SaintyCo IBC Blending System
SaintyCo IBC Blending Systems are cGMP compliant machines with fully automated PLC control system. Equipped with sensitive pressure and infrared sensors, our IBC blending systems guarantee homogenous blending of powders and granules.
As a leading IBC bin blender manufacturer and supplier, SaintyCo has both standard and custom designs.Whether in the pharmaceutical, foodstuff or R&D,SaintyCo IBC Blending Systems are machines you can count on.
IBC Bin Blender and Mixer: The Definitive Buying Guide
If you want a uniform mixture of either powder or granules, then you should read this guide.
Because in this guide, I’m going to discuss everything you need to know about IBC bin blender and mixer.
First, I’ll explain why you need a bin blender and mixer for your pharmaceutical industry.
Then later, you’ll learn about parts, working principle, types, features, applications and examples of IBC bin blender machines.
By the end of this guide, you should be able to choose and evaluate a suitable bin blender and mixer
Let’s dive right in:
- Intermediate Bulk Container Blender Definition
- Why IBC Blending System?
- Main Parts of Bin Blenders
- Bin Blender Working Principle
- Classification & Types of Bin Blenders
- Features of IBC Bin Blender and Mixer for Homogenous Material Processing
- Factors Affecting Efficiency of Bin Blender and Mixer in Pharmaceutical Industries
- IBC Bin Blender & Mixer Applications
- IBC Bin Blender FAQ Guide
- SaintyCo Bin Blender and Mixer
Chapter 1: Intermediate Bulk Container Blender Definition
The truth is:
You need a machine that can produce a uniform mixture.
Of course, it should achieve this without affecting the various chemical compositions or ingredients of the final mixture.
Don’t worry; I will take you through every aspect of IBC bin blender and mixer shortly.
For now, here are a few machines that I am going to discuss here:
Different types of mixers and blenders
I am sure you have seen this equipment before – so, let me get straight to the point.
What is an IBC blender?
It is an irregular shaped container, with an option for charging and discharging material, allowing for uniform mixing. Depending on the unique design, IBC blender can be a dual action accessory that mixes powder and granules.
Basically, a dual action pharmaceutical or laboratory blender implies that the system mixes as:
- Material tumbles within the bin blender and,
- Bin is tilted to a specific orientation say, 60° or 45°
Now, up to this point, I am sure you have a rough idea of the main functions of IBC mixer and blender.
With this information, now let’s move a step further and explore why you need IBC blending systems. Later in this guide, you will learn about the working principle of this machine.
Chapter 2: Why IBC Blending System?
In most cases, you’ll realize that most industrial processes that require IBC blending system are only effective when you choose better units.
You need to obtain this particular machine because apparently, you’ll benefit quite significantly from it in numerous ways.
And that is the reason in this section I want us to look at some of these benefits. The things that will make you not think twice the right time comes to buy this unit.
· Efficient Blending
Undoubtedly, you know how industrial blending can be tasking and challenging. In some instances, it may require you to invest in more human resource to obtain better results.
But the IBC bin blending system is here to help you in making all these tasks comparatively easy and efficient.
The best part:
IBC bin blender manufacturers make sure that they incorporate high technology that will help you as the user during the entire blending process.
IBC bin blender
Additionally, the overall blending time will also reduce irrespective of the type of ingredients that you are using. You know this is vital because no one like performing a similar task multiple times at a slow pace.
· Reduced Labor Cost
One of the most expensive running costs in an industrial process is the labor force.
It can be pretty expensive, and in some instances, you’ll realize that the overall turnover becomes low merely because of this running cost.
But the IBC bin blender is engineered with relatively large shells that take more time to feel and also to empty.
It is estimated that the time saving can get up to 66% if you install the particular bin system correctly. Now, this is remarkable because it is a milestone that helps you considerably to reduce cost related to labor.
SaintyCo team testing IBC bin blender
The net effect is that you’ll in the short or long term increase your income other than just reducing the overall time for production.
Even the maintenance costs for this unit will reduce drastically, which also contributes to high turnover.
· Your Safety is Guaranteed
You know that in whatever industrial process that you’re involved in, the primary element that you have to consider first is safety.
Apparently, it does not matter how efficient, reliable and sturdy a particular machine is if it poses a considerable risk when operating it.
When you get the IBC bin blender and mixer, you’ll notice that it comes with air-driven jacks to make sure that it remains clamped entirely.
Strong clamping mechanism
This happens even when the machine utilities by any chance get lost. Again, this unit also provides an emergency stop option that guarantees safety too.
So that you have composure even when working intensively on a specific project using this machine knowing too well that you are safe.
· Increased Product Quality
Competition in the current market is extremely stiff. This is something that we cannot dispute. So to make it out here you have to produce a product that meets the quality expectations of the clients.
It becomes easy for you to meet the high-quality product standards if you’re using this machine.
The point is:
All ingredients you blend will be transferred to inside a drum or a bin.
Transferring product from bin blender mixer into the bin
And so the chances are high that segregation is likely to take place during the transfer of these product ingredients.
It is during this segregation process that some foreign particles can get into the bin and possibly lower the quality of the product you’re blending.
But when dealing with an IBC bin blender, you will be able to notice that foreign materials will hardly get into the blending bin. This, therefore, assures you of obtaining high-quality product from the entire process.
In the long run, it places your product in a better position in the market since you’ll rarely find a client that would prefer an inferior quality over super quality.
The good news:
Once you meet the recommended quality standards, you also stand better chances of preventing revocation of your operational license.
So at the end of it all, you not only benefit from increased revenue but you also boost your chances of operating in that particular industry.
· Easy to Operate
This is also another reason why you also need to consider purchasing an IBC bin blender and mixer. Many at times you’ll find yourself in a situation with machinery that has several knobs.
Then you start wondering which one is used for what – trust me, the confusion can be overwhelming and also risky.
The IBC bin blender helps you to process your products quite easy and faster because the controls are also easy to use.
Use this panel to operate your machine
Ideally, this machine is user-friendly, and you do not necessarily need to have in-depth knowledge to operate it.
It is quite straightforward to operate thus making it possible for you to use it efficiently in blending the particular ingredients.
· Superior Throughput
The IBC bin blender functions quite effectively in regards to limited interruption. It happens that it can run throughout the day non-stop.
Actually, the only moment you can choose to stop it is when you’re exchanging the bins, which in most cases often happens quite fast.
All these depend on the specific design of the bin blender machine.
Machine and design
So it is this limited downtime in the course of production that helps you in increasing the overall output. This is vital because you’ll also increase your revenue at the end of it all now that production rate will be high.
· Integrated Technology
Here is the truth, in the current generation, any high-end machinery that does not incorporate technology is kind of unnecessary.
And you also need to know that it is somewhat unsafe to use the kind of machine that does not support modern technology.
A section of ribbon mixer machine
So the good thing with the IBC bin blender is the type of technology it supports. Some of these technologies include the NIR systems and Light-Induced Fluorescence (LIF).
The IBC bin blender and mixer integrate these technologies among other in measuring particle movement and the in-process conditions at the time of blending.
This is crucial because it allows you to understand the powder behavior which is ideal for improving research and development and process control.
These technologies also improve swift validation of new product, which results in improved containment and productivity.
So what’s the bottom line?
Whether you’re looking for a laboratory blender or bin blenders pharmaceuticals, this is the only accessory that can guarantee uniform or homogenous mixture. The process neither interferes nor alters specific ingredients of powder or granules.
Chapter 3: Main Parts of Bin Blenders
One thing that many people often fail to realize is that the efficiency and productivity of a pharmaceutical bin blender depend on its parts.
There is no way you can expect to attain the best results even an ideal Return on Investment (ROI) if you’re using a blender with inferior parts and features.
It’s quite funny because you’ll always find some people looking for elements such as stability, user-friendliness and structure among others.
While all these and others are also essential considerations when choosing a suitable IBC bin blender, they aren’t enough.
So, what am I trying to say here?
You have to dig deep and understand various elements revolving around the vital parts of these units.
At the same time, you must note that, the number of parts will depend on the specific design of the machine.
Even before we move on, let’s compare these two machines:
Different series of bin blenders and mixers
From above, it is quite clear that mixers and blenders come in different shapes, sizes and designs. Therefore, it is a common knowledge that they have the different number of parts.
However, for the scope of this a section, I will focus on the main parts.
Just stay with me on this page – I am going to explain everything you need to know about the main parts of IBC bin blenders and mixers.
This way, it will be easier for you to appreciate how IBC bin blenders work later in this guide.
For now, let’s have a quick overview of the main parts of IBC bin blenders:
· Rotation Counter
This is one of the central components of an IBC bin blender. It offers blending function by making sure that all the ingredients are mixed efficiently to produce a homogenous high-quality product.
This part also provides additional competencies specifically for a pedestal blender. The rotation counter is also essential in lifting and placing the IBCs appropriately.
Technical drawing of an IBC Bin Blender
This is beneficial more so for the combined suite systems and makes it possible for the IBC to blend swiftly move over a tablet press for compression.
The significant element of the rotation counter is that can accommodate various sizes of IBC bin containers.
It, therefore, means that you’ll have the flexibility to determine the particular size of the IBC bin containers to use for blending.
Which is actually good especially when you have to blend different volumes of solid ingredients at different times.
· Laser Guard
It is also an essential part of the IBC bin blender. It is located somewhere in the corner of the blending suite approximately 75mm above floor level.
Laser guard is critical when it comes to guaranteeing your security. Because it can detect people as well as items that are inside or when they enter the danger area.
It is efficient in its functionality and provides elegance. So that as much as it prevents people from harm, it still does not compromise the attractiveness of the unit.
IBC blending and mixing machine equipped with various safety sensors
During material processing, the operators can move around different parts of the safe area and comfortably operate the devices.
The laser guard comes with an alarm system that is triggered upon the operator entering the warming zone. The blender also performs an emergency stop whenever the operator gets into the danger area.
This primarily shows how effective this particular component is and the role it plays in material processing.
In fact, we have different classes of laser guards. You will find some IBC bin blenders with class 1 laser guard that harmless and also invisible to the eye.
But the bottom line is that they are suitable especially for the relatively irregular rooms. Moreover, you can mount the scanner on the wall to attain high-quality GMP finish.
Nonetheless, it would be important also to note that the laser guard is not ideal for the Ex-rated areas.
· Clamping Bars
The clamping bars are typically meant to provide support or stability to the unit. So that when it is under operation, it remains solid irrespective of the level of vibration.
In most cases, you’ll find out that the clamping bars are welded on the IBC bin blenders. In a significant way, these bars allow you to handle the blender by an elegant “C” frame blender.
Arm holding the blending/mixing container in position
The other good thing about this design is that it allows for simple opening and accessing of the valve and the lid.
The clamping bars are therefore suitable parts of this particular machine that you can never dispel given that they play a significant role.
· Operator Controls
The IBC bin blender is one of the most tech-oriented units of the current generation. So it means that there is a need for integrating the technologies accordingly during operations.
The easier way of doing is by using the controls available on the device. You see, for the one you can’t operate the machine if you don’t know how the controls work.
Control panels for automatic IBC bin blender machine
And secondly, it can be risky even to attempt operating it having it clearly in mind that you are unaware of how it works.
So the part controls, which fortunately are well marked helps you in making the task somewhat easy. You won’t find yourself in a situation where you even compromise the quality of the end-product when processing the material or ingredient.
But the other good thing about this part is that it can guide you to regulate the entire process from different perspectives.
Nevertheless, you need to understand that it is possible to supply most of these operator controls to any particular level of sophistication.
Some are basic whereas others tend to be relatively complicated. So you need to understand better what button does what during the process.
· Light Guards
This mainly helps in enhancing the efficiency of the machine during operation. The light guards for this device contain a transmitter and receiver units that you can flush mount in a wall for a GMP finish.
This component is also elegant and efficient system hence making it relatively easy for it to integrate well with other parts.
Also, the light guards contain the infrared beams which tend to be invisible during the operation.
· Blending Container
IBC bin blending container come in different shapes and designs depending on the unique specifications as you’ll see later in chapter 5.
This is where everything takes place.
As you can see, they come in different shapes and designs – so it forms yet another important aspect for classifying bin blenders.
Different shapes of bin blenders
The designs of these blending containers aim to maximize and guarantee uniform mixing.
· Charging and Discharge Ports
These are the two extreme ends where you fill and empty the IBC bin and mixer. In most cases, you will find them at the two extreme ends as you can see in the diagram below.
Charging and discharging ports of IBC bin and mixer
The two ends should form an airtight sealing to prevent instances of powder spilling when the bin is rotating.
Below is a structure of a discharge port of bin blender.
Structure of discharge port
Normally, they have valves and effective sealing mechanism.
The bottom line:
Some of the main parts of bin blender and mixer machines include:
- Blending and mixing container
- Sensors for security purposes and automation
- Clamping bars
- Control panel
- Base that supports the entire structure
- Rotating mechanism
To know more about machines bin mixer parts and structure, please request for a machine manual.
With that in mind, let’s move a step further to evaluate more aspects of this machine.
Chapter 4: Bin Blender Working Principle
This section covers yet another important aspect of this pharmaceutical equipment – the working principle of the bin blender machine.
But first, let me make one thing clear here:
Whether you go for:
- Double cone mixer
- Cone blender
- Double cone blender or,
- V-cone blender
The working principle of IBC bin blenders and mixers will still remain the same.
Therefore, for the scope of this section, I will focus on a standard working principle of IBC bin blender and mixer.
But first, even before proceeding, I want you to watch this video – how bin blender works. It will give you an idea of what I am about to discuss in this section.
With that in mind, let me take you through a quick overview of this process.
First, I want you to note that a bin blender may come in different designs where:
- Blending Container may be fully Fixed on the Machine
A good example of such machine is the SaintyCo V-Type Mixer:
These IBC mixer machines are suitable for small scale or R&D.
- Blending Container not Fixed to the Machine
This is the second alternative that is available in the market. In this machine, you may fill the bin separately then attach it to the system.
In most cases, we use this type of IBC bin and mixer machines in large scale production processes.
A good example is the SaintyCo Pharma IBC Blending System:
Pharma IBC Blending System
Irrespective of this design, the working principle still remains the same.
So, let’s go straight to that:
Step 1: Filling the Blending Container with Right amount of Material
First, you need to fill the container with the right capacity of the material. That is, you should fill it to its capacity.
It doesn’t matter whether the blending container is fixed or removable.
Step 2: Set the Blending/Mixing Time from the PLC Panel
Once you fill the blending container, clamp it appropriately on the main stand of the machine.
Then set appropriate parameters that may include mixing or blending speed and time. After this, the machine will begin to rotate either in a clockwise or anticlockwise direction depending on the configuration.
During this time, material will move randomly within the blending container. The final products will be a uniform mixture of two or more products.
Step 3: Step the Machine and Empty the Product
Once you have the uniform mixture, stop the machine then empty the content to an appropriate bin.
Of course, even at this juncture, you should be able to assess the quality of the final product to be sure that it meets the right quality standards. That is, the mixture should be uniform.
The point is:
As you can see, the working principle of IBC bin blender and mixer involves:
- Filling bin blender or mixer with right capacity of material
- Clamping the bin to rotating mechanism
- Initiating the rotation process to initiate the blending process
- Empting material for further processing
With all these in mind, let me take you to yet another critical section in this process – classification of bin blenders.
Chapter 5: Classification & Types of Bin Blenders (Geometrical Shade & Design)
In most cases, a number of double cone blender manufacturers tend to adopt many classification criteria for their products. For the scope of this guide, I will take you through some of the most popular options.
These will include:
- Production capacity
- Internal construction
- Geometrical shape of the blending container
I know with this information, alongside everything you’ve learnt throughout this guide, you can definitely choose an appropriate machine.
Now, let’s go straight to the point
· Types of IBC Bin Blenders and Mixers
This mode of classification is of course the easiest and straightforward. It basically refers to the amount of powders or granules a machine can produce within a specific time frame.
Generally, you can opt for:
- Low Capacity IBC Bin Blender and Mixer
It is specifically designed for low capacity production processes. This includes R&D, clinical trials, laboratory and other low scale production processes.
Bench Top Laboratory Blender
- High Capacity IBC Bin Blender and Mixer
This is a high capacity IBC blender and mixer for large foodstuff and pharmaceutical industries. Obviously, the design of these machines is such that they can process large volume of powders and granules.
Post Bin Blender
Of course, when you compare the two machines, the high capacity blender machine is larger than the small blending machine.
Apart from these two, you may also focus on the general construction of the machine.
· Types of Bin Blenders and Mixers depending on the Construction
I know this may also seem to be a broad subject due to the many brands available in the market. Construction and design is a key aspect that differentiates models of IBC bins and mixers.
As you will see later, geometrical shape also plays a crucial role here – I will discuss that later.
For now, let’s focus on these two:
- Ribbon Blender
It is a popular accessory in food processing industry. Quite a number of designs feature ribbon shaped blades and U-shaped trough.
These machines mix materials in an axial direction as ribbon-shaped blades move on the entire trough.
The unique design guarantees fast and uniform mixing of products.
- Bin Tumbler Blender
This is a suitable accessory for mixing free-flowing granules and powder. With this blender there is no need for discharging products and a perfect choice processing many products.
In addition to these, let’s go further and look at another important aspect for classifying bin blender and mixer.
· Types of IBC Bin Blenders based on Geometrical Design
This basically refers to the design of the blending or mixing container. As you have seen in various examples in this guide, it is quite clear they come in different geometrical shapes and designs.
Well, for the scope of this guide, I may not cover all here.
However, to illustrate what I mean here, I will give you just a few examples. But still, it is important to mention that all these design aims to optimize the blending or mixing process.
Below are some of the most common examples:
- V cone blender
Example of a V cone blender
As you can see, the blending container is in the shape of letter “V”.
- Cuboid and cone blender
Example of bin blender with two different shapes
I hope you can see the structure of the above blending container.
Can you see what I had highlighted earlier?
Well, this classification depends solely on the shape and design of the blending container. That’s why you can find double cone mixer, double cone blender mixer and many other shapes.
Closely related to this is the clamping mechanism.
For example, you can have these:
- Bin blender with a clamping bar like this:
Bin blender with only one bar holding the container
- Hoisted bin blender
Hoisted bin blender machine
Here, this bar lifts the bin up before the blending process begins and down once the process is complete.
- Cage bin blenders
Blending container in a cage
As you can see, the blending container is in a cage.
In short, what am I trying to say here?
You have many options of bind blender and mixer machines at your disposal. Take your time to choose designs that meet the unique specifications of your material processing needs.
That is, a machine that can produce uniform mixture.
Again, it will be unfair, to end this discussion without evaluating the main features of this machine.
Here we go….
Chapter 6: Features of IBC Bin Blender and Mixer for Homogenous Material Processing
In this section, I am going to take you various features you need to look for whenever you’re sourcing for an IBC mixer and blender.
It doesn’t matter whether you’re looking for bin blender pharmaceutical or laboratory blenders.
By the end of the day, it is these features that will determine the efficiency of mixers and blenders.
With that, why don’t we go right into the subject of this section?
But, before that, I want you to watch this video:
Ideally, the IBC blenders enable homogenous blending of various ingredients without the necessity of transferring the substance to and from a different machine.
It is essential because it prevents issues that would result in segregation and possible cross-contamination.
All the efficiencies of the IBC bin blender arise from the fact that it’s engineered to provide the best user-friendly results.
To get a better understanding, let’s look at some of these features:
· Speed Controls
It is always easy to operate a particular unit when it comes with a variety of user-friendly control systems.
The IBC bin blender and mixer gives you the ability to determine the particular speed when processing the recipes or ingredients.
Control system of IBC mixer
This unit features variable speed controls that enable you to load the blend ingredients comfortably. They also make it possible for you to print the information regarding the completed batches.
The speed controls also allow you to determine your preferred level of blending the materials to end up with desirable results.
Furthermore, it also makes it easy even for anyone around to operate it since it does not require in-depth knowledge or skills to understand how to operate the controls.
· Robust Construction
This unit has a sturdy design that allows it to remain stable before, during and after the blending processes.
It comes with a clamping cage that provides a safety connection to its top and bottom parts. The essence here is that it reduces any form of mechanical stress that might arise during rotation.
Stainless steel structure
The net effect, therefore, is damage prevention which also leads to a relatively long working life of this machine.
Who doesn’t want this kind of device to serve them for long anyway? I’m sure you don’t.
Moreover, it is this robust construction that also plays a major role in enhancing safety standards when using this unit.
Remember, these mixers and blenders are made from stainless steel. They are also cGMP compliant.
· Blending Prism
The IBC bin blender and mixer feature a blending prism. Apparently, this helps in providing a reasonably low shear mixing to spinning IBC.
This feature is also helpful in enhancing homogeneity and reducing the blending duration.
The blending prism adds turbulence to the tumbling product.
Technical drawing of a double cone blender specification
So the prism turns at the right angles to the rotational center anytime you load the IBC into the blender.
Well, the prism then separates the prism when the IBC rotates and forced to move on the out towards the corner sections of the container.
This particular feature is essential during dry blend process. It is at this time that the IBC blending is the primary process step.
· Swinging Arms
This feature allows for control of a broader range of IBC volumes within the same blender. The moment you load a comparatively smaller IBC into a blender the spacer arms tend to swing out into the IBC’s path.
Swinging arms of IBC bin mixer
The good news:
Typically, this would help in reducing the height difference. The other good thing with the swinging arms is that they assist in maintaining the IBC’s position at the central rotational axis thus decreasing the compressing time.
Now, this is vital because other than enhancing the efficiency of the blending process. It also makes it possible for you to process different volumes simultaneously.
· Electrically Powered
This unit is exclusively powered using electricity. You see this is imperative because it is this full electric operation that allows this machine to provide reliable function.
Electrical motor system
The complete electricity operation also makes this machine to operate more smoothly and trouble-free compared to the pneumatically and hydraulic powered units.
This feature also makes it possible to reduce the maintenance needs of this particular machine.
· Mirror Finish
This particular unit comes with a shining surface from the inside. It makes it look appealing to the eye and the same time tidy.
Of course, the entire surface is made from stainless steel.
This is irrespective of the ingredients that it blends and mixes from time to time, which is equally vital.
Interior section of IBC Mixer
On the same note, it also features an adequate hopper angle. It is from this angle that makes it easy for the unit to discharge the products entirely.
· Elegant Through-the-wall Design
The design of the IBC bin blender and mixer is generally stylish. This is in the sense that it allows for easy loading even without the need for using a forklift.
The housing of the IBC blender is also in a technical section, and the clamping cage is in the process section. In between the two rooms, there is an airtight wall plate that acts as the barrier.
Stainless steel bin blender
You see, having this smaller processing room is essential because it reduces the overall running costs and the area of operation.
Moreover, it has a cGMP design. This basically means that it conforms to the recommended specifications of the current Good Manufacturing Practices Compliance.
It is necessary because it shows that other than efficiency, it is also safe to use which is equally fundamental.
· Durable Material
The IBC bin blender and mixture is constructed using high-quality stainless steel materials that enhance its strength and durability.
Commonly, the materials often used include stainless steel and carbon steel. For sure, you and I know how hard-wearing these two materials can be.
As you can see a structure is made of stainless steel
It is vital because it enables this unit to be resistant to most of the unfavorable conditions that would emanate from the surrounding.
Or better still, these types of materials make the machine to be resistant to corrosion as much as they blend ingredients of different elements all the time.
Now that we’ve looked at some of the salient features of the IBC bin blender and mixer let’s see some elements that determine its efficiency.
Chapter 7: Factors Affecting Efficiency of Bin Blender and Mixer in Pharmaceutical Industries
There is always need for doing meticulous research before selecting the ideal bin blender and mixer.
The truth of the matter is that several performance characteristics affect the manner in which such a unit operates.
Again, you have to understand that solid pharmaceutical mixing is a relatively complicated process. So it mathematical process can barely be used.
In this chapter, we want to discuss some of the many elements that affect the operation of this type of machine in attaining its efficiency.
· Cleaning of the Equipment
It is an indispensable aspect that you need to bear in mind. This especially comes to play when you need to mix batches of different nature simultaneously in the same unit.
In this case, it is critical to ensure that it is reasonably less strenuous to frequently and thoroughly clean the equipment.
Plain tumbling is often comparatively easy to clean as long as there is the availability of sufficient openings.
Stainless steel bin mixer
Some of the sections that can arguably be challenging to clean include the corners, seals, crevices at baffle support and discharge arrangements.
If you find it somewhat difficult and time-consuming to clean the equipment between different batches, you should then consider doing several small mixers.
This would be comparatively easy than it would be if choose to go for a single large unit.
· Loading and Discharge Arrangements
These are also vital elements which also tend to be more crucial when it comes to the continuous operation mode.
Ideally, you have to consider the total handling system to make it possible for the equipment to attain the optimum charging and discharging situations.
Some of the factors that determine it include using weight hoppers and surge bins and location of discharge gates.
Charging and discharging material in mixers and blenders
Others also include a minor ingredient premixing as well as any other particular additional device used in enhancing the continuousness of the process.
· Mixing Homogeneity
Here is the truth:
An extended duration of mixing ingredients is always related to worsening the efficiency of the process rather than improving it.
For that reason, you can quickly evaluate the mixing rate together with the blending uniformity using the design graphs.
While at it, you also have to bear in mind the fact that the tendency for segregation also degrades the effectiveness of the process.
The solids mixing can happen in a batch or a continuous operation.
Powder ready for mixing
But an essential element which you have to know is that appropriate mixing design produces the desired to blend in short time. However, this can only happen specifically if the setting is in batch mode.
· Power Requirements
These are also essential concerns that you must have in mind when selecting a bin and mixer equipment.
Nevertheless, they do not seem to supersede the other considerations which are often predominant when it comes to determining this unit’s efficiency.
But still, there has to be sufficient supply of power to help in handling maximum needs other than preventing changes during the mixing process.
Power must be available for efficiency in handling heavy bulk density materials and also for extreme operating conditions.
IBC blender machine specifications
If at all you want to start the loading equipment from rest, it is ideal for sufficient power to be available. Again, enough power also becomes necessary particularly when you deem speed variations to be desirable.
· Dust Formation
It is imperative to always prevent this particular element from happening. Majorly, its prevention enhances the safety of both the equipment and the user. Loss of dust may also considerably affect the batch composition.
One of the best approaches for minimizing dust formation on the equipment is merely by using batch ingredients that are relatively less dusty but equally satisfactory.
You can also do it by proper venting to make it possible for filtering of displaced air. All in all the most significant issue is ensuring that you prevent the equipment from accumulating dust.
All these depend on the design of the machine. So, you must analyze the technical drawing of the machine.
Technical drawing of a V Type Mixer
Because, other than degrading its level of efficiency, it also puts you through the high cost of maintenance and possibly reducing the lifespan of the equipment.
· Residence Time
In a continuous operation, it is somewhat a difficult task to determine the residence time.
But then again, if you consider the core properties of blending solid ingredients, you’ll realize that it happens within the shortest time possible.
Commonly, you will find that ribbon type mixer used in continuous blending. Nonetheless, you can still use it for batch mixing.
You also need to consider continuous mixing as the only alternative on two conditions; when you can run a single formulation for a comparatively long duration.
And when the fluctuations of the outgoing material fall within the specific process specifications.
Compromising any of the abovementioned conditions suggests a batch mode of operation as ideal preference guarantee the most achievable mixing homogeneity.
· Ingredients and Operating Conditions
The components that you mix have a significant effect on the overall effectiveness of this particular equipment.
In general, the ingredients come in different properties. For instance, you will realize that some of them tend to have larger particles.
In some instances, the proportions of materials to be mixed also vary as well as the flow properties of the end product.
Mainly, you need to understand that different materials have a different temperature sensitiveness, corrosiveness and compaction properties among others.
So you ought to ensure that you look into all these elements because in one way or the other they affect the efficiency of this equipment.
Chapter 8: IBC Bin Blender & Mixer Applications
Here’s the truth:
IBC bin blender is used in several industrial applications. In fact, you need to know that this unit plays an essential role in most of the material processing plants.
These equipment have become a necessity in most of the chemical labs, food processing, and pharmaceutical industries among many more.
IBC bin blender rotating
The other surprising element is that most of the material processing plants are currently turning to these accessories as a means of maximizing production and income.
In this section, we will look at some of the typical applications where IBC bin blenders and mixers are utilized for various purposes.
However, you need to be conscious of the fact that in most of the IBC bin blender applications the process is more than merely mixing materials.
Let’s first explain some of these applications, understand and get the gist;
· Used in Enhancing the Efficiency of Material Blending
The truth of the matter is that we have a wide range of machines in the market. Most of them seem appealing and useful until you try them out.
But ideally, not all of these machines are can provide the level of efficiency that you can obtain from the IBC bin blender.
The engineering of this particular machine is merely epic and focused on the core functions and properties.
When you probably start using it or even watch a tutorial about it, you’ll realize that it is somewhat possible to offset it to various angles.
Laboratory blender and mixer
As much as the offset is dependent on the type or design of the machine, the bottom line is that the efficiency it offers is top-notch.
The intermediate bulk containers are also available in irregular shapes. This is essential because it allows you to have wide-ranging options whenever you need to use any.
Now if you didn’t know, these are some of the critical elements that establish the efficient the IBC bin blender applications.
So definitely you’re guaranteed of high quality and high blending efficiency with these elements.
· Used in Mixing Varied Materials
Apparently, this one looks like a most evident industrial application of the IBC bin blender and mixer. We commonly use this accessory to blend dry powder, granules or both.
The design of the bin stands somewhat at an angle that allows it to rotate efficiently and in the process mixing all the contents to the required standards.
Multi directional mixer
The best part:
You can use the machine to blend more than two substances and still find the right proportion.
Whichever way or approach you look at it, this particular aspect is a definition of efficiency. It is not easy to find equipment that can be able to automatically mix two or more substances and still attain the desired proportion.
· Used to Prevent Dry Material from Cross-contamination
Ordinarily, you would find that the blending process exposes the solid ingredients to somewhat unfavorable conditions.
This could quickly lead to cross-contamination of these materials which in the end can become hazardous in varied aspects.
But then the IBC bin blender becomes handy in such situations because of their exceptional uniformity of the product and first product change over.
Good sealing to prevent product cross-contamination
So in a way, it helps in preventing a possible cause of cross-contamination of the ingredients during the blending process.
The net result is that other than increased productivity there will also be high income given that most of the products will not go to waste.
· Used in Efficient Speed Blending Applications
This accessory is suitable for most of the blending applications that require a comparatively fast and efficient speed blending.
In most cases, the ideal IBC bin blender can always mix the solid ingredients in less than 10 minutes. This is to some extent fast.
In that case, should you have the larger containers then you’re sure of attaining an increased production.
IBC bin blender
Alternatively, if you have this type of equipment; you can be confident of increased output within the shortest time possible.
And that is why it is also suitable in different manufacturing sectors whether in pharmaceutical or Research and Development industries.
· Used for Blending Lubricants into Powder
This is also another quintessential industrial application of the IBC bin blender and mixer. What often happens is that in some instances the material processing may not end with producing a uniform powder mixture.
So perhaps there would be that need for you to add lubricants into these blends. And the truth of the matter is that the only equipment to bank your hope on regarding this is the modern IBC blender.
Discharging material from IBC bin blender
This tool performs it in the best way possible to ensure that at the end of the process you attain the desired product.
Still, you can use this bin in various pre-blending applications. What it necessarily implies is that you can blend active low-dose ingredients together with other rations of the excipients.
Apparently, this is one of the most common practices in many of the drug manufacturing industries or pharmaceutical plants.
It is quite clear that ability to maintain the quality of the product, consistency, and efficiency are fundamental reasons for considering bin blender future projects.
Now, let me take you through yet another critical aspect of IBC bin blenders.
Chapter 9: IBC Bin Blender FAQ Guide
I know how frustrating it can be when you don’t get accurate answers to the various concerns you have about IBC bin blender and mixers.
So in this section, I am going to address all those issues – keep reading to learn more.
But first, you can watch this video as a reminder of the critical aspects about bin blenders pharmaceutical or laboratory blender.
1. How does IBC Blending/Mixing Work?
Bin blenders have the same working principle.
This is where the bin is inserted into the lifting arm of the machine which lifts it off the ground.
To initiate the blending action, the bin is rotated at a predetermined speed and in set cycles.
All these happen with the aid of the rotary frame which does the rotation/cycling of the bin, the driving system which rotates the rotary frame and the lifting system that lifts the bin off the ground.
There is also the control system from which you key in commands like the speed of rotation, some cycles, stop, start, etc. these help you to control the blending action.
In other words, an IBC bin blending systems is very simple and easy to use.
2. Is IBC Bin Blending New? How Long Ago was it Introduced?
IBC bin blending is not new.
In fact, the first IBC bin blender was made and introduced in the market in the early 1970s. During that time, the blender proved to be one of the more popular items as far as quick and efficient industrial blending was concerned.
3. Is blender Clean Up Required in the Case of IBC Blending?
Since products in bin blending only contact the bin, cleanup is not required and especially not between recipes/batches.
This helps to save time as well as eliminating the need for frequent cleanups. It also helps to reduce the risk of airborne and cross-contamination, product segregation and spillage.
The bottom of the coupler probe may, however, need to be occasionally wiped with a clean cloth in case the bin was too full, and products spilled.
4. How are IBC Blending Systems Controlled?
IBC bin blenders come with two methods of operations.
One is where you as the user are allowed to control the blender remotely through a host system. Two is where the blender comes with a standalone programmable control system.
5. Are there any Moving Parts?
Not those that you can access.
Bin blenders have very few movable parts, and these are located inside the blending unit.
6. How can you Evaluate a New System?
The best way to test your IBC blending system is by using your products in your operating environment.
This way you will get to see and know the results quickly.
You can try emptying the blender/mixer after products have been mixed and filtered out to see if any residue is left at the bottom.
7. How Durable is an IBC Bin Blender?
You should, however, note that IBC bin mixers are mechanically designed for durability and reliability. These products feature a robust construction with a clamping cage that provides a secure connection to the top and bottom of the IBC.
All these are meant to help reduce operation stress and prevent damage.
8. What Performance Guarantee to do you get by using an IBC Bin Blender?
IBC bin blender manufacturers have enough years of research and understanding of the mechanisms of IBC blending.
With this knowledge and experience, you can rest assured that the IBC blender is expertly designed to ensure that you get homogenous product blending.
The all-inclusive technology used in the designing and constructing the blender also guarantees you steady production capacities and performance with regards to intermediate bulk container (IBC) blending.
9. What Materials are used to make the Bin Mixers?
Well, IBC blending equipment for food processing, pharmaceutical, and chemical processing purposes are made with FDA approved materials.
In this case, silicon, neoprene rubber, EPDM, and nitrile are often used in the construction of IBC bin blending systems.
Stainless steel and mild steel are also used as metals in IBC bin blending equipment. Keep in mind that IBC bin blender manufacturers can construct your unit using materials that you prefer and those that are suitable for your application.
10. What Advantages does IBC Bin Blending have over Traditional Blending?
There are quite a number.
Traditional blending as we all know is labor intensive, difficult and outright challenging. Utilizing IBC bin blenders, on the other hand, will help you cut on both labor and facility costs.
This, unlike traditional blending, ensures limited downtime during operation which helps to increase production levels and an overall superior throughput.
11. How Safe are IBC Bin Blenders and Mixers?
IBC bin blending systems are quite safe to use.
Manufacturers during design and construction of the system take into account the safety aspect. They incorporate all the necessary safety measures in their construction processes to have a smooth, efficient and above all safe operation.
Nonetheless, you also need to ensure that operators are well educated of the safety hazards related to this machinery.
Additionally, it is your responsibility to ensure that the operating environment of the system is friendly and doesn’t pose any hazardous risks.
12. Are there any Specialized Tools or Training Needed for IBC Bin Blenders/Mixers?
Well not really.
While there are tools that the unit will need to equip with, special operator training is not required.
Operators can instead review user manual and guidelines which are often provided upon purchase of the unit
Online videos can also be used to equip users with the necessary operating know-how for IBC bin blending systems.
13. Is the System Affected by Dust or Dirty Operating Environments?
IBC bin blender work as closed systems. This means that they are not affected by dirt, or dust neither is the products in the bin.
Ideally, however, proper care and maintenance are essential for any price of machinery, especially those operating in dirty or dusty environments.
14. How do you tell if an IBC Bin Blending System is Operating as it should?
Being a closed system, you should expect to hear an inordinate sound about one time per second anytime the system is in operation mode.
The products inside the bin will also begin to take on the appearance of a homogenous blend.
If your bin is translucent, you should be able to see the material inside the container rolling and churning. This should indicate that the system is working well and that blending/mixing is taking place.
15. Can IBC Blending Systems be Continuously Used?
Yes, they can.
Understand that IBC blending systems are designed to operate consistently and continuously.
16. Is there a Possibility of Leaking?
None – so you don’t have to worry about this.
The only time that you can see a product is if the bin is overflowing with material and/or if the system is overworking (higher speed/cycles than what is recommended).
If there is leaking, you should see this at the outlet of the coupler vent.
17. What Sort of Maintenance does IBC Bin Blending Systems Require?
IBC bin blender designs have evolved, and there are models currently that require “zero” maintenance.
With minimal maintenance, you are sure of virtually no downtime hence, you can increase productivity.
18. Is there a Standard Design for IBC Blending Systems?
Although bin blenders take on similar structural design and concept, their shapes and size vary widely depending and application and user preference.
Please refer to chapter 5 where I did discuss a number of drum lift blender systems.
You can have a round, rectangular, or square IBC blender bin depending systems on your type of application and what suits you best.
19. What can you Get for your IBC Bin Blender?
Main features of IBC blending systems include bin manual lock, rotation and speed adjustments, volume adjustment, remote control panel and inclination setups.
Optional features that you can have include; remote control for automatic programming, barcode reader for identification of batches, touch screen HMI, printer, process analytical systems, among others.
20. How much do IBC Bin Blenders and IBC Mixers Cost?
There isn’t a standard price for any of this equipment.
Take note that IBC bin blending systems are custom engineered and designed to meet the unique blending/mixing requirements of individual users.
The varying shapes, sizes, and complexities determine the ultimate price of any single unit.
Therefore, it is only wise if you research and contact manufacturers for quotes regarding the same and then go with what you feel most comfortable with.
But, wait a minute:
I don’t imply that the FAQs end here – No.
In case you have any questions about this machine, feel free to leave a quick comment below.
For now, let me take you through yet another important aspect of these machines. That is, the various examples of mixers and blenders.
Chapter 10: SaintyCo Bin Blender and Mixer
I know this is what you have been waiting for. And, for that reason, let me take you straight to the point.
Below are some of the most popular types of bin mixers and IBC bin blending systems.
Here at SaintyCo, we offer 4 different types of bin mixers. They vary in performance and working capacity as you will see shortly.
- SaintyCo FX-Square Cone Mixer
SaintyCo FX-Square Cone Mixer features a steady structure, with the mixing bin held between two standards. It is precisely designed for batch mixing and it comes in 12 different models.
SaintyCo bin mixer machine
For more information about this machine, you can follow this link: SaintyCo Square Cone Mixer.
- HD – Multi-Directional Motions Mixer
SaintyCo HD – Multi-Directional Motions Mixer has a cylindrical shape with two slanting edges (cone shaped edges). This makes it suitable for mixing powders and granules within the shortest time possible.
Besides, it can rotate freely, allowing for homogenous mixing in pharmaceutical, food processing and chemical industries.
HD – Multi-Directional Motions Mixer
For more information about this equipment, you can follow this link: HD – Multi-Directional Motions Mixer.
- RB –Ribbon Mixer
SaintyCo RB –Ribbon Mixer offers better material processing standard in the foodstuff, pharmaceutical and chemical industries. It is a cGMP and CE compliant and super-efficient when it comes to material processing.
As an industry leader in IBC bin blender and mixer, SaintyCo offers both standard and custom designs, depending on the unique specifications for their customers.
RB –Ribbon Mixer
For more information about mixer machine, you can follow this link: RB –Ribbon Mixer.
- V Type Mixer
SaintyCo V Type Mixer features uniquely designed V-shape for fast and efficient mixing of products in pharmaceutical, foodstuff and chemical industries. Looking at its design, SaintyCo V Type Mixer is basically two cylindrical tubes joined together to form a “V”.
V Type Mixer
For more information about this accessory, you can follow this link: V-Type Mixer.
· SaintyCo IBC Blending System
Apart from the above 4, SaintyCo offers the following key accessories:
- HZD400-2000 Pharma IBC Blending System
This unit comes with a complete automated mixing system. You can control a wide range of elements including blending speed and offsetting angle.
This machine has no dead angles, concave-convex surface and screws hence meeting the necessarily safety standards.
HZD400-2000 Pharma IBC Blending System
Its design features pressure sensors which guarantee high-efficiency safety standards. Additionally, this machine prevents cross-contamination due to its superior dust handling ability.
For more information about this machine, follow this link: HZD400-2000 Pharma IBC Blending System.
- HTD50-1500 Post Bin Blender
SaintyCo HTD50-1500 Post Bin Blender comes with a single column hopper lifting, which assists in saving on appropriate space. You can as well set the blending speed and time through its touchscreen HMI panel.
HTD50-1500 Post Bin Blender
This blender also features sensitive pressure and infrared sensors. The other good thing about it is that it can handle bins of varied capacities and models.
For more information, you can follow this link: HTD50-1500 Post Bin Blender.
- HYD Series Holder Type Bin Blender
SaintyCo HYD Series Holder Type Bin features a double hosting structure, and it has fully automated systems.
HYD Series Holder Type Bin Blender
It is also a suitable unit for both food and pharmaceutical processing applications given that it reduces material cross-contamination.
Also, it guarantees safety during operation as well as enhancing accuracy for better results.
For more information about this machine, you can follow this link: HYD Series Holder Type Bin Blender.
- HSD5-100 Bench Top Laboratory Blender
SaintyCo HSD5-100 Bench Top Blender is mainly engineered for lab applications and R&D functions. It offers homogenous blending from the fact that it supports high tangential tilting and double movement.
HSD5-100 Bench Top Laboratory Blender
It is also safe to use it since it is made of stainless steel with no any dead angles. This machine also conforms to the up to date PLC control system hence guaranteeing consistency and accuracy.
For more information about this machine, you can follow this link: HSD5-100 Bench Top Laboratory Blender.
HDD400-1200 Single Arm Bin Blender
SaintyCo HDD400-1200 Single Arm Bin Blender complies with the cGMP requirements that come with high mixing and discharge co-efficiency.
HDD400-1200 Single Arm Bin Blender
It features a PLC control system, and it is entirely automated hence allowing you to configure blending time and speed.
This unit also has pressure sensors that help in preventing the wrong operation.
For more information about this machine, you can follow this link: HDD400-1200 Single Arm Bin Blender.
Clearly, you can see that there are quite a number IBC bin blenders and mixers.
Still, by the end of the day, it will depend on your ability to assess and choose a suitable machine with the right design. I
So far, I have shared everything you need to consider in this guide.
Now, it’s your turn:
Do you need an IBC bin blender and mixer?
Or do you have any questions on how to choose an appropriate blender or mixer?
Feel free to leave a quick comment or send me an email – I am here to offer you free consultation on pharmaceutical equipment.
Wait a minute – I also have some links you can learn from:
- IBC Bin Blender Analysis– By SaintyCo
- Characterization of the Performance of Bin Blenders– By A. Alexander Et al.
- Continuous Mixers for Powders– By Academia
- Design and Development of V-blender Machine– By Wong Fei Yong
- Applications of IBC Bin Blenders and Mixers– By SaintyCo
IBC Blending System: The Ultimate FAQ Guide
If you’re planning to buy or learn more about the IBC blending system, then you should read this guide.
It covers basic to advanced aspects of an IBC blending system, making material processing in the pharmaceutical industry easy.
Here is what you should know:
- What is IBC Blending and Handling System?
- What are IBC Blending Systems used for?
- What are the Advantages of IBC Blending System?
- How do you use IBC Blending System with Lifting Column?
- What are the Disadvantages of IBC Blending System?
- Why is cGMP compliance Critical for IBC Blending and Handling System?
- How do you Choose IBC Blending System?
- Which Factors Affect Efficiency of IBC Blending and Handling System?
- How can you Classify IBC Blending and Handling System?
- What are the Components of IBC Blending System?
- How do IBC Blending and Handling System Work?
- Is there difference between a Mixer and IBC Blender System?
- What is a Double Cone Blender?
- How can you Improve Efficiency of the Pharmaceutical Bin Blending System?
- Can IBC Blending System guarantee Homogeneous Blending?
- What is the difference between IBC Blending Systems and Ribbon Blender System?
- What are the Benefits of using V Blender System?
- Which Industries use IBC Blending System?
- What are the Structural Design of IBC Blending Systems?
- What is an IBC Tumbler Blender?
- Which Factors Affect Efficiency of Powder Mixing with IBC Bin Blender System?
- Is there difference between Powder Mixing and Blending?
- Do Rotating Angle Affect Efficiency of IBC Blending System?
- What are the Quality Standards for IBC Blending System?
- What are the Benefits of Automated IBC Blending Systems?
- How do you Choose Holder Type for IBC Bin Blender?
What is IBC Blending and Handling System?
An IBC blending and handling system is an irregularly shaped container.
It has both an inlet and an outlet essential in uniform in mixing.
The machine’s productivity is dependent on its design.
As such, these are dual-action blending and handling machines that mix both powder and granules.
Their dual action is evident when the device is in operation.
Materials being mixed tumbles in the blender.
Secondly, the bin is usually tilted at either 60° or 45°.
The expected result is a uniform mixture.
This happens without compromise on the chemical composition of the ingredients.
IBC Blending system
What are IBC Blending Systems used for?
The IBC blending system has several applications in different industries.
One of the industries that use bin blenders is the food industry.
IBC blender system helps in ensuring that all food products are mixed sufficiently.
IBC blending is also used in the pharmaceutical industry.
In most instances, medical drugs are composed of different products with varying chemical compositions.
IBC blending machine is essential in ensuring that these products are mixed expertly.
Companies manufacturing cosmetic products also rely on IBC blending machine.
Just like pharmaceutical products, cosmetic products are manufactured from products with varying chemical compositions.
IBC blending machine ensures that the contents are perfectly mixed.
What are the Advantages of IBC Blending System?
IBC Blender System
Over the years, Intermediate Bulk Container (IBC) blending has been of great importance to the chemical and pharmaceutical industries.
One of the essential advantages is that it prevents cross-contamination.
IBC blending machine is also essential in minimizing blend quality problems.
When such issues arise, the safety of end products is in jeopardy.
This can be disastrous in the pharmaceutical industry as the quality of drugs will have been compromised.
IBC blending system also contributes to ease in both loading and unloading.
This is possible because it enables complete product containment.
IBC blender’s stand-alone characteristic makes it possible to load it using a forklift.
Compared to other conventional blenders, IBC blender hygienic standards can be easily maintained.
This is because IBC blenders do not need clean-up.
This means that you will have minimized machine cleaning times.
Another advantage you are bound to enjoy is less blend time.
As such, you can be assured of an increase in productivity for your company.
As this goes on, you can be assured of batch integrity.
IBC blending system also helps in ensuring that contaminations and spillages are eradicated.
This is also an essential feature in ensuring product safety and quality.
Safety is further ensured by the fact that the product does not come into contact with the container.
This helps in preventing cross-contamination.
How do you use IBC Blending System with Lifting Column?
Lifter column for blenders have been in the market for the past three decades.
These blenders combine a lifting column and an IBC blending drive.
Lifting column with bin blender
When using this machine, you will be able to perform two functions.
With the additional equipment, you can perform both filling and discharging steps.
IBC blending systems with lifting columns can be built using a sidearm clamping system.
There are also lifter blenders with cage clamping design.
What are the Disadvantages of IBC Blending System?
IBC blending machines also have weaknesses, just like any other machine.
IBC Blending systems consume a lot of power.
This can be expensive on you, especially if its productivity is not maximized.
Size limitation is another disadvantage with the IBC blender.
This is because it has to be easily portable using the pallet track.
The user-interface can, at times, be complicated.
This is because it incorporates a lot of technology as a strategy for ensuring that the machine functions effectively.
You can overcome this through training from the manufacturer.
This is often done through user manuals.
Why is cGMP compliance Critical for IBC Blending and Handling System?
The current Good Manufacturing Practices (cGMPs) are a fundamental set of rules that helps in enhancing the functionality of machines.
For IBC blending machines, they also improve market performance.
Compliance with these standards assures customers of the product’s quality and capabilities.
As such, all manufacturers of IBC blenders strive to ensure that these standards are met.
When these standards are observed, IBC machines become more comfortable to maintain.
This is also evident in cleaning where IBC machines that have observed cGMPs standards are easier to clean.
cGMPs rules also help in ensuring that the correct materials are used in the manufacture of the blender.
Materials used are expected to be reliable and hygienic.
They are also likely to be rustproof.
How do you Choose IBC Blending System?
IBC Blending system
The first step in choosing an IBC blending system is ensuring that it has a stable structure.
This helps in providing that it is durable whenever in use.
This helps in ensuring that the machine has a longer life span.
For smooth operations, you will have to ensure that the IBC machine you are choosing is electricity-powered.
Also, this will also help in keeping the maintenance costs at manageable standards.
This is in contrast to when you are using hydraulic machines.
Ensure that the IBC blending system you are purchasing has clamping cages that connect the top and the bottom.
This increases the lifespan of the IBC blending system.
Another factor to consider is whether the IBC blending system you are purchasing has a friendly control system.
You don’t want to purchase a machine that you won’t be able to operate.
The machine should also be automatic.
Automated IBC machines are more comfortable to use.
All you will have to do is to enter the parameters required and let it do the rest of the work.
Be keen on finishing. Both the inner and the outer parts of the system should be smooth, and having a mirror-like finishing.
Which Factors Affect Efficiency of IBC Blending and Handling System?
There are several factors that one should consider before purchasing an IBC blending and handling system.
From the subsequent discussion, you will realize that all these factors are essential in ensuring efficiency.
· Cleaning of the IBC Blending and Handling System
This is one of the most important considerations, especially when mixing substances of different natures concurrently in one unit.
You will have to ensure that the IBC blender you are choosing is more comfortable to thoroughly clean under such circumstances.
Some of the parts you should pay attention to are the seals and the corners.
A similar consideration should be made on the discharge points.
· Charging and Discharging Arrangements
This is also an essential factor affecting efficiency in IBC bending machines.
One of the key considerations you should make is the optimum charging and discharge capabilities of the machine.
Several factors inform this, including weight hoppers and surge bins.
The location of the discharge gates is also an essential factor.
Ingredient premixing capability is also another factor worth considering.
Remember also to check out other devices that have been included as a strategy for improving continuousness.
· Homogeneity in Mixing
When the period taken in mixing the ingredients is more extended, then the efficiency of the machine should be scrutinized.
To assess such capabilities, you are advised to use design graphs.
This will help you determine the mixing rate and blending uniformity.
The segregation tendency is also known to degrade performance quality.
Look out for a machine that mixes products appropriately within the shortest time.
· Power Requirements
This is another essential consideration you should make when purchasing the IBC blending system.
There is a need for a constant supply of power for efficiency, especially when handling heavy materials.
· Dust Formation
You should ensure that this does not happen.
When you adequately prevent dust formation, you will have protected both the machine and the user.
Also, when you lose dust also, the composition of the batch will also be affected.
You can prevent dust formation by using less dusty ingredients.
Proper venting is also a reliable strategy in filtering and displacing air.
You can check out this from the technical drawing of the machine you intend to purchase.
· Ingredients and Operating Conditions
The components you intend to mix also affect the efficiency of the equipment.
For instance, there are ingredients with large particles and others with smaller particles.
Ingredients are also likely to vary in terms of sensitivity to temperature and sensitiveness.
Some ingredients also tend to be corrosive, while others are not.
How can you Classify IBC Blending and Handling System?
There are several considerations made when classifying IBC blending and handling systems.
These include the production capacity of the machine, the machine’s internal construction, and the shape of the blending container.
Low capacity IBC blenders: These are designed to handle low scale capacity productions.
High capacity IBC blenders: This is used in large scale productions in both pharmaceutical and foodstuff industries. Compared to the previous machine, this is larger.
Classification of these machines can also be done by focusing on general construction.
Ribbon Blender: these machines mix materials in an axial direction.
They also have ribbon-shaped blades.
Bin Tumbler Blender: This is preferred in mixing free-flowing granules and powder.
It’s the most effective when processing a variety of products.
What are the Components of IBC Blending System?
The IBC Blending system has several parts that are all essential in its functions.
Blending container: It is within this container that blending and mixing happens.
Blending containers are of different shapes depending on the kind of production.
Rotation Counter: It is this part that helps in ensuring that the ingredients are effectively mixed in a container.
Charging and discharging ports: these are the respective inlet and outlet of a lending container.
They have valve seals, which are essential in preventing spillages.
User interface: this is also referred to as the control panel.
In IBC blenders, this is usually a touchscreen.
You can set the parameters you would want the machine to undertake on this panel.
It is labeled for ease of use.
How do IBC Blending and Handling System Work?
Rotating IBC Blending system
IBC’s blending system working principle is simple and efficient.
The process starts by inserting the bins in the lifting arm.
The lifting arm lifts the bin off the ground.
Subsequently, the driving system will rotate the rotating frame.
On rotation, the rotating frame will see the bin in set cycles.
Depending on the speed you had set, the lifting arm lifts it.
As a result, the blending action will take place.
For these processes to be undertaken effectively, the correct commands have to be entered in the control panel.
You can always enter new commands whenever need be.
Most IBC blending systems in the market have a similar working principle.
Is there difference between a Mixer and IBC Blender System?
Mixer and IBC blender systems usually perform the same function.
However, IBC blenders are used for industrial functions.
The difference between the two is based on the quality of output and efficiency.
IBC blenders are more precise in their functions and tend to work faster compared to mixers.
This is attributed to the use of container blending.
This ensures that there are faster loading and unloading.
The result is improved containment.
This explains IBC blender’s preference by most industries involved in mixing and blending products.
What is a Double Cone Blender?
Double cone blender
Double cone blenders are characterized by one access cover.
It is used in chemical and pharmaceutical industries.
Because of the one access cover, this blender s easier to inspect and to clean.
It is the most preferred when mixing 2-5 ingredients.
The working principle for this machine is free-flow.
This makes it the most preferred blender when blending free-flowing granules and even powders.
How can you Improve Efficiency of the Pharmaceutical Bin Blending System?
To improve the efficiency of an IBC blending system, you will have to consider the speed.
Higher blending speed denotes ability in productivity.
The fill volume and the loading order also imply improved containment and batch integrity.
Another factor that contributes to efficiency is the friendliness of the control system.
The control system makes loading easier.
What is the best Material for IBC Blending System?
The most reliable material for making IBC blenders is stainless steel.
This is the most preferred material for the part of the machine that comes into contact with the material.
The preference for stainless steel is anchored on several reasons;
Stainless steel is usually non-reactive.
This helps in curbing contamination that might result from the production process.
This is an essential step in safeguarding the health of users of end products.
Stainless steel is also resistant to dust and rust.
This directly translates into a longer life span compared to other metals.
This proves economical for such industries that use them as it saves them the costs associated with periodic replacements.
Stainless steel easier to clean and to maintain.
Can IBC Blending System guarantee Homogeneous Blending?
Yes. IBC blending systems can be relied on for the homogeneous blending of different ingredients.
There is never a need to transfer substances from one machine to another to realize homogenous blending.
This is further made possible by the easily understood control system.
All one has to do is to set the blending process for the intended results precisely.
Homogeneous blending will hence be realized within a shorter time
What is the difference between IBC Blending Systems and Ribbon Blender System?
IBC blending systems are relied on when mixing free-flowing powders and solids.
This is the most reliable machine for immediate product turn-over and containment.
This makes it the best machine for companies that produce several products.
The ribbon blenders, on the other hand, have ribbon-shaped blades.
The blades rotate throughout the U-shaped trough.
This usually happens in an axial direction.
They are relied on by food industries when mixing different types of ingredients.
It is fast and ensures quality output.
What are the Benefits of using V Blender System?
These are v-shaped blenders.
They are also used in pharmaceutical and food industries, just like the double cone blender.
The cosmetics industry also relies on this blender compared to double cone blenders.
For the v blender system, there are two connected cylinders divide and intermesh the particles of the products.
For each cylinder, there is an access cover.
The accesses are essential for loading the materials.
They can also be relied on for cleaning and inspection.
One remarkable advantage of these blenders is that it can mix between 2-10 different ingredients.
Which Industries use IBC Blending System?
Two primary industries rely on the pharmaceutical and food industries.
In the pharmaceutical industry, the IBC blending system is used in blending active ingredients.
Drugs are composed of various ingredients that are integral in making them effective.
In the food industry, the IBC blending system is relied on in preparation of spices and flavors.
It is also built on in cake mix.
In the chemical process industry, IBC blending systems are relied on in mixing chemicals and fertilizers.
The machines are also essential in mixing explosives, powdered detergents, and rubber compounds.
A similar fate befalls the glass and ceramic industries.
What are the Structural Design of IBC Blending Systems?
The IBC blending system’s design incorporates several parts essential in ensuring the machine functions appropriately.
The rotating frame: It is this part that rotates the bin.
This depends on the number of cycles.
The rotating frame helps in holding the bin securely and in readiness for blending.
The structural design also incorporates a driving system.
It is this part that rotates the rotary frame.
This is an essential process in the actualization of blending.
It is made possible by an electric motor.
The electric motor is has a rotating frame that uses a shaft, gears, and conveyors.
The other part of the structure is the lifting system.
This uses a hydraulic system that lifts the bin off the ground.
The PLC control system is the control panel for the machine.
It controls the blending action.
All the IBC blending machines have a similar structural design and working principle.
What is an IBC Tumbler Blender?
An IBC tumbler blender is a rotating mixing machine.
There are a variety of styles inherent in such blending machines.
Which Factors Affect Efficiency of Powder Mixing with IBC Bin Blender System?
There are several factors that one should consider when mixing powders.
The first approach to this is to decide whether to go for batch or continuous manufacturing.
For the production of the same product throughout, then the most preferred mode should be continuous production.
Batch production is only applicable when you intend to change the recipes often.
Most companies will, however, go for the batch production to satisfy customers’ preference for variety.
Factors such as the characteristics of the powder and the size of the batch also influence efficiency.
There are also factors such as cleaning and duration that the machine takes to mix the products.
Change-over-time is also a critical factor to consider.
Manufacturers are also advised to check on the risk of contamination.
This is because it affects the quality of the final product.
The space available viz a viz the size of the machine is also another determinant of the efficiency of the machine.
These factors will ensure that you get not only the best machine but also the best quality products.
Is there difference between Powder Mixing and Blending?
In most instances, people tend to use these words interchangeably.
However, this should not be the case because there exist small differences between the two.
For both processes, two or more products are mixed.
However, for blending, this is a rather gentle process.
In blending, you can be assured of the homogeneity of the combined products.
This process makes the products inseparable.
Comparatively, mixing is aggressive as it entails beating products that are being mixed.
Do Rotating Angle Affect Efficiency of IBC Blending System?
Yes, it does.
The rotating angles usually range between 200 and 300.
When you offset the IBC blender at these angles, the powder change direction of flow for each rotation.
The result is a shorter blending time and consistent results.
With the correct rotating angle, the best results are obtained within the shortest time.
What are the Quality Standards for IBC Blending System?
Before you choose an IBC blending system, there are several quality standards that you can check out.
Different regulatory bodies develop these quality standards.
In the subsequent section, you will familiarize yourself with some of the standardization marks to look out for.
Current good manufacturing practice regulations are one of the most important standardization regulations.
The Food and Drug Administration (FDA) develops these standards.
This is an important step that helps you determine whether the IBC blending system has been designed appropriately.
This set of rules are also essential in regulating the manufacturing processes production facilities.
This standardization certification is common in the European Economic Area.
For a product to get CE certification.
Some of the standards here include health standards and user-safety standards.
It also entails environmental protection standards.
You would want to check this out when purchasing your IBC blender from Europe.
This standardization is also essential for products manufactured outside Europe for the European market.
Restriction of hazardous substances is also a standardization mark originating from the European Union.
It protects consumers by restricting use of dangerous substances on the products.
Such hazardous materials include lead and mercury.
Other include chromium and cadmium.
This standardization mark is common in the Chinese market.
All products that are sold in the Chinese market have to conform to these standards.
Checking this out will help you determine whether the IBC blending machine you are purchasing is safe and of quality.
ISO 9000 is customer-centered standardization.
It aims at ensuring that the customers’ needs are addressed appropriately.
This should be done without compromising the quality regulations set for the product.
This is a globally accepted standardization organization.
All the standards agreed upon are published.
It applied also in the service industry.
Any product bearing this standardization mark has achieved quality.
What are the Benefits of Automated IBC Blending Systems?
One of the most significant benefits of IBC blending systems is the ability to prevent cross-contamination.
It also helps improve the quality of the blends and in minimizing batch integrity issues.
With an IBC blending machine, you can be assured of faster loading and unloading.
This is achieved through product containment.
This usually means that the IBC blender is a standalone unit.
As such, it can be loaded with the use of a forklift.
It doesn’t need clean-up, unlike conventional mixers.
With the automatic IBC blender, you will have guarded against spillages and contamination.
This reduces the number of times you will need to clean both the room and the machine.
With all these qualities, you can be assured of increased productivity.
How do you Choose Holder Type for IBC Bin Blender?
When you request a customized bin blender, one of the factors that come to mind is the handle.
The handle that you chose should be adaptable go different materials processing environment.
The holder you chose should be able to handle more than a particular size of the bulk container.
Another factor you should consider is the manufacturer of the machine.