What Should You Know about Double Cone Mixers?

If you work with powders or dry granules, you must be familiar with a double cone blender. Whether you are newbies or experienced workers, it is necessary to know more about this machine. Here are some key points you should know:

• Meaning of double cone mixing equipment
• The working process of this machine
• Double cone blenders vs V blenders
• Double cone vs octagonal blenders

What is a double cone mixer?

A double cone blender is used to mix dry powders and granules uniformly. It gets its name from the shape—two cone-shaped sections joined at their wide ends. The double-cone shaped chamber is also the key part. It is mounted on a central shaft that allows it to rotate smoothly. As the chamber turns, the materials inside tumble and fold over each other. This motion helps mix the contents evenly without high force. So this machine is ideal for delicate or light powders.

Because of its shape, the materials move in multiple directions during the rotation. This helps reduce the chances of dead spots. The simple design also makes the blender easy to load, unload, and clean. However, this machine is not suitable for sticky or wet materials. They can stick to the inner walls and may not mix well. Moreover, compared to high-speed mixers, a double cone blender may take more time to achieve a uniform mix, especially for large batches.

Uses of a double cone blender

Double cone blenders are commonly used in pharmaceutical factories, supplement production, and chemical processing plants. These areas all require clean, even, and gentle mixing.

• Pharma industry. It mixes API with excipients evenly to make pills like tablets and capsules.
• Nutritional and dietary supplements. The machine mixes protein powders, herbal blends, or vitamin mixtures for consistent packaging.
• Chmical areas. Fine chemical powders or additives could be mixed for further processing.
• Food industry. It blends spices, flavorings, or dry food mixes to prepare food products.

How does a double cone mixer work?

It is not difficult to operate a double cone mixer. Here is a video for your reference.

Load the blender and seal the chamber

At first, operators put the materials into the chamber through a top opening. The fill level is usually kept between 50% and 70% of the total volume. This space allows the powders to move freely during rotation. Once the material is loaded, the inlet is securely closed. This prevents dust from escaping and keeps the material safe during blending.

Mix the material

Then, the operator can press the button to start mixing. The blender rotates around its central axis. As it turns, the materials inside tumble and fall over each other. The cone shape helps the powder move in multiple directions and create a good mix.

The mixing time is usually based on the material type and the level of mixing needed. Mixing can take several minutes to over an hour. It is also influenced by batch size and product behavior.

Discharge the material

Finally, once mixing is complete, the powder is discharged through a bottom outlet valve. This design makes it easy to collect the blended material without spillage. Then the material could be used for further processing, like compression.

Double cone blenders vs V blenders

These two equipment differ in many aspects. Here are some examples.

Shapes

V blenders have totally different shapes compared to double cone blenders. They consist of two cylindrical sections forming a V shape. The powders move from one arm to the other during mixing. The different shapes cause the materials to flow in different ways. It affects how fast and how well they mix.

Mixing motion

The double cone blender mixes by turning the cone slowly. This makes the powder inside tumble and roll over itself. The powder moves gently in all directions. This is good for mixing powders that break easily or need to stay in their original form.

In the V blender, the two arms move the powder from one side of the chamber to the other as it rotates. This creates more random movement. It often mixes the powder more efficiently. You can check the video for more information.

Fill level

Double cone blenders work best when they are filled to 50%–70% of their total volume. This gives the powder enough space to move and mix properly. V blenders work best at a fill level of 40%–60%. This is slightly lower because the powder moves mainly through the arms. If the V blender is too full, the powder will not move from side to side. This leads a poor mixing.

Cleaning

The inside of a double cone blender is usually smooth and round. It has few corners or tight spots. So it is easier to clean after mixing. The V blender has sharp angles where the two arms connect. These spots can collect powder and they are harder to reach during cleaning. Therefore, double cone blenders are often preferred when hygiene is a key consideration, like in pharma production.

Double cone blenders vs octagonal blenders

Structures

Compared to double cone mixers, an octagonal blender has an eight-sided drum. The shape is more boxy. It does not have sharp corners, but the flat surfaces and angles lift and drop the powder during rotation. The octagonal design has a larger mixing area than the other. It is suitable for high-volume production.

Mixing movement

In a double cone blender, it depends on tumbling to mix powders. In an octagonal blender, the mixing is also done by tumbling, but the motion is more controlled. Because it has flat surfaces. The powder falls from one side to another more frequently. It can improve the mixing time in some cases. Octagonal mixers are more ideal for blending materials with different particle sizes or densities.

Space

Double cone blenders are more compact and easier to install in smaller spaces. They have a balanced design and require less room to rotate. Octagonal blenders are usually bulkier, especially in larger sizes. They need more space for operation. So if you have a limited area, a double cone mixer is more practical.

Partner with iPharMachine to get high-quality mixers

iPharMachine is a leading Chinese manufacturer to make different types of machines, such as capsule fillers, mixers, tablet press, etc. We provide a series of models for you to choose from. We also offer customization. When you tell us your requirements, we’ll discuss with you in every detail and then put them into action. Moreover, extra services like quality checks or shipping could also be conducted.