Industrial Pharmacy

Lecture 3

Dr. Myasar Alkotaji

Continuous Mixing:
The process of continuous mixing produces an
uninterrupted supply of freshly mixed material
and is often desirable when very large
volumes of material are to be handled. It can
be accomplished essentially in two ways:
1-In a tube or pipe through which the material
flows & in which there is very little back flow
or recirculation.
2- In a chamber in which a considerable amount
of holdup & recirculation occur.
To ensure good mixing efficiency, such devices as
vanes, baffles, screws, grids or combinations of
these are placed in the mixing tube and mixing
takes place mainly through bulk transport. In
tube the materials flow in one direction. Mixing
in such systems requires the careful control of
the feed rate of raw materials if a mixture of
.uniform composition is to be obtained
The materials to be mixed are continuously charged into the
.mixer per formulation
Radial and axial mixing takes place as the material travels from
.the feeding point to the discharge point
The time taken by the material to travel from the feeding point
to the discharge point is known as the retention time of the
.material in the mixer

Unlike batch mixers where product retention time is carefully

controlled, with continuous mixers, material retention time
is not uniform and can be directly affected by mixer speed,
feed rate, mixer geometry, and the design of mixer internals.
Material is continuously discharged at a constant rate which
is generally termed as the capacity of the continuous mixer.
.This capacity is measured in kg/hr of mixed product
 Advantages of Continuous Mixing

– High Capacity - Compared to batch type mixers,

continuous mixers of smaller volumes and power can be
used to produce large quantities of uniform mix. Hence for
a given capacity they are more compact than batch mixers.
– Lower Mixing Time - The residence time in continuous
mixers is lower than in batch mixers.
– Consistent Mixing Performance – With proper feeding
arrangements, online instrumentation and operation
controls, a consistent mixing performance and uniform
product quality can be achieved.
– Suitability for Automatic Control - Operation of
continuous mixers can be automated using online
monitoring and measuring instruments.
– Minimum Segregation – Continuous mixers can
reduce and control segregation of products as they
can be located in proximity of the next processing
station.
– Lower Cost of Mixers- Continuous mixers tend to
be cheaper than the equivalent batch mixers
because they are compact and require less space.
However the cost of feeders for metering the
product into the mixer, instrumentation and
control may result in a higher overall cost of the
system.
– Minimum Labor – Since material feeding and
discharging processes are automated, minimal
labor is required for continuous mixing.
 Disadvantages and Limitations of Continuous Mixing
– Lack of Flexibility – Continuous mixing systems are designed
for a particular application and cannot be easily tailored to mix
different formulations. Even if a new ingredient is to be
introduced, it calls for a change in the protocol, and the system
has to be recalibrated.
– Component Limitations – When a large number of ingredients
are to be added, continuous mixers have limitations with
respect to mixing uniformity when compared to batch mixers.
– Higher Overall Maintenance Cost – Continuous mixers heavily
depend on feeders, instrumentation and online control
systems. Failure, malfunction in any one component can lead
to complete stoppage. Hence, overall maintenance costs for
continuous mixers are higher compared to batch mixers.
– Calibration and Checking – The feeding devices in a
continuous mixing require careful calibration and
frequent checking for accuracy.
– Critical Applications – Continuous mixers are not suited
for critical applications where product formulations
need to be exact. Batch mixers are better suited to
processes that require a very tight product formulation,
uniform composition.

Continuous mixers are generally dedicated to a single high

volume product. Continuous mixers can be designed for
capacities as high as 500 Tons/hour. Even though continuous
mixing is gaining popularity, selection of continuous mixers
is much more complicated than batch mixers.
 Mixer Selection
 
Equipment Selection
One of the first and most often important
considerations in any mixing problem is equipment
selection. Factors that must be taken into
consideration include:
1- The physical properties of the materials to be
mixed such as density, viscosity and miscibility.
2- Economic considerations regarding processing,
e.g., time required for mixing and the power
expenditure necessary.
3- Cost of equipment and its maintenance.
 Monophase Systems
• The viscous character and density of the fluid(s) to be mixed
determine to a large extent the type of flow that can be
produced and also, therefore, the nature of the mixing
mechanisms involved. Fluids of relatively low viscosity are best
mixed by methods that generate a high degree of turbulence
and at the same time circulate the entire mass of material.
• So these requirements are satisfied by air jets, fluid jets, and
the various high-speed impellers.
• Thick creams, ointments, and pastes are of such high
viscosity that it is difficult if not impossible to generate
turbulence within their bulk and laminar mixing, and molecular
diffusion must be relied upon.
• Mixing of such fluids may be done with a turbine of flat blade
design.
 Polyphase Systems
The mixing of two immiscible liquids requires the subdivision of
one of the phases into globules, which are then distributed
throughout the bulk of the fluid. The process usually occurs by
stages during which the large globules are successively broken
down into smaller ones by two forces:
1- The interfacial tension of the globules in the surrounding liquids
2- Forces of shear within the fluid mass that act to distort and
ultimately disrupt the globules.
The relationship between these forces largely determines the
final size distribution in the mixture.
Low- viscosity systems, high shear rates are required and are
commonly produced by passing the fluid under high pressure
through small orifices or by bringing it into contact with rapidly
moving surfaces.
Highly viscous fluids, such as are encountered in
the production of ointments, are efficiently
dispersed by shearing action of two surfaces in
close proximity and moving at different
velocities with respect to each other. This is
.achieved in paddle mixers
Such mixers are relatively efficient since they not
only generate sufficient shear to reduce
globule size but if properly constructed, also
induce sufficient circulation of material to
ensure a uniform dispersion throughout the
.completed mixture
The mixing of finely divided solids with a liquid of low viscosity
in the production of suspension is often carried out in a single
mixing operation, providing that shear forces of sufficient
intensity to disrupt aggregates. High-speed turbines, frequently
fitted with stators to produce increased shearing action, are
often employed.

As the percentage of solids is increased or if highly viscous

fluids are employed, the solid liquid system takes on the
consistency of a paste or dough. In these cases, the forces
required to induce shear are considerable, and equipment used
is of heavy design. The choice of a mixer is limited to those that
rub the material.
A sigma- blade mixer with overlapping blades is an
example of such mixer used for this purpose.
 Roller mills consisting of one or more rollers are
in common use. Of these, the three-roll type
seems to be preferred. A material coming
between the rollers is crushed, depending on the
gap, and is also sheared by the difference in rates
of movement of the two surfaces.