Bin Blender

Bin Blender Comprehensive Overview

The bin blender is also known as the IBC bin mixer, IBC bin blender, Post bin blender and hopper lifter mixer. These names refer to the same type of equipment, which is designed for efficient mixing and handling of powders andgranules in industries such as pharmaceuticals, food, and chemicals. The interchangeable terms highlight its versatility in both mixing and material handling processes.

A Bin blender is a crucial piece of industrial equipment designed to lift and mix materials in a variety of sectors, including food processing, pharmaceuticals, chemicals, and plastics. This type of mixer is particularly useful for applications where large quantities of bulk materials need to be transported, blended, and processed efficiently. Below is a detailed guide on the Bin blender, covering its introduction, functions, materials, structure, applications, and important considerations when using it.

Bin Blender Loading Methods

The Bin blender offers flexible feeding methods to suit various material handling needs. The primary options include manual feeding, vacuum feeder feeding, and a dust-free feeding station with a vacuum feeder for bagged materials.

 1. Manual Feeding

Operators manually load raw materials into the IBC hopper. This method is simple and cost-effective, making it suitable for small-scale production or specific ingredient additions.

2. Vacuum Feeder Feeding

 A vacuum feeder automates material transfer to hopper lifter mixer , ensuring efficient and dust-free loading. This method is ideal for large-scale production, reducing manual labor while maintaining a clean working environment. However, this method is not suitable for bagged materials.

3. Dust-Free Feeding Station for Bagged Materials

 When handling bagged raw materials, a dust-free feeding station can be connected to the vacuum feeder. This system allows operators to safely empty bags without dust contamination, improving workplace hygiene and protecting workers' health. At the same time, the dust-free feeding station can be equipped with a single-layer screen to filter out impurities and lumps from bagged materials, significantly reducing the entry of clumped materials and contaminants into the mixer.This kind of agglomerated material needs to be crushed by a pulverizer (pin mill) and then put into the IBC bin blender for mixing.

By selecting the appropriate feeding method, manufacturers can enhance efficiency, maintain cleanliness, and ensure smooth material flow in their production processes.

4. Platform Loading

If your raw materials are stored on the second floor, we provide a matching loading platform and then push the hopper under the platform. This solution is suitable for the feeding needs of raw materials on the second floor, avoiding the inconvenience of manual handling, and efficiently processing through platform unloading. However, if it is only for loading, but the materials and the mixer are on the same floor, it is not recommended to use the platform loading method.

Please inform us based on the specific situation of your company's raw materials, and we will recommend the best feeding solution for you based on your needs.

Fully Enclosed Powder Mixing Process Flow Diagram

Fully Enclosed Powder Blending Process 

Bin Powder Blender Introduction

The bin powder blender's mixing hopper is set at a 30-degree angle to the rotation axis. As it rotates, the material moves tangentially along the hopper wall while also overturning and shearing at high speed, ensuring efficient mixing.

Controlled by a PLC system, the hopper lifter mixer includes an infrared safety device and an anti-misoperation discharge valve for safe operation. Since the entire process happens in one container, there is no need for frequent transfers, reducing dust, cross-contamination, and material loss while preventing segregation. This setup optimizes production and meets GMP standards for pharmaceutical manufacturing.

A Bin blender combines two main functions: lifting and mixing. It requires minimal maintenance and eliminates leakage risks. Its advanced control system features programmable settings, safety stops, automatic positioning, simple operation, and automated record printing, making it ideal for pharmaceutical production.

With full automation, the machine is user-friendly. High-quality outsourced components ensure durability, while the GMP-compliant hopper allows complete material discharge without residue and is easy to clean.

Post Bin Blender Working Video

Post Bin Blender Specifications

Model	Total volume (L)	Operation Volume(L)	Maximum loading (Kg)	Power (kw)	Weight (Kg)	Size (mm)
HTD-200	200	160	80	4.75	1200	2150x2210x3000
HTD-400	400	240	120	4.75	1500	2460x2410x3200
HTD-600	600	480	240	7	2200	2950x2860x3200
HTD-800	800	640	320	7	2600	2950x2860x3500
1.Hywell machinery reserves the right to the design without notice 2.All specifications of Bin Blender are as accurate as is reasonably possible, but they are not binding. 3. This IBC bin blender have good accessibility for cleaning in between 2 batches

Applications of Bin Blenders

Bin blenders are widely used across different industries, including:

Food Processing

  These post bin powder mixers blend dry ingredients like flour, sugar, and spices in large quantities, ensuring uniform mixtures for products such as cakes, biscuits, and powdered mixes.

Pharmaceuticals

  Used in tablet, capsule, and powder production, powder bin blenders mix active ingredients with excipients, maintaining hygiene and precision to meet industry standards.

Chemical Industry

  Ideal for blending powders, granules, and liquids, these mixers ensure uniform mixing for chemical formulations and processing.

Plastics & Polymers 

    Used to mix resins, additives, and colorants, bin blenders help maintain consistent quality in plastic manufacturing.

Agriculture 

  Essential for preparing feed additives, fertilizers, and pesticides, these mixers ensure thorough blending for uniform end products.

Structure of a Bin Powder Blender

The design of a bin powder blender focuses on efficiently lifting and blending materials. Its key structural components include:

Hopper

The hopper serves as the core component, where materials are stored before lifting. Typically designed in a conical or cylindrical shape, it facilitates smooth material flow. Some models feature vibrating or tilting hoppers to prevent material clumping or sticking.

Lifting Mechanism 

Depending on production requirements, the lifting mechanism can be mechanical or hydraulic. It is designed to transport materials from the hopper to the mixing height, ensuring smooth and reliable movement.

Mixing Mechanism

After the hopper is lifted to a designated height, the mixing system rotates the fixed hopper clockwise and counterclockwise, ensuring uniform blending of the materials inside.

Control System 

The lifting bin blender is equipped with an automated control system, allowing operators to monitor and regulate the mixing and lifting processes. These systems may include timers, speed regulators, and sensors      to ensure consistency and optimize production efficiency.

Discharge Mechanism 

After mixing, the powder mixing machine includes a discharge system to transfer the blended material to the next production stage, such as packaging, granulation, or storage. Our company typically integrates a hopper elevator to lift the hopper to a packaging or tablet press machine for discharge.

Advantages of IBC Bin Powder Blender

Hywell Machinery’s HTD Series Bin Powder Blender offer significant advantages over conventional mixing solutions, ensuring high efficiency, safety, and compliance with GMP standards.

Superior Mixing Homogeneity

The IBC bin blender ensures uniform mixing as all materials remain in continuous motion.

Particle Integrity Protection 

Gravity-based mixing applies minimal and equal forces, preventing material degradation.

Short Mixing Time 

The absence of friction eliminates temperature rise and prevents localized hot spots.

Quick & Easy Cleaning 

Designed for hygienic security with effortless cleaning.

Low Energy Consumption

 Efficient operation reduces power usage.

Multiple Safety Interlocks

 Equipped with multiple safety mechanisms for secure operation.

Intelligent PLC & HMI Control

Features an intuitive graphical interface for seamless operation.

Flexible Material Transfer 

Easily movable with a trolley-mounted IBC bin.

Adjustable Mixing Time & Speed 

 Settings can be customized via the touchscreen interface.

Automated Positioning & Reporting 

 Includes auto-positioning, record printing, failure reports, and alarm alerts.

Interchangeable IBC Containers 

Compatible with different materials for versatile production.

Fully Automated Operation

 Automatically performs lifting, and mixing.

Compact & Modern Design

Space-efficient with a sleek appearance and 99% mixing uniformity.

Hygienic & Easy Discharge 

Highly polished inner and outer surfaces, with no dead corners, preventing cross-contamination.

IBC Bin Powder Blender Construction Material

Hywell Machinery offers the HTD Series hopper lifting Blender with contact parts available in SS304, SS316L, Titanium, Duplex Stainless Steel, and other materials as required. The electrical components of the control system can be customized to meet the specific needs of customers.

IBC Bin Blender Operation

The IBC Bin Mixing Machine is a widely used solid powder mixing system, known for its high mixing uniformity and efficient material loading capacity. The movable IBC bin enhances operational convenience by simplifying the processes of loading, mixing, unloading, and cleaning. Additionally, the machine can be seamlessly integrated with upstream and downstream equipment to form a complete solid granulation line, effectively reducing dust emissions and preventing cross-contamination caused by repeated material transfers. The HTD Series IBC Bin blender machine is designed to handle large batch sizes and a wide variety of product formulations.

Post Bin Blender Operational Process

The IBC bin is placed into the rotary frame.

The operator sets parameters via the touchscreen control panel.

The bin is lifted to the desired height.

The driving system starts rotating, mixing the contents for the preset time at the specified speed.

Once the mixing cycle is complete, the system automatically stops at the required mixing level.

The lifting system lowers the bin to the floor.

The operator removes the IBC bin, marking the completion of the mixing process.

The system records and generates a report of the entire mixing process for quality control and traceability.

The HTD Series Bin Blending System ensures a highly uniform mixing of powders and granules, making it ideal for industries that require consistent product quality.

Custom Design & Technical Support

Hywell Machinery offers customized solutions based on your production capacity and facility layout requirements. Our engineers will design an optimal layout plan tailored to your specific workshop conditions and operational needs.

If you are interested in our IBC Bin Mixing Machine, please contact Hywell Machinery for expert consultation and further details.

IBC Bin Diffusive Mixers had the following options

1.Total volume of IBC Bin Diffusive Blender

Total volume sizes from 100 to 1000 lit.

 2. Materials of IBC Bin Diffusive Blender

Drums can be built in SUS304,SUS316L ,Titanium, Duplex stainless steel.

3.  Control system of IBC Bin Diffusive Blender

The lifting  powder mixer has more choices, such as push button or HMI+PLC.

4.   Feeding system of IBC Bin Lifting mixer

The feeding system for the powder blending machine can be by manual or pneumatic conveyor or vacuum feeder.

Cleaning Method of the Bin Powder Mixer

1. Stop operation

 Before cleaning, push the hopper of the bin mixer to the cleaning station and push it to a fixed position of the cleaning station so that the cleaning ball can enter the hopper.

2. Clean up the residue

Open the upper cover of the hopper and clean the residue in the mixer. Material adhering to the inner wall and mixing blades can be removed using tools such as scrapers or brushes.

3. Install the cleaning device: manually move the cleaning ball of the lower cleaning station into the hopper.

3. Cleaning process

Turn on the switch of the CIP cleaning station for automatic cleaning interior of the bin.

4. Manual surface cleaning

Use a hand-held cleaning gun to spray dust on the surface of the hopper. You can use a damp cloth or detergent to wipe down the device case to keep it clean and tidy

6. Drying and assembly

 Place the cleaned parts in a well-ventilated area to dry. After making sure the parts are completely dry, assemble the parts according to the equipment manual or instructions for use. Make sure all parts are installed and tightened correctly.

IBC Bin Blender Cleaning Process Video

Drying Method of the IBC Bin Powder Blender

After cleaning, the square cone hopper (IBC Bin) should be left to dry naturally. Hywell Machinery also has an integrated cleaning and drying machine. This clean IBC bin device can automatically clean the hopper. After cleaning the hopper, it can switch to the process of automatic hot air drying inside the hopper. The specific usage process is as follows:

1. Move the hopper to the designated position of the cleaning station.

2. Open the upper cover of the IBC bin, lower the cleaning nozzle, and put it into the hopper.

3. Set the cleaning time and turn on the cleaning button. After the automatic cleaning time ends, the cleaning process ends.

4. Set the drying temperature and drying time, and turn on the drying button. After the automatic drying time ends, the drying process ends. If PLC control is adopted, all cleaning and drying settings can automatically complete the cleaning and hopper drying process.

IBC Bin Blender Cleaning and Drying Process Video

HTD IBC Bin Lifting Mixer