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Technical Feature/Benefit Analysis Agitator Shafts

FEATURE: Shaft Diameter BENEFIT: The agitator shaft transfers the rotational force produced by the
drive assembly to the paddles or ribbons. Assuming like materials and torque requirements, smaller diameter shafts have higher stress concentrations than larger diameter shafts. (Stress = Force / cross sectional area of material) where Force = Torque / Radius of the shaft). The main shaft should be designed to keep stress levels below the "fatigue limit" of the shaft material. Smaller diameter shafts are more likely to break due to fatigue failure than larger diameter shafts.

FEATURE: Static Deflection BENEFIT: Static shaft deflection occurs due to the weight of the shaft,
arms, blades, ribbons, hardware, etc.. The shaft acts as a continuously loaded, simply supported beam. Maximum deflection occurs about midway between the bearing supports. Shaft Deflection = (WL3 )/( EI76.8) where E is the agitator shaft "moment of inertia." To decrease deflection the shaft's cross sectional moment of inertia needs to be increased. The moment of inertia of a solid 4I5/V shaft is more than 2 times that of a 4'/2" I.D. (5" O.D.). schedule 80 pipe. Excessive shaft deflection will promote metal fatigue and accelerate seal wear.

FEATURE: Dynamic Deflection BENEFIT: Dynamic shaft deflection occurs when the mixer is operating. In
general, the force exerted by the "down-sweep" side of the agitator is greater than that of the "up-sweep." Unlike static deflection which bends the shaft downward, dynamic deflection forces the axis of the shaft upwards towards the upsweep side of the mixer. The exact angle of deflection is dependent on variables such as: paddle or ribbon design, material flow characteristics, product loading, etc. Excessive shaft deflection, due to dynamic loading, will increase the clearances between the agitator and the trough on the "down-sweep" side of the mixer. Solid shaft designs will have less deflection than hollow shafts (of similar diameter); thus promoting better mixing action.

FEATURE: Reduced Stress Risers BENEFIT: Industrial mixers are a capital investment intended for
decades of productive service. Even though horizontal blenders operate at relatively low speeds (25 to 45 rpm's). over several years they can become subject to metal fatigue. For example... a mixer running for 2 shifts per day for 20 years will rotate approximately 175 million times. To avoid metal fatigue (and breakage) in the main shaft, stress risers should be minimized. For bolted arm agitators, key ways must have radius comers. For welded agitator assemblies, "drilling and pinning'' the arms to the main shaft prior to welding should be avoided.

FEATURE: One Piece Shaft BENEFIT: As described above, the agitator shaft of a mixer is subjected
to several rotational and bending stresses. Within the industry today, there are mixers using "stub shaft assemblies... for easy agitator removal when required." This feature allows the manufacturer of these mixers to build the agitator assembly completely outside of the mixer. Stub shaft assemblies rely on threaded fasteners (which are much smaller in cross sectional area than the main shaft) to transfer the energy created by the mixer drive assembly. One piece, solid core, agitator shaft material should be used to reduce Stress loading and minimize agitator deflection. If removal of the agitator is a concern, mixers are available with bolted and gasket end plate designs.

FEATURE: Shaft Straightness BENEFIT: Welded agitator assemblies are used in applications where
cleaning the mixer is a concern. All mating surfaces have welded fillets which are ground and polished to a specified finish. During fabrication, the heat created by welding and grinding these surfaces will warp the agitator shaft. Many times the deformation is not noticeable to the naked eye. As a final step in the fabrication process, the shaft should be re-straightened. Excessive warping ("run-out" > .005") will accelerate wear of seals and bearings; thus creating higher, long term maintenance Costs.

FEATURE: Blade or Ribbon Clearance BENEFIT: Independent studies have proven that clearances between the
agitator blades or ribbons and the trough can significantly impact mixing performance. Larger gaps produce higher coefficients of variation and longer mixing times. For most applications the gap between the mixer's agitator and trough should be .020" or less. (Note: Some applications require larger gaps to prevent degradation of the product being mixed). To verify accurate agitator clearances, documented quality control tests are to be conducted to measure residual material clean-out.

Technical Feature/Benefit Analysis Drive Components

Drive Assembly
FEATURE: Horse Power Selection H Factor BENEFIT: Horse power calculations are the most important
considerations in designing a mixer to match a given application. Based on horse power requirements, components such as shaft, gear reducer, bearings and seals are sized. Horse power selection is based on variables such as: mixer length and diameter, batch size, agitator speed, size of blades or ribbon, number of arms, start-up conditions and properties of the product being mixed. Computer models of the mixer "drive train" predict safety factors for critical components. An under powered (or under sized) drive train will have limited safety margin. For long term production needs, undersized drive trains may have increased maintenance and downtime. 3

FEATURE: Application Experience C Factor BENEFIT: Application experience is key to the selection and design of a
mixer. Variations in product characteristics, mix times, temperature and moisture content will effect the quality and quantity of the customer's finished product. Through years of proven application experience, product characteristics have been ranked according to energy requirements and mix speed. New applications are compared against this proprietary list. Energy consumption ("C" factor) and agitator "tip" speed are critical components to the horse power calculation described above. Documented case studies and laboratory experiments with test equipment are needed before designing the "right mixer for the job."

Motor
FEATURE: Locked Rotor Torque BENEFIT: The National Electrical Manufacturer's Association (NEMA)
is a self governing organization for producers of cast iron motors. NEMA has created minimum standards for duty ratings, energy efficiency and torque. All motor manufacturers publish actual performance data on their motors. Not all brands of motors are built alike... consult actual motor performance data before specifying a motor. An important characteristic to consider when selecting a motor is the locked rotor torque. Locked rotor toque capabilities, may determine if the mixer will start under loaded conditions.

Gear Reducer
FEATURE: Shaft Mount BENEFIT: Shaft mounted gear reducers provide speed reduction and
transfer of torque from the motor. Double tapered bushings ensure exact alignment of reducer with the center line of the agitator shaft (even with controlled amounts of shaft deflection). Shaft mounted designs reduce the number of exposed moving components, thus reducing ongoing maintenance requirements Shaft mounted reducers without double tapered bushings may fret and weld to the agitator shaft, making routine maintenance more difficult.

FEATURE: Duty Rating Class II Service Factor BENEFIT: Gear reducers are designed based on horse power
requirements and overall speed reduction. Operating conditions experienced with mixing applications may require a Class II service factor be applied when sizing the gear reducer. The rating is recommended based on previous experience of difficult mixing applications. This rating applies a 140% safety factor to the actual horse power requirements for the application. Class II service factors facilitate reduced stresses on the internal bearing surfaces and decreased wear of the gear face as a result of shock loading from the mixer.

Bearings
FEATURE: Radial and Thrust Loads BENEFIT: Double interlocking bearings, designed to carry radial and
thrust loads should be used to support the main agitator shaft. Mixer agitators are designed to move product around and along the axis of the mixer. The force required to move the customer's product laterally (or toward the discharge openings) is transmitted through the bearing. Bearings should be sized for "heavy service" applications. Bearings should be statically self aligning within the bearing housing to accommodate any controlled shaft deflection. Failure to accommodate all of the features listed above may reduce bearing life and increase maintenance.

FEATURE: Externally Mounted BENEFIT: Main shaft bearings typically operate at slow rpm's for long
periods of time. Protection against dusty and dirty environments is essential. It is important to mounted bearings away from seal housing areas. Since most seals have controlled amount of leakage, horizontal ledges below the seal housings should be eliminated. Isolation of the main shaft bearings from the seal housing will reduce maintenance and prevent costly down-time.

FEATURE: Expansion Type BENEFIT: A set of main shaft bearings should consist of (1) expansion
and (1) non-expansion type bearing. The non-expansion bearing transfers the thrust loading of the agitator which is described above. The expansion bearing accommodates for changes in length of the main shaft. Variations in temperature (especially on jacketed mixers) will cause the metal shaft to expand and contract. Without the use of an expansion type bearing, the life expectancy of both bearings may decrease and maintenance increase.

FEATURE: Positive Position BENEFIT: Non-homogeneous or unevenly distributed batches may

cause cyclical loads on the bearings in both the vertical and horizontal axis. Bolts positively fasten the bearing to bearing plate in the vertical axis. Metal stops are welded to the bearing plate to prevent any movement in the horizontal axis. Without the use of welded positioning blocks, the movement of the agitator will work the bolts back and forth until the shaft moves out of alignment.

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Technical Feature/Benefit Analysis Structural Trough and Ends

FEATURE: Plate Thickness BENEFIT: The structural integrity of the mixer starts with the trough
and end plates. Based on the abrasive properties of the customer's product, the rolled trough of the mixer is subject to wear. Often the wear will be most pronounced around the discharge area. Undersized trough material will lessen the productive "life span" of the mixer. In general, material thickness should be at least... For mixers 12" to 27" dia. 7 gauge For mixers 36" to 54" dia. 1/4"thick For mixers 66" to 72" dia. 3/8" thick

Trough Wall
FEATURE: Horizontal Support BENEFIT: Structural supports, welded the length of the mixer are designed to
transfer lateral loads to the end plates. Undersized stiffeners may allow the trough sides to deflect and fatigue as the agitator forces product against the trough side walls. First signs of fatigue may appear at the welded connection of the trough and the end plates. In general, structural support members should be at least. 1" x 1" x 3/16 For mixers T to 21/,' long For mixers 3 to 9 long 2 x 2 x For mixers 10 to 14 long 3 x 3 x For mixers 16 to 20 long 4 x 4 x 5/16

Bearing Plate and Gussets

FEATURE: Material Thickness BENEFIT: Bearing plates and gussets transfer loads produced by the main
shaft and drive assembly to the mixer. Often times, worst case loading occurs when mixing unevenly distributed batches of material. This situation creates cyclical, impact loads. Undersized bearing plates and gussets may deflect and distort allowing increased wear on bearings, seals and end plates. In general, bearing and gusset plates should be plasma cut for appearance and fit and have dimensions at least. For mixers 12" to 27" dia. 1/2" thick For mixers 30" to 66" dia. 3/4" thick For mixers 72" in. dia. 1" thick

Welding
FEATURE: Equipment and Process BENEFIT: Welding is a "core technology" for any manufacturer of industrial
mixers. MIG and variable frequency TIG are preferred weld processes depending on the weld application and location. All welding should be performed, in compliance with ASME standards while fixtured "in position" (ie: not up side down). This practice creates symmetric heat penetration and uniform weld legs. Before a mixer is completely assembled, it should be rotated to each of the 6 surfaces for welding (i.e.: top, bottom, sides and ends). Short-cuts in welding set-up may create weaker welds and increased splatter.

3575 3 AVENUE P.O. BOX 286 MARION, IOWA 52302 PHONE 319/377-6371 FAX 319/377-1204 WWW.MARIONMIXERS.COM

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Dare to Compare
November, 2007 Agitator Design By Doug Grunder
President, Marion Mixers, Inc.

Whats better, a ribbon or a paddle? Lets Compare.

Ribbon Agitator
Good when blending materials of like size. shape and density such as powders or granular ingredients. Lateral scrubbing action of inner ribbon against the outer ribbon produces heat. This can be useful when coating ingredients. Choppers can be added when incorporating liquids or pastes and to disperse minor ingredients. Ribbon agitators are most commonly used in the food industry where bulk products are repeatedly blended.

Ribbon

Double Ribbon Flighting

Chopper

Paddle Agitator
Good when blending materials of dissimilar size, shape and density. Paddles scoop ingredients from the bottom of the trough and lift them into the product stream. Low shear mixing is useful when blending friable or oversized ingredients. Choppers are often used in conjunction with paddle agitators to reduce product size, incorporate colorants or other minor ingredients. Sanitary paddle agitators are the easiest to clean and sanitize. Paddle agitators are fitted with tighter clearances with the trough than ribbons to allow more efficient clean-out at the end of each batch.

Paddle agitators are efficient with batch sizes down to 20% of the rated capacity of the blender. Bolted paddle agitators are frequently used in abrasive or corrosive applications where maintenance is a concern. Bolted style paddle agitators can be modified in the field to increase or decrease agitation points to accommodate changes in the customers products. Paddle style agitators can be used in both batch and continuous style mixers.

Welded Arm Bolted Paddle

Welded/Paddle

Bolted Arm Bolted Paddle

Hybrid Agitator
Combine the benefits of both the ribbon and the paddle agitator designs. Inner ribbon flighting moves product towards the end-plates, thus leveling the product load. Outer paddles provide tight clearances for efficient mixing and thorough clean-out. Choppers can be added with hybrid agitators to provide controlled amounts of mixing energy.

Hybrid Paddle/Ribbon