Batch Mixer Rotation Reversal for Deposit Control
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Solution Overview
Problem
Batch mixers face significant downtime and labor-intensive cleaning due to material deposits, which reduce efficiency and increase the risk of cross-contamination, especially when handling large quantities of ingredients like corn, maize, and soybeans.
Innovation Solution
The method involves alternating the direction of rotation between batches to prevent deposit buildup, utilizing symmetrical mixing paddles and injection nozzles that are partially self-cleaning, and ensuring consistent mixing parameters to maintain quality and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the batch mixer operates continuously in one direction to maximize productivity, then production output increases, but material deposits accumulate on the mixing chamber surfaces and equipment components, requiring frequent cleaning interruptions
Solution Approach 1:
The patent applies periodic reversal of the mixing chamber rotation direction. After a predetermined number of batches, the rotation direction is reversed, which prevents material deposits from accumulating on the same surfaces continuously. This periodic action allows the mixer to maintain productivity while minimizing cleaning downtime, as deposits are redistributed rather than concentrated on specific areas.
2Reliability
If cleaning is performed frequently to remove material deposits, then cross-contamination between batches is minimized, but production downtime increases and labor costs rise
Solution Approach 1:
The patent implements a self-cleaning mechanism where the reversal of rotation direction causes material deposits to be redistributed and scraped off surfaces by the mixing paddles and material flow itself. This self-service approach minimizes the need for manual cleaning interventions, thereby maintaining cross-contamination prevention while preserving production efficiency without requiring external cleaning operations.
3Productivity
If material deposits are allowed to accumulate to extend operational time between cleanings, then productivity increases, but mixing efficiency decreases and equipment load increases
Solution Approach 1:
By periodically reversing the rotation direction after a predetermined number of batches, the system prevents excessive deposit accumulation on critical mixing surfaces. This maintains mixing efficiency and reduces equipment load while extending the operational time between thorough cleanings, as deposits are continuously redistributed rather than allowing thick layers to form that would hinder mixing performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes the need for frequent cleaning, extends the batch mixer's operational time, reduces power consumption, and ensures consistent mixing quality, allowing for thousands of batches before thorough cleaning is required, thereby increasing productivity.
Implementation Method 1
the friction between said materials to be mixed and said mixing element sweeps said deposited mixtures clear of said mixing chamber surfaces
Data Source
AI summary
The invention provides a method of operating a batch mixer for producing first and second numbers of mixtures from first and second numbers of batches of materials to be mixed in the batch mixer, the batch mixer comprising a mixing chamber, a mixing element disposed within the mixing chamber, the mixing element and the mixing chamber being configured for providing an identical flow of the materials to be mixed within the mixing chamber and around the mixing element regardless of in which of the first and second opposite directions the mixing element is rotated, and a motor assembly coupled to the mixing element for rotating the mixing element for mixing the first and second numbers of batches of materials to be mixed for producing the first and second numbers of mixtures. The method comprises the steps of energizing said motor assembly for rotating said mixing element in said first direction, for each one of the first number of batches of the materials to be mixed: loading the one of the first number of batches of materials to be mixed into the mixing chamber, mixing the one of the first number of batches of materials for producing one of the first number of mixtures, and removing the one of the first number of mixtures from the mixing chamber, energizing the motor assembly for rotating the mixing element in the second direction, and for each one of the second number of batches of the materials to be mixed loading the one of the second number of batches of materials to be mixed into the mixing chamber, mixing the one of the second number of batches of materials for producing one of the second number of mixtures, and removing the one of the second number of mixtures from the mixing chamber.