However, recently GEA Liquid Processing found a producer of a batch mixer technology and refined it, for use in the pharmaceutical, biotech, chemical and personal care industry. This technology, proven to be the most versatile and efficient on products difficult to mix, is now used when producing products ranging from tablet coatings (cellulose-based) over toothpaste slurries (sorbitol, polymer-based) to various creams and ointments.
The keyword put forward by every producer has been efficiency as in short mixing time and short changeover time. A high level of hygienic design for easy CIP and SIP has been another demand. The Batch Formula mixer is fulfilling both demands.
The versatility of the Batch Formula Mixing System allows our customers to produce a wide range of products on the same system without having to make changes to the mechanical part of the system.
This trend is a challenge for the producers of products, where ingredients can be very complex. To be a successful producer in this struggle for the consumers a good and highly educated R&D department is necessary. Also a good co-operation with ingredient suppliers and equipment manufacturers is required in a world with a growing number of recombined products.
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More products are getting sensitive to shear forces, but need at the same time a very efficient and homogeneous base mix. A new technology was developed and patented for handling these products.
This new option we call the dynamic stator. The dynamic stator allows a better control of the shear forces in the mixing process. The shear forces are used for creating dispersions of powders and especially to create stable emulsions. The shear force is the hydraulic force between the rotor and the stator. Taking the centripetal speed - m/sec - and dividing it by the distance between the stator and the rotor - m - the shear force can be calculated.
The fact that one mixing head has both the ability to produce no shear and high shear forces to the product gives the product manufacturer a lot of new possibilities for a highly efficient mixing of their product and the versatility in producing different products on the same equipment.
The combination between the dynamic stator and the powder intake via vacuum under the liquid surface in the mixing vessel is the basis for the reduced mixing time and reduced cleaning time.
There are no circulation loops around the mixer. This means that the entire mixture in the vessel is forced through the mixing head up to 30 times more often than on conventional systems with recirculation loops. This is a big advantage when working with powder with poor wetability or solubility.
Another advantage by not having a circulation loop is that product mixes with very high viscosity (up to 100000Cp.) can be produced in the system.
Easy cleaning and thereby short down time is a must in modern production facilities. The Batch Formula is designed for true CIP and no dismantling is required for cleaning the system.
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Bjarne Darré is Division Manager, Pharma/Biotech & Personal Care, GEA Liquid Processing, Skanderborg, Denmark. www.gea-liquid.dk/geabatchformula
