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LÖDIGE – ALWAYS THE RIGHT MIX
Mixing systems for theFood Industry
Lödige mixingsystems for theproduction ofinternational, highquality products
Processing powders• vitamin powder• ice cream powder• flavourings• oven-ready flour mixes with
addition of fat and lecithin• flour• milk / whey powder• enzymes
Processing granulates, grainsor powders containing pieces
• table salt• convalescent preparations• stock cube mixes• special diet foods• coffee and tea extracts• oven-ready mixes• soluble fruit drinks
Processing fragile materials• muesli• instant, dried soups• spice mixes with concentrates• tea mixes• dried vegetables• frozen fruit and vegetables
Lödige systems provide the mixing andprocess precision essential for opti-mum design of a wide range of produc-tion. Our customers include producersof well-known food brands and oursystems are used worldwide due to
their efficient, cost-effective and opti-mum processing concepts. Lödige processing systems for the foodindustry have been developped on thebasis of wide ranging experience in theproduction of mixers and processing
units in this specific branch. This isbacked-up by process technologyknow-how obtained from innumerablemixing trials.
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Processing viscous products• sauces containing pieces• basic fruit pulps• chocolate ingredients• wafer fillings etc.• glazings• cheese spread ingredients• cooking fat
• margarine• other emulsions and pastes• baby food• creams / dressings• mustard
Combined processes
In addition to the classicalprocess step of pure mixing, it isalso technologically possible tocombine all additional proces-sing steps usually required bythe food industry in a singleLödige Mixer. This means, forexample, that work intensivepremixing is unnecessary.
• alkalinization• fat intermixing• moistening/coating• conching• heating• homogenization• iodizing• crystallization• cooling• lecithinizing
• mixing/granulating• pasteurizing• fusion granulating• sterilization• drying• coating• compacting• melting in polyphase
processes... and many more
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Batch mixing andgranulating in a horizontalLödige system
The invention of the Ploughshare® Mixerhas set a high standard for mixing andprocessing technology. Large numbers ofpatented innovations are based on thissystem. Lödige Mixers guarantee homo-geneous, precision mixing within mini-mum mixing times.
Ploughshare Shovels® rotate as mixing elements in specialarrangement on a horizontal shaft in a horizontal, cylindricalmixing drum.The size, number and positioning, geometric shape andperipheral speed of the mixing elements are coordinated tocause three dimensional movement of the components.Turbulence in the product, with total involvement of allmaterial, prevents the formation of dead or low-movementzones in the mixing drum and promotes high speed, preci-sion mixing.The specially shaped shovels lift the product radially from thewall of the drum to prevent particles from becomingsquashed between the mixing elements and the drum wall.The hurling and whirling principle is, therefore, ideal forgentle mixing if fragile and heat sensitive components areincluded in the mix.
Modified Ploughshare® Shovels – so called Becker Shovels –can be used for special applications or particular componentcharacteristics to further intensify this effect.In special cases, in particular in combined processes, theeffect of the mixing elements may require additional sup-port and this is provided by separately driven, high speedchoppers.A short mixing time with optimum adaptation of the drivepower ensures minimized power consumption.The low-maintenance concept of Lödige Mixers guaranteesmaximum availability of production units. The excellentaccessibility to all inside parts of the mixer reduces consider-ably the time and expenditure for cleaning and inspection.The mixers can be adapted as an option to WIP/CIP proces-ses and therefore provide the highest standard of hygienefor even the most difficult, microbiological components.
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Version A:Liquid inlet through lance
or injector
Version B:Liquid inlet (pressure-free or by sprayingthrough a nozzle)
Ploughshare®mixing elements
Mechanically generatedfluid bed
Chopper
Horizontal Lödige Ploughshare® Mixeroperating on the hurling and whirling principle
variance
time
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Individual production yielddue to precise configurationof the systemLödige systems produce maximum homogenei-ty of even the most difficult products. Quote*:“... Ploughshare® Mixers, running at the appro-priate speed, are the most suitable… The bestpossible mixing quality is obtained under pro-duction conditions after only 16 seconds. In vertical ribbon blenders products are mixedmore slowly and the quality of the end mix ispoorer than that obtained in Ploughshare®Mixers.”
* Lebensmitteltechnik 3/2000
Ploughshare® Mixer type FKM
Batch Mixer
type Easy CleanGMP® Mixer
Batch Mixer
type Eco Line
Batch Mixer
type FKM with
2 inspection/cleaning
doors
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Batch mixing and granulating in a vertical system
Mixing Granulators are standardized systemscompliant with all GMP / WIP design require-ments.They are extremely easy to clean and require aminimum of maintenance.
A three-arm mixing impeller rotates close to the base of avertical, cylindrical mixing drum. The special form of this element and its peripheral speed are coordinated in such a way that the mixing product iscirculated as vortex and thereby accelerated horizontally and vertically. This type of product movement produces a high-speed,intensive mix, even in cases where the granular structure andshape, bulk density and surface condition of components dif-fer considerably. High quality mixing is ensured in minimumtime.If necessary, a high-speed, separately driven chopper dis-perses any lumps and promotes uniform liquid distributionand moist granulation. The granulation endpoint can bedetermined precisely.The MGT of series “S” are “Single-Pot-Machines” with heatedjackets and vacuum design for mixing, granulating and dryingin one single machine.
The concept of the Lödige Universal Container Mixer is basedon the vertical Mixing Granulator.This mixing process is characterized by an excellent traceabili-ty of each batch. The product remains in the same containerstarting with weighing of the raw material until discharge ofthe end product and is therefore protected against contami-nation. This is a vital feature particularly for the food industry (see EUregulation No. 178/2002).
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The Universal Container Mixer is aflexible system designed for small scaleproduction. The weighing, transporta-tion, feeding, mixing and dischargingtake place in one single vessel, withminimum dust. This mixer is designedfor quick and minimized cleaning,suitable for frequent change of product.
The mixing impeller can be raised up
Mixing Granulator
type MGT
with swivelling lid
Universal Container Mixer
with product container in
position
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Continuous mixing and granulating in ahorizontal system
The continuous Ploughshare®Mixers operate on the hurlingand whirling principle intro-duced to mixing technology byLödige. The mixing elements arespecifically adapted to individualapplications. This mixing systemachieves high throughputs
which can be varied dependentupon residence time, fillingdegree and product properties.
The resultant individualisation of theparticles in the mix (fluid bed) allowsthe addition of liquids and coating ofthe particles in a continuous processtoo. The continuous process is opera-ble at filling degrees between 20 and50 % without influencing the mix quali-ty. The mixing elements are adjustablein order to achieve constant backmix-ing during the residence time prior todischarge the mixed product via theoutlet.The adjustment of the size of thedischarge opening by means of a slideror a weir has a direct influence on theresidence time.Dosing fluctuations due to the plantoperation can be compensated by thissystem.
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Continuous unit for the production of salt
comprising weighing and dosing system
Continuous Mixer, type KM-D with
adjustable slider in the discharge chute
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Mixing and processing ina continuous ringlayersystem
The Lödige High Speed Continuous MixerCoriMix® CM excels with wide range ofapplications for mixing, humidifying,granulating and densifying processes. The systems produces constant productquality and provides controlled granu-lation.
The system is based on the high peripheral speedof the mixing shaft of up to 40 m/s, the resultantcentrifugal force forming an annular layer of pro-duct.The profile of the annular layer features a highmixing intensity, which is caused by the high dif-ferential speed between the rotating speciallyshaped mixing tools and the mixer wall.The product is moved through the mixing cham-ber in a plug-like flow, with the residence timebeing influenced by the degree of filling, the rota-tion speed, the geometry and adjustment of themixing tools as well as the mixing drum lengthand the volume flow rate.The system offers the possibility to divide themixing chamber into zones of different shearintensity, thus permitting system optimisationfor varying product properties. The liquid components are directly introducedinto the annular layer. This ensures a homogene-ous distribution within the mixture and avoidswetting of the mixer wall and mixing shaft.CoriMix® systems provide optimal cleaning as themixing drum is divided axially over the entiredrum. High feed rates are achieved with machines ofcompact design (e.g.Type CM 20: 20 – 200 kg/h.)
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CoriMix® CM 175 with liquid addition from the
outside
CoriMix® CM 50 with liquid addition from the
inside (hollow shaft)
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Drying in a DRUVATHERM®Vacuum Shovel Dryer
Lödige horizontal drying systems ensureprecisely reproducible, constant and reliableprocesses. All shovel dryers variations can bemanufactured in containment design.
The large product surfaces produced in a mechanicallygenerated fluid bed increase heat exchange whilst greatlyreducing processing times. Intensive and homogeneousmixing prevents the development of temperature andmoisture gradients in the product and increases at the sametime the contact frequency and thereby the heat exchangebetween product particles and heating jacket. When dryingis carried out under vacuum, the process can be run at low,product-protecting temperatures.A high temperature gradient is obtained between theproduct and the heating jacket resulting in the effectiveintroduction of heat.Mixing and drying processes can be run with high precisionensuring the reproduceability of a product formulation.
Shovel dryers up to 1200 l total volume are constructed withonly one drive-end bearing.Larger dryers are rather built with pull-out mixing shaft.
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Vacuum Shovel Dryer
type VT with one drive-end
bearing
Vacuum Shovel Dryer
with pull-out shaft
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Drying, granulating and coatingin a Fluid Bed Processor
The Lödige Fluid Bed Processor LFP provides awide range of options ensuring customizing toyour production requirements and specific pro-duct properties. The LFP is available in differentsizes suitable for batches from 0,1 to 1800 kg andfor optimal selection of the requested capacity.
The Fluid Bed Technology of the Lödige LFP achieves con-stant and reproducible product quality while ensuring gentleprocess in short process times. Processes ranging from pow-dery materials to free-flowing materials can be carried outas well as the drying of moist products. Powders, granulatesand other shapes can be coated in this system too.
During the process, heated air – in defined quantity andspeed – continuously flows through the special designedvessel bottom (Conidur® bottom) into the product vessel.The product starts to fluidize and can be dried or moistenedand granulated, depending on the application.
Tangential spray nozzles or a Wurster system are used forcoating pellets. Integrated filters hold back the powderparticles in the processor. The particles are retained in theprocess by continuous filter cleaning.
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Fluid Bed Proces-
sor type LFP 140
for production
Fluid Bed Proces-
sor type LFP 8 for
development and
small batches
Manual product handling Pneumatic product handling
Unitherm systems for homogenizing and thermal processing of paste-like andcrystallizing products
The production of high-quality products with specific propertiesrequires defined control of the units. Unitherm systems complyprecisely with these requirements.High throughputs and uniform crystal structure – combined with ahomogeneous product structure – are achieved by using a fullyautomatic evaporation system and having optimal mechanicalinfluence on the product.The process steps cooling / crystallizing / pasteurizing / sterilizing,with the possibility of introducing solid components, are carriedout in one system.
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A shaft fitted with knives rotates in ahorizontal, heated/cooled cylinder.These knives continuously scrape pro-duct from the inside of the heatexchanger surface to prevent productcaking, crystallizing and burning on theinside wall, whereby an effective heattransfer is achieved.Heat transfer is influenced by:
• Material of construction and wallthickness of the cylinder
• Product properties (e.g. viscosity)• How frequently the product is
scraped from the wall (speed ofthe knife shaft, number of rowsof knives)
• Heat transfer of the heatmedium
• Temperature difference betweenheat medium and product.
The system is designed for pressure upto 120 bar and is suitable for processingproducts with a viscosity up to1.000.000 mPas.Even products with pieces up to 20 mmcan be thermally processed.
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Statics systems Scraped surface heat exchanger
Insulating product layer on No product film or insulating
the heat exchange surface product caking
Temp. of hot product (in pipe)
Temp. difference turbulent product area
Temp. difference viscous product layer
Temp. difference on the pipe wall
Temp. difference on the media side
Temp. difference product layer
Temp. difference turbulent product area
Resistance to heat transfer
Unitherm RW 2-375/1800
Unitherm RW 4-180/1800
Unit 2 RW 2-250/2100-2PM
Temperature of cooling liquid
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Machines for research,product development andsmall scale production
Lödige laboratory systems work inaccordance with the same principle asproduction machines and ensure relia-ble scale-up to production machinesizes. Know-how concerning quality ofthe mix, product behaviour and processparameters can be scaled up withoutrestriction. Small scale production canbe therefore carried out in accordancewith the same quality criteria.
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Laboratory Ploughshare® Mixer
type L 5-10-20 with interchange-
able drums
Vertical Laboratory Mixing
Granulator type MGT-L 1 – MGT 30
Laboratory Ringlayer Mixer
type CoriMix® CM 5
Laboratory Vacuum Dryer type VT 20
Fluid Bed Processor type LFP-Mini
Laboratory Scraped Surface Heat
Exchanger type Unitherm RW2
Automated production units
Measurement and control tech-niques are developed and sup-plied according to requirement.Modular components enablethe user to extend automationin sequences, including recipeadministration and integrationinto the host controls.The operation of the unit can becarried out by means of PLC or
PC based controls. Productionand cleaning processes arefreely programmable. All curves, events and errorsare saved in a data base and arereadily printed.
A basic unit control includes a controlpanel, an electric cabinet and – if neces-sary – a pneumatic cabinet. The controlpanel is often placed next the machineand the cabinets are placed in the tech-nical area.
Electrical power part andpneumatic partThis part contains all pneumatic andelectric control elements like frequencyconverter, motor protections, PLC andPC, as well as modems for remoteservicing.
Measurement technologyThis includes measurement recordingequipment and all elements for pre-paring measured values. All relevantparameters are recorded, like forexample temperature, rotation speed,moisture, pressure, product and airquantity, etc.
Control partThe control part of each system con-sists of a monitor integrated in a suita-ble housing. Either a PLC with OperatorPanel is used or a PC-based system(Windows with visualisation system
Win CC). The PC controls usuallycontain the following modes:
• Service mode for the separatecontrol of all functions
• Manual mode for preparatorytasks
• Learn mode for creation of recipes
• Recipe mode with fully automaticexecution of a recipe created inlearn mode ore stored.
The controls are designed for a recipeadministration up to 200 recipes andprotocols.
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Lödige Pilot Plant
The Lödige Pilot Plant is equipped with the mostmodern machines for:
• Mixing• Wet granulating• Drying• Cooling / Heating• Coating
at production conditions and in compliance withhygienic conditions.
Laboratory and Pilot PlantThe Lödige Pilot Plant of more than 400 m2 provides trialcapacity for more than 30 machines including a laboratoryfor physical analysis. A separate area is dedicated to foodtrials. The pilot machines are designed for the production of
small batch sizes under production conditions. All machinesare suitable for WIP / CIP.
Ploughshare® MixerFM 130Working volume 90 l
• Mixing• Granulating• Moistening• Adding lecithin• Adding fat• … and more
Mixing GranulatorMGT 125Working volume 90 l
• Mixing• Granulating• Wet granulating• Drying
Laboratory RinglayerMixer CoriMix® CM 5Throughput up to 240 l/h
• Mixing• Granulating• Densifying
Fluid Bed ProcessorLFP 70Working volume up to 140 l
• Drying• Granulating• Coating
LÖDIGE – ALWAYS THE RIGHT MIX
Gebrüder LödigeMaschinenbau GmbH
P.O.Box 2050D-33050 Paderborn
Elsener Straße 7-9D-33102 Paderborn
Phone: +49.5251.309 0Fax: +49.5251.309 123E-Mail: [email protected]
ServiceSales:Phone: +49.5251.309 147
After Sales:Phone: +49.5251.309 222
www.loedige.deB
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