MIXING & HOMOGENIZATION 2019
MIXING & HOMOGENIZATION
Operation where two or more than two substances are combined together.
Perfect mixing is that in which each particle of one material
lies as nearly adjacent as possible to a particle of other
material.
OB JEC TIVE OF MIXING
Simple physical mixing of material to form uniform mixture..
Promote chemical reaction to get uniform product.
Dispersion of solids in liquids to form suspension or paste.
Dispersion of two immiscible liquids to form an emulsion.
TYPES OF MI X TU R E S
Positive mixture:-
when two or more than two miscible liquids are mixed or soluble solid is
dissolved in water, the mixture are called as positive mixtures.
They do not cause problems in mixing & these mixtures are
irreversible.
Negative mixture:-
when two immiscible liquids are mixed or insoluble solids are mixed
in water the form negative mixtures.
Higher degree of mixing is required.
The mixture so formed is reversible.
Neutral mixtures:-
These mixtures are static in behavior.
The substances do not have tendency to mix with each other immediately, but
once mixed they do not separate.
MIXING OF POWDERS
For tablets, capsules and compound powders.
Mixing mechanisms:-mixing takes place by a combination of one or more
mechanisms given below:-
• Convective mixing:- bulk movements of group of particles from
one part of powder bed to another. It occurs by inversion of
powder beds by means of blades or paddles.
• Shear mixing:- reduces the scale of segregation by thinning of
dissimilar layers of a solid material.
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• Diffusion mixing:- occurs when random motion of particles within
powder bed causes them to change position relative to one another. It is
produced by any form of agitation of powder.
F A C TORS AFF ECTING MIXING OF POWDERS
Particle size
Variation of particles size can lead to separation, due to small particles move
downward through the spaces between the large particles.
Particle shape
Ideal particles shape is spherical shape for uniform mixing. The irregular
shapes can become interlocked and are less chances of separation of
particles once mixed.
Particle attraction
Some particles exert attractive forces due to electrostatic charges on them
which can lead to separation
Material density
It is difficult to mix two powders having different density this is due to fact
that dense material always moves downward & settles down at bottom.
Proportion of material
The best results can be achieved if two powders are mixed in equal
proportions by weight or by volume.
EQUIPMENT'S USED FOR MIXING OF POWDERS
Lab:- mortar and pestle or drug spatula. Process known as Trituration.
On large scale following equipment's are used for mixing.
TUMBLER MIXER
Metallic vessel and may be of various
designs, such as cubical, V shaped, Y
shaped and cylindrical.
Baffles are attached to ensure proper
mixing.
Rotated electrically at slow speed which
ensures proper mixing.
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Baffles lift the powders and allow then to fall over each other
continuously.
DOUBLE CONE BLENDER
Mixing occurs due to tumbling motion and
shearing action with blade.
Made up of stainless steel and is available in
different capacities ranging from 5-200 kg.
Speed must be between 30-100 r.p.m.
Material about 50-60 % of the total capacity
of blender is loaded. As the blender rotates
material undergo tumbling motion and through
mixing occurs.
Mainly used for small quantities.
AGITATED POWDER MIXER
Consists of stationary vessel in which
arms rotate and transit shearing action
to the particles.
The end to end movement required for
mixing is achieved by helical blades
fitted to the agitator.
Mixer is commonly used for mixing free
flowing powders having uniform particle
size and density.
AIR MIXER
Principle:-
The air movement is used for mixing
powders. Air is admitted at its base at an angle
which gives tumbling action and spiral
movements to the powder. Thus mixing is
achieved.
Air should be admitted at short intervals and
not continuously.
A typical method is to use eight air blasts for
two seconds duration with one second interval.
Thus 24 seconds are required for proper
mixing.
MIXING OF LIQUIDS
To prepare true solutions or emulsions.
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Equipment's used for mixing of liquids:-
PROPELLER MIXER
It consists of number of blades, generally 3
bladed design is most common for liquids.
Blades may be right or left handed
depending upon the slope of their blades.
Two are more propellers are used for deep
tank.
Size of propeller is small and may increased
up to 0.5metres depending upon the size of
the tank.
Small size propellers can rotate up to 8000
rpm and produce longitudinal movement.
During mixing of liquids air gets entrapped
in liquids or there is formation of vortex.
This can be avoided by making following
changes in the propeller shaft.
1. Offset from the center.
2. Mounted at an angle.
3. Enter the side of the vessel.
4. Using push pull propeller.
5. By use of baffles.
TURBINE MIXER
Consists of a vessel and a circular disc
impeller.
A number of short, straight or curved
blades are attached to it.
The turbine impeller is usually rotated at
low speed.
These are used for mixing of more viscous
liquids e.g. syrups, liquid paraffin, glycerin etc.
PADDLE MIXER
The flat blades are attached to a vertical shaft
which rotates at low speed of 100 r.p.m.
Mixing of low viscous liquids simple flat
paddles are used.
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Mixing of high viscosity liquids is attained by using big paddles.
MIXING OF SEMISOLIDS
For preparing ointments, creams, pastes etc.
Equipment's used for mixing of semisolids
TRIPLE ROLLER MILL
Principle: - High shear, which causes
crushing of aggregates, particles and
also distributes the drug uniformly
throughout the semi solid base.
Construction:-
The mill consists of 3 parallel rollers
which are made of a hard abrasive
resistant material.
The rollers are arranged in such a way
that they come very close to each
other.
The rollers are rotated at different rates of speed.
The material coming between the rollers is crushed depending on the gap
between them and difference in rates of movement of the two surface.
Working:-
Material after passing through hopper comes in between roller 1 and
roller 2 and is reduced in size in the process.
The gap between roller 2 and 3 is usually less than that between 1 and 2,
further crushes and smoothens the mixture which sticks to roller 2.
A scrapper is arranged in such a way, that it can remove the mixed
material from the roller 3 and does not allow material which has not
passed between both sets of the rollers to reach the scraper.
Uses:- mixing of solid powder in ointment base.
AGITATOR MIXER
Principle shear.
Inter meshing of sigma blades creates high shear
and kneading action.
Construction
It consists of double trough shaped stationary
bowl.
Two sigma shaped blades are fitted horizontally
in each trough of the bowl.
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These blades are connected to a fixed speed drive.
• Working :- Mixer is loaded from top and unloaded by tilting the
entire bowl.
• The blades move at different speeds, one
about twice than the other, which allows
movement of powder from sides to centers.
• The material also moves top to downwards
and gets sheared between the blades and the
wall of the tough resulting cascading action.
• Uses :-
Mixing of dough ingredients in baking
industry.
Used in wet granulation process in the
manufacture of tablets. Used for mixing powdered drugs with an
ointment base.
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PLANETARY MIXERS
Principle:-
Mechanism of mixing is shear.
Shear is applied between moving blade and stationary wall. Mixing arm
moves around its own axis and around the central axis so that it reaches
every spot of the vessel.
The plates in the blades are sloped so that
powder makes an upward movement to
achieve tumbling action also.
Construction:
Consists of vertical cylinder shell which can
be removed.
The blade is mounted from the top of the
bowl.
Mixing shaft is driven by planetary gear and it
is normally built with variable speed drive.
Working:- blades move slowly at the
initial stage for pre- mixing of the material and
finally at increased speed for active mixing.
In this way high shear can be applied for thorough mixing. The blades and
vessel provide a kneading (rubbing) action and shear.
This is due to narrow clearance between the blades and wall of the vessel.
Uses:- used for its kneading action required in wet granulation. Also
used for mixing of powders in ointment base.
SOLID LIQUID SEMI-SOLID
1. Tumbler mixer. 1. Propeller mixer 1. Triple roller mill
2. Double cone 2. Turbine mixer 2. Agitator mixer
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mixer.
3. Agitated powder
3. Paddle mixer 3. Planetary mixer
mixer.
4. Air mixer
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HOMOGENIZATION
Process of preparing fine emulsion from coarse emulsion by converting
large globules to small globules.
Done in an apparatus called homogenizer.
Principle :-
Large globules in a coarse emulsion are broken in small globules by
passing them under pressure through a narrow orifice.
Commonly used homogenizers are:-
HAND HOMOGENIZER
Hand operated.
Emulsion placed in hopper of homogenizer.
The up and down movement of handle causes
coarse emulsion to draw it through inlet valve
and pass through homogenizing valve.
Emulsion is thus passed through the fine orifice
(aperture). The oil globules are broken in fine
globules of uniform size.
SILVERSON MIXER HOMOGENIZER
Construction: - consists of an emulsifier head which is covered with
fine meshed stainless steel sieve.
The emulsifier head consists of number of blades which rotate at a
very high speed, in order to produce a powerful shearing action.
The blades are rotated using
electronic motor fitted at the
top.
Working: - emulsifier head is
placed in the vessel containing
immiscible liquids, in such a
way that it should get dipped
into it.
When the motor is started the
liquid is sucked through the
fine holes and the oil is reduced
into fine globules due to
rotation of blades.
COLLOIDAL MILL
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Principle :- the size reduction is
affected due to shearing, when
the material is passed between
the narrow gap of milling surface
of rotor and stator.
Construction :- Colloidal mill
consists of a rotor and a stator.
The rotor rotates at a speed of
3000-20,000r.p.m. the stator
has conical milling surface
between which there is an
adjustable clearance between
0.002-0.03 inches.
Working :- the material is placed into the hopper of the mill. It is then
passed through the narrow gap between the rotor and stator and thus
reduced to fine particle size.
Uses :- capable of producing particles in micron size. Used to prepare
suspensions and emulsions having particle size less than 1 micron.
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