PRISM PHARMA MACHINERY

Vatva, Ahmedabad, Gujarat

Uniform Mixing Process Technik for Dry & Wet Granulation

Application & Process :

The Mass Mixer is designed for uniformly mixing of dry and wet material and especially suitable for powder of Pharmaceuticals, Food, Herbals, Agro Chemicals & Chemicals.

The mass mixer consists of a rigid fabricated structure motor, gear box, mixing drum, stirrer and tilting device. Specially designed self adjusting sealing arrangement of unique design is provided to ensure that no black particle enters into the mixing drum. The material under mixing process can be monitoring through acrylic dust cover and its controls dusting and contaminations. The tilting device is provided to make easy the unloading of the material and easy cleaning of the mixing drum.

Salient Features :

• Design is cGMP - Current Good Manufacturing Practices compliance.
• All contact parts AISI 316 & non contact parts AISI 304.
• Uniform Mixing with paddle blade stirrer.
• Self adjusting sealing arrangement to avoid entire black particles.
• Tilting device for easy unloading and cleaning.
• The interlocked acrylic covers of product container, enclosed drive & Overloads relay protection.

Safety Features :

• Total drive transmission system enclosed
• Limit switch installed in the top lid ensure lid is closed
• Overload relay Protection.

Sigma Mixer with Extruder Screw

Uniform Kneading, Mixing and Extruding Process

Application & Process :

TheSigma Mixer with extruderis used for mixing, kneading and extruding of highly viscous mass, sticky and dough like products, Mixing of pastes, rubber, and heavy plastic masses, applications in Food, Rubber, Pharmaceutical, Chemical and agro industries, Dry powder to wet phase mixing. This mixer is most suitable for highly viscous material and dough like masses.

Theextruder mixeris designed to handle difficult to discharge products such as hot melts and butyl sealants, as well as other medium to high viscosity pastes. This type of mixer combines the action of the Double Arm Sigma Blade Mixer with an extrusion screw placed in the lower part of the mix trough. During mixing, the extrusion screw is run in reverse which imparts a third mixing action on the product, increasing mixing efficiency.

Thesigma kneaderis a double arm mixer with extruder, the two "Z" blade rotate towards each others at same or different speed inside a W- shaped product container and extruder screw is located between the two blade with separate gear motor drive. The extruder screw is rotates in forward direction for extruding process and rotate in reverse direction during mixing process. Speed of the extruder to be adjustable by VFD. The twin screw basin kneading machine with two horizontally arranged kneading blades, which are deeply geared into one another and strip themselves reciprocally. Each blade moves the material in opposite direction thereby providing excellent cross mixing of all raw materials. The blades pass the trough walls and each other at close clearances resulting in good mixing. The close clearance produces a shearing and tearing action that is beneficial to the size reduction of solids.

The extrusion screw is located in the saddle section and runs in a cylindrical trough tangential to and below the 2 mixing blades.

• When the product has finished the mixing cycle, discharge/extrusion is performed simply by running the extrusion screw in a forward direction.
• The double arm sigma blades normally continue to run throughout the extrusion process providing a thoroughly mixed product at all stages of the production cycle.
• By changing the extrusion die heads, the product can be discharged in round, square, "spaghetti", or any form desired.
• Speed variation of the extrusion screw allows adjustment of the product flow, depending on the viscosity.

Salient Features :

• Designed as per cGMP - Current Good Manufacturing Practices & Non GMP Standard Model.
• Contact parts in AISI 316, AISI 304 or MS as desired by customer.
• Capability to pass from mix phase to extrusion phase without interruption.
• Lateral discharge of product through the extrusion screw without operator interaction.
• Shape of extruded material is adaptable to customer's requirements.
• Mixing, Blending and kneading of high Viscosity Materials, with a combined action of Bulk Movement, Kneading, stretching folding, dividing and Recombining.
• High Mixing Precision, Short Batch Time, Problem free Cleaning and Residue Free Discharge.
• Automated mixing and granulating process in single bowl.
• Available in Capacity from up to 1000 Kg Industrial Productions.
• There are different types of blades: Sigma-"Z" blade, Spiral blade, and Naben blade.
• Selection of appropriate blade shape and speeds result in excellent mixing.

Optional Features :

• PLC Controls with HMI touch screen
• Binder spraying system
• Product Bowl with Jacketing for heating and cooling.
• Flame Proof Electrical.
• Vacuum or pressure designs
• Automatic control of blade speed based on product viscosity.

Safety Features :

• Enclosed mixing and discharge provides protection from product contamination and greater operator safety.
• Total drive transmission system enclosed
• Limit switch installed in the top lid ensure lid is closed
• Overload relay Protection and Emergency stop button

Uniform Mixing & Blending Process of dry Powder

Application & Process :

The Nauta Cone screw mixer is generally used in case of applications that require gentle mixing action and minimal heat generation without any product distortion. The Nauta Mixer is Ideal mixer to mix various small lots to make uniform one lot or to mix many large proportions of powders to a uniform product in Food, Chemical Pharmaceutical, Minerals, Guar Gum, Starch and Cellulose. The Nauta mixer offers low operative cost than any other types of mixers.

The Nauta mixer is a planetary rotating screw near the wall of cone without end resting of screw. The principle of blending is based on the differential travel speeds of product particles in the conical section of the vessel. The material from the bottom section of vessel is lifted by the screw and spread over the upper sections. The screw agitator turning on its axis produces a lifting action as it spirals the material in an upward flow. At the same time the screw orbits the tank, the screw removes material away from wall and deflects it into the centre of the tank setting up a spiral current thought the batch. The material lifted by the screw gravitates downwards thoroughly intermixing with material being spiraled upward. This results in most intimate intermingling of all ingredients.

Thenauta mixeris mixes the powders but also breaks the lumps. This blender/mixer can also be used for applications that requires high shear mixing, which can be accomplished using separately driven lump breakers.

Safety Features :

• Total drive transmission system enclosed
• Overload relay Protection and Emergency stop button

Salient Features :

• Designed as per cGMP - Current Good Manufacturing Practices OR Non GMP STANDARD Model.
• Contact parts in AISI 316, AISI 304 or MS as desired by customer.
• The sizes of Nauta mixer available are 500 liters to 5000 liters
• Nauta Mixer achieves excellent accuracy in mixing even when the components are present in minor quantity.
• Conical mixers, blenders, homogenizers, reaction vessels, vacuum dryers and live storage hoppers.
• Higher efficiency achieved compared to horizontal blenders.
• Easy addition of liquid.
• Shorter mixing time 4 to 10 Minute.
• Low power consumption.
• Gentle Mixing achieved.
• Rotary discharge valves and pneumatic discharge systems employed for faster discharge rate.
• Easy to clean: These conical mixers are easily cleanable either in a dry way using special extra large doors on the vessel or in a wet way using spraying devices.

Optional Features :

• Jacketing Cone for heating and cooling.
• Vacuumized process.
• Different type of mixing stirrer.

Uniform Kneading & Mixing Process

Application & Process :

The Sigma Mixer is used for mixing and kneading for mixing, kneading of highly viscous mass, sticky and dough like products, Mixing of pastes, rubber, and heavy plastic masses, applications in Food, Rubber, Pharmaceutical, Chemical and agro industries, Dry powder to wet phase mixing. This mixer is most suitable for highly viscous material and dough like masses.

The sigma kneader is a double arm mixer, the two "Z" blade rotate towards each others at same or different speed inside a W- shaped product container. The twin screw basin kneading machine with two horizontally arranged kneading blades, which are deeply geared into one another and strip themselves reciprocally. Each blade moves the material in opposite direction thereby providing excellent cross mixing of all raw materials. The blades pass the trough walls and each other at close clearances resulting in good mixing. The close clearance produces a shearing and tearing action that is beneficial to the size reduction of solids. Selection of appropriate blade shape and speeds result in excellent mixing

Salient Features :

• Design is cGMP - Current Good Manufacturing Practices compliance
• All Product contact parts AISI 316/ 316L & non contact parts AISI 304 or M.S.Painted.
• Mixing, Blending and kneading of high Viscosity Materials, with a combined action of Bulk Movement, Kneading, stretching folding, dividing and Recombining.
• High Mixing Precision, Short Batch Time, Problem free Cleaning and Residue Free Discharge.
• Automated mixing and granulating process in single bowl.
• Available in Capacity from up to 1000 Kg Industrial Productions.
• There are different types of blades: Sigma-"Z" blade, Spiral blade, and Naben blade.
• Selection of appropriate blade shape and speeds result in excellent mixing.
• Hydraulically lifting device with power pack for unloading.

Optional Features :

• Jacketing Bowl for heating and cooling.
• Spraying system.
• PLC Controls with HMI touch screen,
• Flame Proof Electrical.

Safety Features :

• Total drive transmission system enclosed
• Limit switch installed in the top lid ensure lid is closed
• Air pressure switch installed to ensure pressure is in limit.
• Limit switch installed at discharge to ensure product container underneath of discharge.
• Overload relay Protection and Emergency stop button

High Shear Powder Mixing Process

Application & Process :

PrismPlanetary Mixeris ideal for mixing of wet/dry powder materials. It has a homogeneous mixing action i.e. emulsions and semisolid. It integrates mixing, vacuuming, heating, cooling and homogenizing functions into single machine, resulting in a considerably reduction in cycle time.

The basis of mixing system ofPlanetary Mixeris a combination of planetary- rotating paddle agitator. 2 Nos. Anchor type agitator with cross baffles rotates in anti-clockwise direction with planetary motion in there axis. While paddle revolves in clockwise direction with planetary action, generating a disturbance in the normally circular flow pattern and dampen vortex formation. The mixing blade and planetary action having dual speed. In addition, adjustable scrapers are utilized to prevent the build-up of a stagnant film between the agitator and the vessel, and assure efficient heat transfer to product during heating and cooling steps. The speed of the agitator and the counter paddle can be varied separately.

The Product container is castor wheel mounted for easy load and unload to the machine. The top mixing blade assembly is motorized up and down during container loading and unloading. The mixing container is jacketed for heating / cooling and completely enclosed. The product container can be designed to operate under vacuum; mixing can then be performed without entrainment of air. Top lid of the product container having charging pot for binder adding, eye glass window and light glass.

Salient Features :

• Designed strictly compliance with the stipulation of cGMP
• Product contact parts AISI 316 Quality and Non contact parts S.S.394 Quality.
• Machine compact in designed single base structure to for simplicity in mounting.
• 2 Nos. Anchor blade with planetary rotation for extremely efficient shearing force.
• Top lid is mounted with motorized lifting device.
• Product container is castor wheel mounted for easy load and unload to the machine.
• Rigid drive with planetary gear and reduction gear box
• Dual speed motor for slow and fast mixing action.
• Scrapper is made from Teflon.

Optional Features :

• Ac Frequency Variable Drive.
• Mixing bowl with heating / cooling jacket and insulated.
• No. of Mixing Blade : Single Blade/ Double blade/Triple Blade.
• Type of Blade: Paddle Blade/ Anchor type/Hart Shape Blade
• Centre located and top mounting high speed homogenizer .

Safety Features :

• Emergency stop button
• Limit switch at top lid
• Over load protection by relay.

Vacuumized Mixing Technic

Application & Process :

Ultra Vacuum Mixer is applicable for a wide variety of viscosity product, i.e. emulsions and semisolid. It integrates mixing, vacuuming, heating, cooling and homogenizing functions into single machine, resulting in a considerably reduction in cycle time. Our range stretches from laboratory model of 10 liters up to production model of 6, 000 liters working capacity.

Application :

• Pharmaceutical: Ointment, Cream, Gel, Lotion, Paste
• Cosmetics: Cream. Gel, Lotion, Mascara, Wax, Lipstick, Sunscreen, Face masks
• Body Care Products: Toothpaste, Shampoo, Conditioner, Liquid soap
• Food: Mayonnaise, Ketchup, Sauce, Mustard, Dressing, Jam, Margarine
• Chemical: Adhesives, Grease, Shoe Polishing, Car Polishing, Lubricants, Household cleaner, Viscoplastics Substance, Lacquer, Putty, Paint

Working Principle :

The basis of mixing system of Ultra Vacuum Mixer is a combination of counter - rotating paddle agitator and internal homogenizer. Gate-type agitator with cross baffles rotates in anti-clockwise direction while counter paddle revolves in clockwise direction, generating a disturbance in the normally circular flow pattern and dampen vortex formation. The blades of paddles are pitched to promote top - to bottom flow. In addition, adjustable scrapers are utilized to prevent the build-up of a stagnant film between the agitator and the vessel, and assure efficient heat transfer to product during heating and cooling steps. The speed of the agitator and the counter paddle can be varied separately.

Homo disperser, locates at the bottom of the vessel, accomplishes emulsification by physical action and centrifugal forces created by high speed rotation of the rotor. These actions would break up oil phase/ aqueous phase liquid stream into tiny and discrete droplets. Then they will be intensively and continuously mixed by counter - rotating agitator mechanism, and become final products. For versatility of use, interchangeable high viscosity and low viscosity homo disperser heads are provided with the system. Homo disperser speed is adjustable by inverter control.

Conical mixing vessel is jacketed for heating / cooling and completely enclosed. All contact parts are stainless steel 316. The vessel is designed to operate under vacuum; mixing and emulsification can then be performed without entrainment of air.

A temperature measuring probe, extending directly into the product, allows exact setting of the temperature with a view to process management. For process reproducibility, mixing time, product temperature, agitator speed, counter paddle speed and homogenizer speed can be controlled to the desired condition.

Raw material feeding to Prism Vacuum Mixer can be manual through the fully open lid, or completely automatic through vacuum system. Finished product is discharges by manual discharge valve or through special design transfer pump on mobile trolley into product container.

Design Features :

• Designed strictly compliance with the stipulation of cGMP
• Product contact parts AISI 316 Quality and Non contact parts S.S.304 Quality.
• Machine compact in designed single base structure to for simplicity in mounting.
• Top Ultra mixer agitator with extremely efficient shearing force.
• Contra Movement of the agitator blade means the both anchor stirrer move anti direction.
• The both agitator having nos. paddle with 45C
• Homogenizer located at lowest point in the vessel for internal homogenization.
• Top lid is mounted with hydraulic lifting device.
• Integrated vacuum pump and vacuum equipments with manual controls.
• Tilt able product bowl to discharge product or clean.
• Top lid having connection for vacuum and charging of the material and visualize window.
• Manual operated valves
• Outer agitator is fitted with self pressure adjustment Teflon scrapper and drives through hollow shaft gear box with motor.
• Centre agitator is having separate drive with gearbox with motor.
• The scrapper is made from Teflon.

Optional Features :

• A C Frequency Drive with variable speed for main agitator, counter agitator and homogenizer.
• Mixing bowl with heating / cooling jacket and insulated.
• Mixing bowl tilting type/ Wheel Mounting / Fixed.
• Type of Mixing Blade: Single Anchor/Double with contra action/ planetary motion with single /double blade.
• High speed homogenizer mounting from top/bottom.

Safety Features :

• Emergency stop button
• Safety vacuum relief valve
• Limit switch at top lid
• Over load protection by relay.
• Semi automatic control system and safety equipments.

A colloid mill is a machine that is used to reduce the particle size of a solid in suspension in a liquid, or to reduce the droplet size of a liquid suspended in another liquid. This is done by applying high levels of hydraulic shear to the process liquid. It is frequently used to increase the stability of suspensions and emulsions. The colloid mill is used for various applications such as Superfine grinding, homogenizing, emulsifying, dispersing, mixing and extracting of liquids, ointments and highly viscous products in pharmaceutical, cosmetics, suspensions & emulsion industry.

The product is fed to the hopper which leads the product into the gap between taper rotor and stator. The product is subjected to a high degree of shearing, cutting and rubbing between two metal toothed surfaces of rotor and stator and towards the discharge section. The processed product continuously leaves the mill through drain pipe if required, it can be re-circulated by three way cock and re-circulating pipe assembly.

Salient Features:

• Design is cGMP - Current Good Manufacturing Practices compliance.
• All contact parts AISI 316 & non contact parts AISI 304.
• Easy to adjustment gap between rotor and stator.
• Three way cock assembly with re-circulating pipe.
• Easy to Moveable and dismantle all contact parts for cleaning.
• Silicon food grade seal.
• Separate discharge spout for highly viscous products.

The Laboratory scale colloid mill is a machine that is used to reduce the particle size of a solid in suspension in a liquid, or to reduce the droplet size of a liquid suspended in another liquid. This is done by applying high levels of hydraulic shear to the process liquid. It is frequently used to increase the stability of suspensions and emulsions. The colloid mill is used for various applications such as Superfine grinding, homogenizing, emulsifying, dispersing, mixing and extracting of liquids, ointments and highly viscous products in pharmaceutical, cosmetics, suspensions & emulsion industry.

The product is fed to the hopper which leads the product into the gap between rotor and stator. The product is subjected to a high degree of shearing, cutting and rubbing between two metal toothed surfaces of rotor and stator and towards the discharge section. The processed product continuously leaves the mill through drain pipe if required, it can be re-circulated by three way cock and re-circulating pipe assembly.

New Design Features:

• Laboratory scale colloid mill is used for Homogenizing, Emulsifying, Dispersing, Mixing, Comminuting of Ointment, Liquid and highly viscous products research and development institutions, pharmaceutical laboratory, and pharmacy colleges.
• All contact parts are in S.S.316 non contact parts in S.S.304 Quality.
• Design is cGMP - Current Good Manufacturing Practices compliance.
• All contact parts AISI 316 & non contact parts AISI 304.
• Easy to adjustment gap between rotor and stator.
• Three way cock assembly with re-circulating pipe.
• Silicon food grade seal.
• Separate discharge spout for highly viscous products.
• Optional: Horizontal or vertical drive model, water cooling systems, Explosion proof electrical.

The Milling & Size reduction Process

Application & Process :

Multi Millis used for wet and dry granulation, pulverization, milling, shredding, chopping, size reduction in Pharmaceuticals, Chemicals, Cosmetics, Ceramics, Colors, Dyestuff, Food products etc. It also finds application in Pesticides, Fertilizers, Spices, Detergents, Insecticides, Plastics and Resins industries

Inmulti millparticle size reduction is done through impact in air, on material by blades moving at high speeds, inside a cylindrical sieve. The particles of the desired size pass out through the screen placed inside the hopper.

Salient Features :

• Design is cGMP - Current Good Manufacturing Practices compliance
• All Product contact parts AISI 316 & non contact parts AISI 304
• High speed milling, granulating, pulverizing, mixing and size reduction of wet & dry material.
• Output capacity 50 Kg to 200 Kg per hour.
• Easy removable contact parts for cleaning & inspection.
• Easy Mobility.
• Variable force by swing better having knife & impact edges are rotating within screen.
• Direction of beaters can be changed by forward- reversible switch.
• Various combinations of perforated sieves & wire mesh.