Intensive Mixers for Mixing&Granulation in the Ceramic Industry

2025.6.23 | CO-NELE

Intensive mixers are high-shear machines crucial for preparing ceramic bodies(tiles,sanitaryware,refractories,technical ceramics)by achieving homogeneous mixing and controlled granulation of powders,binders,liquids,and additives.They outperform simple tumble or paddle mixers in efficiency and quality for demanding ceramic processes.

Intensive mixers are high-shear machines crucial for preparing ceramic bodies

Key Functions:
Intensive Mixing:
Breaks down agglomerates and ensures uniform distribution of fine powders(clays,feldspar,silica,oxides),recycled material,and minor additives(deflocculants,binders,pigments).
Provides the high shear forces necessary to coat particles evenly and achieve a truly homogeneous mixture critical for consistent firing and final product properties(density,strength,color,surface quality).
Granulation(Wet Agglomeration):
Transforms the dry or damp powder mix into free-flowing,dust-free granules with controlled size distribution and density.
Achieved by spraying liquid binders(water,PVA,CMC,lignosulfonates)onto the powder bed while subjecting it to intense mechanical action.
Granules improve flowability for automated pressing,reduce dust(health&safety),ensure uniform die filling,and enhance compaction during pressing(reducing lamination and cracks).
Intensive Mixers in Ceramics:
Vertical High-Speed Mixer-Granulators(Eirich-Type-Industry Standard):
Principle:A rotating vessel(pan)and a high-speed rotor/tool(impeller,muller star)working independently.Often includes a chopper.
Process:Powders loaded into the pan.Pan rotates,moving material towards the high-speed rotor.The rotor provides intense shear and impact.Liquid binder sprayed via nozzles.Granule growth controlled by rotor speed,pan speed,liquid addition rate,and process time.
Advantages:Exceptional mixing intensity,precise control over granule density/size(from dense to fluffy),short cycle times,suitable for a wide range of formulations(dry to sticky),efficient liquid dispersion,good scalability.Excellent de-agglomeration.

Disadvantages:Higher initial investment,more complex mechanics than some horizontal mixers.

Intensive mixers are high-shear machines crucial for preparing ceramic bodies

Advantages of Intensive Mixers in Ceramics:
Superior Homogeneity:Essential for consistent product quality and properties.
Controlled Granulation:Produces granules with optimal size,density,flowability,and compression behavior for pressing.
Dust Reduction:Creates dust-free granules,improving workplace safety and material yield.
Process Efficiency:Faster cycle times compared to low-shear mixers
Flexibility:Can handle a wide range of raw material types and moisture contents.
Recycling:Effective at incorporating recycled body material(grind,scrap)homogeneously.
Reduced Binder Usage:Efficient dispersion often allows for lower binder content.
Selection Intensive Mixers for Mixing & Granulation Considerations:
Material Characteristics:Powder flowability,abrasiveness,moisture sensitivity,stickiness,particle size distribution.
Desired Granule Properties:Size distribution,density(green and fired),flowability,crushing strength.
Batch Size & Cycle Time Requirements.
Liquid Binder Type&Addition Rate.
Cleaning & Changeover Needs.
Automation&Control Level.
Space & Utility Constraints.
Vertical high-speed intensive mixer granulators
Vertical high-speed mixer-granulators are often considered the gold standard for demanding ceramic applications due to their unparalleled combination of intense mixing,precise granulation control,efficiency,and flexibility.

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