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The main purpose of a food mixer is to combine ingredients by thoroughly spreading them out. Mixers are employed in the production of baked products, ice cream, pastry, cheese, and other dairy products, as well as in the manufacturing of some beverages and candies. Smooth, unstable, and thick liquids are the three main categories of liquids that mixers can handle. The process will take a specific time based on the viscosity of the liquid and the machine used. Mixing often involves hydraulic and pneumatic mixing machines.
Mixers aim to consolidate components by wholly incorporating them, whereas agitators aim to stir or move liquids. Mixers focus on the uniform distribution of substances, which may involve precise measurement, whereas agitators are more about the process of stirring without necessarily achieving a homogeneous mixture. Agitators typically deal with lower-speed operations, while mixers work at high speeds. Agitation might include frequency variation, whereas mixing requires variable speed and time settings.
Mixing generally involves a more complex movement pattern, such as cutting, stirring, squeezing, and beating, while agitation is a straightforward, repetitive circular motion. Automation is another feature that distinguishes the two. Advanced mixers may have automated features like programmable settings, whereas agitators are usually manual.
Size
Industrial mixing equipment is made in different sizes for specific purposes. In big factories, machines are often as wide as a room and can hold a lot of liquid at once. This helps when mixing big amounts of stuff. However, for small bakeries or kitchens, smaller, portable mixers are used. The sizes have to be manageable, so they don't take up too much space and can be moved easily.
Power source
Industrial mixers for later-stage production are powered by electricity coming straight from the factory's power grid to ensure consistent, uninterrupted mixing of large volumes of product. This eliminates the need for portable batteries, which are used in smaller food processing equipment because of their versatility and ability to service multiple locations within the facility.
Mixing speed
Industrial stirrer speeds are usually much slower than those of smaller-scale food processing equipment because more torque is required to mix thicker products in larger volumes. Additionally, slower speeds help prevent the product from aerating.
An important difference between mixers and agitators is that industrial mixers have more complex maintenance needs due to their industrial applications and higher usage rates compared to smaller-scale food processing equipment.
Maintaining the motor:
Check the motor regularly and make sure the bolts are properly tightened. If necessary, add lubricant to ensure the gearbox and trolley tracks run smoothly. Lubrication points should be clearly marked. Inspect belts to see if they need to be adjusted or replaced. Adjust the tension, make sure the pulleys align, and look for any signs of wear. If the mixer has a chopper or cutter, inspect the blades to make sure they are not worn out or damaged. Make sure to replace them if they are not cutting well or are not in good condition. Depending on how often the mixer is used, the electrically powered motors may have to be cleaned and maintained more often, while the motors that use belts and pulleys may require less frequent inspections and just some simple cleaning.
Maintaining drive parts:
While the main components are the motor and gearbox, the driving force behind the mixer is the belt and pulley, which also needs to be checked from time to time to ensure that it is functioning properly. Since more food companies are following strict hygiene standards, belts and pulleys now have to be cleaned better and more often to avoid any contamination.
Food and beverage companies are a major user of food mixers. They use high mixers and beaters to make baked foods like breads. Moreover, industrial and commercial businesses use agitators more often than home users. Industries like chemical manufacturing, mining, water treatment, and pharmaceuticals employ the use of agitators for various applications.
Chemicals are mixed to create new products or for better product effectiveness when consumed. For instance, the pesticides used in farming must have been mixed using an industrial mixer before reaching farmers' hands. The same applies to paints which also use a mixer for uniformity. In the mining industry, heavy agitators mix ore with water and other chemicals to help extract minerals.
Water treatment facilities use agitators to mix water with chemicals so that it can easily be purified and made safe for human consumption. Pharmaceutical companies use high agitator technology to create drugs, which are sometimes highly viscous.
Other industries that use chemical agitators include the oil and gas industry, where crude is constantly being agitated as it flows through pipelines, and the cosmetic industry, where creams and lotions are mixed with agitators.
Mixing drinks is also a popular use of agitators. Bars and restaurants often use electric agitators to mix cocktails and other drinks. Some home brewers also use small agitators to mix their brew at home.
Whether mixing drinks or chemicals, choosing the right mixing machine is critical to ensuring product quality and production efficiency. Understanding the differnce between agitator and mixer is the key to selecting the right equipment.
Identify business need first by determining the scale of production and the nature of the fluid to be processed. Will the process involve small, medium, or large volumes? What are the physical properties, such as viscosity and density? Once the business requirements are defined, the suitable mixing machines can be identified.
If a high-intensity mix is a business requirement, a mixer that provides uniform distribution and high shear forces should be considered. Choose a shearing mixer, such as a homogenous or colloid mill, which can apply high shear forces. If a low-intensity mix suffices to process liquids, an agitator might be more suitable.
Then, choose the right design according to production needs and the liquids to be processed. Agitator design varies according to the mixing goal, such as turbine, frame, or propeller. A turbine design with a large-diameter disc can be used for high shear mixing, while a frame agitator with a long cylindrical frame works well in narrow containers and reduces batch-to-batch variation. An agitator with propellers may suffice when mixing non-viscous liquids.
Next, the power required for mixing should be calculated to select a suitable motor. Apart from the mixer/motor's speed, mixing time and the percentage of liquid to be processed are important factors for this calculation. Higher power may be required for a mixture with a high viscosity of more than 2000 cP. Alos, when the percentage of liquid is low, and the mix is required to be homogenous throughout the container, more power may be required. Higher power may also be required when processing liquids with suspended solids, such as slurry.
Finally, consider the electrolytic process and corrosion. Liquid mixing and movement are facilitated by mixers. If corrosive liquids are involved, anti-corrosion treatments should be considered to prolong the equipment's life. Consider whether the liquid's flow is better through the mixer or the container.
Q1: Can an agitator stir food?
A1: Yes, agitators can be used in the food industry, in inkwells, and to stir chemical compounds. However, they may not be suitable for food items requiring gentle mixing, such as dough.
Q2: Which process is more suitable for an agitator, emulsifying or homogenizing?
A2: Homogenizing is more suitable since it requires high shear forces. The emulsifying process requires careful and gentle mixing to avoid breaking the emulsions.
Q3: Can mixers be used while under moving environments?
A3: Mixers should not be used in moving environments. The mixing process requires a stable surface to avoid injuries.
Q4: Do mixers come with speed preferences?
A4: Some mixers have speed preferences and can be adjusted to accommodate different mixing speeds. Generally, the standard speed is around 1,500 to 6,000 RPM.
