PerMix Powder Induction Mixer

The four types of Powder Induction Mixers share similar working principle, but with some difference:
(1) PT-C/Q (Double Wall Design Powder Induction Mixers)

The PerMix PT-C/Q Powder Induction Mixer is the most common type which is also called Tri-blender. It has two key parts, a casing pipe and a stator rotor system.

The casing pipe is built vertically and coaxially into the stator rotor system inlet. This double-wall design prevents the powder going through the casing pipe contacting the liquid and forming lumps before they both arrive at the stator rotor system. As the rotor running at high speed during operation, liquid enters into the chamber and a water ring is created.

Vacuum is generated at the center which causes suction of the powder from the hopper above the chamber. A valve at the bottom of the hopper is used to regulate the falling rate of the powder. As soon as the powder gets in contact with the liquid, it is wetted and dispersed into the liquid by the turbulence and later high shear force when the mixture goes through the precise machined clearance between the stator and rotor, and radiated out through the stator openings.

By choosing different types of stator rotor, it can provide various functions of powder wetting, homogenizing, etc. PerMix provides high shear stator/rotor, low shear stator/rotor; and in some cases where the powder is easily being dissolved into the liquid, only a regular centrifuge pump impeller is used without a stator, and it provides higher volume flow rate and bigger powder induction rate.

2) PT-C/Y (Special Stator Rotor Powder Induction Mixers)
PerMix PT-C/Y series Powder Induction Mixer has a very specially designed stator/rotor, which works by the principle of a water ring pump, that is able to produce relatively high vacuum; this vacuum makes the PT-C/Y Powder Induction Mixer able to suck the powder through a hand-held wand from a bag or other container at ground level. The powder can also be incorporated from a vertical hopper by gravity at a much higher powder sucking rate.

(3) PT-C/F (Two Pumps Design Powder Induction Mixer)
The PT-C/F Powder Induction Mixer System is designed with the combination of a self-priming pump and an inline homogenizing mixer. The self-priming pump draws the liquid from an external container, and when the liquid passes through a venturi pipe which is located at the bottom of a powder hopper, vacuum is generated there and sucks the powder from above. The powder/liquid mixture will first pass through the self-priming pump, and later get further sheared and dispersed at the inline homogenizing mixer.

(4) PCH (Shear Pump)
By adding a hopper at the inlet of the liquid, our PCH Shear Pump can be converted to a Powder Induction Mixer, to provide perfectly good sucking performance for dry and free flowing powders, for example, milk powder, dry flour, etc. Due to the relatively simple and compact design and full stainless steel construction, the PCH is popular in many hygienic applications.

Some typical applications can be:

1. Preparation of syrup, sorbitol, glucose, lactose, etc.
2. Reconstitution of powdered milk, whey, protein, etc.
3. Dissolution of CMC, Xanthan gum, etc
4. Preparation of flour and starch slurries
5. Preparation of brines
6. Pre-mixtures of yogurt and other milk-based desserts
7. Suspension of bentonites, TiO2 in pigment
8. Preparation of pesticides and fertilizers

A lot of options are available for the PT-C Powder Liquid Mixer

1. Powder hand-held hose assembly
2. Variable speed motor; Frequency converter
3. Multi-row, multi-stage stator & rotor
4. Metal part to be SS 316L or others
5. Gasket sealing of FPM, FFPM, etc.
6. Hopper of 50°, 60°, etc.
7. Hopper vibrator or Air sweeper
8. Single or double mechanical seals

Automating the manufacturing of hand sanitizer using PerMix High Shear Mixers involves designing a streamlined, efficient production process that ensures consistent quality, hygiene, and throughput. Here’s how you can achieve this:

1. Equipment Selection

• High Shear Mixer Model: Choose a PerMix High Shear Mixer suited for liquid mixing applications. For hand sanitizer, the inline or batch high-shear mixers are ideal.
• Materials of Construction: Ensure the mixer is constructed from 316L stainless steel for sanitary and corrosion-resistant operation.

2. Integration of Raw Material Handling

• Automated Feeding System:
  • Use a dosing system for liquids such as alcohol, glycerin, and water.
  • Incorporate metered dosing pumps for consistent ingredient ratios.
  • Dry ingredients like thickeners or fragrances can be added via a vacuum conveyor or hopper.
• Storage Tanks: Install sanitary storage tanks with level sensors to hold raw materials before mixing.

3. Mixing Process Automation

• PLC-Controlled Mixer: Equip the PerMix High Shear Mixer with a PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) for recipe management and process automation.
  • Steps to Automate:
    1. Automatic material loading based on predefined recipes.
    2. Mixing time and speed control for each batch.
    3. Temperature monitoring and control (if heating or cooling jackets are used).
    4. Homogenization using the mixer’s high-shear rotor-stator mechanism.

4. Heating & Cooling (Optional)

• For gel-based or viscous hand sanitizers, include a jacketed tank to heat or cool the batch as required.

5. Quality Assurance

• Inline Quality Testing: Install sensors or analyzers for pH, viscosity, or alcohol concentration during mixing.
• Real-Time Monitoring: Use IoT-enabled sensors for continuous monitoring and reporting of critical parameters.

6. Discharge & Filling

• Automated Discharge System:
  • Use pneumatic or pump-assisted discharge to transfer the hand sanitizer to the filling line.
  • Connect the discharge directly to automated bottling machines.
• Filling Line: Automate bottling with volumetric or gravimetric fillers, cappers, and labelers for efficient packaging.

7. Cleaning & Sanitization

• CIP System: Equip the mixer and related equipment with PerMix’s Clean-in-Place (CIP) system for automated cleaning after each batch.
  • Options include water-only, air-only, or a combination of both.

8. Data Logging & Reporting

• Collect and log data from the PLC for each batch, including ingredient amounts, mixing parameters, and quality metrics. Use this data for traceability, compliance, and process optimization.

9. Scale-Up for Large Production

• For larger volumes, integrate multiple PerMix High Shear Mixers with a central control system to manage simultaneous batch processing.

10. Compliance & Safety

• Ensure the entire system complies with GMP (Good Manufacturing Practices) and FDA or local regulations for hand sanitizer production.
• Install explosion-proof mixers and equipment if the alcohol concentration requires it.

This automated system ensures high-quality hand sanitizer production with minimal manual intervention, optimized resource use, and consistent output.