PerMix Double Cone Mixer

How a Double Cone Mixer Works

A double cone mixer works by using gravity-driven tumbling rather than mechanical agitation. This simple but elegant principle is exactly why it remains a trusted solution across UK and EU manufacturing—especially in applications where product integrity and cleanliness matter more than aggressive mixing energy.

The Tumbling Principle

The mixer consists of two conical sections joined at their widest points, forming a symmetrical vessel mounted on a rotating frame. As the vessel rotates:

• Material continuously divides, cascades, and recombines

• Powders move from one cone to the other and back again

• The product naturally redistributes itself through repeated splitting and folding

This motion creates a highly uniform blend without shear, compression, or impact forces.

There are no internal paddles, ribbons, or plows. The product is never forced—only guided by gravity.

Why This Produces Uniform Blends

Each rotation causes the powder mass to:

• Separate into multiple streams

• Flow across changing angles

• Recombine in different orientations

Over time, this repeated redistribution eliminates concentration gradients, producing excellent homogeneity—especially for free-flowing and segregation-prone powders.

Because the mixing mechanism is gentle, particle size, shape, coatings, and bulk density are preserved.

No Internal Agitators = Key Advantages

The absence of internal mixing tools delivers several critical benefits:

• No shear or heat generation

• No dead zones or material trapping

• No shaft seals or bearings in the product zone

• Minimal risk of cross-contamination

For UK and EU manufacturers operating under GMP or hygiene-driven standards, this simplicity directly supports cleanability, inspection, and validation.

Mixing Under Vacuum or Inert Atmosphere

Double cone mixers can be supplied with vacuum-rated construction or gas purging capability. This allows:

• Oxygen-free mixing

• Gentle moisture removal

• Protection of oxidation-sensitive or potent materials

• Fully closed, contained processing

This is especially valuable in pharmaceuticals, nutraceuticals, and specialty chemical applications.

Controlled Speed, Controlled Results

Mixing intensity is controlled primarily by:

• Rotation speed

• Fill level

• Mixing time

Because energy input is low and predictable, double cone mixers deliver repeatable results with minimal operator dependency—a key advantage in regulated UK and EU environments.

Engineered for UK & EU Production

Double cone mixers supplied by PerMix are engineered with:

• UKCA and CE marking

• Hygienic, GMP-friendly construction

• ATEX-compliant designs for dust-hazardous environments under DSEAR regulations

Materials of construction and surface finishes are selected to match both product chemistry and compliance requirements.

In Practical Terms

A double cone mixer works by letting gravity do the work, rather than overpowering the product with mechanical force. That’s why it remains one of the most reliable solutions for gentle, uniform powder blending—especially when product quality, cleanliness, and validation matter more than raw mixing speed.

Applications & Industry Use Cases for Double Cone Mixers (UK / EU)

Double cone mixers are widely used across the UK and European manufacturing landscape wherever powders must be blended gently, uniformly, and cleanly. Their gravity-driven tumbling action makes them especially valuable in industries where product integrity, segregation control, and validation are more important than aggressive mixing speed.

Double cone mixers supplied by PerMix are applied across both regulated and industrial sectors, often as the preferred solution for final blending steps.

Pharmaceutical Manufacturing

In pharmaceutical production, double cone mixers are a long-established standard for:

• API and excipient blending

• Final dosage form blending prior to tableting or encapsulation

• Low-dose and potent compound mixing

• Closed, contained powder handling

Their smooth internal geometry, lack of internal agitators, and ease of validation make them ideal for GMP environments where cross-contamination risk must be minimised.

Nutraceuticals & Dietary Supplements

Nutraceutical formulations often contain vitamins, minerals, plant extracts, and actives with varying particle sizes and densities. Double cone mixers are commonly used for:

• Powdered supplement blends

• Protein and functional nutrition mixes

• Vitamin and mineral premixes

Gentle tumbling helps maintain ingredient integrity while achieving consistent distribution of low-percentage components.

Food Ingredients & Specialty Foods

In food processing, double cone mixers are selected for applications such as:

• Dry ingredient premixes

• Flavours, spices, and seasoning blends

• Functional food ingredients

The low-energy mixing action avoids heat buildup and particle damage, supporting flavour retention and consistent product quality. Hygienic construction also supports food safety and audit requirements across UK and EU facilities.

Chemicals & Specialty Powders

In chemical and specialty material manufacturing, double cone mixers are used where:

• Powders are free-flowing but segregation-prone

• Particle size or morphology must be preserved

• Gentle blending is required before downstream processing

Applications include fine chemicals, catalysts, additives, and speciality formulations where uniformity matters but shear is undesirable.

Advanced Materials & R&D

Double cone mixers are frequently used in:

• Pilot plants and R&D laboratories

• Scale-up trials from lab to production

• Blending of high-value or limited-quantity materials

Their predictable mixing behaviour makes them ideal for transferring formulations reliably from development to commercial production.

Why Double Cone Mixers Are Chosen Across These Industries

Across UK and EU operations, double cone mixers are selected for the same core reasons:

• Gentle, shear-free blending

• Excellent homogeneity for free-flowing powders

• Simple, cleanable, and validation-friendly design

• Low energy consumption and repeatable results

When the goal is uniform blending without altering the product, the double cone mixer remains one of the most trusted and proven technologies available.

Double Cone Mixer Variants & Configuration Options (UK / EU)

Double cone mixers may look simple—and that’s precisely the point—but in UK and EU manufacturing, the details of configuration matter enormously. Capacity, containment, discharge design, and compliance options all determine whether a double cone mixer is merely adequate or truly production-ready.

PerMix double cone mixers are available in multiple variants and can be configured to align precisely with process requirements, regulatory expectations, and plant constraints.

Standard Double Cone Mixers

Standard double cone mixers are designed for gentle batch blending of free-flowing powders and granules. These units are typically used where:

• Shear must be avoided

• Particle morphology must be preserved

• Simple, reliable blending is required

They are widely used for final blending steps in pharmaceutical, nutraceutical, food ingredient, and specialty chemical applications.

Vacuum Double Cone Mixers

Vacuum-rated double cone mixers are selected when product protection or containment is required. Operating under vacuum allows:

• Oxygen-free mixing for oxidation-sensitive materials

• Gentle moisture reduction

• Fully enclosed processing for potent or dusty powders

These configurations are common in pharmaceutical and high-value chemical processing, where exposure control and product stability are critical.

Double Cone Mixer / Dryer Configurations

For applications requiring both blending and drying, PerMix offers double cone mixer-dryers with integrated heating and cooling jackets. This allows:

• Mixing and vacuum drying in a single vessel

• Reduced material handling and contamination risk

• Lower drying temperatures under vacuum

This configuration is often used for pharmaceutical intermediates, APIs, and specialty powders.

Materials of Construction

Double cone mixers can be supplied in:

• 304 stainless steel for general hygienic applications

• 316 / 316L stainless steel for pharmaceutical, corrosive, or high-purity processes

• Polished internal finishes suitable for GMP environments

Material selection is driven by product chemistry, cleanability, and regulatory requirements.

Discharge & Handling Options

To suit downstream processing and containment needs, PerMix double cone mixers can be equipped with:

• Flush or low-hold-up discharge valves

• Butterfly or slide gate valves

• Docking systems for contained discharge

• Drum, bin, or IBC loading and unloading options

These features reduce product loss and support clean, controlled transfer.

Intensifier Bars & Liquid Addition

Where required, double cone mixers can be fitted with an internal intensifier bar. This provides:

• Localised agitation for breaking soft agglomerates

• Improved dispersion of minor liquid additions

• Enhanced blending of low-dose ingredients

The intensifier operates only when needed—preserving the gentle nature of the main tumbling action.

Controls, Automation & Safety

PerMix double cone mixers can be supplied with:

• Manual, semi-automatic, or PLC-controlled operation

• Recipe control and batch repeatability

• Safety interlocks, guarding, and monitoring systems

All designs can be engineered to meet UKCA and CE marking requirements and configured for ATEX compliance under DSEAR regulations where dust hazards exist.

Scalable from R&D to Production

Double cone mixers are available in sizes ranging from lab and pilot scale to full production, allowing manufacturers to:

• Develop formulations at small scale

• Transfer mixing parameters reliably

• Scale production without reformulation

This continuity is especially valuable in regulated UK and EU industries.

In Summary

Double cone mixers are not one-size-fits-all. Their strength lies in how precisely they can be configured—gentle when needed, enclosed when required, and compliant by design.

For UK and EU manufacturers seeking reliable, validation-friendly powder blending, the right double cone mixer configuration delivers long-term confidence—not just a blended batch.

Double Cone Mixer vs V-Blender vs Ribbon Mixer

Which Is Right for Your UK / EU Process?

This is one of the most common—and most important—equipment decisions UK and EU manufacturers face. All three mixer types blend powders, but they do so using very different physics, which means the right choice depends entirely on product behaviour, sensitivity, and process goals.

Choosing incorrectly usually doesn’t fail immediately. It fails later—during scale-up, validation, cleaning, or shelf-life testing.

Let’s make the differences unmistakably clear.

Double Cone Mixer

Best for: gentle, high-uniformity powder blending

A double cone mixer relies purely on gravity-driven tumbling. There are no internal agitators, no shear, and no compression forces.

Choose a double cone mixer when:

• Powders are free-flowing or moderately segregative

• Particle integrity must be preserved

• Shear and heat must be avoided

• Cleaning and validation simplicity are critical

• Final blend uniformity matters more than speed

Strengths:

• Extremely gentle mixing

• Minimal heat generation

• No internal shafts, seals, or bearings in product zone

• Very easy to clean and validate

• Ideal for pharmaceuticals, nutraceuticals, and specialty powders

Limitations:

• Not suitable for cohesive or sticky powders

• Limited liquid addition capability (unless intensifier bar is used)

• Longer mixing times compared to high-energy mixers

Think of the double cone mixer as precision through simplicity.

V-Blender

Best for: gentle blending with faster turnover than a double cone

A V-blender also uses tumbling, but the V-shaped vessel causes powders to split and recombine more frequently during rotation.

Choose a V-blender when:

• Powders are free-flowing

• Faster blending is needed than a double cone

• Minimal shear is still required

• Limited liquid addition may be necessary (with intensifier bar)

Strengths:

• Gentle, low-shear mixing

• Faster blending than double cone in many cases

• Simple mechanical design

• Widely accepted in pharmaceutical processing

Limitations:

• Still not suitable for cohesive or sticky materials

• Can promote segregation with extreme density differences

• Internal intensifier bars add complexity and cleaning considerations

A V-blender is often selected when manufacturers want gentle mixing—but faster.

Ribbon Mixer

Best for: versatility, speed, and handling difficult powders

A ribbon mixer uses internal helical ribbons to actively move material in opposing axial and radial directions. This introduces mechanical agitation and moderate shear.

Choose a ribbon mixer when:

• Powders are cohesive, sticky, or variable

• Liquids need to be added reliably

• Faster batch cycles are required

• Higher throughput is a priority

• Process flexibility matters

Strengths:

• Handles a wide range of materials

• Supports liquid addition, coating, and conditioning

• Faster mixing times

• Scales easily for high-throughput production

Limitations:

• Introduces shear and some heat

• More complex to clean than tumbling mixers

• Internal shafts and seals require proper design for hygiene

Ribbon mixers are chosen when process robustness and speed outweigh the need for ultra-gentle handling.

Quick Selection Guide (Reality-Based)

Choose a double cone mixer if:

• You are blending sensitive powders

• Validation and cleanability are top priorities

• Shear must be avoided at all costs

Choose a V-blender if:

• Powders are free-flowing

• You want gentle mixing with shorter cycle times

• Light liquid addition may be required

Choose a ribbon mixer if:

• Materials are difficult, cohesive, or variable

• Liquid addition is part of the process

• Production speed and flexibility are critical

Compliance & UK / EU Considerations

All three mixer types supplied by PerMix can be engineered with:

• UKCA and CE marking

• Hygienic, GMP-friendly construction

• ATEX-compliant designs under DSEAR regulations

• Materials and finishes aligned to food, pharma, or industrial use

The compliance box can be ticked on all three.
The process box cannot.

The Honest Takeaway

• Double cone mixers excel at gentle precision

• V-blenders offer gentle speed

• Ribbon mixers deliver controlled force and flexibility

If a powder needs persuasion, tumble it.
If it needs direction, ribbon it.

Precision Milling, Engineered by DP Pulverizers Americas

PerMix UK is part of the DP Pulverizers Americas family — a global network dedicated to advancing the science of particle size reduction. From the United States to the United Kingdom, our focus remains the same: delivering reliable, high-performance milling solutions that empower manufacturers in food, pharmaceuticals, chemicals, and advanced materials.

Now operating directly from our UK headquarters, DP Pulverizers brings localized expertise, European compliance, and shorter delivery times, backed by the full engineering strength of our American and Indian manufacturing centers.

Explore DP Pulverizers Americas →

Performance Born from Engineering Excellence

DP Pulverizers designs and builds mills that transform production efficiency. Every model is developed using computational airflow analysis, high-tolerance machining, and precision balancing, ensuring micron-accurate results and continuous uptime.

Our systems are built from stainless steel, Hardox, or alloy steels to suit your application — whether it’s fine sugar powders, conductive graphite, or cryogenically ground polymers. Each design meets ATEX, GMP, and CE standards, ready for industrial and pharmaceutical environments across Europe.

Our Range of Milling Solutions

Pin Mills
Delivering fine, consistent particle reduction for spices, starches, and chemical powders with high energy efficiency and minimal heat generation.

Turbo Mills
Engineered for high-speed micronizing of plastics, pigments, and resins, turbo mills use controlled turbulence for fine results without overheating.

Hammer Mills
The robust, heavy-duty solution for bulk grinding and granulation in food, minerals, and biomass processing. Available in Hardox for abrasive products.

Jet Mills
Utilizing compressed air rather than moving parts, jet mills achieve sub-5-micron fineness ideal for pharmaceutical and nano-material production.

Cryogenic Mills
Low-temperature milling using liquid nitrogen keeps materials stable, preventing softening or clumping — essential for elastomers, thermoplastics, and fine foods.

Universal Mills
A versatile platform that adapts to pin, hammer, or turbo configurations, perfect for manufacturers handling multiple product types on one line.

Cone Mills (Comils)
For gentle deagglomeration and uniform sizing, cone mills are a clean, quiet option for final powder conditioning and pre-mix applications.

Technology Without Borders

With PerMix UK as the European home of DP Pulverizers Americas, customers gain access to a truly global engineering network. From design through commissioning, our teams collaborate across continents to deliver custom-engineered milling systems that integrate seamlessly with upstream and downstream processes — including PerMix mixers, feeders, and conveying systems.

Every machine reflects our shared philosophy: engineering precision, performance, and practicality — all at a realistic price point.

From the Americas to the UK, One Standard: Excellence

DP Pulverizers UK stands as part of a worldwide commitment to innovation in particle processing. With manufacturing in America and India, and local support in the United Kingdom, we provide comprehensive solutions — from initial testing to full-scale turnkey installations.

Discover how our engineering shapes the future of powder processing.