From concept to solution

Process development of customised stirring technology solutions

Customised solutions with simulation and testing

There are no ‘one-size-fits-all’ solutions in mixing technology. Each process requires individual consideration and a tailor-made solution. Process development is the first step on the road to a customised solution. We examine your requirements in detail and then develop the optimal strategy for the entire mixing process to maximise efficiency and performance.

Using modern simulation techniques such as CFD and FEM, we optimise flow behaviour and the mechanical load on the agitator components before the physical test is carried out. This enables us to design the process precisely and identify potential problems at an early stage. At the PRG pilot plant, we validate the developed solutions with practical tests under real-life conditions to ensure that they work optimally in production. The scale-up ensures that the solutions also work efficiently on a larger scale.

With our ConfiMix agitator configurator, we help you select an agitator that meets your specific requirements. Based on your process data, we create an initial design that serves as the basis for further planning.
With this combination of simulation, practical tests and innovative tools, we guarantee you a customised, efficient and economical mixing technology solution.

Visible Efficiency

The computational fluid dynamics simulation (CFD) makes it possible to virtually ‚dive‘ into the stirred tank and to observe the digitally simulated flow behavior in detail. By doing so, the knowledge gained in practical experiments can be supplemented, if necessary, with further data, which is important for the design of the agitator.

Another simulation method

With the finite element method (FEM) we have another simulation process, that is focused on the accurate dimensioning and mechanical construction of the components of your agitator. With this method, all process-relevant parameters can precisely be determined – from the selection and construction of the agitating element to the hydraulic loading of the used components.

From an idea to reality

Practical tests are often indispensable for the design of agitator systems. This is the only way to determine the actual product properties of complex stirring materials in different process conditions. This applies in particular to multi-phase mixtures and products whose viscosity changes dynamically during the stirring process.

In the PRG laboratory we are realizing different test setups that cover our entire product portfolio. A wide variety of test reactors are available for this purpose, which allows extensive test runs under production-like conditions. This allows us to determine all relevant rheological parameters precisely.

The results provide us not only with valuable insights for the final design and construction of the agitator but also form the basis for the scale-up to the final production scale.

Mixing technology in a new dimension

As soon as all necessary parameters for the construction of the agitator have been determined, they must be extrapolated to the size of the actual plant. A complex task, especially when new processes are first tested on a laboratory scale and are supposed to be used later in the industrial production – with the highest possible yields and maximum operational reliability.

Based on the tests carried out in the laboratory, the physical and mathematical models as well as numerical simulation methods, our engineers can make binding statements about the flow behavior as well as the loads and torques on a production scale. These are the best prerequisites for the final design and precisely fitting production of an individual agitator that completely satisfies our customers’ requirements in terms of performance, economy, and reliability.

Would you like to find out more?

Please contact us