Flexible and cost effective solution for growing companies

Our Story

  

Founded as metalworks  supplier for world famous brand of trucks, today, after almost 30 years of continuous evolution, our company has grown into a reliable partner experienced in designing, developing and manufacturing various machinery for numerous known brands.


Having manufactured a vast array of delicate products ranging from agricultural machinery all the way up to human aerial platforms or mobile prefab concrete factories,  we simply couldn't decline one of our long term clients when he turned to us for help. 


Being a producer of various body care products, our client was struggling with a great increase in high volume orders governed by a large UK retail chain.


As it happens more often than not with companies being thrown such an attempting opportunity, our client found himself strapped with time and finances but in urgent need of expensive equipment that would enable him to get the job done. Big-box retailers don't come out with fast growth opportunities like that very often. 


He knew he was facing "go big, or go home" kind of situation.


After agreeing on detailed technical specifications of needed mixing equipment, we started with designs and sourcing of quality suppliers of drives, bearings, gaskets etc. First machines were manufactured within 8 months from project start and went straigt to our clients' production line. 


Having more than 15 large industrial mixers in use already, they certainly knew what level of performance they expected from us. And since this was the first time we were involved in a product development that required also fluid dynamics simulations, which was an "uncharted territory " for us at that time, we were very anxious to get feedback.


In the end we were very relieved to hear, our new mixers easily surpassed their expectations by a wide margin. 


In fact, they were so satisfied they wondered why wouldn't we start making these machines for others too as they will be more than happy to provide us with a stellar refference...and so we agreed. 

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Anatomy of our vacuum mixer


What is most important when looking for a new mixer? Knowing exactly what you will be using it for. This way, a highly specialized solution that will excell at performing this single processing task can be designed and manufactured most effectively.


Unfortunately, for the majority of manufacturers, this is virtually  impossible scenario. Wildly differing processing tasks are more or less the everyday norm. Normally, it requires a highly versatile machine with strong suits in processes you evaluate will be most frequent during your business. 


From the designing standpoint it is always easier to have one clear requirement than several vague ones.  It is vastly different to perform mixing in turbulent regime than it is in a laminar zone. Power requirements, speed regimes, internal flow patterns  are all very different. Yet, the reality demands that we somehow meet those sometimes directly opposite requirements in a single design. 


Well, after doing the reaserch, one thing became obvious; the basis for a consistently high product quality attainable in resonable amount of time is achievable only through some combination of homogenizer and agitator. To put it simply; you need a good internal agitation of the mixture, in radial and vertical sense, which will direct the mixture towards a high shear zone if required by processing task. 


So, which agitator design and which high shear mixer design offer the most versatility? 


After a bit more research we concluded that helical loop style agitator and bottom entry homogenizer are the way to go. 

Heavy duty design incorporating powerful geared motors is aimed at utilising benefits of chosen helical loop type of impeller with respect to continuous vertical pumping of either low or high viscosity fluids. And bottom entry homogenizer complements the helical loop type of impeller the best by utilising flow pattern inside the vessel in handling emulsification tasks when manufacturing different creams and lotions.

The agitation system itself is based on FEM optimized internals comprizing of a single top end drive combined with an inside baffle or two independently and infinitelly adjustable top end drives with counter rotating action. This way we tried to take better control over parameters influencing mixing process as well as to adjust them more precisely in quest for more versatility. The system enables achieving short batch retention times while offering uniform end product mixtures.


Variety of available internal finnishes (as low as 0,4μm) enable ease of cleaning so processing even the sensitive products is not an issue.

To compliment all aforementioned strong points we also took great care in ensuring this kind of performance comes with longevity you have every right to expect from a heavy duty piece of equipment at the very core of your manufacturing process. Heavily oversized structural components simply mean you can rest assured knowing we really did go the extra step in preventing possible breakdowns and related production interruptions.  

Find out more

Key benefits of our range of batch vacuum fluid mixers

  

  • Helical loop type of impeller combined  with inside mounted baffle or counter rotating paddle yields hi-turbulent action,  strong tangential as well as vertical pumping and consequently low  retention time
  • Mixing and de-aeration combined - designed to be operated under full vacuum yielding a better product in shorter batch cycles 
  • Multitude of mixing materials - infinitelly and independently adjustable speeds of all drives enable quality mixing of broad range of materials within 1Pas – 40Pas dynamic viscosity range 
  • Easily added optional high shear bottom  entry homogenizer
  • Optional bottom and side walls half-tube  jacket in two sections 
  • Heavy duty design - built-to-last  ovesized structural components for prevention of breakdowns and ease of maintanence
  • Variety of available internal finnishes - easy cleaning is paramount when product changes are frequent
  • Production flexibility - ability to produce great variety of formulations on the same production line
  • Mixing of minor ingredients is easily accomplished
  • Ability to precisely control mix quality – when ingredient properties change over time and compensation is needed on a batch-to-batch basis 
  • Batch traceability - highly suited where required to identify a batch for further follow up 
  • Highly suited where strict control of mix composition is required
  • Perfectly suited for small to medium capacities applications - lower installation and operating costs for small to medium capacities compared to continuous mixing
  • Use of world class heavy duty Lenze geared motors for ease of servicing
  • Low cost of ownership
  • Detailed technical documentation of all parts and assemblies
  • The mixer can be operated stand-alone or, if need be, form the heart of a complex automated production process

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MODELS

  

VAC1000 

Usable Volume in Litres: 150-1000  

Installed Power: 4,5kW*

Base dimensions:  Ø1200mm x 2250mm

Dry Weight (without jacket): 750kg 

  

VAC 2500

Usable Volume in Litres: 350-2500  

Installed Power: 10kW*

Base dimensions:  Ø1600mm x 3000mm

Dry Weight (without jacket): 1250kg

  

VAC 3500

Usable Volume in Litres: 500-3500  

Installed Power: 15kW*

Base dimensions:  Ø1800mm x 3300mm

Weight (without jacket): 1800kg

  

VAC 5000

Usable Volume in Litres: 850-5000  

Installed Power: 20kW*

Base dimensions:  Ø2000mm x 3750mm

Weight (without jacket): 2600kg

  

VAC 10000

Usable Volume in Litres: 1900-10000  

Installed Power: 43kW*

Base dimensions:  Ø2600mm x 4250mm

Weight (without jacket): 4200kg 

   

* Combined dual drive installed power for handling up to 40Pas fluids. Homogeniser not included


All ours purpose built 316 stainless steel full vacuum mixers utilize either single centrally mounted top end drive or dual top end drive. High powered bottom entry homogenisers are a frequently added option.


Exact equipment specification might vary and is subject to change without prior notice. 

Contact for pricing!

Keeping things tidy during fabrication is understood

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Heavy duty Lenze HF geared motors for piece of mind

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Finnished product is pressure as well as vacuum tested

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Large manhole opening for ease of ingress and egress

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What we exclusivelly use for all wetted parts

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Accuracy during fabrication is being regularly checked

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Standard version

  • Designed for handling up to 40Pas fluids 
  • Basic design enables full vacuum mixing
  • 316Ti or 316L grade construction (parts in contact with the product in S. S. AISI 316L; outer parts in S. S. AISI 304)
  • Heavy-duty Lenze geared motors 
  • Upper drive helical loop agitator with top end mounted baffle
  • Proprietary design drive shaft packing gland seal
  • 450mm to 600mm manhole with built-in sight glass and magnetic safety switch
  • Material charging inlets on the upper head
  • Centered bottom discharge outlet
  • Single side mounted recirculation flow inlet
  • Three vessel stands at 120° each (enables significantly cheaper scales setup)
  • 0,8μm internal finnish grade 
  • Agitating internals with ground and polished welds bolted together
  • Manufactured in accordance with cGMP and PED guidelines 

Options

  • Half pipe heating/cooling jacket (in S. S. AISI 304L ) on sidewalls and bottom dish,
  • Jacket in 2 sections, (reduction of time for heating and cooling operations with small batch sizes)
  • Top mounted counter rotating paddle agitator instead of fixed baffle
  • Helical loop agitator mounted PTFE wetted surface scrapers 
  • Isolation of bottom dish and sidewalls with 50mm Rockwool + aluminium or polished stainless steel cladding
  • Additional side mounted recirculation flow inlets
  • Bottom mounted inlet pipe beside the central discharge
  • Addition of bottom entry high shear homogenizer
  • Power and control pannel includes the Stop/Start, Emergency stop, Speed control helix, Speed control counter rotating agitator and Speed control bottom mounted homogenizer 
  • CIP nozzles
  • Pickling&passivation  

Applications

  • Shower gel 
  • Shampoo
  • Liquid soap 
  • Detergents 
  • Lotions 
  • Ointments
  • Creams
  • Solutions
  • Dispersions 
  • Tooth pastes
  • Decorative cosmetics
  • Hair products


Servicing your equippment

Of course, we have majority of spare parts on stock and can react quickly to your needs. Additionally, we also offer you a possibility to outsource servicing to a preffered servicing partner. Or, in case you have your own internal servicing department you can choose to perform servicing yourself. It's entirely up to you. 


What does it exactly mean?


Well, being a small and relatively young contender in this industry, without service network, we recognized the importance of our customers feeling safely in the long run after purchasing our machines. That is why we are making detailed technical documentation of all parts and assemblies available with purchase of each machine. 


To top it off, even during the initiall design one of the most important constrains was to enable all parts that might theoretically break to be locally sourcable. Combining aforementioned local sourcability and detailed technical documentation at your disposal means you will always be in full control over your equipment. 


We wanted to ensure you have options. Because having options means having a peace of mind. 

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HEAVYDUTYMIXER is a brand of


MARIO-LASER d.o.o.


Antuna Barca 32

35000 Slavonski Brod

Croatia


VAT Reg. No. HR872129972

 

email: mario@heavydutymixer.com

Phone: 00385-91-565-3038