Processing Capacity: 2-10 tons/hour
Material Form: Powder or Granules
Equipment Material: Carbon Steel, Stainless Steel
Operation Method: Batch Mixing
Applications: Organic powders, inorganic powders, agricultural granules, industrial granules, plant fibers, etc.
Horizontal drum: This is typically a U-shaped or cylindrical trough, sealed at both ends to prevent material leakage and dust spillage, ensuring sufficient mixing distance.
Ribbon mixing system: This drum houses a horizontal main shaft, on which are fixed two inner and outer ribbons. The two ribbons rotate in opposite directions. The inner ribbon pushes the material along the main shaft, conveying it from the center of the drum toward the ends. The outer ribbon gathers the material from the ends toward the center. This "inner and outer" counter-rotating motion creates intense convection in both the axial and radial directions, achieving seamless mixing.
Feed and discharge: The feed port is located at the top of the drum, while the discharge port is located at the bottom or end.
Drive system: This system, consisting of a motor, reducer, and coupling, drives the main shaft at a low speed.
Application Areas
1. Organic Fertilizer Raw Material Pretreatment: Main ingredients such as livestock and poultry manure, shredded straw, and mushroom residue are mixed with fermentation agents and conditioners in appropriate proportions to provide a uniform starting material for composting and avoid incomplete composting due to insufficient localized inoculum.
2. Post-Composting Nutrient Blending: The composted organic fertilizer undergoes a "secondary blending" process, adding inorganic fertilizers such as nitrogen, phosphorus, and potassium, or functional additives such as humic acid and amino acids, to produce a formulated fertilizer that meets specific nutrient standards.
3. Material Conditioning Before Granulation: The uniformly mixed materials are adjusted to an appropriate moisture content to ensure high pellet formation and consistent strength during subsequent granulation.
Working principle of horizontal mixer:
1. Basic Structure： The main structure of the equipment consists of a horizontally positioned U-shaped mixing tank, within which is mounted a stirring shaft consisting of two layers of inner and outer spiral ribbons. The inner and outer spiral ribbons spiral in opposite directions and may have different pitches to enhance mixing.
2. Axial and Radial Movement of the Material： As the stirring shaft rotates, the inner and outer spiral ribbons propel the material in opposite axial directions, creating a reciprocating axial flow within the tank. Simultaneously, the friction and shear forces between the spiral ribbons and the material drive radial movement, causing the material to be swept up, tumbled, and interpenetrated by the spiral ribbons.
3. Forced Mixing and Homogenization： The combination of axial reciprocating propulsion and radial shearing and tumbling continuously disperses, convects, and shears the material within the mixing tank, breaking up material agglomerates and achieving rapid mixing of the different components. Even materials with widely varying densities and particle sizes can be uniformly mixed thanks to the forced action of the spiral ribbons. 4. Discharge Principle: After mixing is complete, the material is discharged from the equipment by opening the discharge valve at the bottom of the mixing tank (or using an inclined tank design) under the influence of gravity and residual thrust from the screw ribbon.
Advantages of horizontal mixers:
1. High mixing uniformity:
The double-layered spiral ribbons with reverse circulation eliminate dead spots and thoroughly mix materials with varying densities, achieving a uniformity exceeding 95%, far exceeding that of conventional paddle mixers. This ensures consistent distribution of organic fertilizer agents and nutrients, as well as optimal composting.
2. Suitable for highly viscous materials:
The spiral ribbons continuously push materials to prevent sticking and accumulation, while the U-shaped drum and spiral ribbons work closely together to scrape the material off the drum wall, reducing waste and cleaning difficulties.
3. High throughput and high efficiency:
A single unit can process 0.5-20 tons per batch, while continuous mixers can process 10-50 tons per hour. Mixing is not affected by the fill level, making it suitable for large-scale continuous production.
4. Low energy consumption and low wear:
The spiral ribbons maintain surface contact with the material, resulting in slow wear of vulnerable parts and a long lifespan. Low-speed mixing consumes 10%-20% less energy than paddle mixers.
5. Convenient operation and maintenance:
Adjustable mixing time and speed, with some models featuring variable speed control. Access to the drum allows for easy inspection and cleaning.
Model | ASLWJ - 7015 | ASLWJ - 9015 | ASLWJ - 1630 |
Dimensions (mm) | 2350×1200×1000 | 2550x1500x1000 | 3950×1720×2100 |
Motor Power (kw) | 7.5 | 11 | 22 |
Reducer Model | ZQ350 - 23.34 | ZQ350 - 23.34 | ZQ500 - 48.57 |
Stirring Speed (r/min) | 46 | 39 | 21 |
Main Plate Thickness (mm) | 4 | 4 | 10 |
Capacity (t/h) | 2-3 | 3-5 | 10-15 |
What types of mixing blades are available for mixers? What materials are suitable for each?
Common types of mixing blades include:
① Spiral blades, which achieve convective mixing through spiral propulsion and are suitable for powdered and granular materials, offering high mixing efficiency.
② Paddle blades, which are distributed in a paddle-like pattern and are suitable for semi-wet, sticky materials, enhancing shear and reducing agglomeration.
③ Combination blades, which offer both convection and shear, are suitable for mixing a variety of materials, especially those with a small amount of agglomeration. For example, when processing highly sticky cow dung, paddle or combination blades are more effective.
Can horizontal mixers operate continuously? Do they require intermittent downtime?
Ordinary horizontal mixers primarily operate in batches. If you require continuous operation, consider an ASL single-shaft mixer, which achieves batch mixing through continuous feeding and discharging. After 4-6 hours of continuous operation, it is recommended to stop the machine for 10-15 minutes to allow the motor and reducer to cool and prevent overheating that could affect their lifespan.
How should horizontal mixers be used in conjunction with other equipment?
In an organic fertilizer production line, a horizontal mixer can be paired with a front-end crusher and a back-end granulator.
① The crushed material from the crusher enters the mixer via a conveyor belt and is mixed with other raw materials.
② The mixed material is directly conveyed from the mixer discharge port to the granulator, forming a continuous production process. Some manufacturers offer customized solutions, matching equipment models to production capacity to ensure smooth integration of each link and improve production efficiency.
What are the wearing parts of a horizontal mixer? How often are they replaced?
The main wearing parts include:
① The mixing blades should be replaced every 3-6 months when handling normal materials, and this is reduced to 1-3 months when handling materials with high sand content.
② Seals should be inspected every 2-4 months and replaced promptly if they deteriorate.
③ Bearings should have a lifespan of approximately 1-2 years under normal use and require regular lubrication to extend their lifespan.
④ Drive belts should be inspected for tightness and wear every 6-12 months and replaced if necessary.
What are the safety features of a horizontal mixer?
A standard horizontal mixer is equipped with multiple safety features:
① A guardrail on the feed inlet prevents operators from accidentally reaching in;
② An emergency stop button quickly shuts down the machine in the event of an abnormality;
③ An overload protection device automatically cuts off power if the motor is overloaded;
④ A discharge door limit switch prevents mixing from starting if the discharge door is open; and
⑤ A protective shield covers the transmission components to prevent clothing from getting caught in them. These features must be kept in good working order and must not be removed at will.
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