- Fast, homogeneous mixing
- Flexible and adaptable
- Short residence times
- Very limited temperature increase
- Fast response time
- Capacity of 2 kg/h to 200 kg/h
- Virtually no need for up-scaling
- Variable shear conditions
- Compact design
- Low residual materials (even after an emergency stop)
- Excellent cleanability
- Optional: Sequential mixing with multiple mixers
- Optional: Heating and cooling jacket
- Optional: Sanitary construction
- Optional: Integration with PAT tools
CONTINUOUS MIXERS
for Powders & Bulk Solids
Modulomix Horizontal Paddle Mixer
The Modulomix is a continuous mixer designed for processing fine and cohesive powders. Thanks to its high tip speeds, it is very effective at dispersing materials in a short amount of time. It can be used for low, medium, or high shear applications in the chemical, food, mineral, metal, and pharmaceutical industries.
The Modulomix horizontal paddle mixer was designed to be compact, with fast reactivity, minimal residue, and quick start-up and shutdown protocols. It produces homogeneous mixtures with little change to PSD or temperature. It is capable of extremely high heat transfer efficiency, thanks to the close contact between the material and the heated inner surface.
The Modulomix is also a modular mixer; meaning that if a mixing process consists of multiple mixing steps, which require different mixing regimes, this can easily be overcome by cascading multiple Modulomix units in series.
Continuous Pharma Mixer
For decades, pharmaceutical powder ingredients have been blended using a batch process. However, increasing competition has created a strong commercial imperative to reduce processing costs. One promising solution is continuous blending, which offers significant cost-saving opportunities for pharmaceutical companies.
Transitioning to continuous processes, however, brings its own set of challenges that must be addressed effectively. These challenges include:
- Validation: Ensuring the process meets stringent regulatory standards.
- Process Analytical Technology (PAT): Implementing real-time monitoring and control.
- Defining Batches: Establishing clear batch definitions within continuous operations.
- Integration: Incorporating new processing equipment into existing production lines.
- Scaling Up: Addressing complexities of scaling processes to production levels.
- Waste Reduction: Minimizing losses during start-up, changeovers, or emergency stops.
- Product Quality: Managing off-spec products efficiently.
The Modulomix blending system provides a proven, reliable solution to address these challenges. Unlike traditional blenders, this innovative blending concept has demonstrated success in both test environments and operational pharmaceutical production. The Modulomix not only ensures efficient and cost-effective blending but also integrates seamlessly into existing production lines, delivering consistent results and minimizing waste.
By choosing Modulomix, pharmaceutical companies can confidently transition to continuous blending while meeting operational, regulatory, and cost-saving goals.
Principle of Operation
The Modulomix horizontal paddle mixer consists of a horizontal cylindrical process chamber in which a paddle agitator rotates. The paddles are mounted on a shaft and rotate at a fixed distance from the process chamber wall. The powder is moved back and forth in the chamber by paddles for a more efficient mixing process.
Its intensive agitation regime creates a perfect mixture with extremely short residence times, making it ideal for small quantities. Short residence times also ensure a beneficial increase in energy efficiency. Although high shear forces can be applied to the mixture, attrition effects from impact forces are limited.
The Modulomix is fast and can be adapted to varying mixing conditions thanks to its adjustable rotor speed and the design of its agitator blades. For example, mixing Mg-stearate requires a different mixing regime than drug blending. This can be solved by cascading multiple Modulomix mixers in series.
The Modulomix is also ideal for coating applications. In many cases, difficult-to-wet proteins can be instantized with the addition of less than 1% lecithin surfactant. In a similar process, calcium carbonate materials can be encapsulated or effectively rendered insoluble with a coating of less than 1% stearate powder.
Key Features
Applications
The Modulomix horizontal paddle mixer is suitable for a wide range of process applications, including:
- Dry powder mixing
- Hydrating difficult to wet powders
- Slurry mixing
- Coating
- Sterilization
- Crystallization
- Agglomeration / granulation
- Homogenization
- De-lumping and finishing
Models
The Modulomix horizontal paddle mixer is available in several models. Their typical characteristics are described below. Please note that these values are indicative only. Detailed information is available on request.
| Model | [-] | MMX-1 | MMX-2 | MMX-2.5 | MMX-3 |
|---|---|---|---|---|---|
| Capacity (bulk density 0.5 kg/l) | [kg/h] | 2.5 - 120 | 10 - 480 | 15 - 750 | 22.5 - 1080 |
| Typical motor power | [kW] | 1.6 | 7.5 | 11 | 15 |
Ancillaries
Our design and engineering team can help you to design a full continuous blending system, including all necessary ancillary equipment:
- PTS sytems
- Hicoflex systems
- LIW (Loss in Weight) feeders
- PAT (Process Analytical Technology) technologies
- (Wet) Granulators
- Dryers
- Compactors
- CIP (Clean-In-Place) skids
- SIP (Sterilization-In-Place) skids
- Control systems
- Tablet presses
Continuous Mixing Systems
Hosokawa Micron has been developing innovative solids processing systems for more than a century. As a result, we can draw on an unparalleled amount of know-how when designing new powder mixing systems. In a powder mixing system, the equipment, process steps and interacting parameters must all work together as an integral solution in order to ensure the optimal functionality, quality and efficiency of your total system. That's why we carefully select, configure and integrate all the components and processes when designing a powder mixing system.
Testing & Process Development
Our Test and Process Development Centre in the Netherlands offers unique possibilities for testing your product to determine the most efficient process, system or plant prior to final design. We can provide laboratory-level as well as production-sized trials.
Whether you wish to test a single machine or a complete powder processing system, the same skilled and experienced staff are here to help ensure that your requirements are met, and that you are entirely satisfied with the results.
We offer process equipment and technologies from individual units to large scale bespoke system solutions. Our principle is to deliver high performance yet affordable solutions that meet our customers' demands and long term challenges.
Talk to Our Experts
Let our process specialists help you develop the optimal solution for your powder and bulk solids processing – from the first trial in our test centre to a full-scale industrial production system.
Applications
The Modulomix horizontal paddle mixer is ideal for a wide range of products. Here are a few examples:
Sustainable Process Technologies
Hosokawa Micron B.V. is committed to sustainable and responsible process technology. Our ISO 14001 certification covers key environmental aspects such as air, soil, energy, waste, water, noise and hazardous substances. With an EcoVadis Silver Medal, we rank among the top 15% of EcoVadis-rated companies in the special machinery industry.
