DOUBLE CONE
BLENDER
A low-shear batch blender for homogeneous dry mixing of free-flowing powders and granules. The sealed double-cone vessel rotates around a horizontal axis, repeatedly lifting, cascading, dividing and recombining the product bed without a standard internal agitator.
HOW THE BLENDER WORKS
CHARGE
Load ingredients through the wide sanitary manway.
SEAL
Close the vessel and prove guards and interlocks.
ROTATE
The vessel slowly lifts the powder bed.
CASCADE
Gravity divides and recombines the moving product
VERIFY
Confirm the blend endpoint by time or sampling.
DISCHARGE
Index the outlet downward and empty by gravity.
APPLICATION FIT & PROCESS VALUE
RIGHT APPLICATION
Free-flowing dry blends
Best suited to powders and granules that tumble and cascade readily
under gravity.
Fragile granules
Gentle vessel rotation limits attrition, heating and particle damage.
Multi-product duty
Smooth internal geometry supports inspection, cleaning and recipe
changeover.
DESIGN VALUE
Low-shear operation
No standard internal agitator means low power input and gentle particle handling.
Dust-tight batch mixing
A sealed vessel and sanitary closures support contained production.
Know the limits
Cohesive, sticky or highly segregating blends require trials or another mixer technology.
CONSTRUCTION & CONFIGURATION OPTIONS
PRODUCT CONTACТ
SS304 or SS316L with application-specific internal finish and weld treatment
VESSEL
Symmetric double-cone shell on horizontal trunnions; no agitator in standard execution
DISCHARGE
Flush sanitary butterfly or slide valve selected for product flow behaviour
DRIVE
Geared motor, VFD speed control, position sensing and controlled indexing
CLEANING
Wide manway, smooth internals, access for dry or validated wet cleaning
SAFETY
Drive guard, zero-speed proof, position lock and interlocked perimeter protection
TUMBLING & GRAVITY MIXING CONCЕРТ
The sealed vessel rotates slowly about its horizontal trunnion axis. Gravity keeps the powder free surface approximately level while the rotating cone geometry lifts, divides, cascades and recombines the batch through repeated cycles.
CONTROLLED BATCH SEQUENCE
CHARGE
Confirm valve closed and add ingredients.
SEAL
Close manway and prove all safety interlocks.
ROTATE
Tumble at the validated speed and fill level.
VERIFY
Sample or confirm the established endpoint.
INDEX
Stop at the validated discharge position.
DISCHARGE
Index outlet downward and empty by gravity.
CONTROL, SAFETY & MAINTENANCE
Start permissive
Rotation starts only with manway and outlet closed and all guards proven.
Dynamic protection
Current, vibration and bearing monitoring detect abnormal rotating load.
Position control
Proximity sensing indexes the vessel for charging, sampling and discharge.
Safe access
Zero-speed proof, isolation and mechanical position lock are required before access.
Recipe control
Rotation speed, direction, blend time and stop position are stored by formulation.
Cleaning access
Wide manway and smooth crevice-controlled internals support validated cleaning.
STANDARD RANGE & PRELIMINARY SIZING
Screening guide for conventional free-flowing dry powders and granules. Working volume is shown at 60% of gross vessel volume; final fill level, speed, dynamic load, power and discharge must be validated for the actual formulation.
|
MODEL
|
WORKING VOLUME
|
GROSS VESSEL VOLUME
|
BATCH MASS AT 0.5kg/L
|
INDICATIVE DRIVE RANGE
|
OUTLET CLASS
|
EXECUTION
|
|---|---|---|---|---|---|---|
|
DCB-100
|
60 L
|
100 L
|
30 kg
|
0.75-1.1 kW
|
DN100-150
|
Lab / pilot
|
|
DCB-250
|
150 L
|
250 L
|
75 kg
|
1.5-2.2 kW
|
DN150-200
|
Pilot/production
|
|
DCB-500
|
300 L
|
500 L
|
150 kg
|
2.2-3.7 kW
|
DN200-250
|
Production
|
|
DCB-1000
|
600 L
|
1,000 L
|
300 kg
|
3.7-5.5 kW
|
DN250-300
|
Production
|
|
DCB-2000
|
1,200 L
|
2,000 L
|
600 kg
|
5.5-7.5 kW
|
DN300-400
|
Heavy duty
|
|
DCB-3000
|
1,800 L
|
3,000 L
|
900 kg
|
7.5-11 kW
|
DN400-500
|
Heavy duty
|
PRELIMINARY SIZING BASIS
BATCH MASS
Mass = working volume x bulk density
Example: 1,000 L x 0.5 kg/L = 500 kg
Use loose bulk density at charging condition
CYCLE CAPACITY
Batches/h = 60/total cycle minutes
Include charge + blend + verify + discharge
Do not size from mixing time alone
WHAT CONTROLS THE FINAL SELECTION
Bulk behaviour
Density range, flowability, cohesion, angle of repose and tendency to aerate.
Blend objective
Ingredient ratio, required CV, sampling method and segregation sensitivity.
Mechanical duty
Gross batch mass, rotating imbalance, start torque, bearings and dynamic support load.
Product protection
Fragility, abrasion, temperature sensitivity and permitted tumbling intensity.
Process limits
Cohesive, sticky or very low-dose blends may need baffles, trials or another mixer.
Hygienic duty
MOC, surface finish, closures, gaskets, cleaning method and validation standard.
FINAL ENGINEERING CHECK
Confirm formulation data
Define test and CV target
Complete representative trial
Verify motor torque and seal
Agree FAT acceptance criteria
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