MIXING

DEDFINITION: -
Mixing is defined as a process that tends to result in a randomization of dissimilar particles within
a system. The term it means to put together in one mass or assemblage with more or less thorough
diffusion of the constituent elements among one another. The term blending means to mix
smoothly and inseparably together. During blending a minimum energy is imparted to the bed.
These terms are commonly used interchangeably in the industry. Some of the mixing operations
in the dispensing practice are spatulation, trituration, tumbling, geometric dilution etc, However,
industrial pharmaceutical mixing involves large-scale equipment. A major complication in the
intimate mixing of particles is the segregation of particulate.
The diverse characteristics of particles, such as size, shape, volume, surface area, density, porosity,
flow and charge, contribute to the solid mixing. It is difficult to predict the inter-particle
interactions, particularly in solids. Therefore, some empirical correlations are possible. In practice,
optimum mixing is considered satisfactory.

Depending on their flow properties, solids are divided into two classes; cohesive and non-cohesive.
Non-Cohesive materials such as grain, dry sand and plastic chips readily flow out of a bin or silo.
Cohesive materials such as wet clay is characterised by their resistance to flow through openings
of the containers. There are significant differences between solid mixing and liquid mixing. These
are given below.
APPLICATIONS:
Mixing is one of the most common pharmaceutical operations.
It is involved in the preparation of many types of formulations. Mixing is also an intermediate
stage in the production of several dosage forms.
Wet mixing in the granulation sleep in the production of tablets and capsules.
Dry mixing of several ingredients ready for direct compression as in tablets.
Dry blending of powders in capsules, dry syrups and compound powders (insufflation).
Production of pellets for capsules.
In the manufacture of tablets, normally a number of additives are added. Therefore mixing of
powders becomes an essential part of the process. When the dose of the active substance is high
(for example paracetamol tablets) mixing is not a problem. But in case of potent drugs and low
dose drugs, high amounts of adjuvants (for example lactose) are added. Therefore, mixing is
considered as a critical factor. Otherwise, content uniformity of tablets does not conform to
pharmacopoeial specifications.
Similarly, weight variation increases Mixing of cohesive materials is even more difficult due to
form a of aggregates and lumps. Wet mixing is also encountered in pharma as an individual
operation or as a subsequent step after dry blending several situations, these operations are carried
out in a vessel and some mixing clement. Hence, this section describes some aspects theoretical
considerations and equipment for dry as well as wet mixing.
FACTORS INFLUENCING MIXING
Particle and powder characteristics influence the mixing process. Aggregation inhibits proper
mixing. Therefore, higher shearing forces are applied. Hence, correct mixing of one component
does not imply good mixing of other components. Therefore, adding dye to the mixture is often
misleading. The dye may not aggregate, but active substance may aggregate.
A single factor can in no way be considered as a unique indication of mixing. However, flow
properties of the components is the most important consideration which is again influenced by a
number of Factors.
NATURE OF SURFACE:
Rough surface of one of the components does not induce satisfactory mixing This can be due to
the entry of active substance into the pores of the other ingredients.
Adding a substance, which will be adsorbed on rough surface particles, can decrease aggregation.
Example is the addition of aerosol (colloidal silicon dioxide) to zinc oxide. Thus, a strongly
aggregating zinc oxide becomes a fine dusting powder, which can be mixed easily.
DENSITY OF PARTICLES:
It is of minor importance. Demixing is accelerated when the density of the smaller particles is
higher or when the mixing process is stopped abruptly This is due to the fact that dense material
always moves downward and settles at the bottom.
PARTICLE SIZE:
It is easy to mix two powders having approximately the same particle size. The variation of particle
size can lead to separation, because the small particles move downward through the spaces
between the bigger particles. As the particle size increases, flow properties also increase due to the
influence of gravitational force on the size. Beyond a particular point, flow property decreases.
The powders with a mean particle size of less than 100 um are free flowing, which facilitates
mixing.

PARTICLE SHAPE:
The ideal particle is spherical in shape for the purpose of uniform mixing. The irregular shapes can
become inter locked and there are less chances of separation of particles once these are mixed
together
PARTICLE CHARGE:
Some particles exert attractive forces due to electrostatic charges on them. This can lead to
separation or segregation.
PROPORTION OF MATERIAL:
The best results can be obtained if two powders are mixed in equal proportion by weight and by
volume. If there is larger difference in proportion of two powders mixing is always done in the
ascending order of their weights.
SIGMA BLADE MIXER

The sigma blade mixer is a commonly used mixer for high viscosity materials. One of the most
popular used for mixing and kneading of high viscosity materials. It belongs to the family of double
arm kneader mixers.

Principle:
• The mechanism of mixing is shearing.
• The inter meshing of sigma shaped blades creates high shear and kneading actions.

• The mixing action is a combination of bulk movement, shearing, stretching, folding,

dividing, and recombining as the material is pulled and squeezed against blades, saddle,
and side walls.
Construction:
• The design is mostly based on the curvature and concavity of the kneading blades.
• It consists of double trough shaped stationary bowl.
• Two sigma shaped blades are fitted horizontally in each trough of the bowl.
• These are connected to a fixed speed drive.
• The mixer is loaded from the top and unloaded by tilting the entire bowl by means of a
rack and pinion drive.
• It consist of saddle shaped container made of either Mild Steel or Stainless Steel 304 or
316 with jacket of covering two side for heating or cooling application & dust free cover
to get Vacuum if desired or normal cover.
 • The mixing elements (Blades) are of Sigma type Steel casted and duly finished two in
number which contra rotate inward fitted at close or specified clearance with the container
to give thorough and uniform mixing.
• There is a Gland pusher of Gun Metal Bush which ensure minimal friction and extend the
life of mixing elements (Blades) Shaft.
• The complete Mixer is Mounted on Steel Fabricated stand of suitable strength to withstand
the vibration and give noise free performance.
Different types of Sigma Blades:
Two wing blade Sigma- or Z-form blade. The shape of the kneading blades enables a steady flow
of material from the side walls of the kneading trough to the middle of the trough.

Figure 2: Different types of blades

Drive: The Drive Consists of Motor of type TEFC Or TEFC Flameproof of Specified 440 RPM,
Reduction Gear Box of Reputed Make having suitable size and ratio, Spur Gears, are also provided
of adequate size and having machine cut teeth, between the front and rear blade complete with
guard suitable for grease lubrication.
Working:
• Different powders are introduced from the top of the trough.
• The body is covered because considerable dust may be involved during dry blending and
granulating solution may evaporate during wet granulation.
• The kneading blades first squash the mass flat and then roll it on itself and squash once
again.
 • It tears the mass apart, and shear it in between the moving blades and the stationary surface
walls. Through the fixed speed drive, the sigma blades are allowed to rotate.
• The blade move at different speeds. The effectiveness of mixing depends upon the kneader
blade design, sometimes they are made very rugged, and of different shapes. The edges of
the blades may be more serrated to give higher shredding action.
Applications:
• The sigma mixer is the best suited mixer for pasty, sticky, and gritty slurries with high
viscosities.
• The following are some of the commonly used products that are mixed in the sigma mixer:
Adhesives, Biscuit dough, Butyl rubber, Bakery, Carbon pastes, Ceramics, Chemicals,
Chewing gum, Crayon and pencil lead, Explosives, Fiberglass resin dough's, Food and
confectionery products, Gaskets and gland packing's, Grinding wheel preparations, Hot-
Melts, Inks and pigment products, Marzipan, Mastics, Metal powders, Moulding
preparations, Pencil erasers, Pharmaceuticals, Plastics, Sealing compounds, Silicone
rubber, Soaps and detergents, Solid propellants, Sugar pastes and Viscous rubber solutions
.
Advantages:
• Sigma blade mixer creates a minimum dead space during mixing.
• Ideal for mixing, kneading, of highly viscous mass, sticky & dough like products
Disadvantages:
• Sigma blade mixer works at a fixed speed, extruding.
• These mixers and their variants (double arm kneader mixer extruders) are capable of
handling material with viscosities as high as 10 million centipoises.
• The power consumption in double arm kneader mixer is very high compared to other types
of mixers and can range from 45 to 75 kW/m3 of mix material.

PLANETARY MIXER
Planetary Mixers are used for intensive mixing, dispersing, kneading, and deaerating products
such as adhesives, sealants, light caulks, pastes, coatings, granulations, and similar products of
medium to high viscosity. Rotation of the Planetary Blades on their own axis while they travel
around the centre of the mixing bowl ensures complete and effective mixing.
The mixers are available in various sizes, with or without self-aligning bowl scrapers, and manual
or hydraulic lifts. Heavy-duty construction allows the production of newer and tougher compounds
in a trouble-free manner, while also being very durable and reliable in operation. The mixers are
manufactured to rigid standards with many features and options available.

The planetary mixer is an industrial equipment conceived/made to prepare food, chemical,

ceramic dough or other type of product, replacing manual labour through a mechanical system that
allows to produce, continuously, large quantities of dough. Mixing element (whisk, hook, flat
beater, scrapper or other system)

COMMON FEATURES: -
• Single or Double Planetary Blades.
• Floating scraper blade adjusts to bowl contour.
• Single base structure to for simplicity in mounting.
• Lift manually or hydraulically operated (air/oil or electric pump)
• Special steel planetary gears, heat treated and hardened for durable, long life.
• Stirrup, Vertical, or combinations of blades available.
• Heating, Cooling or Vacuum Construction
PRINCIPLE: -
• Planetary mixer is a new high efficiency and no dead-dead mixing equipment, it has a
unique, novel mixing form, the kettle has two or 3 of multi-layer pulp-leaf mixer and 1~2
an automatic scraper, agitator in the body axis around the vessel revolution, and at different
speeds around its own axis high-speed rotation, so that the material in the kettle for complex
movement.
• The efficiency of a strong shearing and rubbing is usually several times that of an
ordinary mixer.
• Currently common planetary mixers usually have two low speed planetary agitator
(usually multiple oblique blades, twist, frame), one or two high speed planetary agitator
(dispersing plate) and scraping paddles.
CONSTRUCTION & WORKING: -

• The planetary mixer is so named because the mixing blade (commonly known as the
beater) rotates in a planetary motion inside the mixer bowl.
• The bowl of the single planetary mixer consists of an upper cylindrical section and a lower
hemispherical section.
• The mixer bowl is secured to a semi-circular frame (also termed as “fork") at the time of
mixing.
• The beater profiles are shaped to match the lower curved surface of the bowl. The beater
has two types of movements: it revolves on it own vertical axis at high speed.
• At the same time, this vertical axis rotates around the centre of the bowl at a relatively
lower speed
• The direction of rotation of the beater on its own axis and that around the axis of the bowl
is in opposite directions.
• The planetary motion is generated by mounting a gear pinion on the beater shaft, which is
driven on a stationary internal gear ring. is a schematic representation of the drive
arrangement for creating the planetary motion.
• The planetary motion of the beater is very effective in mixing the contents of the bowl.
There are virtually no dead spaces in the mixing bowl.
• Scrapers with Teflon edges may be provided to wipe any material which may stick onto
the internal surface of the bowl.
• Single planetary mixers are relatively inexpensive, versatile, and can be constructed in a
range of sizes. The popular features of this mixer are the possible use of multiple bowls
and beater designs with the same mixer assembly.

ADVANTAGES
• Optimum homogenization of mixing material, even in challenging applications
• Low wear and minimal maintenance
• Minimal waste
• Mixing stars rotate on different axes
• Material is completely recirculated with only one revolution of the mixing tools
APPLICATIONS OF PLANETARY MIXER
• General Chemical Industries
• High-Viscosity Compounds
• Adhesives and Sealants
• Caulking, Putty and Wax Compounds
• Pharmaceuticals and Biotech
• Inks of Medium to High Viscosity
• Thixotropic Dispersions and Emulsions
• Dental Fillers and Gel Products
• Castable Ceramics
• Battery Pastes
 • Metal Composites
• Electronic Dispersions
• Powder Coatings
SILVERSON MIXER:-
PRINCIPLE: -
• Produces intense shearing forces and turbulence by the use of high-speed rotors.
• This turbulence causes the liquids to pass through fine interstices formed by closely
placed perforated metal sheets. circulation of material takes place through the head by the
suction produced at the inlet at the bottom of the head.
• Circulation of the material ensures rapid breakdown of the dispersed liquid into smaller
globules.

CONSTRUCTION: -
• It consists of long supporting columns connected to a motor which give support to the
head.
• The central portion consists of a shaft, one end is connected to motor and the other end is
connected to head. The head carries turbine blades.
• The blade is surrounded by a mesh which is enclosed by a cover having openings.
WORKING: -
• The emulsifier head is placed in the vessel containing immiscible liquids in such a way
that it is completely dipped in the liquid.
• When the motor is started the central rotating shaft rotates the head, which in turn rotates
turbine blades at a high speed.
• This creates a pressure difference. As a result, liquids are sucked into the head from the
centre of the base and subjected to intense mixing action centrifugal forces expel the
contents of the head with great force through the mesh and onto the cover.
 • As a result, a fine emulsion emerges through the openings of the outer cover. T
• he intake and expulsion of the mixture set up a pattern of circulation to ensure rapid
breakdown of the bigger globules into smaller globules.
USES: -
• Preparations of emulsions and creams of fine particle size.
ADVANTAGES: -
• Available in various sizes that can handle liquids ranging from few millimetres to
thousands of litres.
• Used for batch operations and continuous operations by incorporating a pipeline through
which the immiscible liquids flow.
DISADVANTAGE: -
• Occasionally there is a chance of clogging of pores in the mesh.
REFERENCE: -
Pharmaceutical Engineering by CVS Subrahmanyam.
 DECCAN SCHOOL OF PHARMACY
DARUSSALAM, AGHAPURA
HYDERABAD-500001, TELANGANA

PHARMACEUTICAL ENGINEERING
ASSIGNMENT- 2

MIXING-DEFINITION, APPLICATION, FACTORS

INFLUENCING, PLANETARY, SIGMA BLADE AND
SILVERSON MIXERS
SUBMITTED TO: Mr. M. SURESH BABU
ASSOCIATE PROFESSOR
DEPARTMENT OF PHARMACEUTICS

PREPARED BY: HALEEMA SADIA SIDDIQUI

REGISTRATION NUMBER: - 170718881023

B. PHARMACY, SECOND YEAR: 3RD SEMESTER

 DECCAN SCHOOL OF PHARMACY
DARUSSALAM, AGHAPURA
HYDERABAD-500001, TELANGANA

PHARMACEUTICAL ENGINEERING
ASSIGNMENT- 2

MIXING-DEFINITION, APPLICATION, FACTORS

INFLUENCING, PLANETARY, SIGMA BLADE AND
SILVERSON MIXERS
SUBMITTED TO: Mr. M. SURESH BABU
ASSOCIATE PROFESSOR
DEPARTMENT OF PHARMACEUTICS

PREPARED BY: NOORA SALEEM

REGISTRATION NUMBER: - 170718881043

B. PHARMACY, SECOND YEAR: 3RD SEMESTER

 DECCAN SCHOOL OF PHARMACY
DARUSSALAM, AGHAPURA
HYDERABAD-500001, TELANGANA

PHARMACEUTICAL ENGINEERING
ASSIGNMENT- 2

MIXING-DEFINITION, APPLICATION, FACTORS

INFLUENCING, PLANETARY, SIGMA BLADE AND
SILVERSON MIXERS
SUBMITTED TO: Mr. M. SURESH BABU
ASSOCIATE PROFESSOR
DEPARTMENT OF PHARMACEUTICS

PREPARED BY: MOHAMMED MUQTHADIR

REGISTRATION NUMBER: - 170718881003

B. PHARMACY, SECOND YEAR: 3RD SEMESTER

 DECCAN SCHOOL OF PHARMACY
DARUSSALAM, AGHAPURA
HYDERABAD-500001, TELANGANA

PHARMACEUTICAL ENGINEERING
ASSIGNMENT- 2

MIXING-DEFINITION, APPLICATION, FACTORS

INFLUENCING, PLANETARY, SIGMA BLADE AND
SILVERSON MIXERS
SUBMITTED TO: Mr. M. SURESH BABU
ASSOCIATE PROFESSOR
DEPARTMENT OF PHARMACEUTICS

PREPARED BY: MOHAMMED MAHBOOB SHAREEF

REGISTRATION NUMBER: - 170718881033

B. PHARMACY, SECOND YEAR: 3RD SEMESTER

 DECCAN SCHOOL OF PHARMACY
DARUSSALAM, AGHAPURA
HYDERABAD-500001, TELANGANA

PHARMACEUTICAL ENGINEERING
ASSIGNMENT- 2

MIXING-DEFINITION, APPLICATION, FACTORS

INFLUENCING, PLANETARY, SIGMA BLADE AND
SILVERSON MIXERS
SUBMITTED TO: Mr. M. SURESH BABU
ASSOCIATE PROFESSOR
DEPARTMENT OF PHARMACEUTICS

PREPARED BY: MOHAMMED ABDUL REHAAN

REGISTRATION NUMBER: - 170718881013

B. PHARMACY, SECOND YEAR: 3RD SEMESTER