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Industrial Mixers for Continuous and Batch Mixing

Batch Mixers and Continuous Mixers for Process Solutions

Quality Batch Mixers and Continuous Blenders can last 20 to 30 years on a factory floor, so choosing your next process mixer is arguably one of the most important stages in designing your next system. Our team of experts will consult with you on the optimal type of mixer, and help you analyze the choice between continuous and batch mixing to ensure that your individual ingredients are transformed into valuable products. The main factors that will influence your decision are: throughput, precision and inflow/outflow from the mixer. For certain applications, some factors are needed to be taken into consideration, such as the need for thermal processing and coating or specific regulatory or sanitation requirements. Whatever the case may be, our team is ready to take on your next project and guide you on design and implementation of your next system.

Continuous Mixing is the process of continuously metering ingredients directly into the mixing chamber and generating a continuous stream of mixed product at the exit of the mixer. The mixing may be done in stages to ensure all ingredients are properly incorporated. Continuous mixing is typically relevant when there are fewer than three ingredients and precision is not a priority. The benefits are high throughput and low energy use, as well as a smaller footprint.

Batch mixing is a process in which the ingredients for one batch are loaded (either at once or in a pre-defined sequence), mixed, and discharged from the mixer before another batch is introduced. Batch mixing is appropriate for mixes with three or more ingredients, and where the precision of the mix determines the quality. Almost any type of consumable product falls into this category.
Fluidizing Paddle Blenders create a fluidized mixing action using various paddles in a dual-directional movement. This process mixer's paddles move inward and outward simultaneously, ensuring proper mixing and blending of delicate materials.

  • Fast and Gentle Process Mixing
  • Large Blender Paddles with Two-Directional Mixing Motions
  • Designed for Delicate Materials
  • Patented Conical Shape for Complete Material Discharge
  • Low Maintenance Costs
  • Food-grade Finish
  • Easy Emptying and Cleaning Process
Ribbon Blenders are ideal for low density, free-flowing materials that are similar in size and shape. The inner and outer ribbons move ingredients from end–to-end in opposite directions, creating a blending action that occurs by rolling material back and forth against each particle.

  • Circulates the product in 2 directions simultanuously
  • Double Helix Reduces Mixing Time by Half
  • Excellent for Low Density, Free-Flowing Materials
  • Excellent Shearing Action for Agglomerates
  • Consistent Quality of Mixes
  • Continuous Helix Ensures Uninterrupted Flow
  • Food-Grade Materials and Finish
Double-Cone Blenders offer rapid, low-impact mixing designed for abrasive solids and semi-dry powders. This process mixer's revolving action induces a highly uniform mix as the end result. The Double-Cone blender is good for mixing materials with trace components.

  • Clean by Design, With No Internal Moving Parts
  • Easy Discharge and Drainage
  • Operator Safety Options Such as Guards and Barriers
  • Intensifiers for Speed and Clump-Breaking
  • Food-Grade Materials and High-Grit Finish
  • Comparable Price for Higher Quality Design and Finish
  • Minimized Vibration Using Sand Ports in Stands
V Cone Blenders are designed to rotate on its axis, with material gently converging and dividing for an even, consistent blend. The simple slant cone design of this process mixer features no internal moving parts, making cleaning and discharge easier than ever

  • No Internal Moving Parts Allows Easy Cleaning
  • V Cone Slant Design Allows Easy Discharge and Drainage
  • Minimized Vibration Using Sand Ports in Stands
  • Thorough Blend with Optional Extended Cone
  • Optional Intensifiers to Help Break Up Clumps
  • Food-Grade Materials and High-Grit Finish
  • Operator Safety Options Such as Guards and Barriers
View Our Selection Matrix to Help You Decide
Industrial Blenders and Complete Process Systems
Marion Industrial Blending Machines Logo
Industry Mixers for Powders and Bulk Solids
Since 1938, Marion Process Solutions has delivered the insight needed to develop innovative process mixing, blending and drying equipment that generates a competitive advantage for our customers here at CMT. Regardless of the industry, application or challenge, Marion puts decades of expertise into key markets in the mixing industry, and continues to build their reputation on manufacturing the highest quality Industrial Blending Machines on the market.

Plastics can include powders, pellets, flakes and coatings, and consistency is the key here. Considerations for plastics tend to vary depending on the applications, so consider different types of agitators depending on the need. For recycled plastics, a bolted agitator is best, but in medical applications, food-grade paddles are necessary. Anything that might be used for laboratories or medical procedures must adhere to all the sanitary requirements outlined in the Foods section of this handbook. Plastics today are used for everything from implants to surgical equipment, so anything that’s going to be inside someone’s body requires the same level of sterility as pharmaceuticals and consumables. Because of the nature of plastics, they tend to leave residue in the mixing chamber, which can affect the consistency of the next batch in the line. Often there’s a micro-dust that’s hard to see with the naked eye but is quickly detectable with the white-glove test. For that reason, it’s important to consider the ease of cleaning the mixers to prevent these types of problems. Delays in sanitation mean slower throughput. Easy sanitation increases the number of batches you can cycle per day.

Precision is the name of the game when it comes to pharmaceuticals. Every single mix must be precisely the same with absolutely no room for  error. Batch mixing is the only way to  go for precision formulations. Experienced vendors can help with different techniques around the order of the batch mixing and ensuring the inflow, outflow and mixing times are optimized for the specific ingredients and materials being handled. Furthermore, as with foods, sanitation is key to prevent any types of contamination and to allow manufacturers to use one mixer for different mixes. Anything consumable needs to adhere to 3-A Sanitary Standards, so you’ll want to review the details in the Food section of this manual and make sure any mixer you choose has all of the appropriate options for sanitation.

Biomass covers a huge range of applications, so customization is key here. Continuous mixers provide rapid throughput, so it’s important to work through the specifications for the conveyors both for feeding the mixer and for the outflow. Applications such as colored mulch and waste recovery can use continuous mixers because the applications don’t require high consistency of the output. If there is a variation tolerance of 5% or more for the output mixture, continuous mixing is probably the way to go. On the other hand, with mixes that demand extremely consistent precision in the percentage of the mix, continuous mixing might not provide the best output. Finally, some biomass products are quite sensitive, or need both drying and mixing. Marion provides a large variety of machines to customize for this demanding market.

Abrasion tends to be a central issue in handling mineral mixes. It’s important to choose a process mixer that has features such as replaceable paddles and replaceable trough liners to extend the lifetime of the mixer. Any mixer without these kinds of replaceable parts will have to go out of service prematurely. Materials such as glass, sand, cement, concrete, aggregates, soil reclamation, pastes, epoxy, adhesives, gypsum, fiberglass and resins, and wood compounds can take their toll on machinery so make sure to choose a mixer that features easy replacement of any parts that come in contact with the mix. While some manufacturers may calculate that it’s cheaper to replace the mixer every few years than purchase replacement parts, often these calculations neglect the cost of teardown and disposal of the machine, as well as transport, site preparation and installation of a new machine.

Chemical mixes are varied and can require a variety of temperature and sanitation precautions. Similar to pharmaceuticals, working with the right vendor will allow you to achieve a high level of precision and accuracy in the mixes for the specific chemical materials being processed. With chemical reactions, it’s important to have a high level of control around the temperature of the mix. For exothermic reactions, cooling jackets should be installed to control the temperature of the drum. Conversely heating jackets or mechanisms provide control in chemical reactions that need to stay within a warmer temperature range. An important factor when handling chemicals is the safety of the environment around the process mixer. Classified processes and materials require explosion-proof electrical parts, valves, motors and safety switches. It’s extremely important to make sure the environment is safe and that there is no escape of fumes that could endanger people in the facility. Often, reactionary or classified materials require an isolated process mixing room. Vendors with extensive experience in setting up safety rooms can help with the site specifications and installations, so that you ensure the highest level of safety at your facility.  
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