PerMix Sigma Mixers & Sigma Mixers & Extruders

Working Principle of Sigma Mixers and Sigma Mixer Extruders

PerMix’s sigma mixers and sigma mixer extruders are engineered to deliver exceptional mixing performance, making them the preferred choice for a wide range of industries. Their superior design ensures optimal mixing, kneading, and extrusion of high-viscosity materials, setting a new standard for efficiency and reliability.

How a Sigma Mixer Works

The sigma mixer operates using two Z-shaped blades housed within a horizontal mixing chamber. Here’s how it works:

1. Shearing and Kneading Action
   • The blades rotate at different speeds, creating a high-shear zone.
   • This kneading action efficiently combines ingredients, ensuring homogeneity even for challenging materials like viscous pastes, rubber, and doughs.
2. Precise Mixing Control
   • The speed and direction of the blades can be adjusted to suit specific materials and processes.
   • With optional heating or cooling jackets, the temperature of the mixing chamber can be precisely controlled, enabling processes like polymerization, vulcanization, and paste formation.
3. Vacuum Capability
   • When equipped with a vacuum, the sigma mixer eliminates trapped air, enhancing the quality of products like adhesives, pharmaceuticals, and food pastes.

This design makes PerMix sigma mixers ideal for handling materials with a wide range of viscosities and complexities.

How a Sigma Mixer Extruder Works

The sigma mixer extruder combines the mixing and kneading capabilities of a sigma mixer with an integrated extrusion system. This dual functionality streamlines production by mixing and discharging the material in a single, seamless operation.

1. Mixing Process
   • The mixing chamber works similarly to a standard sigma mixer, ensuring thorough kneading and blending of materials.
2. Extrusion Process
   • After the mixing cycle, the material is discharged through an extrusion screw or die located at the bottom of the mixing chamber.
   • The extrusion process applies controlled pressure, shaping the material into a specific form or facilitating its transfer to the next stage of production.
3. Efficiency and Precision
   • This setup minimizes product handling, reduces process time, and ensures consistent output quality.
   • Customizable extrusion options allow for precision in product shape and size.

Sigma mixer extruders are particularly suited for high-viscosity applications such as producing sealants, putties, and rubber compounds.

Advantages of PerMix Sigma Mixers and Sigma Mixer Extruders

1. Unmatched Efficiency
   • Powerful Z-shaped blades ensure thorough mixing, reducing process times and improving consistency.
2. Versatility
   • Designed for a variety of applications, from pharmaceuticals and food to adhesives and chemical compounds.
3. Custom Features
   • Options for vacuum, heating, cooling jackets, ATEX-certified construction, and abrasion-resistant materials allow tailored solutions for every industry.
4. Streamlined Production
   • The sigma mixer extruder reduces handling, enhances precision, and increases output efficiency.

Why Choose PerMix?

At PerMix, we combine decades of expertise with cutting-edge technology to deliver best-in-class sigma mixers and sigma mixer extruders. Our commitment to quality, innovation, and customer satisfaction ensures that you receive a mixer that outperforms the competition.

There are mainly three ways for discharging the product after mixing:

1. Tilting Tank
   For small machines (PSG-1 to PSG-15), tilting can be done manually with a mechanical type (hand
   lever or hand wheel). For greater machines, electro-mechanically or hydraulically powered tilting system is supplied. PerMix supplies the feature that at tilted position, the blade will rotate at low speed (usually 20% of full speed) in reverse direction to aid the discharge by pushing two buttons with both hands.
2. Extrusion Screw 
   The extrusion-discharge screw is located in the saddle section and runs in a cylindrical trough tangential to, and below the 2 mixing blades. During the mixing cycle the screw moves the material within the reach of the mixingblades, thus assuring a thorough blending of all the ingredients, and, at the same time, accelerating the mixingprocess. At discharge time, the direction of rotation of the screw is reversed and the mixed material is extruded through suitable die openings in the side of the machine. The extrusion screw has its own separate drive so that blades and screw operate independently.
3. Bottom Discharge
   The Sigma Mixers, since also used in pastes, reductions, and concentrates, can also be equipped with a bottom type discharge valve, which allows for discharge via two valves, located on each side of mixing trough.

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PerMix Sigma Mixers: Meeting Pharmaceutical & Nutraceutical Standards with Precision

PerMix Sigma Mixers are meticulously engineered to meet the rigorous standards of the pharmaceutical and nutraceutical industries. Combining innovation, quality, and performance, our mixers ensure precise and consistent results while adhering to stringent compliance requirements.

Why Choose PerMix Sigma Mixers for Pharmaceutical & Nutraceutical Applications?

1. Sanitary Design
   • PerMix Sigma Mixers are crafted with hygienic design principles, featuring polished stainless steel surfaces (304SS or 316/316L) to minimize contamination risks.
   • Interior contact surfaces are mirror-polished to ensure ease of cleaning and meet sanitary regulations, making our mixers ideal for cGMP environments.
2. Compliance with Industry Standards
   • Our mixers are built to comply with pharmaceutical-grade requirements, including FDA, cGMP, and ASME standards, ensuring reliability in regulated environments.
   • Optional pharmaceutical-grade construction includes passivated surfaces and electropolishing for added durability and sterility.
3. Seamless Integration of Cleaning Systems
   • PerMix Sigma Mixers can be equipped with Clean-in-Place (CIP) systems, making cleaning efficient and hassle-free. Options for water-only, air-only, or combined systems offer flexibility for various production needs.
   • Wash-down-rated controls and seals enhance the cleaning process, maintaining peak operational efficiency while minimizing downtime.
4. Precise Mixing for Uniformity
   • The dual blade design of our Sigma Mixers ensures thorough mixing of powders, pastes, and semi-solids, achieving homogeneity even with delicate or challenging materials like active pharmaceutical ingredients (APIs) and nutraceutical powders.
   • Optional heating and cooling jackets allow precise temperature control, essential for sensitive formulations.
5. Vacuum Mixing & Drying
   • For advanced applications, PerMix Sigma Mixers can be outfitted with vacuum capabilities, enabling efficient mixing and drying in one unit.
   • This is particularly advantageous for heat-sensitive products, ensuring quality without compromising integrity.
6. Customizable Features for Specific Needs
   • Gas purging options protect sensitive materials by eliminating oxygen during mixing.
   • Load cells for precise ingredient weighing ensure batch consistency.
   • PLC/HMI controls with recipe entry simplify production, ensuring repeatability across batches.
7. Material Options for Versatility
   • In addition to stainless steel, our mixers are available in Hastelloy and titanium for highly corrosive or specialty applications, ensuring durability and adaptability to various formulations.

Applications in the Pharmaceutical & Nutraceutical Industries

PerMix Sigma Mixers are trusted by manufacturers for:

• Mixing granules, pastes, or cohesive powders for tablet formulations.
• Blending nutraceutical powders, including protein powders and dietary supplements.
• Preparing semi-solid formulations, such as ointments or creams.
• Drying powders and granules under vacuum conditions.

Why PerMix?

At PerMix, we understand the unique challenges faced by pharmaceutical and nutraceutical manufacturers. Our Sigma Mixers are the result of decades of engineering expertise, innovative design, and an unwavering commitment to quality. With a focus on meeting the highest standards, we ensure our mixers deliver consistent results while providing cost-effective solutions.

Choose PerMix Sigma Mixers and experience the difference in quality, performance, and compliance that sets us apart in the pharmaceutical and nutraceutical industries.

PerMix Sigma Mixers & Sigma Mixer Extruders: Engineered for Plant-Based Protein Applications

PerMix leads the way in innovation and engineering with our Sigma Mixers and Sigma Mixer Extruders, specifically designed to meet the growing demands of the plant-based protein industry. Whether you’re manufacturing plant-based meats, protein-rich snacks, or other sustainable food alternatives, our equipment ensures superior performance, efficiency, and quality.

Why Choose PerMix Sigma Mixers for Plant-Based Protein?

1. Optimal Mixing Action
   PerMix Sigma Mixers feature two counter-rotating sigma-shaped blades that provide a powerful, thorough kneading and mixing action. This ensures homogeneity in every batch, making it ideal for blending plant-based proteins, starches, and other critical ingredients.
2. Tailored for High-Viscosity Applications
   Our mixers excel at processing high-viscosity materials, such as dough-like mixtures required for plant-based meat production. They maintain consistent texture and quality, meeting even the most stringent industry standards.
3. Temperature Control for Precision
   With heating and cooling jacket options, PerMix Sigma Mixers and Extruders allow precise temperature control during mixing. This is crucial for ensuring proper protein binding, flavor infusion, and achieving the perfect texture for plant-based protein products.
4. Efficient Extrusion Capabilities
   Our Sigma Mixer Extruders are designed to streamline production. They mix and extrude material in a single operation, reducing processing time and enhancing efficiency. This feature is perfect for producing plant-based meat alternatives with consistent shapes and sizes.
5. Sanitary & Durable Construction
   PerMix mixers are available in 304SS, 316SS, and other food-grade materials, ensuring compliance with food safety standards. The mixers are easy to clean, minimizing downtime and cross-contamination risks.
6. Customizable Options
   PerMix offers a range of customization options to suit your production needs:
   • Vacuum capabilities for removing air pockets and enhancing texture.
   • PLC/HMI control systems for recipe management and automation.
   • CIP (Clean-In-Place) systems for sanitary, hands-free cleaning.

Applications in the Plant-Based Protein Industry

• Plant-Based Meats: Achieve the perfect texture, moisture retention, and protein binding for products like burgers, sausages, and nuggets.
• Protein Snacks: Blend high-viscosity doughs for bars, chips, and other snacks.
• Dairy Alternatives: Mix and extrude formulations for cheese and yogurt alternatives.

Advantages of PerMix Sigma Mixers in Plant-Based Protein Production

• Enhanced product consistency and texture.
• Increased efficiency with mixing and extrusion in one machine.
• Precise temperature control for sensitive formulations.
• Customizable features to meet diverse manufacturing requirements.

PerMix: Your Partner in Plant-Based Protein Innovation

At PerMix, we understand the unique challenges of plant-based protein manufacturing. With over 70 years of expertise in mixing and process equipment, our Sigma Mixers and Sigma Mixer Extruders are trusted by manufacturers worldwide. We combine advanced engineering, superior performance, and cost-effective solutions to help you succeed in this rapidly growing market.

Contact us today to learn how PerMix can elevate your plant-based protein production with our cutting-edge Sigma Mixers and Extruders.

Customizable Options for PerMix Sigma Mixers and Sigma Mixer Extruders

PerMix offers a wide range of customizable options for our sigma mixers and sigma mixer extruders, allowing you to tailor each unit to meet the unique demands of your industry and application. From advanced temperature control to precise ingredient loading systems, we ensure your mixer is optimized for efficiency, safety, and performance.

1. Heating & Cooling Jackets

Our sigma mixers can be equipped with heating and cooling jackets to maintain precise temperature control during the mixing process.

• Applications:
  • Heating: Ideal for processes like polymerization, vulcanization, or cooking food products.
  • Cooling: Essential for controlling heat-sensitive materials or solidifying mixtures.
• Features:
  • Available in single or dual-zone designs for maximum flexibility.
  • Compatible with steam, hot oil, water, or glycol systems for efficient heat transfer.

2. Heating & Cooling Arms

For applications requiring even more precise temperature control, PerMix offers heating and cooling arms.

• These arms directly transfer heat or cooling to the product inside the chamber, providing faster and more uniform temperature adjustments.
• Perfect for high-viscosity products where thorough heat distribution is critical.

3. Vacuum Capabilities

Vacuum functionality enhances product quality by:

• Removing trapped air, resulting in a denser, more homogeneous product.
• Enabling vacuum drying for industries like pharmaceuticals, adhesives, and food.

Vacuum sigma mixers/dryers can also integrate with condensers for vapor recovery, improving efficiency and sustainability.

4. ATEX & Explosion-Proof (ExP) Construction

For hazardous environments, PerMix sigma mixers can be built to meet ATEX and ExP standards.

• Safety Features:
  • Explosion-proof motors and controls.
  • Anti-static construction to prevent ignition risks.
  • Fully sealed designs for handling volatile or flammable substances.

These mixers are ideal for chemical, pharmaceutical, and coatings industries.

5. Materials of Construction

We offer a variety of materials to suit your specific product requirements:

• 304 and 316 Stainless Steel: Ideal for sanitary applications in food and pharmaceuticals.
• Hastelloy and Titanium: Best for highly corrosive substances.
• Hardox Steel: Exceptional durability for abrasive materials.
• Carbon Steel: A cost-effective option for less demanding applications.

Each construction option is tailored to balance performance, longevity, and budget.

6. Ingredient Loading Options

Efficient ingredient loading is key to streamlining production. PerMix offers:

1. Manual Loading
   • Simple and cost-effective for small batches or low-viscosity materials.
2. Automatic Dosing Systems
   • Precision dosing via load cells ensures accurate ingredient addition for consistent product quality.
   • Compatible with powders, liquids, and bulk materials.
3. Vacuum Loading
   • Uses vacuum to draw ingredients into the chamber, eliminating the need for separate loaders.
   • Reduces dust, contamination, and manual handling.
4. Integrated Bulk Bag Unloaders
   • Designed for high-volume production, enabling seamless ingredient transfer from bulk bags to the mixer.

Tailored Solutions for Every Application

With these customizable options, PerMix sigma mixers and sigma mixer extruders are versatile enough to handle:

• High-viscosity pastes and doughs.
• Heat- or cold-sensitive materials.
• Hazardous or volatile environments.
• Abrasive or corrosive products.

Why PerMix?

PerMix leads the industry with:

• Innovative engineering to optimize performance.
• Flexibility to meet diverse application needs.
• Competitive pricing without compromising quality.