A well-developed mixing strategy is essential to production efficiency. Ideally, mixing equipment and procedures are evaluated periodically, as production needs change or when new formulations come through the pipeline. However, mixing is often overlooked in terms of upgrades, at least until it becomes a source of drastic losses whether because of low yield, recurring contamination, inconsistent product quality or excessive labor hours.
In mixing, it is not too difficult to find "something that works." Yet, while there may be several ways to make good product, not all are efficient, competitive or even sustainable. Limitations in capital expenditure and overreliance on legacy equipment are common obstacles that keep processes stagnant for years and decades even as various aspects of the business are constantly undergoing significant changes. The irony is that a careful re-evaluation of mixing procedures can reveal achievable steps to significantly reduce costs.
One technique is to examine the entire production flow and determine if multiple mixing operations can be performed in a single machine without sacrificing product quality. One major benefit to "one-pot processing" is the reduction of energy consumption though many other incentives are equally justifiable including faster throughput, easier cleanup, less transfer steps and lower operating cost.
Table 1 shows a few examples where multiple mixing steps were successfully consolidated into a single mixer. In each case, the simplified mixing operation gained tremendous competitive advantage for the manufacturer.
