It s the Mixing Possibilities of Dipl.-Ing. Hans-Ulrich Siegenthaler Table of Contents 1. Mixing, Extrusion and Compounding 2. Compounding Systems 2. Processes and Requirements 3. Examples 4. Connections & Players 5. Summary 1
Mixing, Extrusion and Compounding Aggregates 5-50 µm Primary Particles nano - 5 µm Agglomerates 50-1000 µm Mixing, Extrusion and Compounding Mixing Principles: - Distributive Mixing statistically homogeneous distribution of particles - Dispersives Mixing breaking agglomerated particles apart 2
Mixing, Extrusion and Compounding Dispersive and Distributive Mixing Distributive Mixing poor good Dispersive Mixing good poor Mixing, Extrusion and Compounding Physical Principles: - Grinding - Shear Forces = [ 1/sec ] - Folding relaxation réorientation 3
Mixing, Extrusion and Compounding Overview Batch vs. Continuous Processes Roller Mill Batch Banbury Mixing in the Viscous Phase Screw based Single Screw Oscillating Single Screw Continuous Twin Screw Multi Screw Rotor based Mixing, Extrusion and Compounding Compounding: - Single Screw Extruder - Twin Screw Extruder: - Multi Screw Extruder 4
Process Design Typical Process Steps: Humidification / Melting Fragmentation (dispersive Mixing) Wetting Distribution (distributive Mixing) Homogenisation Deaerating / Degassing Filtration Shaping Application: Pasta Ingredients Huminfication of Surfaces Dissipation of Shear Energy Compression & Kneading Shaping Source: Bühler, CH 5
Application: Pasta Ingredients Huminfication of Surfaces Dissipation of Shear Energy Compression & Kneading Shaping Source: Bühler, CH Application: Pasta Source: Bühler, CH 6
Product temperature Application: Chewing Gum Gum Base Premix (Solid) Sorbitol pintemperature [ C] 70 60 50 40 30 20 10 0 5 10 15 20 25 total pin no. T1 T2 T3 T4 T5 359 023 359 023 381 758 368 467 366 275 361 816 381 758 366 275 356 106 368 467 Maltitol Sirup Glycerin Flavour Source: Buss, CH Application: Chewing Gum Source: Buss, CH & Gabler, D 7
Application: Chewing Gum LR 200 7 L/D LR 300 7 L/D Source: Buss, CH Application: Ice Cream Heating-/ Cooling Zones At the Barrel Supply / Return Heating-/ Cooling Screw Rotating Planetary Screws Supply / Return Heating/Cooling Barrel Rotating Central Screw Source: Entex, D 8
Application: Ice Cream Source: Entex, D Application:.and many more Further Examples: - Cereals - Candys - Doughs - Chocolate pre-products - etc. 9
Important Players Research and Development - ETHZ, Institute of Food, Nutrition, Health, Zürich, CH Prof. Dr. Ing. E. Windhab - KTI, Institut für Bio- und Lebensmitteltechnik, Karlsruhe, D Prof. Dr. Ing. H. Schuchmann - Plant Engineering and Systems - Bühler Group, Uzwil, CH - Buss AG, Pratteln, CH - Clextral, Firminy, F - Coperion, Stuttgart, D - Entex, Bochum, D - Summary - The properties of the ingredients, the required process steps and the final quality of the product are influencing the choice of a system - The mixing process is often the key. Appropriate configurations and process parameters allow the optimisation of quality/quantity of the product. - Proven scale-up procedures allow a save transfer from the lab scale of g/h to the big amounts of t/h - Increased requirements related to safety, reliability and the availability of the ingredients are challenging the science and industry - Creative and innovative solutions are continuously developed and will surprise us also in future. - Cross industry experiences i.e. Food, Pharma, Plastics can play a relevant role 10