We work with an enormously diverse range of customers, from foodstuffs to pharmaceuticals, base chemicals to cosmetics. The market exposure gives us real insight into mixing trends and how the market is moving.
If we wanted to sum up this movement in one word, that word is REPEATABILITY.
At the heart of this is repeatability regardless of batch size.
Greaves’ Top 10:
Here are our Top 10 reasons why end users are demanding more from our mixer customers:
Need to produce low volume, high value products for niche markets
Demand for repeatable high quality across a wide range of production batch sizes
Produce the volumes customers require and remove the barrier of minimum order quantities
Lean manufacturing to minimise inventory and waste
Launching new products with low commercial risk i.e. stock risks, seasonal variations
Elastic volume capability of say 60L to 10L (i.e. 6:1 turndown ratio. Historically this was only 3:1)
Reduced cycle times to keep costs down (typically less than 5 minutes vs historic 20 minutes+)
Ability to mix hundreds of product types with quick clean down & change-over
Rapid, accurate repetition of product formulations
We see our business as providing effective mixing solutions rather than simply supplying mixers and vessels. Clients frequently ask to meet with Greaves’ Process Consultants to tap into our extensive experience and knowledge to help them solve specific issues including:
Reducing cycle times
All of these tend to be driven by customer specification and the drive for ever-increased efficiency in competitive markets.
Our initial recommendation is normally a full process review.
Investment in new processing equipment can often open up potential to increase capability, flexibility and efficiency. To make the most of this opportunity it is important to establish a comprehensive understanding of both current and future needs.
While it may seem obvious to extend capacity by duplicating current equipment, our experience and knowledge can often identify a better solution bringing additional benefits. These can lead to a faster return on investment through shorter cycle times and greater flexibility.
Our Consultants challenge an existing process by :
Analysing the most effective way to mix products
Considering other options available to save time and improve consistency
Looking at ways to reduce operator input
Exploring mixer configurations offering greater viscosity and volume flexibility
Improving process efficiencies with heat, cooling and/or vacuum or pressure)
Always ensuring compliance with safety legislation, ATEX and CE marking
Greaves look at end to end process optimisation
Throughout every process review, we aim to help customers make strategically sound investment decisions that support future operational needs. This can include the use of hire equipment to test a proposed solution prior to committing to permanent investment.
Customers can hire Greaves mixers to test the performance and process benefits in several ways:
Free of charge 14 day trial
Extended hire periods (minimum 1 month)
Leasing or Hire purchase
Our hire equipment is naturally of the highest performance standard you expect from us and includes:
High Shear – top entry & in-line
High Speed Dispersers
Laboratory – high shear & HSD types
45 Gallon drum blenders & dispersers
If you would like to talk to us about improving processes to exceed your expectations – get in touch
Its always good to hear from established clients who are looking to add capacity. We recently heard from one of our customers in the cosmetics industry with this type of request.
A simple response might be to provide additional and/or larger versions of existing mixers. However, following a process review, it became clear neither of these options offered the most effective solution.
Under increasing pressure to reduce processing time & cost, our customer needed a more efficient mixing solution.
Greaves proposed a new high speed, high shear batch mixer which promised to reduce process time by around 80%.
With such a dramatic improvement on offer, mixing trials were arranged on site with one of Greaves large range of demonstration mixing machines.
With the original “paddle” type mixer, process time was 95 minutes.
The trial mixer produced improved product consistency in just 12 minutes. A reduction in process time of 83%!!!!