Many of the food we ingest, the drinks we swallow and the medicine we take starts out as a powder or bulk solid. It obtains its shape only after it undergoes a blending or mixing process. Although the mixers may take different shapes and look quite unalike, in reality, there are only two types. These are batch and continuous blending. The preference for one over the other may be personal, but it should be the result of several practical considerations.
What Is Continuous Blending?
As the name indicates, this process is a means through which the material – either bulk solids or powders, combines to produce a specific product. This occurs as the selected material travels from the initial entry point to the discharge point. In other words, during this form of blending, the four major steps of the process:
- Weighing
- Loading
- Blending
- Discharge
Occur simultaneously and continuously. The equipment employed may be designed specifically for this process. However, certain types of equipment can be adapted to perform this form of blending.
When to Use this Method
Whether the best option is to use continuous or batch blending depends upon a variety of factors. Among them are:
- Quantity of the material requiring mixing
- Bulk density
- Particle size and shape
- Desired levels of homogeneity
- Pre-mixing equipment
- Material handling equipment
- Post-mixing procedures
- Formulation requirements
In the case of the continuous type of blending, processors should consider employing this method when the following characteristics apply:
- Production rates need to be both high and continuous
- Continuity of batches are essential
- It is necessary to combine process streams (integration) effectively
- Improvement of efficiency
- Eliminate load errors
- Reduce labor costs
What is extremely important for food, beverage and pharmaceutical companies is not only the amount of production, but also the level of blend uniformity. By opting for continuous over batch blending, companies can achieve this level of product continuity.
With pharmaceutical products, this exactitude is essential. A poorly mixed or blended item may result in the injury or death of a customer. Until the last couple of years, however, pharmaceutical companies have been reluctant to utilize anything but batch systems. While the food and beverage companies have long since grasped their worth, pharmaceuticals have only discovered that this system can work safely and effectively in producing their products as well.
Continuous Blending: Fast, Productive and Safe
If you are starting a new blending operation or rejuvenating an older one, you still have two basic choices when it comes to blending. You can opt for a batch or a continuous system. While both do offer advantages, many companies, including pharmaceuticals, are currently realizing the profits that can arise from a continuous blending system, including the perfect mix time-after-time.
