Sizing the Perfect Type of Mixer for Your Process

Choosing the perfect mixer for your tank is about more than just getting the job done—it’s also about unlocking peak performance and saving valuable resources.

No matter your role—whether you're a manufacturing engineer, chemical processor, or process system operator—the right mixer can elevate your process to the next level. The mixer you select makes a difference in your process capabilities and is greatly impacted by the size and shape of a vessel, in addition to the products you’re mixing.

This guide article will help you narrow down the right influences when selecting a mixer, from understanding types of mixers and key considerations to reaping the rewards of an ideally sized mixing solution.

Factors Affecting Mixer Selection 

Several variables should be considered when sizing a mixer to ensure compatibility with your tank and process requirements. 

These are some key factors to help influence your decision:

• Tank size and shape
• Liquid viscosity
• Process requirements
  
  

Tank Size and Shape 

The tank dimensions directly affect the mixer size and power. 

Taller tanks may require longer shaft mixers, while wider tanks need larger blades to ensure adequate coverage. Similarly, internal tank baffles, corners, or other design elements can influence mixing.

Liquid Viscosity 

The viscosity of the mixed materials is a significant factor in selecting a mixer. Lower viscosities, such as water or thin oils, are easy to blend and require minimal power input. 

However, for higher viscosities such as creams, sludges, or gels, you’ll need a more powerful mixer with sufficient torque to create uniform mixing.

Process Requirements 

Every process has its unique specifications:

• Mixing goal: Whether blending, suspending particles, or emulsifying, your process goal determines the mixer's optimal speed and shear level.
• Temperature and pressure: Tanks operating under high temperatures or pressures may require mixers with specialized seals and materials to maintain pressure integrity.
  
  

The Role of Power and Speed 

Mixer power and speed are directly tied to performance. A low-power mixer may fail to achieve the desired mixing intensity, while excessive speed can lead to energy waste or even damage to delicate components. 

Be sure to strike the right balance by matching the speed, power, and blade type to your process needs.

Understanding Different Types of Mixers 

Choosing the right mixer begins with understanding the variety of mixers available and their applications. Different industrial mixer designs are tailored for specific tank configurations and mixing intensities, and choosing the wrong type of mixer may slow down your progress.

Here are two common different categories of industrial mixers used in stainless steel tanks:

Tank-Mounted Mixers 

Tank-mounted mixers are securely fixed directly to tank fittings, ensuring stable and effective mixing for larger tanks containing hundreds to thousands of gallons. 

Depending on the application and tank configuration, some common types of mixers can be used:

• Plate mounted mixers: These attach to a 12x12" plate either on the tank itself or on a 'bridge'—a structure spanning the width of an open-top tank to allow for mixer installation when direct fittings are unavailable.
• Flange mounted mixers: These mixers connect directly to a 150# ANSI flange, which is typically welded to the top of tanks to accommodate various auxiliary equipment.
• Side entry mixers: are a variant of flange-mounted mixers attached to flanges at the bottom of tank walls. They are designed for ultra-high flow mixing and are primarily used in large vessels to circulate liquids.

Need a customized tank for your specific needs? 

Customize your stainless steel tank design here

Key Features of Tank-Mounted Mixers: 

• Efficiency: Designed for high-volume and low-viscosity applications, these mixers ensure thorough mixing across the tank.
• Customization: These mixers can often be tailored to accommodate specific tank shapes and internal fittings.
• Durability: Built to handle heavy-duty mixing over extended or continuous periods.

Typical industries using tank-mounted mixers include oil and gas, chemical manufacturing, water treatment, and food and beverage processing. 

For example, a tank-mounted mixer might emulsify liquids or mix high-viscosity creams. 

Portable Mixers 

Portable mixers are designed to be easily added and removed from a variety of tanks and mixing vessels. These mixers are lightweight, versatile, and highly adjustable, making them an excellent choice for smaller tanks or processes with variable mixing needs. 

Key Features of Portable Mixers: 

• Mobility: Quickly attach or detach the mixer for use across multiple tanks. 
• Flexibility: Adjust mixing angles for targeted results. 
• Suitability: Great for medium to low-viscosity liquids where quick mixing is required. 

Portable mixers are commonly used in industries such as paints and coatings, beverages, and cosmetics, where they excel at blending ingredients in batches for various processes. 

Key types of portable mixers include:

• IBC tote mixers
• 55-gallon drum mixers
• Clamp mount mixers

These are specifically designed for open top tanks. These versatile tools facilitate efficient mixing and can be adapted for various applications. 

However, selecting the perfect mixer goes beyond just researching—it requires a deeper examination of your tank and process.

Benefits of Properly Sized Mixers 

Investing the time to size your mixer properly results in significant advantages for your operations in the following areas: 

Maximizing Efficiency 

An appropriately sized mixer distributes materials uniformly within the tank, eliminating hotspots or uneven mixing. This ensures process consistency and saves energy, as the mixer uses exactly the power needed to achieve the desired results. 

You’ll notice reduced mixing time and increased product quality in multi-component systems.

Reducing Wear and Tear 

Correct sizing also reduces unnecessary strain on the mixer’s motor and blades, lowering the risk of overheating and mechanical failure. This minimizes unplanned downtimes and enables a longer lifespan for your equipment, directly reducing maintenance and replacement costs.

Find Your Competitive Edge: Choosing the Right Mixer

Getting the perfect mixer for your tank isn’t just about picking the first option that seems to fit—it's about achieving the perfect balance of efficiency, functionality, and durability specific to your needs. 

By considering factors like:

• Stainless steel tank design
• Leveraging tank-to-mixer ratios
• Liquid properties
• Operational goals

You can create a highly optimized setup that elevates your entire process.

Contact the Mixer Experts at MXD Process

Are you still unsure which mixer is right for your operations? 

Contact our team of experts, who can evaluate your needs and recommend the perfect solution. Together, we’ll ensure your processes run smoothly.