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Design & Fabrication of Double Helical Spiral Mixer

Nikhil S. Ahire¹, Hemant R. Wamane², Chetan P. Chavanke³, Shivaji R. Chaudhari⁴
1,2,3Students, Department of Mechanical Engineering, SVIT, Nasik, Maharashtra, India.
4Professor, Department of Mechanical Engineering, SVIT, Nasik, Maharashtra, India.
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Abstract - Recent advances in mixer and blender designs which move opposite direction in one cycle. For that motion
have contributed to the growing success of food companies, we using the crank and fork mechanism. Which form the
meeting their requirement for consistency and developing new turbulence in mixer and make homogeneous mixture.Mixing
products while also lowering production costs. This white is one of the qualities of the product.
paper discusses both traditional and new specialty mixing At the heart of transforming raw ingredients into food for
technologies available to food manufacturers today. Phase and human consumption is the mixing operation. One of its main
viscosity are used to classify different mixing categories. tasks, which other food processing steps also share, is to
Sample applications are presented as well to illustrate certain establish consistency. Whether a food product requires
processing challenges and the mixing technologies used to small-scale mixing by hand or high volume blending of
resolve them. multiple ingredients, at-home cooks and process engineers
alike know the importance of proper mixing. Even with the
In conventional method of mixing the mixing is carried out on right amount of ingredients and flavors, a great recipe will
‘Unidirectional Stirring Machine’. The stirrer of conventional not transform into good food unless the components are
machine rotates in one direction only which creates a well-mixed. Taste, texture, color, appearance – these are all
particular flow pattern in the fluids hence the particles tend to crucial parameters intimately influenced by the mixing
stick to the walls of container owing to the centrifugal force process. Consumers expect that the food products they
rather than mixing thoroughly in mixture of paint, ultimately patronize will be exactly the same as the one they had last. It
results into poor quality mixture of paints there by poor is easy to understand that within the food industry a high
quality output of paint. level of consistency is required not just batch-to-batch but
facility-to-facility. In this market, consistency is the backbone
In order to have a homogeneous mixing would be appropriate of consumer loyalty. Various types and styles of mixing
to make this process a dynamic process by incorporating the equipment are utilized within the food industry.
two set of spiral blades making it a spiral mixing machine
resulting into thoroughly mixed paint mixture preparation Their use and application are determined by the phases
which will create the good quality of mixing. being mixed (liquid-liquid, solid-liquid, or solid-solid) as well
as physical characteristics of the end product (like viscosity
Key Words: Unidirectional stirring, Homogeneous mixing, and density). In reality, many mixing technologies overlap in
Spiral blades, Bidirectional Motion, Dynamic process., etc. use and function such that certain applications can actually
be successfully produced by two or more types of mixing
1. INTRODUCTION systems. In these situations, economics rule out the more
costly initial investments, but differences in efficiencies must
also be taken into account. Proper mixer selection is vital to
General
process optimization.
Process industries like chemical plants, food processing 1.1 Necessity
plants, paint industry etc. Largely employ mechanical mixers
In this market, consistency is the backbone of consumer
to carry out mixing of powders, semisolid jelly fluids etc.
Mixing is a process where powder or jellies are mixed loyalty. Various types and styles of mixing equipment are
together through in the form of uniform mixture where utilized within the food industry. Process industries like
stirring is the process to mix the fluid and powder to chemical plants, food processing plants, paint industry etc.
Largely employ mechanical mixers to carry out mixing of
dissolve the powder thoroughly in given mixture and form a
uniform product or output. In either of above cases thorough powders, semisolid jelly fluids etc. Mixing is a process where
mixing of material is desirable to give and good and uniform powder or jellies are mixed together through in the form of
uniform mixture where stirring is the process to mix the
quality output. Mixing of powders of different material in
order to form a uniform product or a powder mix is quiet fluid and powder to dissolve the powder thoroughly in given
easy but when it is desirable to mix powder in a fluid matter mixture and form a uniform product or output. Hence mixing
of multiple colour paint in paint industry. Mixing of metallic
specially when the density of powder is high the problem
occurs due to heavy weight of particles of powder has a powders in pigment in preparation of ionic paints. Can be
tendency to settle down, so we make bidirectional mixer used as skimming machine for creams, lotions, toothpaste,
gels, and ointments.

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 06 | June 2020 www.irjet.net p-ISSN: 2395-0072

2. LITERATURE REVIEW This type of chemical mixers are used in process industries
like paint industries, chemical industry, food processing
For the manufacturing of a Double helical spiral mixer we plants etc. They are mainly employee for mixing of powders,
refer various literature, papers etc. The review of previous chemical solutions semisolid fluids etc. This paper Proposed
method used given below: Suraj P. Mail et al. (2016) work of a chemical mixer. This work was undertaken
proposed that now a days cleaning has become most considering reducing human efforts in small scale and
important part in Hospitals, Educational institutions and institutional level. The conventional method of preparing
industries. This paper describes about the mechanical design cleaning solution is replaced by the “bi-directional electrically
and analysis of mixer on the fluid that is to be stirred in the powered mixer” by using this we can stir large amount of
mixing vessel. As we all knew that mixing is a very important various types of chemicals used.
processing any chemical, paints and food process industry. To Charles Ross & Son Company (2015) presented an overview
attain the uniform mixing of the solution with the desired of mixing technologies implemented across many of today’s
quality and in order to remove the drudgery of human folk highly competitive pharmaceutical and medical industries, as
this newly designed mixer is suggested. The cleaning well as new equipment designs that are increasingly being
department requires large amount of cleaning chemical recognized as potential solutions to prevailing mixing
solutions (phenyl) daily. challenges. Mixing applications falling within the broad
Siddhant Dange, et al (2016) this research paper aims to spectrum of mass produced pharmaceutical goods and
study the various types of concrete mixers, discuss the medical devices are too many and complex to discuss in detail
advantages of the planetary concrete mixer over all the other hence this paper will touch on a few general classifications as
type of mixers, and study the various components of the well as a few examples within that mixing category.
planetary mixer in detail. The mixing is certainly the most Osokam Shadrach ONYEGU et al. (2012) this paper presents
critical phase of the concrete production process and the the design and fabrication of a poultry feed industrial tumble
quality of the concrete depends heavily on the quality of the mixer. The design computations to handle a 50Kg mass of
mixer. Due to the efficiency of the compulsory mixing action, feed was done in the MS Excel environment for proper
the planetary mixers meet the requirements of various machine design approach. The machine was designed using
production processes. The mixing flow is highly efficient due AUTOCAD 2D/3D design software and proper material
to integrated action of central stars combined with different selection was done before the assembling and fabrication of
peripheral scrapers. parts. Proper design analysis was carried out on the machine
Raghunath Rajput (2015) presented the properly mixing of to avoid failure on both the blades and the shaft
the fluid in mixing vessel. Helmut Brod, et al. (2011)The Invention relates to a device
In conventional method of mixing the metal oxide powder which comprises of 2 Rotating Agitators, at least one of those
and vehicle mixing is carried out on ‘Unidirectional Stirring being a Helical or Anchor Agitator arranged centrally in the
Machine’ The stirrer of conventional machine rotates in one housing, and at least one of the other agitators being an
direction only which creates a particular flow pattern in the eccentrically arranged screw or Blade Agitator. A mixer
fluids hence the particles tend to stick to the walls of having improved axial and radial mixing which retains good
container owing to the centrifugal force rather than mixing mixing time even during large viscosity changes, comprising a
thoroughly in mixture of paint, ultimately results into poor housing with at least one helical located centrally in the
quality mixture of paints there by poor quality output of housing in combination of a helical
paint. In order to have a homogeneous mixing the directions Energy source especially for gas based source of power .But
of rotation of stirrer shaft which rotated stirrer blades in our lawn cutter is not based on solar because of its cost and
opposite directions in one cycle which formed turbulent flow create some complexity during working. So we avoided solar
pattern there by leading to creation of irregular flow pattern powered lawn mower. In this hydrogen based lawn mower,
and resulting into thoroughly mixed paint mixture the advantage of powering a lawn mower by hydrogen rather
preparation which created the good quality paint. than by gaseous material is mainly ecological. We don’tuse
S. N. Waghmare et al. (2015 )here they have discussed this for our lawn cutter because it is very old method and
various views from their study on different topics. They say many overcome produced from this type lawn cutter.
mixing process has been performed which conform that the
proposed mixing prevent the formation of segregated region
hence shorten the mixing time than other mixing method.
Also he said that by using the bidirectional mixer in container
create turbulent flow of mixture and we get the homogenous
mixture. The cleaning department requires large amount of
cleaning chemical solutions (phenyl) daily. Mixing of chemical
solution can be defined as to create or form solution in the
form of liquid by combining ingredients. This mixer is been
designed and fabricated for mixing of chemical solution,
which is used to for cleaning purposes in educational
institutes, offices, hospitals, large shop floor industries etc.

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Volume: 07 Issue: 06 | June 2020 www.irjet.net p-ISSN: 2395-0072

3. PROJECT METHODOLOGY Mixing fulfils many objectives beyond simple combination

of raw ingredients. These include preparing fine emulsions,
Block Diagram
reducing particle size, carrying out chemical reactions,
manipulating theology, dissolving components, facilitating
heat transfer, etc. So even within a single pharmaceutical
product line, it is not common to employ a number of
different style mixers to process raw ingredients, handle
intermediates and prepare the finished product.

Fig.1: Processing Steps

4. Construction and Mechanism

Working Principle

A chemical mixer is being designed which consist of a

container ,impeller spiral blades, electrical motor, pair of
pulleys, pedestal bearings, pneumatic rams, timer ,solenoid
valve and drive shafts. We are using the container made up
of stainless steel; it is placed at about 6inches from ground,
so that it is easy to pour the material for the workers
preparing the chemical solution. The motor is placed
vertically in order to mount the pulley and belt assembly on Fig.1: Planetary Mixer
the motor shaft. This machine is designed to mix the cleaning
solution used for cleaning the floors. In electrically powered 5. Machine Components
system an electrical motor is used to run the motor shaft. As
the motor shaft rotates, the pulley mounted on motor shaft
1. Planetary Gear
also rotates. The power transmission will be takes place
from motor to impeller shaft. As the impeller shaft rotates
A planetary gear system will not assembled unless the
the spiral impeller blades also rotate along the direction.
number of teeth for each gear is selected properly. Once the
Simultaneously the arrangements of pneumatic rams move
design requirements are specified, the remaining parameters
up & down the head of driver to maximize the agitating
must be calculated to create a working configuration. Let’s
performance as per operation of timer. Hence the mixing of
say the desired gear ratio is 5:1.
chemical ingredients is obtained.
This means the sun gear must make 5 revolutions for each
o Planetary Mixer Mechanism
revolution of the output carrier (Note: this assumes that the
sun gear is the input, the planet gears drive the output
Industrial Mixers and Blenders are used to mix or blend a
carrier, and the ring gear is stationary. Other configurations
wide range of materials used in different industries
are possible depending on the application. One more design
including the food, chemical, pharmaceutical, plastic and
requirement must be specified to do the remaining
mineral industries. They are mainly used to mix different
calculations. Let’s say the sun gear must have 24 teeth. The
materials using different types of blades to make a good
other parameters can be found using the following
quality homogeneous mixture. Included are dry blending
equations:
devices, paste mixing designs for high viscosity products
and high shear models for emulsification, particle size
R: Gear ratio, to 1
reduction and homogenization. Industrial mixers range
Nr: Number of teeth on the ring gear
from laboratory to production line scale, including, V
Ns: Number of teeth on the sun gear
Blender, Cone Screw blender, Double Cone Blender, Double
Planetary High Viscosity Mixer, Counter-rotating, Double &
Plugging in the known values, we get solving for Nr, we find
Triple Shaft, Vacuum Mixer, Planetary Disperser, and
that the required number of teeth on the ring gear is 96. We
Dispersion Mixers, Mobile Mixers and Drum Blenders.
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can now begin to solve for the number of teeth on the planet 3. Pedestal Bearing
gear: Np: Number of teeth on the planet gear(s) Plugging in
the known values, we get Solving for Np, and we find that the This bearing is fixed in the upper two plates to accommodate
required number of teeth on the planet gear is 36. This is the shaft in it. It makes the rotation of the shaft smoother
independent of how many planet gears are used. Note that and also helps in reducing the vibrations and frictional heat
the pitch of the gears is not specified. These equations hold and damage to the components.
true regardless of the pitch, but a pitch will ultimately need
to be selected when designing a planetary gear system.
Either the pitch itself will be a design requirement, or size
limitations will be a factor, and the pitch can be selected
accordingly. The following table gives an example of the
gears used in a particular planetary system, with all
specifications included: Sun Gear Planet Gear Ring Gear.

Quantity 1 3 1
Module 1 1 1
Number of Teeth 24 36 96
Pressure Angle 20° 20° 20° 6. Product Description

Sr. No. Parts Quantity

1. AC Motor 1
2. Pedestal bearing 2
3. Shaft 1
4. Bush 8
5. Nut And Bolt 8
6. Tank 1
7. Frame structure 1
8. Spiral Blades (Opposite Hand) 2
9. V-Belt 1
10. Pulley 2
11. Double acting Pneumatic 2
* cylinders
12. 5/2 Solenoid valve 1
2. Motor 13. Pneumatic fittings 8
14. Pneumatic hose pipe 5
This is an electrical motor which runs on 60rpm speed. It is
mounted on the upper head of the machine. On the motor
7. Advantages
shaft a smaller pulley is mounted and the motor transmits
the motion to the larger pulley by means of the belt  Stirrer has bi-directional i.e. it rotates in both
drive.And it helps to rotate the shaft and it automatic rotate directions; this gives uniform mixing.
the helical spiral stirrer and it mixes good quality mixing  Quality of mixing is very high.
material.  Low cost of mixing.
 Fast production rate.
 Compact size so minimal space requirements.
 Low power consumption.
 Optimal mixing homogeneity
 Short mixing time
 Excellent reproducibility of batch production
 Minimum wear and low maintenance
 Easy access to mixer/ Easy to cleaning
 Excellent mixing at any product level
 Low power consumptions

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8. Disadvantages have prepared and hence shall proceed towards the

project work accordingly.
 The machine developed by us is having capacity
only 20 litres, which can be made only to prove Future Scope
models reliability or change in functionality for
models synthesis. It is not an actual production  The model prepared was a scaled model. It was
model, but fulfils all basic requirements. prepared for 20 litres capacity. This model after
being tested successfully was decided to apply for a
 The machine developed by us is having small larger scale model in the industry. In the upcoming
capacity of motor, so that it cannot be used large future the certain modifications in the model can be
quantity of chemicals or liquids. made and can be applied for more widespread
applications. This model can also be used with a
9. Applications hydraulic circuit in order to handle the higher
capacity model with larger volumes of the tank.
 Mixing of multiple color paint in paint industry.
 Mixing of metallic powders in pigment in
REFERENCES
preparation of ionic paints.
[1] Sachin N. Waghmare, Suraj P. Mail, Pranav S. Nalawade,
 Can be used as skimming machine for creams, Digambar A. Mohite, Pranil D. Salunke, (2016), “Design
lotions, toothpaste, gels, and ointments. And Analysis of Electrically Powered Mixer for Phenyl”,
 Chemical Industry International Conference on Recent Innovations in
 Pharmaceuticals Industry Engineering and Management, ISBN 978-81-932074-5-
 Food Industry 1.
 Animal Feed
 Metallurgy [2] Jagdish M. Chahande Dr. A. V. Vanalkar V. D. Dhopte,
 Construction Material (2015) “Methodology for Design and Fabrication of
 Ceramic Powder Planetary Mixer for Preparing Cake Cream - a Review”,
 Mining Industry International Journal for Scientific Research &
Development, Vol. 3, Issue 01, ISSN (online): 2321-0613,
pp 792-802.
10. CONCLUSIONS AND FUTURE SCOPE
[3] Amruta K. Wankhede, Dr. A.R. Sahu, (2015), “Design,
Till now we carried out the market survey of the mixer Modification and Analysis of Concrete Mixer Machine”,
visiting the Industry and taking into the consideration the International Journal on Recent and Innovation Trends
existing components and mixers in the industry then we in Computing and Communication, Vol 3, Issue 12, pp
also found out the problems faced by the personnel while 6613-6616
carrying out the mixing process and then took those all
into consideration while designing the new modified Authors
mixer. We have completed the design of the mixer till
date. We referred certain research papers related to our 1’st Mr. Ahire Nikhil Sanjay
topic which are mentioned in the literature review of our Author BE Student, Mechanical Dept.,
topic and also we have provided their references. The SVIT, Chincholi, Nashik,
work we completed now was on the design side of the
Photo
Maharashtra INDIA.
project which contained the numerical analysis of the
mixer and its supporting literature survey. From this
work we concluded that the mixer we are designing 2nd Mr. Chetan Popat Chavanke
solves a few problems of the conventional mixers. From Author BE Student, Mechanical Dept.,
hereby we have planned the detailed activity scenario as SVIT, Chincholi, Nashik,
Photo
to how it is going to proceed. In the upcoming days we Maharashtra INDIA
will be carrying out the activities such as load
calculations, analysis of the component against the
calculated loads, finding the factor of safety for the entire 3rd Mr. Wamne Hemant Rajaram
components, here we will be undertaking the analysis of Author BE Student, Mechanical Dept.,
the project design by taking into consideration the real Photo SVIT, Chincholi, Nashik,
time operation of the mixer. Then we will be sure on the Maharashtra INDIA
design calculations we have made and then we will be
sure to fix the dimensions of the mixer as decided. Hereby
we conclude that we are in the mid stage of the project
and we need to focus on the detailed activity chart we
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