Traditional versus new technology is always a battle across all industries and even in everyday life.  However, when it comes to industries and industrial plants in the majority of cases, it comes down to cost-effectiveness, efficiency, and durability.  Let’s compare tank or dynamic mixers against a static mixer.

Traditional Tank Mixer

A tank or dynamic mixer is a mixer with any moving part, such as an impeller, responsible for creating the mixing action within.  Due to their dynamic nature, tank or dynamic mixers require added electrical energy to function and produce the desired end result increasing overall manufacturing costs and overhead. Along with added cost, while running the machine, the modular components of the installation make it relatively difficult to disassemble and clean properly as it requires an expert to ensure proper reassembly.

Static Mixer

Static mixers are usually inserted into sections of existing pipe with an intricately assembled insert that causes the mixing medium to change direction over and over again to achieve a homogenous mixture without the need of added energy like electricity.  The mixing energy comes from the already existing kinetic energy that is held by the mixing medium passing through the piping system. This kinetic energy is often an afterthought, but with a Komax Systems static mixer, it is a main component in the process. Harnessing this intrinsic force allows a mixing system to produce a homogenous mixture without the added cost that would come with running a dynamic mixing feature.  A static mixer also eliminates air from getting into the mixer, which can affect bonding in liquids, as it is placed directly into the piping system rather than having to divert to an auxiliary tank.

Along with being cost-effective and air-tight, static mixers are simple to clean as the triple-action mixing elements are installed as a single unit and can be removed easily for cleaning.

Having each of these characteristics allows a static mixer to not only be highly effective in providing a top-tier end product, but it can do it at a fraction of the cost to the manufacturer.

Comparing the Two

When deciding upon which is the better fit for your needs, comparisons need to be made on energy efficiency, maintenance, space and time.

Time and Space

Tank Mixers are large and require a large space and materials to be able to efficiently perform the mixing.  This makes the mixing time very long, quite possibly over a period of days.

Static mixers blend the materials as they are extruded, dramatically reducing the mixing time.  They also do not require a large space they are part of the piping.  They need no extra space to put them into a plant.

Energy Costs

Tank mixers run on electricity and require an external power source.  When large amounts of materials are mixed, not only does the production time increase, but also the expenses increase because of the high energy costs.

Static mixers have no moving parts, require no electricity, thus not contributing to the growing power consumption.  They cut down on energy costs.

Maintenance and Cleaning

Tank mixers are more difficult when it comes to maintenance and cleaning.

Static mixers have the clean-in-place (CIP) option, making them easy to maintain and clean.  As well as with no moving components makes it easier to clean.  Because they lack moving parts, there’s very little need for maintenance or replacement parts.

Komax Takes the Static Mixer to the Next Level

Komax created a Triple Action Static Mixer that includes 3 distinct types of mixing: Two by Two Division, Cross Current Mixing, and Counter-Rotating Vortices & Back-Mixing.

• Two by Two – They divide and re-divide the process stream with a series of elements set at right angles to each other. Each element doubles the number of previous divisions.
• Cross-Current Mixing – Special cavities randomize the distribution of material by direct steam impingement.
• Counter-Rotating Vortices & Back Mixing – Under turbulent flow w, both sides of each Komax element produce elliptical vortices rotating in opposite directions. This eliminates the streaming or tunneling effects associated with early static mixer designs.  In addition, an optimum degree of back mixing occurs as it orbits material in the vortex from the front to back of an element before continuing downstream.  This produces a substantial improvement in mixing efficiency.

Komax Systems Precision Engineering

A static mixer is a precision-engineered device that is used for the continuous mixing of materials without moving components.  There are so many designs of static mixers and construction materials, they can fulfill so many applications.  With so many benefits associated with static mixers, many industrial plants are moving away from traditional tank mixers and going with cost-effective, efficient static mixers.

Get in touch with us to get a free quote customized to your specific project.