Disc Mixer
Vertical Pan Type Dead-Zone-Free Powder & Granule Mixing Machine for Fertilizer, Building Material & Chemical Industr
Disc Mixer is a professional vertical pan-type industrial mixing equipment designed for powder, granule and tiny block materials. Different from traditional horizontal mixers with dead zones, it adopts inclined disc circulation stirring and multi-directional flipping technology, realizing 360° full dead-zone-free uniform blending. Featuring low shear, no material crushing, high mixing uniformity and energy-saving operation, it is widely used in fertilizer production, building material processing, chemical industry and solid material blending projects.
High Uniformity
Gentle Mixing
Energy-Saving
What is Disc Mixer?
In industrial production such as fertilizer processing, building material batching and chemical material blending, traditional mixing equipment has prominent defects. Horizontal mixers are prone to mixing dead zones at corners and bottoms, resulting in uneven material proportioning and inconsistent finished product quality. High-shear stirring structures easily crush granular materials, damage material particle integrity and affect product grade. In addition, residual materials in the tank cause raw material waste and frequent manual cleaning, which restricts large-scale continuous production.
Our Vertical Disc Mixer optimizes the core mixing structure for bulk powder and granular materials. It adopts a unique rotating disc circulation convection principle, so materials form continuous flipping, scattering and blending motion in the pan body. The low-speed and low-shear design ensures full mixing without crushing particles. The fully enclosed structure and self-cleaning design solve residual pollution and dead zone problems thoroughly. It has become the preferred high-efficiency blending equipment for medium and fine industrial materials due to stable operation, high uniformity and low operating cost.
Contents
Complete Equipment Composition of Disc Mixer
1. Heavy-Duty Vertical Rotating Disc System
The core component adopts thickened wear-resistant alloy disc with inclined structural design. Driven by low-speed stable reducer, the disc generates uniform centrifugal diffusion and gravity convection. Materials spread from the center to the edge and roll back cyclically, forming a three-dimensional circulating mixing track. It completely eliminates static dead zones at the bottom and corners of the mixing tank, laying the foundation for uniform overall blending.
2. Multi-Group Anti-Blockage Stirring Blade Assembly
Equipped with multiple sets of high-wear-resistant curved stirring blades, matched with the disc rotation direction for reverse auxiliary stirring. The curved blade design avoids rigid shearing and particle crushing, gently breaks material agglomerations, and fully mixes different proportions of powder and granules. The blade spacing is scientifically optimized to ensure no material accumulation and thorough blending of fine powder and large particles.
3. Low-Noise Cycloidal Speed Reduction Drive System
Adopts industrial-grade cycloidal reducer and low-speed high-torque motor. The stable transmission output avoids vibration and jitter during operation, ensuring uniform disc rotation speed. Compared with ordinary direct drive motors, it has stronger load resistance, lower noise and longer service life. It can stably cope with high-density and large-volume material mixing for a long time without overload failure.
4. Fully Sealed Anti-Dust Feeding & Mixing Tank
The whole machine adopts fully sealed cylindrical pan structure with closed feeding port. It effectively prevents dust overflow and raw material splashing during high-speed mixing, ensuring clean and environmentally friendly production. The inner wall is polished smoothly with anti-adhesive treatment, which is not easy to stick materials and reduces residual waste, meeting industrial environmental protection and food-grade auxiliary production standards.
5. Quick Discharging & Residual-Free Discharge System
Equipped with large-caliber quick-opening discharge valve and auxiliary scraping device. After mixing, materials are discharged quickly and thoroughly without dead angle residue. The discharge speed is adjustable, which can match the front-end batching and back-end granulation production rhythm. It effectively solves the problem of material waste and batch cross-contamination caused by incomplete discharge of traditional mixers.
6. PLC Intelligent Timing Control System
Presets professional mixing parameter programs for fertilizer, building materials, chemical powder and other materials. It supports intelligent timing mixing, automatic start-stop and speed regulation. Equipped with overload protection, blockage alarm and power failure protection functions. Workers can set mixing time and operation parameters with one key, realizing standardized and batch automatic mixing production.
Core Product Advantages of Disc Mixer
1. 360° Dead-Zone-Free Mixing, Ultra-High Uniformity
Relying on three-dimensional circulating convection formed by inclined disc rotation and multi-blade flipping, all materials in the tank participate in mixing movement. There is no static accumulation area at the bottom, wall corners and center. The mixing uniformity is far higher than traditional horizontal mixers, ensuring consistent component ratio and stable quality of each batch of finished materials.
2. Low Shear Gentle Mixing, No Particle Crushing
Different from high-shear violent stirring equipment, this disc mixer adopts low-speed circulating blending mode. It can fully mix powder and granular materials while protecting the original particle integrity. It solves the industry pain point of particle breakage and finished product grade reduction, especially suitable for granular fertilizer and shaped building material raw materials.
3. Energy-Saving & High Efficiency, Low Operating Cost
The optimized transmission structure and circulating mixing track shorten the mixing cycle and reduce invalid power consumption. Compared with traditional mixing equipment with the same output, the energy saving rate reaches more than 30%. The whole machine has simple structure, few vulnerable parts and strong wear resistance, greatly reducing daily maintenance and replacement costs.
4. Dust-Free Sealed Operation, Green & Environmental Friendly
Fully closed pan body and sealed feeding structure effectively suppress dust overflow and material splashing during operation. The working environment is clean without secondary pollution. The equipment operates with low noise and low vibration, fully complying with global industrial environmental protection production standards, suitable for standardized factory production lines.
5. Residual-Free Discharging, No Raw Material Waste
The smooth anti-adhesive inner wall and full-range scraping structure ensure thorough material discharging without dead-angle residue. It avoids raw material waste and batch cross-contamination, improves raw material utilization rate, and ensures pure and stable ingredients of each batch of mixed materials.
6. Wide Material Adaptability & Strong Compatibility
It can freely adapt to dry powder, fine particles, tiny block and low-viscosity wet materials. It covers diversified materials such as compound fertilizer, BB fertilizer, mortar, clay, slag powder, chemical powder and feed additives. One machine meets the mixing needs of multiple production lines with ultra-high cost performance.
Working Principle & Production Process of Disc Mixer
Working Principle
The Disc Mixer adopts vertical disc circulating convection + multi-directional flipping mixing principle. After materials enter the fully sealed pan body from the top feeding port, the motor drives the reducer to operate stably, and the inclined rotating disc generates continuous centrifugal diffusion and gravity circulation. Materials spread from the center of the disc to the edge, and roll back to the center under the action of the tank wall and gravity, forming a three-dimensional closed mixing loop.
The matching curved stirring blades gently break material agglomerations and assist flipping blending. All materials participate in cyclic movement without static dead zones. The low-shear operation ensures uniform mixing of different proportion powder and granular materials without particle crushing. After reaching the set uniformity, the materials are quickly discharged through the bottom discharge port to complete efficient and standardized batch mixing operation.
Standard Production Flow
Proportional Raw Material Feeding → Sealed Pan Body Loading → Disc Circulation Convection Mixing → Blade Auxiliary Flipping & Dispersion → Uniform Blending & Agglomeration Breaking → Quick Residual-Free Discharging → Next Process Production
Application Scenarios of Disc Mixer
This high-efficiency Vertical Disc Mixer is widely used in fertilizer industry, building material industry, chemical industry and agricultural processing fields. It is specially suitable for uniform blending of compound fertilizer, BB fertilizer, organic fertilizer raw materials, mortar, clay, slag powder, chemical powder particles and feed additives. It can perfectly match the front-end batching system and back-end granulation, pressing and forming production lines, providing stable and high-uniformity raw material pretreatment for industrial production.
Core Application Fields: Fertilizer production line mixing, building material mortar blending, chemical powder proportioning, industrial solid material mixing, agricultural feed processing
Real Project Cases of Disc Mixer
Case 1: Compound Fertilizer Mixing Project | Thailand Fertilizer Factory
Project Info: The customer needs uniform mixing of multi-component fertilizer powder and granules, requiring no particle breakage and stable proportion. Our disc mixer adopts low-shear circulating mixing mode, with mixing uniformity up to 98.8%. No dead zone or residual materials, effectively improving finished fertilizer quality. The automatic timing operation reduces manual error and realizes standardized batch production.
Case 2″>Building Material Mortar Blending Project | Malaysia Construction Material Plant
Project Info: Dry mortar production requires high-precision proportioning and uniform mixing of multiple powder materials. Traditional mixers have uneven mixing and serious residue problems. Our disc dead-zone-free mixing structure ensures consistent mortar composition in each batch. The fully sealed dust-free operation meets factory environmental protection standards and improves production efficiency by 35%.
Case 3″>Chemical Powder Blending Project | Indonesia Chemical Processing Plant
Project Info: Multi-component chemical powder proportioning mixing requires high cleanliness and no cross-contamination. Our residual-free discharging and fully sealed structure thoroughly solve mixing dead zones and material cross-mixing problems. The stable low-energy operation reduces long-term production costs, helping customers obtain stable and qualified chemical mixed raw materials.
Technical Parameters of Disc Mixer
| Model | DLPJ-1600 | DLPJ-1800 | DLPJ-2000 | DLPJ-2200 | DLPJ-3000 |
| Outline Dimension(mm) | 1600*1600*1800 | 1800*1800*1800 | 2000*2000*1800 | 2200*2200*1850 | 3000*3000*2000 |
| Disc edge height（mm） | 400 | ||||
| Disc diameter（mm） | 1600 | 1800 | 2000 | 2200 | 3000 |
| Power（kw） | 7.5 | 7.5 | 7.5 | 7.5 | 15 |
| Reducer model | BLD15-87 | BLD15-87 | BLD15-87 | BLD15-87 | XLD9-87 |
| Stirring speed（r/min） | 16 | 16 | 16 | 16 | 16 |
| Main plate thickness（mm） | 5 | 5 | 5 | 5 | 5 |
| Bottom plate thickness（mm） | 8 | 8 | 8 | 8 | 8 |
| Capacity（ton/hour） | 2-4 | 3-5 | 4-6 | 6-8 | 8-12 |
Get Custom Disc Mixer Solution
Our Disc Mixer breaks through the defects of traditional mixers such as dead zones, uneven mixing and particle crushing. Featuring dead-zone-free uniform blending, low-shear material protection, energy-saving high efficiency and residual-free discharging, it provides standardized and high-precision material mixing solutions for global fertilizer, building material and chemical enterprises, helping customers improve product qualification rate and reduce production costs.
Contact us now to get free model selection, material-matched mixing scheme and accurate quotation!
FAQs of Disc Mixer
Q1: What materials can the disc mixer process?
A: It is mainly suitable for dry powder, fine particles and tiny block materials, including various fertilizers, mortar, clay, slag powder, chemical powder and feed additives. It supports customized mixing processes for different material densities and proportions.
Q2: Does the mixer have mixing dead zones and residual materials?
A: No. The unique three-dimensional circulating convection design eliminates all mixing dead zones. Equipped with full-range scraping and quick-discharging structure, the material discharging rate is close to 100%, no residual accumulation and no batch cross-contamination.
Q3: Will the mixing process crush granular materials?
A: No. Different from high-shear stirring equipment, it adopts low-speed gentle circulation and flipping mixing without rigid shearing. It fully protects the integrity of granular materials while ensuring uniform blending, effectively improving finished product grade.
Q4: What is the mixing uniformity of the disc mixer?
A: The industrial-grade disc mixer has a mixing uniformity of ≥98.5%, which is far higher than traditional mixing equipment. It can ensure uniform distribution of trace additives and stable proportion of each batch of materials.
Q5: Is the equipment easy to operate and maintain?
A: Yes. PLC one-key automatic timing operation is simple and easy to learn. The whole machine has few vulnerable parts and wear-resistant structure. No frequent maintenance is required, and the daily cleaning workload is extremely low.
