Process / Product quality benefits
- Uniform and rapid dispersion of starch powder
- Stable slurry viscosity and texture
- Reduced recirculation time and cycle variability
- Minimized clumping and agglomeration
- Process time cut by 75%
Previously unsuccessful methods
Before implementing the Fristam solution, the mixing process exhibited several limitations:
- Manual dumping of starch bags elevated a risk of slips, falls, and overexertion injuries.
- Top-entry agitator struggled to wet and disperse powder quickly, resulting in long recirculation times.
Fristam’s solution
Fristam recommended the installation of an inline Powder Mixer, combining a self-priming FZX Liquid Ring Pump for controlled powder draw-in with high-shear FS shear mixer for rapid dispersion. This configuration allows dry solids to be inducted at floor level into a flowing liquid stream, eliminating the need for manual powder dumping at elevation.
For this application, the selected Powder Mixer featured:
- An ergonomic, waist-height induction funnel to improve operator safety
- A high-capacity suction pump enabling efficient draw-in of low-density starch powder
- High-shear blending to wet and disperse powder immediately upon entry
This configuration ensured safe, controlled induction and efficient integration of starch into the liquid phase.
Process set-up
1. Floor-level installation
The Powder Mixer was installed alongside the batch tank at ground level, allowing operators to feed dry starch safely without ladders or scaffolding.
2. Controlled powder induction
Powder was introduced into the Powder Mixer funnel, where vacuum suction pulled solids into the liquid stream beneath.
3. Inline blending and dispersion
As product flowed through the Powder Mixer’s rotor-stator section, close clearances and high shear ensured rapid wet-out and dispersion of starch particles.
4. Continuous operation oversight
Production staff monitored mixing behavior, induction rates, and batch cycle times to ensure stable performance and consistency.
A successful outcome with the Fristam Powder Mixer
Implementation of the Fristam Powder Mixer delivered measurable improvements in both safety and process efficiency:
- Severe safety hazards were eliminated by removing the need for operators to climb and pour starch from elevated positions.
- Airborne dust exposure was significantly reduced, minimizing inhalation risk and housekeeping burden.
- Process time was reduced by approximately 75%, cutting typical batch recirculation from around 40 minutes (40 min) to approximately 10 minutes (10 min).
- Product quality improved with consistent starch dispersion and stable viscosity achieved across batches.
The Powder Mixer has become a core component of the starch processing line, improving workplace safety and increasing production throughput without additional capital investment.
Sustainability benefits
- Lower energy usage due to shorter mixing cycles
- Reduced dust emissions improve air quality in production areas
- Minimized material waste from efficient powder induction
Financial benefits
- Faster batch turnaround increases effective throughput
- Reduced labor time and housekeeping effort
- Lower indirect costs from safety incidents
- Improved productivity from consistent process performance
Other benefits
- Floor-level ergonomic design enhances health & safety compliance
- Powder induction system integrates into existing facility layouts
- Reliable long-term performance with minimal maintenance
- Reduced operator fatigue and exposure