What is an industrial agitator?

While these components define industrial mixers, it is also important to recognize that each model has unique functionalities that set it apart.

Quote and buy an industrial agitator requires understanding these characteristics and their role in the process. Having a guide for proper use of every part can be helpful.

Power unit

This is the first part that we will discuss, which handles generating the equipment’s rotation. It consists of an agitator motor, a reducer, or gear motor. The choice of these components will decide the strength and rotational speed of the agitator.

Motor

A motor is defined as a machine capable of transforming energy into rotational movement, making it a fundamental part of an industrial agitators' components.

An agitator motor supplies the energy needed to move the shaft and impellers, enabling the homogeneous mixing of materials within a tank.

It is the heart of the agitator, without it, the mixing system would not function across different industries with diverse agitation needs.

There are two main types available:

• AC Motors: these use electrical energy to work. They are the most used in agitation due to their low cost and versatility.
• Pneumatic Motors: these run by injecting compressed air and are used in settings where an existing air power infrastructure is available or where access to electricity is limited. A notable example is the CT(F) series pneumatic agitator.

All Autmix industrial agitators feature a power unit carefully selected based on:

• Optimal power for each application.
• Adaptability to different processes and product types.
• Guaranteed efficiency and durability, even under demanding conditions.
• Compilance with safety standards such as ATEX regulations.

Reducer

A reducer or gearbox selection for agitators is based on the design focuses in decreasing the rotational speed delivered by the motor while increasing torque. The key difference between a gear motor and a reducer lies in the equipment connections:

• A reducer requires a solid shaft with the input to accommodate different reduction ratios.
• Gear motors are directly connected to the motor, limiting the speed reduction capabilities.

Likewise, there are three reducer configurations for agitators, depending on the input position and the available space for the reducer:

1. Coaxial reducer: the motor shaft is concentric with the reducer shaft. This type is typically used in small equipment. 2. Bevel gear reducer: the shafts are positioned perpendicularly, making it a common choice for compact spaces or horizontally mounted equipment. 3. Parallel shaft reducer: the shafts are parallel to each other, making it the standard configuration for medium and large-scale equipment.

Some agitator models emphasize the importance of the reducer in their application. Examples include:

• The ZB(R) side-entry agitator, which features a specialized reducer.

• The CT(R) compact agitator, which integrates an optimized reducer for its design.

Mounting system

The mounting system, one of the essential components of an industrial agitator; it secures the mixing equipment and the product container. This ensures stable operation, preventing vibrations or misalignments.

There are various types of agitators mounting systems, ranging from simple clamps to support for IBC/GRG containers.

Agitator mounting options are available in three configurations: plate, flange, or lantern, allowing the customization. For example, plate mounting can be adapted to any type of entry, depending on the specific requirements.

Typically, the flange is made of stainless steel or carbon steel. This agitator component is standardized according to ANSI regulations, meaning that most tanks have adaptable inlets for this piece.

If couplings or the sealing system need to be installed outside the tank, a lantern flange can be added.

The mounting system plays a crucial role in mixing systems as it ensures operational safety, prevents unnecessary movement, and adapts to the specific needs of each project.

The stability of agitators is an important aspect during installation. In cases where height adjustments or mobility are needed for operation, lifting systems come into play.

What are mixers lifting systems? Are devices designed to provide height adjustment and mobility to your agitators. This enables free movement in tanks with variable volumes.

Sealing systems

The sealing system is the part in charge of keeping the product contained within the tank. It acts as a barrier that prevents leaks of liquids, gases, or powders at the point where the shaft passes through the tank or reactor.

This component must be carefully selected based on the specific requirements of the process to ensure safety and prevent contamination.

For example, in top mounted agitators, where it is necessary to keep a gas-tight seal or provide extra protection against external agents, an industrial seal (retainer) can be used.

Similarly, for bottom side-entry agitators, where a higher degree of sealing is required due to the pressure exerted by the fluid, a mechanical seal is typically installed.

The mechanical seal consists of a stationary component and another rotating, allowing lubrication with the process fluid. Moreover, if extra protection is needed, packing glands can be installed alongside the mechanical seal.

This system works with a stationary face and a rotating face, allowing lubrication with the process fluid. Additionally, if extra protection is needed, it is possible to install packing glands to reinforce the sealing.

Also, agitators also include mechanical seals, which come in two specific models for specialized applications:

• Double seal
• Cartidge seal

For an in-depth understanding of this topic, read installation and use of mechanical seals.

Shaft-motor or shaft-gearbox coupling

The coupling in an industrial agitator serves the crucial function of securing the shaft and ensuring it rotates in sync with the power unit.

For small-scale equipment without a gearbox, the sleeve and set screw mounting method is commonly used. In this setup, both shafts are fitted into a custom-machined component, and pressure is applied through small cylindrical elements known as set screws.

When adding a bearing, a support tower must be installed over the sleeve. Similarly, if the shaft is coupled to a coaxial gearbox, the same method can be applied, or alternatively, a solid shaft can be used. This approach involves attaching a flange to the ends of both shafts and securing it with bolts and nuts.

The sleeve coupling to secure the shaft to the motor can be achieved using keyways, mechanical systems, or flexible couplings depending on the application.

Shaft

Another vital part of agitator's assembly is the shaft coupling that connects the motor or reducer to the whole system. It ensures the efficient transmission of rotational movement from the power unit to the agitator's shaft.

Important considerations in manufacturing this piece are rigidity, stability, and concentricity. To achieve this, the diameter and shaft thickness should be calculated, if it's a tube, in relation to the forces exerted by the rotation of the blades.

This helps reduce the shaft's flexibility under load, preventing a decrease in agitation efficiency. Additionally, it's important to note that the shaft ends are customized based on the coupling that will be used.

Shaft-to-impeller coupling

There are various methods to couple the impeller to the shaft, depending on the specific application. One of these methods involves using blade mounting lugs, where each blade is screwed and previously welded to the shaft.

Another option is the welded mechanical hub, which is a system made up of three pieces with the blades welded on, and it is bolted together around the impeller.

However, bushing as an intermediary, this is a tubular part, which the impeller blades are welded and can be mounted onto the shaft according to process needs. One method of coupling the shaft is through welding, which is recommended in applications requiring extreme hygiene. Another option is clamping screws, where these elements secure both parts together.

Finally, there is the keyed coupling, where the bushing is bolted to the shaft, and a key is inserted to prevent rotation.

Impellers for agitators or mixers

Finally, we need to talk about the impeller, otherwise, mobile, profile or impulsor, as an agitator part, has the aim of agitation and mixing.

The impellers are chosen after the product and process that will be performed. With this information we can figure out if the flow will be axial, or radial, perpendicular to the shaft.

There are even models capable of tangential flow, for example, the marine impeller.

When buying an agitation system, it is essential to consider the desired outcome of your process. For instance, if working with a highly viscous product, you can keep it slowly moving with an anchor-type impeller or reduce its viscosity with high shear stress using a Cowles disc.

You should also evaluate the relationship between power consumption and pumping capacity, especially when selecting an axial-profile impeller.

Some enhancements can be incorporated to improve efficiency, such as scrapers or turbulence fingers. Beyond these considerations, it is crucial to account for each component during manufacturing, installation, and operation to prevent issues like the vortex effect.

Why are industrial agitators essential?

Agitation is a fundamental process adaptable to the specific needs of various industries, ensuring efficiency, quality, and consistency. Whether for homogenization, dissolution, suspension, or energy transfer, agitators are a key factor in the success of your production.

• Chemical industry: we need agitation in the production of resins, paints, and detergents that requires constant reaction.
• Food and beverages: agitation ensures a perfect mix of ingredients and keeps stability throughout the process.
• Pharmaceutical: our agitators meet strict safety standards and enable precise processing.
• Cosmetics: an agitator for cosmetics is essential to produce creams, lotions, shampoos, and more, reducing processing time and ensuring high quality.
• Mining: in heavy-duty applications such as leaching and flotation, a reinforced agitator improves operational costs and ensures long service life.
• Oil and gas: agitators and mixers can improve crude pre-mixing and emulsifier blending, enhancing safety in the entire refining process.
• Water treatment: processes like flocculation, coagulation, and aeration rely on industrial agitators to achieve the desired effects.
• Paper processing: pulp treatment requires substance control for bleaching. Autmix agitators integrate with monitoring systems to improve this process.

The importance of getting the right agitator

As we know, in the industrial agitator market, as the demand keeps growing, the costumer expectations need to be met, with the aim of achieving better products.

Every agitator component plays a critical role in the mixing process. Therefore, selecting each element carefully is essential for optimal performance.

At Mixing Solutions, we know how to improve your operations to help you with the best mixing system and industrial agitators. We provide you with the best purchasing experience while improving the efficiency of all equipment.