1.0 OBJECTIVE: To describe the different types of Blenders in pharmaceutical Applications

2.0 SCOPE

This procedure is applicable to Blender selection in Tablet and powder department in XXX company

3.0 RESPONSIBILITY

3.1 Executive- Production

3.2 HOD-Production

4.0 PROCEDURE

4.1 It’s essential to pick the right blender for blending the pharmaceutical ingredients. There are various types of blenders for different uses, and the choice is made based on the needs. In the pharmaceutical sector, a blender is essential since medicine is made by combining a variety of medications and ingredients. Depending on the chemical properties and reactions permitted, this mixing must be done dry or wet. Blenders come in a variety of shapes and sizes, each with its unique function.

For the Purpose of Blending different types of blenders are used namely

1) Double Cone Blender

2) Octagonal Blender

3) V Cone Blender

4) Ribbon Blender

5) Mass Blender

6) Vertical Blenders

4.1.1 Double Cone Blender

Working principle of Double Cone Blender

Double cone blender comes in a standard and compact design. All the powder and granules are loaded into the cone for the mixing process to start. Only two-thirds of the cone is filled to ensure complete mixing. The cone of the double cone blender is placed statistically so the chances of overload on the mixture are eliminated.

The paddle type baffle in the cone strategizes the uniform mixing in the cone. The stipulated time is taken to mix which may vary depending on how difficult the substance to be mixed may be. The side-valve then helps in the discharge of the mixed material. The double cone blender has a polished surface which makes it very easy to be cleaned manually.

Design and Construction of Double Cone Blender

The double cone blender is available in different designs, models, and capacities.

You can find a blender that is specifically for sensitive mixtures with the risk of breaking.

The breakage will assist in minimizing the generation of dust.

The time a blender takes in mixing ingredients will depend on the nature of ingredients and the mixture you desire.

Looking at the interior, you will see a cone on a pivot axis on the two sides of the blender.

This design assists in gravity discharge and the elimination of dead space.

The design specifications have to meet the quality standards set by different organizations such as AISI 316 and AISI 304.

AISI 316 is for every part that is in contact with the products you are blending.

AISI 304 is the quality standard for the support and the other parts of the equipment.

The external and internal parts have a bright and shining quality finish.

Due to the absence of edges and corners, and the polished surface, it becomes easy to clean the unit.

You can either clean it manually or automatically using the CIP system.

The design usually incorporates electrical safety with the help of a guard rail which is in accordance with EC safety standards.

There are however a few options that you may desire in a double cone blender.

These include:

i. The design might have a liquid spray system that will introduce the liquids during the blending process.

ii. Some of the modern double cone blenders have automatic stop positions.

These positions include loading, sampling, and discharging where the blender performs a cycle to slow down the mixture.

It will reach the stopping position with the highest precision and remain at a halt.

iii. You can also opt for a unit with an automatic loading system for introducing granules and powders.

It loads the machine by the means of a vacuum unit that has self-cleaning hoses preventing the creation of dust.

iv. It might also include a monoblock vacuum with a liquid ring pump.

v. You can also opt to install an automatic discharge system.

The system includes a receiving hopper with automatic self-cleaning filters.

The design and construction are not complete without knowing the parts of the double cone blender.

In the next section, you will learn about the parts of a double cone blender.

Let us go through some of them.

Parts of Double Core Blender

The double cone blender consists of different parts.

Below is a diagram that gives you an overview of the parts of a double cone blender.

Feeding Port

The feeding port is an opening on top of the double cone blender barrel.

It serves as the main inlet for the double cone blender.

It has a lid that you have to close during the blending operations.

Barrel

It is a huge container with a conical shape that houses the twin cones.

It also receives the solid ingredients that you will be blending.

Apart from that, it protects and secures the solid ingredients from falling off the machine.

The main material is stainless steel with a completely smooth and shiny surface.

Helical Blades

The helical blades are usually inside the barrel.

The blades are responsible for cutting the solid ingredients into very small pieces.

Besides that, the stainless steel blades help in blending the ingredients to form a uniform mixture.

Actuating Unit

The actuating unit assists in controlling and moving a system or mechanism of the double cone blender.

Basically, it controls the opening and the closing of the valve that discharges the mixture from the blender.

Machine Structure

The structure of the machine is the whole unit that stands on the ground.

It provides enough support for the barrel and all the other parts of the double cone blender.

It is strong enough to hold the whole system in place during normal operations.

Injection System

The injection system allows you to add small amounts of liquids into the barrel during the blending process.

It may be in a form of the spray gun to splash the liquid into the mixing barrel.

It is one of the optional parts that you can request.

Covering

The covering is the lid that you will use to cover the barrel.

It has a safety pin that will ensure that the cover is in place.

It protects the ingredients from falling off during the blending process.

Injection Tip

The injection tip allows you to inject more ingredients into the blending process.

It is a small nozzle inside the barrel that injects liquids during the blending process.

It is also an optional part that you can request from the manufacturer.

Operating System

The Operating system is the digital control unit that allows you to operate the whole system.

Most of the machines are automatic so the operating system will control all the operations.

You can comfortably control all the variables from the operating system apart from loading the ingredients.

Flanged Hole

It is a connection of pipes, pumps, valves, and other parts of the double cone blender.

It gives you the allowance for easy access to cleaning, modification, and inspection of the double cone blender.

You can make a flange hole by bolting, welding, and screwing different pipes.

Hinged Cover

It is a type of a cover with a hinge connection to the barrel.

The hinge makes it easy to open and close the cover of the barrel.

Apart from that, it holds the cover in place from falling off in case the cover pops out.

Slide/Butterfly Valve

This is the part of the double cone blender that will assist you in discharging the mixture from the barrel.

It uniformly discharges the mixture from the barrel after a successful mix.

It has a smooth and shiny surface of stainless steel to allow the mixture to slide off.

Intensifier Bars

The intensifier bars make the double cone blenders more adaptable to more applications.

Also, the bar runs through trunnions and into the barrel of the double cone blender.

The connection is in sync with the spray pipes for the addition of liquids.

Double cone blender parts

Fully Integrated motors and controls

The motors and controls help in monitoring the movement of ingredients and other parts of the double cone blender.

The machine depends on the motors and controls to determine the slanting angle among other key movement issue.

You will use the controls in conjunction with the operating system.

With the arrangement of the parts at your fingertips.

The main functions of the double cone blender include:

i. You can use the double cone blender to homogenously mix dry granules and powders. This is the main function of the double cone blender.

ii. Again, you can also use it to mix other forms of solid substances that are not necessarily dry.

This will depend on the type of double cone blender that you are using.

Some of them have injectors that will add in liquids during the blending process.

iii. De-agglomeration of different solid particles into smaller and finer particles for the proper and uniform mixture.

iv. You can also use it to dry the wet components.

As much as you will be adding liquids, the machine can ensure proper drying of the wet components.

v. You can also use it for the purpose of wet massing to make granules.

As much as it can de-agglomerate, the machine can also granulate through wet massing.

Well, let us proceed with the advantages and disadvantages of the double cone blender.

ADVANTAGES OF BLENDER

i. Has an attractive structure that is easy to clean and operate.

ii. The working stability is high and less noisy.

iii. Has very high uniformity for blending of almost all materials.

iv. You can vacuum feed the blender and discharge the mixture by the butterfly valve.

This will help in reducing the amount of dust that the machine emits.

v. It has overloading protection that will protect the motor.

It also has a tachometer that will control the location of discharging materials.

vi. Comes with a force agitator as an option in case materials lack fluidity.

vii. Also available are spray devices that inject small-scale liquids whenever necessary.

viii. There is a jacket that assists in heating, cooling, and drying materials.

ix. It also has flameproof electrical as an option for you to choose from.

x. The cone shape on both ends enables easy mixing and uniform discharge.

Despite the advantages of the double cone blender, it has its demerits.

Let us look at some of them.

DISADVANTAGES

i. Operating double blender equipment can be a daunting task.

You will need to have professional guidance to assist you in the operations.

ii. As much as it has a greater capacity, you will not use the whole capacity.

It limits you to a certain level thus rendering the other part of the barrel useless.

iii. It is bulky and therefore limits the ability to move it from one place to another freely.

iv. You need to have enough space to place the double cone blender.

This is because of the big size that will occupy a lot of space.

v. As much as it is safe, you need to ensure that you protect yourself.

It is prone to mechanical failure just like any other machine.

vi. Do not dwell so much on the disadvantages as they are never a big deal.

You can avoid most of them by being careful and planning in advance.

Let’s have a look at some of the designs and construction of a double cone blender.

4.1.2 Octagonal Blender

The name “Octagonal” is given because of its form and the ability to hold larger quantities of particles. Octagonal Blender might be similar to double cone or even “V” adjuster but occupies less space and power.

Equipped with a shell of octagonal shape supported by both ends, the special thing about this machine is that even though it operates in low speed operation, it balances high proportion of material in a very convenient manner.

Similar to double cone Version, it gently mixes dry particular and fine granules in a homogenous mixture and has a vacuum charging system for dispatching.

Octagonal blenders are a perfect match for the pharmaceutical industry where the gentle blending of dry ingredients /powder needs to be done.

4.1.3 V Cone Blender

One of the most equipment in this category, V cone blender adjuster or twin shell adjuster comes with two hallow cylindrical shells wielded at an angle of 75 degree of 90 degree.

The equipment is mostly used when there is a need of precise formulation of powder and granules mixing & lubricating. The containers having the “V” shape creates continuous split and recombines the materials creating minimal attrition.

The equipment is mostly used in pharmaceutical, food, cosmetics, nutraceutical, plastic and other allied industries. Easy to clean and with an option of intensifier bar for special applications, V cone mixer is designed in a manner to give its customers a wear resistant discharge, minimal maintenance and zero contamination.

4.1.4 Ribbon Blender

Ribbon Blender consists of a “U” form or “W” shaped horizontal trough containing double helical ribbon agitator that rotates inside.

This light duty model is well suited for solid materials such as powders and other fluids with low shear capacity. The appliance is designed in such a way that it achieves efficiency with triple mixing action.

Although designed for handling solids, this model is versatile and can also handle liquids and gas streams. Ribbon Machines are one of the most efficient machines available for blending in the market.

This technology is used in a variety of sectors such as pharmaceutical, food, chemical, plastic and other sectors. Despite these benefits, optimal usage depends on proper customization and depends from batch to batch.

The ribbon mixer has a lot of advantages such as wear resistant, corrosion resistant, easy to dispatch, belt driven power transmission, and cooling jackets for a variety of applications.

4.1.5 Mass Blender:

This machine is ideal for lump, dry and wet mixing, as well as tablet granulation. In a horizontal plane, the mixer cabin only rotates at one speed.

For easy granulation, blades shaped like paddles are placed inside the cabin in a horizontal orientation.

The polycarbonate covering is dustproof and transparent, allowing for close control without sacrificing quality. When the cover is opened, an automated safety catch shuts down the mixer.

4.1.6 Vertical Blenders:

These blenders are ideal for mixing solids such as pellets, powder, granules, and granules. They are versatile because they are available in a variety of sizes and can be customized to meet the needs of the industry.

These blenders have the following features:

(a)Complete discharge is possible because there are no bearings to support the bottom.

(b) They are simple to clean in place and pose little risk of contamination.