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Top-entry high-speed disperser blade blender:
The pharmaceutical manufacturer used this style of mixer to combine oil with dry powdered ingredients in a liquid base. However, this often failed to fully emulsify the oil.
Competitors shear mixer:
This mixer featured an impeller and screen designed to smooth the product. However, the unit didn’t deliver the required shear, so droplet sizes remained too large, even after prolonged recirculation.
Fristam’s solution – a bespoke mixing system
Based on Fristam’s standard Powder Mixer design (a waist height table, hopper, induction pump and shear blender) but with an added oil injector nozzle positioned just before the shear blender to allow precise injection of the oil into the circulating stream of dry powder and liquid.
To ensure the pharmaceutical manufacturer could see real-world performance before purchase, a live on-site trial was arranged using the Fristam Powder Mixer. Here’s how the process worked:
Trial set-up
A Fristam Powder Mixer was connected to a small batch mixing tank. Product was set to recirculate from the bottom of the tank to the top, maintaining continuous motion.
Controlled powder induction into liquid
The dry powdered ingredients were slowly poured into the hopper.
Gravity and suction generated from the FZX induction pump below the hopper, pulled the powders into a liquid stream below.
The gradual powder induction into liquid allowed precise control over the liquid-to-solid ratio. This helps prevent clumping and helps achieve a uniform mixture.
Injecting the oil
With the powders fully dispersed into the liquid base, the oil-based medication was introduced using an inline injector nozzle, which was located directly infront of the FS shear blender.
The oil was emulsified directly into the flowing product stream for a homogenous, stable blend.
High-shear blending
Once in the system, the pre-wetted mix of powder, liquid and injected oil entered the Fristam FS shear blender, where intense shear forces ensured full particle dispersion of the powders and oil in a single pass.
The trial proved that the Fristam Powder Mixer could produce a perfectly mixed, shelf-stable product in which the oil phase was fully emulsified. Satisfied with the results, the manufacturer purchased a Powder Mixer for the new plant expansion and has since ordered additional units for other production sites across the world.
