Mixing pumps Manufacturers online

Mixing pumps are indispensable components in all industries in which homogenized media must be produced directly during conveying.

Depending on the industry, they can have different characteristics, as they are used in the construction industry, process engineering and the chemical industry.

Below you will find the definition and function of different types of mixing pumps, typical applications, as well as their advantages and limitations for their use:

What are mixing pumps:

Mixing pumps are conveying systems that simultaneously fulfill two tasks:

1. Conveying liquid or pasty media.
2. Homogeneous mixing of two or more components such as liquids, powders or solids.

Mixing pumps are always used when media have to be intensively mixed or dispersed during transportation. They therefore combine a pump and mixing unit in one system.

How mixing pumps work:

The mode of operation depends heavily on the pump type. Here are the most important types:

1. Inline mixing pumps (rotating):
   These mixing pumps work on a rotor-stator principle:
   A rapidly rotating rotor generates high shear forces.
   A fixed stator with narrow gaps ensures fine distribution.
   Liquids or liquid-solid mixtures are mixed inline.
   Frequently used types: Gear mixers, colloid mills or rotor-stator systems.
2. Progressive cavity mixing pumps (continuous, high shear):
   Based on the progressive cavity pump principle.
   A mixing spiral or mixing tube is connected downstream or integrated.
   In the construction industry, for example, cement or plaster is mixed with water and pumped directly.
3. Ejector or injector pumps (jet mixers):
   Utilize the flow velocity of a main stream to draw in and mix a secondary stream, e.g. powder or gas.
   No moving parts, low maintenance.
   More commonly used in the water treatment or chemical process industry.

Typical applications of mixing pumps:

1. Construction industry:
Plaster, render and mortar pumps: dry mixtures are mixed with water and processed immediately.
Floor coating and screed laying: Homogeneous mixing of binders, fillers and water.

2. Food and cosmetics industry:
Emulsifying oil and water e.g. mayonnaise, lotions.
Stirring in sugar, stabilizers or thickeners.

3. Chemical industry:
Production of dispersions, emulsions and polymer solutions.
Homogenization of acids, alkalis and reaction mixtures.

4. Environmental technology:
Addition of milk of lime, polymer solutions or flocculants to the waste water stream.
Mixing injectors for dosing and mixing.

5. Energy and petrochemicals:
Mixing additives into fuels or oils.
Introduction of catalysts or pigments into reaction streams.

Advantages of mixing pumps:

• Space-saving, as pumping and mixing are combined.
• Time and energy efficient, especially in continuous processes.
• Consistent product quality thanks to reproducible mixing.
• Can be automated and precisely dosed.
• Hygienic design also suitable for CIP/SIP processes.

Restrictions for the use of mixing pumps:

• Abrasive wear with solids → Selection of robust materials important.
• Sensitivity to air bubbles or gases, especially in high-pressure systems.
• Residue-free cleaning (important in the food/pharmaceutical industry).
• High energy consumption with intensive mixing performance.
• Not all pump types can handle shear-sensitive products gently.

Mixing pumps offer a space-saving, economical solution for complex mixing tasks, especially in continuous processes. The choice of the right type - whether rotor-stator mixer, progressive cavity mixing pump or injector pump - depends heavily on the product properties, the desired mixing quality and the operational requirements.

Here you will find an overview of the most important criteria that you should pay attention to when purchasing mixing pumps:

When buying mixing pumps, it is particularly important to consider the dual function of these pumps - conveying and mixing - holistically. In contrast to conventional pumps, it is not just about delivery capacity or pressure, but also about mixing quality, homogeneity and process compatibility.

• Which requirements of the medium and the mixing process influence the selection of a suitable mixing pump?
• The nature of the media is at the center of the selection process:
• Which phases are to be mixed e.g. liquid-liquid, liquid-solid, gas-liquid?
• Are there shear-sensitive ingredients that must not be damaged?
• What is the viscosity of the components before and after mixing?
• How strong is the abrasiveness or corrosiveness of the media?
• Do the components need to be completely and homogeneously mixed or only slightly dispersed?
• These factors not only determine the pump technology, but also the choice of material and the design of the mixing system.
• Depending on the type of application, the requirements for the pump differ considerably:
• In continuous processes, e.g. food, chemical or sewage treatment plant operation, the mixing pump must run continuously and deliver consistent quality.
• In batch processes, e.g. recipe production, flexible dosing and mixing times are often required.
• Robust, easily automated systems are required for continuous processes, while batch systems often require variable speeds, controllability and precise dosing systems.
• Not every mixing pump works on the same principle:
• Rotor-stator systems generate high shear forces for fine emulsions or dispersions.
• Progressive cavity mixing pumps convey viscous media continuously and mix using special screw geometry.
• Inline mixing pumps are ideal for homogeneous mixing during the flow, without a separate mixer.
• Injector or jet pumps work without moving parts and are more suitable for simple, low-maintenance applications.
• The mixing technology must be suitable for the product and the process. Excessive shear forces can damage products and insufficient mixing intensity can lead to instability.
• The pump must not only mix, but also reliably deliver the right quantity:
• The delivery rate and mixing ratio must be precisely adjustable.
• The pump should ensure even, low-pulsation delivery - particularly important for sensitive media or exact recipes.
• Speed control, e.g. via frequency converters, enables flexible adjustment.
• Material compatibility is crucial for service life and product safety:
• Stainless steels, e.g. 1.4404 / 316L, are standard in hygienic or chemical applications.
• Plastics or coated materials are used for aggressive chemicals.
• Elastomers and seals must be resistant to media and temperatures, e.g. EPDM, FKM, PTFE.
• For abrasive media, wear-resistant materials such as hard metal or ceramic should be used.
• The type of seal - mechanical seal, stuffing box or magnetically coupled seal - should also be suitable for the application.
• Special requirements apply in the food, pharmaceutical and cosmetics industries:
• The pump must be CIP (cleaning in place) and, if necessary, SIP-capable (sterilization in place).
• Dead spaces and poorly accessible areas must be avoided.
• Approvals according to EHEDG, 3-A or FDA are often mandatory.
• It is not only the design that counts here, but also the quality of the surfaces and sealing points.
• Operating costs also play a major role for mixing pumps:
• High-shear systems often require a lot of energy - efficiency is important here.
• The wear of rotors, stators or mixing heads should be calculated.
• Maintenance intervals and spare parts costs have a significant influence on the overall costs.
• Professional systems often have to be integrated into an existing plant control system:
• Interfaces such as Profibus, Profinet, Modbus or analog/digital inputs and outputs are required.
• Integration into batch systems or continuous process control systems.
• Safety functions such as dry-running protection, pressure relief valves or temperature monitoring can also be important.
• Reliable operation depends heavily on how easy the pump is to maintain:
• Quick access to wearing parts without removing the entire unit.
• Modular design facilitates replacement of individual parts.
• Good availability of spare parts, ideally with local stock locations.
• Technical support, training courses and service contracts from the supplier.
• A favorable purchase price can quickly be offset by high follow-up costs. This is why life cycle costing (TCO) is particularly important.
• A strong partner not only supplies hardware, but also know-how and support over the entire life cycle of the pump.

When purchasing mixing pumps, it is not just about technical key figures such as flow rate or pressure. The decisive factor is process suitability: Can the pumps mix the desired components safely, efficiently and evenly - and at the same time operate economically, easily and reliably? Only if all relevant aspects, from media compatibility and mixing technology to automation, are taken into account will the investment be sensible and stable in the long term.

Mixing pumps can be purchased from various suppliers. Comprehensive information on manufacturers and suppliers of Mixing pumps from all over the world can be found on Exportpages.