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Catalogue No. 4
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PHLAUER HIGH
PERFORMANCE
MIXERS
™
15 SECONDS
Good people to mix with!
Since 1995
30 SECONDS
Why mix in 1 Minute?
Accuracy – the speed of mixing overcomes
segregation for higher accuracy to Cv. 5%.
Small systems, high production, lower cost per ton,
and are predictable, repeatable and reliable.
PH
See our
value package
See the
video
LAUER
Horizontal Mixers for Dry Ingredients
www.ajmixing.com
Starting in 1995,
A & J have built a business
around the invention of the PHLAUER™ paddle
mixing rotor (patented), and their Shearmaker.
400 installations are now making more money for the
users through better quality and higher production.
We specialize in the process — not just mixers.
Customizing and integrating is our way to get you the
best results. Here are some examples:
A specialty spice company in the Midwest started
supplying a fast food chain in 2009. By 2014 they
had all the business just because the product tasted
better than their competitors.
A company in Thailand bought a cement mixing
system for thinsets in 2005 and got a 3 month
return on their investment. They have since
purchased 3 more systems and 7 mixers. They got
higher quality, higher production, saved pigments
and other minor ingredients.
An animal feed company wanted to make a horse
feed with 25% molasses. We did it, and they just
rewarded us with two more machines lined with
UHMW for easier cleaning.
An infant nutritionals company first put our mixer in
Iran, and this year purchased a 3A system for
Bangladesh. The mixing is accurate and consistent.
Our goal is to get and retain customers. Repeat orders
are traditionally more than 50% of our business. One
company has 26 machines, several have 8 or more.
This is the story of High Performance Mixing:
HIGHEST QUALITY, LOWEST COST PER TON.
The applications are in:
• Food Mixers
• Biomass
• Cement Products
• Animal Feed
• Construction Materials
• Aquaculture & Pet Food
• Chemical
• Plastics
Unique features & benefits
HIGHEST QUALITY AT LOWEST COST PER TON
• Make your product accurately to Cv. 5% repeatedly in small samples in
one minute or less with a low speed rotor. Every supplier says they can
mix accurately, and thee difference is in the size of the sample, and if the
quality can be repeated.
d. The importance of the speed is to overcome
segregation in the mixer,
er,
and to get more production.
ction.
Some suppliers can mixx fast
“We put 100 grams live
and accurately but theyy are
spores in 500 lbs of carrier
using either a high speed
ed
and it is perfect every time
rotor, or dual rotors.
in 1 minute mix time.”
Examples: Infant
nutritionals, colored tilee
Ben Thompson
grouts, meat spices, colored
olored
Manager
masonry cement, vitamins
mins
and minerals.
• The rotor has no shear,, no heat generation. It can mix friables such as
nuts, extruded kibble, flakes
flakes, roasted coffee beans
beans, roasted and ground
coffee, pressure pelletized products, enzymes and live spores.
• If the quality is dependant upon removing lumps, we have the most
aggressive shear that can be added, predictable, repeatable, reliable.
The majority of mixtures require shear.
Examples: color development while saving pigments. We have a
customer who could not repeat on a animal feed additive. The problem
was lumps in the samples. With our shear an independent test showed
Cv. 2.4%, the best result on our single rotor mixer.
• Excellent for high or low liquid additions. Several methods are used
depending upon the absorbency of the base and the tendency to
agglomerate. For example, we would spray on spices or vitamins &
minerals or other powders. For high amounts on kibble or pellets, we
would slug load through a distribution pipe. Vacuum infusion available.
Also see http://www.ajmixing.com/liquid-addition-systems.shtml
• High production in small building space. We have a customer who
replaced 26 mixers, got their production up by 40%, got quality up and
saved pigments, and all without raising the roof of any building.
g
qqualityy at the lowest cost pper ton. Customers in cement
• Highest
products, meat spices, vitamins and minerals, animal feed, are
dominating their markets.
“Their system has given us the edge in the
marketplace because the quality of our products,
bar none, is better than any other cement toll
processor's; others can't compete with us because
we can produce large volumes of high-quality
products at a low cost.”
Mixing flour
2
Billy-Joe Lovett, Division Manager
The Scruggs Company
Shearmaker
How we do it
A Shearmaker is a device that inserts blades through the
side of the mixer turning at high speed to add shear to the mixer.
PHLAUER™ mixers are not a knock off of some other
design. They were developed specifically using an old
principle in a new way that produces fantastic results,
predictable, repeatable, reliable. Our Shearmakers
were designed to develop color in non-abrasive
materials in a predictable time.
The design is so much different than the chopper that we gave it our own
name being Shearmaker. It has a different blade design, different speed,
two-bearing pedestal, and our own patented seal that uses a film of air
around the shaft to do the sealing.
The PHLAUER™ patented rotor is the component completing the marriage
that gets results. First, we can install as many Shearmakers that will fit both
sides of the machine, and we can compensate the paddles so there
is no loss of mixing action. This is unique worldwide.
All the particles pass each Shearmaker every 6 to 10 seconds, a portion are
reduced in size, quickly mixed in and transported to the next or same unit.
We don’t classify particle sizes so the norm is to run long enough or add
enough Shearmakers to reduce the particles as far as they need to be.
We use a unique, full sized seal block - complete removal from outside
the mixer, so you have the added safety of not having someone inside the
machine.
Both of these are significant developments. Every mixer
mixes perfectly if the sample is the entire batch. What
makes the difference is the size of the sample taken
directly from the mixer. Our samples only have to be
big enough to have the mathematical probability of
having particles from the smallest ingredient.
For more information, see
http://www.ajmixing.com/highperformance-mixing.shtml
Mixing is a randomization process that requires voids
for particles to randomly change place, and organized
transportation to get ingredients from end to end.
Quality of mixing is determined by statistical analysis
and a Coefficient of Variation (Cv.) of 5% is considered
nearly perfect when determined using small samples.
That is what our AJSP mixers do.
Voids are created mechanically using paddles. A high
volume of voids is created by the sizing of the paddles
with the voids equal to the batch size per rotor
revolution in medium sized mixers. Demixing is
controlled by the zone size serviced by the paddles
which is always less than 10 inches (250 mm).
Are You Developing Color This Well?
These draw tests of the same formula show
undeveloped color on the left from a typical
Ribbon Blender, and fully developed color
on the right from a PHLAUER™ mixer
and less pigment
Demo machines are available
for use at your plant. All have
Shearmakers, liquid addition
systems, and their own
control panel.
A mixer is divided into zones and each zone is served
by two paddles: a longer paddle near the housing that is
biased to move the material in one direction as it
creates a void; and a shorter paddle opposite that is
biased to move the material in the opposite direction.
The flow is balanced to have the material horizontal
from end to end and in reach of the paddles.
When the mixer is started, all particles are immediately
in motion. The volume of voids created is controlled
through the paddle sizing so that all mixers mix the
same. Mixing takes 1 minute or less in a single rotor
mixer, and 30 seconds in a dual rotor mixer.
The high particle movement and the rapid mixing make
it ideal for adding liquids. Perfectly mixed material
passes a point every six to ten seconds. Holding a
spray for multiples of that time, typically 30 seconds,
will apply liquid to all the particles. For relatively
non-absorbent product, the mixer action will wipe liquid
from particle to particle in seconds.
Please visit our website
www.ajmixing.com
3
Single Rotor Mixers
This horizontal single shaft batch mixer is our most
popular, as we expected it would be. The price/
performance ratio is favorable in many industries. It is very
versatile and ideal for adding shear. The majority of mixes do
require shear, and it is a benefit to some customers to do no
shear mixing and high shear mixing in the same machine at
different times
Cement Mixers - Severe Duty
The PHLAUER™ patented mixer rotor is ideal for
customizing and introducing high shear. The mixing
zones are typically 10” (250 mm) served by two paddles, an outer
and inner that creates randomized flow in both directions. The
paddles can be notched and compensated so the mixing action is
not compromised, and square Shearmaker™ blades can operated
between the shafts.
PHLAUER™ single rotor mixers mix in ONE MINUTE to Cv.
5% with a unique low speed rotor. It will mix different sizes
and weights of particles.
Reverse knife-edge cover, stand-up grate,and plenum to hook dust collection.
Model 426S dual port, carbon A/R with two Shearmakers
Double Rotor Mixers
PHLAUER™ double rotor horizontal batch mixers
mix in 30 SECONDS to Cv. 5%. Each rotor is an
independent mixer and adding two rotors also adds a dynamic
interchange between them that reduces mix time, and makes
them ideal for adding liquids. It will mix different sizes and
weights of particles.
The rotor mixes to Cv. 5% in one minute. The Shearmaker™ was
developed specifically to develop red and salmon colors in masonry
cement which is non-sanded, in a fixed time, and these are the
colors we usually design for. There is a mallard green that takes
longer, and our customers just take less production on this color as
it is not a big seller. Lighter colors take less time but most
customers can’t package any faster, so we work on a fixed time.
We believe we are the only company who can develop in
non-sanded material.
Very popular for low shear mixing, accurate liquid addition and
high volume mixing. Examples include coffee beans, ground
coffee, cereals, animal feeds, pet and aqua feed coating,
convection drying.
Model 5512 dual rotor, carbon, continuous. capable of
21,600 cu. ft. (60,000 l) per hour
4
All sealed bearings, spring loaded packing gland over a hardened sleeve, split
receiver.
Mixing Systems
Our staff has considerable experience in designing
mixing systems for cement, minerals, aquatic feed,
pet food, spices—almost any application. We do a lot of work in
existing buildings because of our high production from small
machines, and can model the pieces so they fit the building and
also fit together.
Systems may include design, mixers, weigh hoppers, receivers,
discharge hoppers, structural concept, control panels, control
systems, valves, scales, connectors, bag dumps, screw
conveyors, bucket elevators, pail fillers, pail closers, conveyors,
bulk bag unloaders, bulk bag fillers, screeners, metal detection,
samplers, vacuum pumps, liquid pumps and spraying systems,
dryer packages.
"Plug And Play" Mixer,
Dust Collection, Pail Filling
The PHLAUER™ Model AJSP304SPIS is shown with the filtered
bag dump which also collects dust from the heavy duty pail filler.
The system comes with the control panel, programmed scale
and gravity conveyor. The batch is
loaded manually in the mixer and
mixed. The mixer is switched to slow
speed for filling pails. The scale is
programmed to fill different weights.
High Shear Mixing
Abrasion Resistant Mixers
Our aggressive shear has many uses in the food industry to
remove lumps with repeatable performance so an additional
milling or screening step may be eliminated.
A & J makes wear resistant machines in two general categories,
either to resist wear for a reasonable life, say 20 to 25 years
without repair, or, if we know the machine won't stand up, then we
make it repairable and use sacrificial materials, replaceable
paddles, etc. It is our experience that our customer either has not
tried equipment to resist wear or they have experience that can
help us. We have experience with a lot of items, and we have
some resources from suppliers.
There is a difference in shear levels. Here is an example:
A customer was using a competitive device on guar gum,
screening, and scrapping about 20%. We took our demo
machine to their scrap pile and recovered the whole thing.
Here are some other uses for our industrial food mixers:
salad dressings, barbeque sauce, chocolate brownie mix,
yellow cake mix, angel food cake mix, concentrate for
extruding, calcium enrichment of chocolate.
More info
http://www.ajmixing.com/abrasion-resistant-mixers.shtml
5
Food Mixers
Sanitary & 3A Mixers
Mixers are available in both batch and continuous
configurations and mix to Cv. 5%. The rotors have no
shear and mixes different sizes and weights of particles in one
minute or less.
All sanitary mixers have in common that they must
be free from cracks, crevices, undercut welds, and
have welds ground. The categories are then defined by the
end use.
Aggressive Shear can be added to remove lumps or develop color.
We make six categories of sanitary mixers, all are CDA, USDA,
FDA accepted: sanitary carbon, general food grades, super
sanitary food grade, 3A, pharmaceutical.
We construct the units in sanitary stainless steel with a variety of
finish levels suited to each application.
Blending of heat sensitive or friable ingredients is not a problem.
With a one-minute blend time from our low intensity agitator
product integrity is not compromised.
Model 558, All Stainless. 3A dairy quality. dual port discharge,
capacity 110 cu. ft. (3116 l) used for salad dressings.
Model 365D, All Stainless, drop bottom discharge, capacity 62 cu. ft. (17
(1756 l)
sugar.
Used for applying tallow to dextrose with additives for icing sugar
Continuous Mixers
with
Model 366S, stainless contact, port discharge, capacity 37 cu. ft. (1048 l) w
two Shearmakers. Used for flour based mixes.
No Shear Mixing
The reason for using mixing without shear is to mix without
degradation and heat generation. This is important for any
sugar based items such as sugar with rolled oats; sugar based
drinks like iced tea, orange crystals or fiber, except when
sugar plating is required. No Shear Mixing is also used for
mixing cereals, fruit, vegetables, coffee beans, flavored coffee,
tea, baby formula, milk powder, whey powders, spices with
fiber, granola, trail mix.
For the sticky products like fruit, we can offer Teflon
impregnation or electro-polish.
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• Completely randomized forward and
backward mixing
• Two rotors are put end to end to get distance to feed ingredients
• Average dwell of 1 minute will give Cv. 5% or better
• High volume from small machines – 150 to 12,000 cu. ft. per
hour. (4,200 to 34,000 liters)
• Works on volume controlled flood feed principle using volumetric
or gravimetric feeders
• Adjustable end continuous discharge
• Bottom discharge for cleanout
• No material lost on start or end of a run
• Best suited for high volume and low number of ingredients
• Applications: beverages, baby formula additions, detergents,
ceramic; Portland cement/CKD/Flyash, nutritionals,
pharmaceutical
• Available materials: carbon, carbon AR400; stainless food grade,
sanitary, and 3A
Animal Feed, Vitamins
and Minerals
QUALITY MEANS PROFIT: Horse and Dairy Feed
More companies are using the PHLAUER™ dual shaft mixers
for horse, race horse, dairy feeds and vitamin and minerals.
The reason is that they get the highest quality at the lowest
cost per ton with mixers that are predictable, repeatable, and
reliable.
The mixers perform consistently at Cv. 5% based on small
samples taken directly from the mixer. The sample only has to
be big enough to statistically contain the particles of the
smallest ingredient.
Accurate liquid coatings as low as 0.6% can be done on
pressurized pellets. Extruded kibble can be coated as there is
no shear in the mixer rotors. Flakes can also be mixed.
http://www.ajmixing.com/animal-feed.shtml
More info http://www.ajmixing.com/animal
feed.shtml
Model 428D, Carbon with liner above, 135 cu. ft. (3800 l) mixing capacity.
Applies up to 25% molasses in one minute or less.
Model 428D Carbon, Drop Bottom discharge. Mixing zone lined with UHMW
for ease of ccleaning when using molasses.
M d l 365D
Model
D Carbon
C b A/R
i PPortt Di
h
ith ttwo Sh
k
A/R, TTwin
Discharge
with
Shearmakers.
Oil addition. Capacity 62 cu. ft. (1756 l)
for vitamin and mineral mixing.
Our recommendation
recomm
Dry Mixer Rebuild Kits
A retrofit/rebuild kit is a way of getting the advantages of the
patented PHLAUER™ mixing rotor, accuracy and speed at a lower
investment by rebuilding your existing mixer.Rebuild kits are
available for ribbons, Marion paddle, plow mixers, and some
Forberg’s. Each mixer has to be evaluated for viability.
More info
http://www.ajmixing.com/dry-mixer-rebuild-kits.shtml
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Specifications and Options
• Batch sizes available from 1 cu. ft. (28 l ) to 670 cu. ft.
(18,900l) Contact us for dimension drawings.
• Seals: lip seals, spring loaded packing gland, air
purged lip, air purged patented controlled orifice.
• Capacity is based on height of short paddle arm,
approx. 80% of rotor.
• Drive – all helical shaft mounted, TEFC motors,
explosion proof motors, all voltages available.
• Types of construction: bolted partial endplate with solid
rotor preferred; alternatve, all welded with rotor
installed with stub shafts.
• Cover customized to suit your application; bag dumps,
grates, vibratory screen.
• Materials: Carbon steel, carbon/AR400, all stainless,
stainless contact.
• Finishes outside: painted, epoxy coating, glass bead,
polished.
• Finished inside: as rolled, glass bead, welds ground,
polished, electro-polish, Teflon impregnation, UHMW
lined.
• Discharges: flush drop bottom or ports, ports both
ends, end discharge, all air operated.
• Bearings: all sealed ball or axial roller in pillow blocks
bracket mounted.
• Cleaning assists: side doors, gussets in ends, drains,
vibrators, wash nozzles.
• All levels of controls available: manual, PLC, PLC and
computer, computer based.
• Mixers are piped to a dump valve. All devices wired to
a junction box.
• Liquid addition systems.
• Shearmakers for high or low shear.
• Weighing systems.
• We will supply anything that we can make work,
guarantee, and you are willing to pay for.
DEMO MIXERS AVAILABLE
Request
a demo
Representative/Licencee
PH
LAUE R
Good people to mix with!
Since 1995
8-2345 Wyecroft Road, Oakville, ON, Canada, L6L 6L4
Phone: 1-905-827-7288 • US/CAN 1-800-668-3470
Fax: 1-905-827-5045
Email: [email protected] • Website: www.ajmixing.com