How much breakage will I get during mixing?

The amount of breakage during the mixing process depends on several factors. The product properties, the type of mixer and the process settings, such as filling level, are decisive here.

Product properties: is the product crystalline or amorphous? But other product properties such as moisture content, compressibility and shape can also play a role. Some products have a vulnerable shape, such as angularly shaped fish from an extrusion process in pet food.

The type of mixer also affects the break. For example, a mixer that creates more shear forces will cause more breakage. The combination of properties of the mixer and products can affect breakage. For example, product dimensions and the distance from the moving machine parts to the wall of the mixer have an influence on the fracture. If this distance is not chosen correctly, the product can be “pinched” between moving parts and the wall. This results in damage with breakage. In addition, it is important that there are no bumpers in the mixer to prevent breakage.

The mixing process also affects breakage. If the mixing process takes too long, unnecessary breakage can occur. In addition, this can also increase the risk of segregation.

Finally, the fill level influences crack formation. A (over) full mixer generates more pressure on the product and thus creates more breakage.

With the correct settings and design of the mixer, breakage can be kept to a minimum.