![]() Even in ideal circumstances, scale-up will require some degree of tweaking to optimize your process in a larger volume. Partner with a supplier with extensive experience in scale-up engineering.By significantly reducing cycle time, you can work with more manageable batch sizes and still achieve the desired output volume per day or shift. Examples include switching from a saw-tooth disperser to a rotor/stator mixer to improve dissolution rates, installing a solids induction system to accelerate powder wet-out and dispersion, utilizing an ultra-high shear mixer to finish emulsions much faster than a traditional rotor/stator, and other solutions that depend on the specifics of a particular application. If scale-up calculations point to a prohibitively large mixer size, consider alternative mixer technologies that can potentially supplement or even replace your current mixing procedure and accomplish the same end point in a fraction of the time.For instance, a single mixer may be supplied with multiple interchangeable vessels that cycle through a sequence of charging, mixing, discharging and cleaning. Scaling up to a larger mixer with a change can design can further increase throughput and equipment utilization by enabling semi-continuous processing.Determine the quantity of full and partial batches that can be made on a particular mixer model to accommodate fluctuations in product demand.To obtain reliable data for scale-up, a good rule of thumb is to test on a mixer no smaller than 10% of the capacity you are looking to eventually install. Renting equipment for in-house trials at your facility is another option. ![]() Well-equipped manufacturers offer testing services that are supervised by mixing experts.
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