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Mixing Tips from Silverson Machines
This year Silverson Machines will be celebrating 80 years of business. In that time, we have helped thousands of customers around the world across a range of industries. From small start-ups to large, multinational companies, we’ve come across hundreds of mixing applications and products that have been improved by introducing high shear mixers into the mixing process.
Although each customer and application vary, common problems arise during the mixing process. In this article, we share some of our top mixing tips for these issues:
How to Avoid Agglomerates Suppliers of gums and thickening agents will advise you to sprinkle the powder slowly on the liquid surface to reduce the formation of lumps and fisheyes, because the washing action of conventional agitators cannot readily break these down, resulting in inconsistent product quality and poor yield. With a Silverson High Shear mixer, the opposite approach should be taken; the powder should be added to the liquid all at once, in a controlled manner but as quickly as possible. The mixing/shearing action of the rotor/stator workhead rapidly disperses and hydrates the powder before the viscosity starts to increase, ensuring an agglomerate-free solution is achieved with maximised yield and consistent, repeatable results.
operate at a more efficient level since it doesn’t need to be specifically sized to handle the highest viscosity component. This approach optimises the mixer’s performance and reduces the overall energy consumption during the blending process. When incorporating colouring or dye into the mixture, it is advisable to add it last. This deliberate sequencing serves as a visual indicator, allowing you to visually assess the consistency of the blend.
Optimal Particle Size Reduction When dispersing powders where a degree of particle size reduction is required, best results can be obtained by adding the powder to the smallest possible volume of liquid. This focuses the mixer’s energy on dispersing and milling the powder rather than moving the full volume of the batch, and the concentration of powder provides attrition which accelerates the reduction of particle size. Once the required particle size is achieved the remaining liquid can be rapidly blended into the mix using the Silverson mixer.
Mixing Tips from Silverson Machines
Looking to Eliminate Aeration from Your Mixing Process? With a conventional stirrer or agitator, vigorous in tank movement is required to complete some mixing tasks, and this can lead to aeration. A Silverson mixer minimizes and in many cases eliminates aeration because the circulatory pattern of mixing is all below the surface. The mixer, pipework and vessel form a closed system, and the flooded suction provided by the self-pumping In-Line mixer cannot introduce air into the product. This makes it ideal for the processing of aeration-sensitive products such as shampoos and detergents.
Blending Liquids of High and Low Viscosity Achieving an optimal blend of liquids with varying viscosity levels requires a strategic approach. When mixing liquids of high and low viscosity, it is recommended to start with the low-viscosity liquid and gradually introduce the higher-viscosity liquid. This sequence offers several advantages, including enhanced energy efficiency and improved mixing performance. By initially adding the low-viscosity liquid, the mixer can
Efficient Emulsion Preparation When forming an emulsion, it is crucial to add the dispersed phase to the continuous phase correctly. While this might be less critical at laboratory scale, it becomes essential when dealing with larger volumes, a common problem when scaling up. The key to creating a stable emulsion is obtaining the finest
possible droplet size. The more shear energy introduced into the mix, the smaller the suspended droplets will become, creating a fine stable emulsion. Silverson In-Line mixers mixers are ideal for the preparation of emulsions, including water-in-oil (W/O), oil-in-water (O/W), and water-in-oil-in-water (W/O/W) emulsions. Adding the dispersed phase just prior to the In-Line mixer will ensure an instant emulsion, maintaining uniformity and stability throughout the process.
48 DECEMBER 2025/JANUARY 2026 | FACTORY&HANDLINGSOLUTIONS
Trouble Scaling Up from the Laboratory to Full Production? Do you find it difficult to replicate the results from the pilot plant? The key to successful scale-up is to use equipment that matches as closely as possible the production plant. Many suppliers of laboratory mixers are specialists in small units, but do not produce large scale equipment. Silverson’s laboratory mixers are scale models of their production counterparts, and will give identical end results, enabling you to replicate in the laboratory, the performance of every mixer in Silverson’s product line with accurate and repeatable results.
To find out more, or to trial a Silverson High Shear mixer for your application, get in touch with Silverson Machines.
Silverson Machines.
sales@silverson.co.uk www.silverson.co.uk
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