.	It is hard to clean because of its ribbon fixtures.

7.Does a V mixer come temperature modulation options?

Temperature Modulation- Picture courtesy: AKCP

You may have an interest in learning the answer to this question if you’re dealing with specialized powders. Well, for your information, it can be said that a standard V mixer doesn’t have cooling or heating features. Because it is mainly developed for dry blending. However, you can procure a customized V mixer with these temperature control features, including:

A V mixer with a jacket around its shell is available in the market, which has a flow of hot or cold liquid inside the jacket. You can use this model when you need a controlled temperature during blending.

Numerous options are available for heating, for instance, steam, electric heaters, or hot water. The jacket of a V mixer is equipped with these alternatives to indirectly heat the machine contents. You can easily soften your feed through these features and have better fluidity.

Sometimes, cold water, chilled air, or refrigerated fluids are circulated in the jacket to lower the temperature during or after mixing.

8.What is the difference between a V mixer and a planetary mixer?

V Mixer VS Planetary Mixer

A V mixer and a planetary mixer are routinely seen in industries for mixing purposes, but you will observe some major differences between these machines due to their vastly diverse designs and mixing principles. Let’s learn about their detailed comparison to make an informed decision during selection:

Feature	V Mixer	Planetary Mixer
Design	It is composed of two V-shaped shells joined at their base.	This machine is comprised of a stationary mixing bowl found at the bottom while one or two rotating blades are present at the upper part.
Mixing Principle	You can think of its mixing principle as a tumbling action in which materials fall and blend due to the gravitational force and rotation of the vessel.	On the other hand, the mixing mechanism of a planetary mixer is like the rotation of planets in the solar system. The agitators spin around their axis and rotate in the bowl concurrently.
Applications	You can utilize a V mixer if you’re mixing dry powders or granules.	It is mostly used in conditions where, the starting feed is sticky, viscous, slightly moist, or damp, for instance, dough, pastes, and creams.
Shearing Forces	It operates on low shear forces.	Since it needs stronger mixing action for thicker consistency materials. therefore, high shear forces are produced during its operation.
Mixing Efficiency	It takes more time to completely mix substances.	More rapid and effective.
Cleaning Process	Doesn’t have stationary parts, which makes cleaning tasks much simpler.	With numerous mobile blades and bowl assemblies, it may take some time and effort to clean it.

9.What safety precautions should be taken before using a V mixer?

Safety And Precautions for V Mixer

Safely and smartly operating a V mixer goes a long way in preventing accidents in the workplace. It only not guarantees the safety of operators but also the working environment. To help you, here are some important safety precautions:

Closely Examine the Equipment

Before turning on the V mixer, you must examine its interior, exterior, mobile components, and electric parts for wear and turn. Don’t start the machine if you notice burn or frayed wires. Tightly secure every bolt, nut, and safety lock. Properly close the discharge valve before filling the material in the vessel.

Safety Tips for Workforce

Don’t allow untrained operators to run the machine. Operators should only operate a V mixer if they have successfully completed the required training and certification. Every person must equip themselves with proper protective gear, such as gloves, masks, overalls, closed shoes, and safety goggles.

Caution for Filling Feed

It is a very essential step because improper filling may damage the machine. Hence, always make sure that the V-tank is loaded at its optimal capacity (50–60% of total volume). Don’t overload or underload the machine in any circumstance.

10.What are the main things that should be considered before purchasing a V mixer?

Think about it: a V mixer requires some major investment. And no manufacturer will spend that kind of money unless they’re 100% sure the equipment will be a perfect fit for the setup and efficiently carry out its mixing tasks.

Planning and considering different aspects of a machine is more important than the actual buying process. So, we’re discussing some major factors that should be pondered before going into the market for acquiring a V mixer:

Working Capacity & Batch Size

Working Capacity & Batch Size- Picture courtesy: Stock cake

To buy an ultimate machine, you should figure out your batch size and the total capacity of the V mixer. It is worth mentioning that if your processing volume is low then don’t waste your money on buying larger-sized machines and vice versa.

Keep in mind that the working volume of a V mixer is about 50-60% of the total volume of a V-tank. This information will help you decide the best working capacity of a V mixer for your setup.

Construction Material

Construction of machine

It is the most vital aspect as unsuitable material impacts the durability and operativity of the machine. Mostly you will see a V mixer with stainless steel (SS304, SS316L) engineering. It is a resilient and anti-corrosive material that will surely resist impact, wear, and corrosive substances. And improve machine life.

Also, select a machine with specialized coatings or polishes (Teflon, mirror-polished), if you’re processing hygroscopic or harsh feed.

Mixing Time

Mixing Time

More than often, you’ll find various models of V mixers with a diverse range of mixing speeds in the market. Are you interested in learning a smart move for your purchase? Then first estimate the mixing time for your powders or granules. That way you can confidently pick out a V mixer with ideal mixing speed for your blending tasks.

Discharging & Cleaning

Discharging & Cleaning

To attain the best outcomes, you must search for a V mixer with butterfly or rotary valves. These valves drastically reduce your offloading time and allow you to process more batches per shift.

Cleaning a machine is a major hustle in its operation. But you can go around this nuisance by choosing a design that allows you to quickly clean it without leaving behind any residue.

Setup Space & Installation

Installation space

Do you want to ensure that your machine perfectly fits your existing space? Then start your buying process by first measuring your installation space. Only then you will self-assuredly pick out a V mixer with just the right size for your setup.

11.What are troubleshooting tips for technical problems in the V mixer?

You will certainly encounter some serious technical problems in a V mixer during its operation, which will lead to interruption in smooth production flow and lower target achievement per shift. But by arming yourself with proper knowledge about the machine, you can fix every issue in a V mixer.

Hence, you can read some major technical problems and their solutions below:

Issues With Rotation of Mixing Vessel

Issues With Rotation of Mixing Vessel

You might have noticed that the mixing vessel is not rotating or there is some sort of disruption in its rotation. Several causes may contribute to this issue, such as, malfunctioning motor, overloading of mixing container, old and defective belts or gears, and the presence of foreign materials in the vessel.

Solution

To rectify these issues, you should always check the motor or drive belts for damage and repair them immediately. To avoid overloading, you should load the V tank by 2/3 of its total capacity. Routinely check and install new belts or gear in case of their evident wear. Lastly, remove any unwanted object before loading the vessel.

Blended Products Have Slow or Incomplete Offloading

Incomplete Offloading- Picture courtesy: Lactis Ingredients

This problem in a V mixer is more common than you think and poses a significant challenge for manufacturers. It is linked to multiple reasons, for instance, jammed or blocked discharge valves, material deposited around the unloading vents, poor fluidity of blended mixture, and, improper alignment of machine.

Solution

You can troubleshoot material discharging problems by following the advice of industrial experts, like thoroughly cleaning the discharge vents, valves, and their surrounding areas to get rid of any accumulated blend, using vibration forces or fluidity-boosting agents to increase product flow, leveling the V tank on trunnion and adjusting its discharge angle.

Unsatisfactory Mixing or Powder Separation After Blend

Unsatisfactory Mixing

Definitely, it is a significant mixing problem that impacts all the processes down the line and drastically damages product quality. It can happen due to shorter mixing duration, improper rotational speed (either very high or very low), incorrect quantity of materials in vessels (overloading or underloading), and, the intrinsic nature of feed making it highly difficult to blend.

Solution

There are some easy ways to remedy this issue. You basically slowly increase the mixing duration and check the material mixing output after a few minutes. You should experiment with mixing speeds to choose the speed range that ensures optimal mixing quality. Check and modify the batch size in the mixing vessel so that it is in the range specified by the manufacturer. Consider adding additives for hard-to-mix products, it may improve mixing outcomes.

Material Buildup on Vessel Walls

Inside View of V mixer

If an excessive amount of material is sticking to the walls of a V-tank then immediately examine its causes. It typically happens when you’re mixing hygroscopic or cohesive powders, the interior of the vessel doesn’t have a smooth surface polishing and finish, and also when you are not properly cleaning the container after completing the shift.

Solution

The recommended suggestion to solve this problem is: you incorporate anti-caking agents to feed to prevent its stick. You must use this mixer with a polished or Teflon-coated interior. Lastly, you should clean your machine after every shift with a dry cloth as well as cleaning agents and damp cloths.

Conclusion

In a nutshell, a V mixer is a handy machine perfect for pocket-friendly mixing of powdery or granular materials. It may come as intriguing to you that more and more businesses are opting for this machine in their setups owing to its even, clean, and efficient mixing. With its simplicity and consistency, manufacturers can easily have superior quality outcomes and attain top success achievements. Now if you are convinced to add this unit to your facility, then contact us, AIPAK, with all your needs, preferences, and, work details. And we will match you with a solution that will exceed your expectations.