Horizontal Mixer

Equipment Introduction

The horizontal ribbon mixer, also known as a horizontal agitator, is a mainstream intermittent homogenizing mixing equipment in the powder engineering field. Standardized and mass-produced by equipment manufacturers such as Zhengzhou Huaqiang Heavy Industry, its core technology relies on a double-layer counter-rotating spiral ribbon to achieve material convection and circulation mixing. It boasts five core advantages: high mixing uniformity, low material residue, wide material compatibility, gentle low-speed mixing that does not damage particles, and simple maintenance.

Key Performance Features:

1. High Mixing Uniformity: Batch mixing coefficient of variation (CV) ≤ 5%, uniformity up to 97%~99%, capable of handling multi-component materials with density differences ≤ 10 times;

2. Low Residue Optimization: The gap between the screw ribbon and the cylinder wall can be adjusted to near zero, with a large bottom unloading door, resulting in a residue of < 0.5%;

3. Gentle Agitation: Main shaft speed is generally below 45 r/min, resulting in low shear force and a breakage rate of < 5% for fragile particles;

4. Strong Functional Expandability: Can be equipped with jackets (heating/cooling), top spray system, vacuum feeding, pneumatic dust removal, and frequency conversion speed regulation;

5. Low Installation Threshold: Minimal operating vibration, no need for heavy concrete foundation, carbon steel/304/316L stainless steel materials can be customized as needed.

Equipment Structure

1. U-shaped cylinder: The main body carrying the material, usually made of carbon steel or stainless steel, with a polished inner wall to prevent material accumulation.

2. Double-layer helical rotor: The core working component, consisting of a main shaft and inner and outer helical blades.

3. Drive unit: Includes a motor, pulleys, V-belts, and a reducer. Huaqiang equipment typically uses nylon pins or sprockets for easy maintenance.

4. Frame: Supports the entire equipment, welded with high-quality channel steel to ensure stable and vibration-free operation.

5. Discharge device: Located at the bottom center of the cylinder, usually a pneumatic/manual flap valve or butterfly valve to ensure clean unloading.

Working Principle of the Equipment

The horizontal ribbon mixer employs a three-dimensional composite mixing mechanism of "convection-diffusion-shear":

1. Axial Convection: The main shaft rotates at low speed (typically 10–50 r/min). The outer ribbon pushes material near the cylinder wall from both ends towards the center, while the inner ribbon pushes material near the axis from the center towards both ends. These two opposing material flows form a continuous circulating convection.

2. Radial Shear: The minute gap (≤5mm) between the ribbon and the cylinder wall shears the material, breaking up agglomerated powder.

3. Circumferential Tumbling: The material tumbles and diffuses as a whole under the drive of the ribbon, achieving all-around mixing.

The material is continuously intercepted and redistributed within the U-shaped cylinder. A typical mixing cycle takes only 2–15 minutes, with a mixing uniformity coefficient of variation (CV value) ≤7%, enabling micro-scale mixing at a ratio of 1:10000.

Applications of the Equipment

The horizontal ribbon mixer has a wide range of applications:

1. Fertilizer Industry: Mixing and batching raw materials for organic fertilizers, inorganic fertilizers, compound fertilizers, BB fertilizers, and blended fertilizers;

2. Chemical Industry: Coatings, dyes, ceramic powders, refractory materials, catalysts, putty powder, and stone paint;

3. Food and Pharmaceutical Industry: Food additives, premixed pharmaceutical raw materials and excipients, pastes and sauces, and feed;

4. Building Materials Industry: Dry mortar, thermal insulation mortar, and putty paste;

5. New Energy: Mixing of lithium battery positive and negative electrode powders;

6. Environmental Protection: Mixing and treatment of sludge and organic waste.

It is particularly suitable for mixing viscous or cohesive powders and granules, as well as mixing processes where liquids and pastes are added to powders and granules.

Raw Materials for the Equipment

This equipment can process the following types of raw materials:

Raw Material Requirements:

1. Material Moisture Content: It can adapt to higher moisture content, but materials with excessive viscosity are difficult to clean;

2. Avoid mixing in large stones, iron blocks, and other hard objects to prevent damage to the mixing blades;

3. For materials with high fiber content and significant density differences, applicability needs to be assessed.

Lubrication and Routine Maintenance

1. Regular Lubrication System

1) Gear Reducer: Change gear oil after 50 hours of operation for the first time; change gear oil every 4 months during normal production, and check oil temperature and for leaks daily during operation;

2) Main Shaft End Bearings: Add/replace lubricating grease every 3 months;

3) Unloading Gate Wrench, Pneumatic Valve Hinges: Apply lubricating oil every shift to reduce opening and closing resistance;

4) Seals: Check shaft end seals weekly, and replace packing/mechanical seals promptly if powder leakage occurs.

2. Graded Maintenance Cycle

1) Daily Maintenance: Check operating noise, temperature, bolts, unloading mechanism, and oil level; clean accumulated material in the cylinder;

2) Weekly Maintenance: Conduct a comprehensive inspection of seals, belt tension, and electrical control circuitry;

3) Quarterly Maintenance: Disassemble and inspect the wear of the threaded belt and bearing clearance; replace lubricating grease;

4) Annual Overhaul: Correct the clearance between the threaded belt and cylinder wall; replace worn threaded belts, bearings, couplings, belts, and other vulnerable parts. 3. List of Consumable Parts: Triangular drive belt, nylon shaft pins/chains, main shaft bearings, shaft end seals, screw ribbon blades, unloading gate sealing gaskets, spray nozzles.

Common Equipment Problems and Solutions

Equipment Application in Production Lines

In organic fertilizer or dry powder production lines, the horizontal ribbon mixer is typically located after the automatic batching scale and before the granulator or packaging machine. It plays a crucial role in connecting these processes, ensuring that the raw material components entering subsequent stages are completely consistent, which is a key factor in guaranteeing product quality stability.

Equipment Application in Production Lines

1. Core Position in Organic Fertilizer and Compound Fertilizer Production Lines

The horizontal ribbon mixer is the key link between the crushing and granulation processes in organic fertilizer and compound fertilizer production lines. In the entire fertilizer production line, the horizontal mixer is usually located after crushing and screening and before the granulator.

Core Function: It precisely homogenizes the crushed organic powder, nitrogen, phosphorus, and potassium fertilizer powder, trace elements, and microbial agents, providing stable and nutrient-uniform raw materials for the granulation process, directly determining the pelleting rate and granule strength.

2. Automated Production Line Configuration

The equipment boasts a high degree of automation and can be integrated with batching machines, conveyors, and granulators to form a fully automated production line. This achieves continuous feeding, intelligent mixing, and quantitative discharge, supporting 24/7 uninterrupted production and fully adapting to the needs of large-scale fertilizer processing.

3. Key Process Indicators

Mixing Uniformity: The coefficient of variation (CV) can be stably controlled within 5%, far exceeding the 10%–15% of vertical models.

Residual Rate: Utilizing the reverse thrust of the screw conveyor, materials can be completely discharged within 3–5 seconds, with a residual rate of less than 0.5%, effectively preventing cross-contamination between different batches of formulations.

Single Batch Mixing Time: 3–8 minutes

4. Multi-Process Integration Capability

The equipment can simultaneously complete multiple processes such as material dispersal, microbial inoculation, and moisture adjustment. It is capable of handling both dry powder proportioning and semi-wet material mixing.

Target Customers for this Equipment

1. Organic Fertilizer/Environmental Protection Equipment Manufacturers and Organic Fertilizer Processing Plants: Processing livestock manure, sludge, and straw fermentation and mixing; Huaqiang Heavy Industry's WJ series is a primary suitable choice.

2. Feed Companies and Premix Processing Plants: Batch mixing of complete feeds and trace element premixes.

3. Food Seasoning Factories, Baking Raw Material Factories, and Solid Beverage Manufacturers: Hygienic stainless steel mixing requirements.

4. Pharmaceutical Raw Material, Veterinary Drug, and Pesticide Powder Manufacturers: Anti-corrosion and high-uniformity mixing conditions.

5. Building Material Factories, Putty Mortar, and Stone Paint Manufacturers: Large-scale continuous mixing of dry powders.

6. Chemical New Material Factories, Lithium Battery Material, Pigment and Dye, and Plastic Filler Masterbatch Processing Plants.

7. Laboratories and University Research Institutions: Small-scale experimental horizontal ribbon mixers for small-scale formulation testing.

8. Powder Equipment Complete Set Engineering Companies: Providing customers with complete mixing main units for their entire production line.

Analysis of the advantages and disadvantages of the equipment