A number of problems can be encountered when using conventional powder/liquid blending systems and agitators:• Powder must be added at a controlled rate to reduce agglomeration of particles.• Premixing of powders, often carried out to reduce agglomeration, increases costs and process time.• Conventional systems do not produce sufficient shear to break agglomerates down.• Long processing times are required to complete dispersion and achieve a satisfactory consistency.• Poor dispersion can lead to clusters of partially hydrated material building up on the walls of the heat exchanger, impairing heat transfer.• Agglomerates can also adversely affect homogenizer performance, leading to inconsistent results.• Frequent cleaning cycles are required, resulting in increased costs from down time, cleaning chemicals and waste of expensive raw materials.• Incomplete hydration also reduces yield of raw materials.• Many formulations contain unnecessarily high levels of these raw materials to compensate for poor yield and wastage.
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