Pilot Batch Double Cone Blender

Q: What are the key features and technical specifications of the Pilot Batch Double Cone Blender?

Model : DCB-5 (Cantilever type, Interchangeable design) Gross Capacity : 8 Liters approx. | Working Capacity : 4 Liters approx. Contact Parts : SS 316 (mirror polished, 2mm thick plate) Motor : 0.5 HP, with VFD control option Key Features : Interchangeable cones, butterfly valve discharge, worm reduction gear, safety guards (SS 304), charging port with openable cover, and compact cGMP-compliant design.

Description

Pilot Batch Double Cone Blender is a tumbling mixer designed for homogeneous blending of dry powders and granules in pharmaceutical R&D and small-scale production. It features a dual-cone vessel that rotates to gently tumble materials, ensuring uniformity without damaging fragile particles, making it suitable for testing formulations before full-scale manufacturing. Pilot-scale models typically handle batch sizes from 50-200 liters (or equivalent in kg, depending on material density), bridging lab experiments and commercial production.

While octagonal blenders offer multi-directional flow for enhanced efficiency in larger capacities, double cone blenders provide simpler, more compact designs for pilot scales with effective tumbling via the conical shape, though they may require slightly longer mixing for certain densities. Double cone models excel in ease of discharge and minimal dead spots, making them preferable for fragile pharmaceuticals in R&D.

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Salient Features of Pilot Batch Double Cone Blender

Compact model.
Interchangeable design hence different capacity cones can be attached on same machine.
The conical shape at both ends enables uniform mixing and easy discharge.
All contact parts are made out of Stainless Steel 316 quality material.
Maximum care has been taken to ensure safe operation of the unit.
Cantilever type design mounted on single shaft.
Safety guards made from SS 304 pipes provided in front of the machine.

Cone will be mirror polished from the inside & outside & structure will be matt polished.
All moving parts covered with SS 304 covers.
Suitable size of butterfly valve at one end of the cone provided for material discharge & hole with open able cover provided at other end of the cone for material charging & cleaning.
Panel fabricated from SS 304 material with facility of three phase indication, start – Stop – Inch Buttons, VFD control.
Worm reduction gear use for speed reduction.
All safety guards & covers made out of SS 304.

Working Principle of Pilot Batch Double Cone Blender

The Double Cone Blender operates on the principle of free-flow tumbling, where the vessel’s rotation causes materials to cascade and intermix. The process involves:

Loading: Powders or granules are loaded through the top port(s), typically filling 50-70% of the vessel to optimize mixing.

Mixing: The vessel rotates on its horizontal axis, creating a tumbling motion. The conical shape ensures axial and radial mixing, as materials flow from the ends to the center and back. Mixing time is 5-15 minutes, depending on material properties like particle size, density, and cohesiveness.

Discharge: The vessel is stopped, and the blended material is released through the bottom/side valve, often gravity-fed or assisted by slight tilting.

Technical Specification of Pilot Batch Double Cone Blender

Model	DCB – 5
Orientation	Cantilever type
Type of Design	Interchangeable
Gross Capacity	8 Liters approx.
Working Capacity	4 Liters approx.
Contact Parts	Stainless Steel 316 grade 2mm thick plate
Shafting	Stainless Steel
Bearing	Double Roller Bearing
Motor	0.5 H.P., 1440 RPM, 3 Phase, Non-Flame Proof
Electricals	440 volts, 3 Phase, 50 Hertz
Discharge Valve	Through Butterfly Valve
Gear Type	Reduction type gear, Ration 30:1

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

Types of Mixer, Blender and Dryer

Multi Mill

Octagonal Blender

Double Cone Blender

V Cone Blender

Ribbon Blender Mixer

Tray Dryer

Vibro Sifter

Rapid Mixer Granulator

Jacketed Mixing Vessel

Heavy Duty Toothpaste Mixer

Applications of Mixer, Blender and Dryer

Advantages of Pilot Batch Double Cone Blender

Uniform Mixing: The conical shape ensures three-dimensional mixing, achieving high blend uniformity.

Gentle Handling: Low-shear tumbling preserves particle integrity, ideal for friable or sensitive materials.

Compact and Scalable: Small footprint suits labs or pilot plants; designs scale to larger units.

Ease of Cleaning: Polished SS surfaces and removable baffles (if present) facilitate cleaning, meeting GMP standards.

Cost-Effective: Low power consumption (0.5-3 kW) and minimal maintenance compared to high-shear mixers.

Key Components of Pilot Batch Double Cone Blender

Design and Construction: Consists of two conical sections joined by a central cylindrical body, made from stainless steel with mirror-polished interiors to meet cGMP standards and facilitate cleaning. The slant or balanced cone design minimizes dead spots, and it includes a charging port and discharge via butterfly valve. Optional baffles or intensifier bars enhance mixing for denser materials.

Operation: Rotates at low speeds via a motor and gearbox, promoting end-over-end tumbling for gentle diffusion. Fill to 35-70% capacity (ideally two-thirds) for optimal homogeneity, with mixing times of 5-15 minutes. Features like digital timers, speed controls, and interchangeable cones support flexibility in pilot testing.

Capacity and Efficiency: Pilot models offer 50-200 liters, with some R&D variants as small as 5-25 liters for initial trials, scalable to production sizes up to 5000+ liters. Low power and energy-efficient compared to high-shear alternatives.

Safety and Maintenance: Includes interlocks, emergency stops, dust-tight seals, and safety rods to prevent accidents. Minimal moving parts allow easy cleaning and low downtime, with options for vacuum-rated or PLC-controlled versions.

FAQ for Pilot Batch Double Cone Blender

What is a Pilot Batch Double Cone Blender and what is it used for?

The Pilot Batch Double Cone Blender is a tumbling mixer designed for homogeneous blending of dry powders and granules in pharmaceutical R&D, pilot plants, and small-scale production. It features a dual-cone vessel that rotates to gently tumble materials, ensuring uniformity without damaging fragile particles. It is ideal for formulation development, scale-up studies, and bridging lab experiments to commercial manufacturing in the Pharmaceutical, Ayurvedic, Herbal, Nutraceutical, Biotech, and Cosmetic industries.

How does the Pilot Batch Double Cone Blender work?

It operates on the principle of free-flow tumbling. The double-cone vessel rotates on a horizontal axis, causing materials to cascade and intermix through gravity-driven axial and radial movement. Powders or granules are loaded to 50–70% of the gross volume. The conical shape promotes excellent mixing, typically achieving homogeneity in 5–15 minutes with minimal shear and heat generation.

What are the key features and technical specifications of the Pilot Batch Double Cone Blender?

Model: DCB-5 (Cantilever type, Interchangeable design)
Gross Capacity: 8 Liters approx. | Working Capacity: 4 Liters approx.
Contact Parts: SS 316 (mirror polished, 2mm thick plate)
Motor: 0.5 HP, with VFD control option
Key Features: Interchangeable cones, butterfly valve discharge, worm reduction gear, safety guards (SS 304), charging port with openable cover, and compact cGMP-compliant design.

What are the main advantages of the Pilot Batch Double Cone Blender?

It provides uniform three-dimensional mixing, gentle low-shear handling for fragile materials, and easy discharge with minimal dead spots. Additional benefits include compact footprint, scalability, low power consumption, cost-effectiveness, and full cGMP compliance, making it perfect for pilot-scale process validation and small-batch production.

How easy is it to clean and maintain the Pilot Batch Double Cone Blender?

It is designed for easy cleaning and fast product changeovers. Mirror-polished SS 316 surfaces with no dead corners, cantilever design, accessible ports, and easily removable covers allow quick disassembly and thorough cleaning. This ensures compliance with GMP standards in laboratory and pilot-scale environments.

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