Readco’s Continuous Processor (CP) has been serving a large range of industries for over 60 years. This equipment can mix multiple dry materials with multiple liquids continuously, ensuring a homogenous mix at the end of the mixing cycle. Its durable design allows it to handle high-shear and high-viscosity materials with ease. It doesn’t stop there — the Continuous Processor can also be used for low-viscosity applications and gentle kneading.

Trust Readco Kurimoto LLC to deliver quality continuous mixing equipment that meets the most stringent processing needs.

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What Is a Continuous Mixer?

Continuous mixing is a process that creates a consistent mixture of solid and liquid materials by precisely metering the raw materials as they enter a mixing chamber and then subjecting them to the required amount of shear intensity. Individual raw materials are constantly fed into the processor, mixed, and then homogenous material is discharged.  This process is often used in industrial settings to streamline and automate production on a single, uninterrupted line.

Continuous mixing eliminates irregularities often associated with batch-to-batch variability. The raw materials are added at a consistent ratio to ensure optimal product quality while maintaining the maximum degree of throughput. Additionally, indirect heating or cooling is available as required to obtain the product characteristics and/or specifications.

The entirely enclosed design of the mixing chamber is helpful in two ways, depending on the application. For starters, it prevents external pollutants from contaminating the product being blended. Second, it aids in the reduction of unwanted emissions in production.

10 Reasons Continuous Processing Is Better Than Batch Mixing

  1. More consistent product. Using loss-in-weight feeders and pumps eliminates batch-to-batch variation associated with manual loading and increases finished product consistency.
  2. Safety. Fully enclosed continuous processors don’t require opening to add ingredients, mitigating the risk of accidents near moving components.
  3. Lower labor costs. Continuous processing eliminates many of the manual loading and handling operations involved with batch mixing, resulting in higher output per labor hour.
  4. Less floor space. By eliminating surplus equipment and reducing material storage requirements, a continuous processing system needs less space than a conventional batch processing operation of the same or greater capacity.
  5. Shorter cycle times/faster throughput. A continuous processing system will compress the total production cycle time by removing the steps and delays inherent to batch mixing. The Continuous Processor is scalable and can provide high throughput.
  6. Reduced environmental impact. Dust and other airborne contaminants are kept inside a continuous processor, unlike batch processing systems that can contaminate a work area.
  7. Less waste. Since continuous processors only work on a small quantity of material at a time, the material waste is greatly reduced should a rare processing error occur.
  8. Fewer steps. A continuous processor performs multiple operations in a single unit, such as mixing, crystallizing, evaporating, and reacting.
  9. Less equipment. Combining processes in a continuous system eliminates unnecessary equipment, simplifying the total system and reducing overall costs. It also provides better integration with automated machinery.
  10. Less work in progress. A continuous processing system facilitates just-in-time manufacturing by minimizing costs associated with material handling and inventory. Lot tracing can also be provided with continuous processing.

Why Choose Readco Kurimoto's Continuous Processor?

The processor shifts production from large volume, low shear batch mixing to a smaller volume chamber with variable shear intensity. This helps to improve efficiency and effectiveness while maintaining a high level of quality. Additionally, the processor can produce material at varying throughputs without compromising the product’s integrity. The Continuous Processor is particularly effective for high viscosity applications — one million centipoise is considered light duty in this machine!

In general, the Continuous Processor allows for a more consistent mix, better quality control, and increased production rate. At the same time, it consumes less energy, requires less floorspace, creates less waste, and reduces the personnel needed to accomplish the required production needs. With such a durable design, the Continuous Processor also offers high performance for longer periods, reducing operational downtime during your production processes.

Industries That Benefit From Our Continuous Processor

Readco Kurimoto LLC serves a variety of industries, helping manufacturers achieve quality production methods while maintaining compliance with their respective industry standards. Explore some of the applications of our continuous processor machines:

  • Food and confectionery: Our continuous mixing equipment can be used to process various food items, including cheese, chocolate, chewing gum, nutrition bars, and peanut butter.
  • Chemical: The Continuous Processor is ideal for chemical processes such as crystallization, catalysts, polymerization, composites, and pesticide and herbicide production.
  • Pet food and care: Readco’s equipment can help you comply with the Federal Food, Drug, and Cosmetic Act (FD&C Act) to produce animal food with safe and sanitary mixing methods.
  • Pharmaceutical and nutraceutical: The pharmaceutical and nutraceutical industries have strict standards to adhere to, including FDA, ASME, ASTM, and USDA regulations, and our mixing equipment can help you stay compliant.
  • Building materials: Our industrial continuous mixers can produce high-quality products for the building industry, including roof coatings, caulk, synthetic stone and brick, gypsum board, and loaded polyurethane foam.
  • Sealants and adhesives: Readco’s Continuous Processor can handle the high viscosity of sealants and adhesives with ease, providing excellent dispersion and precise shear control.
  • Battery and energy: Battery materials for lithium ion batteries, solid state batteries, and lead acid batteries can be performed without metal entrainment using alternative materials in the mixing chamber.

 

Other industrial applications of our continuous mixing equipment include:

  • Pigment or die encapsulation
  • Flavor encapsulation
  • Brake lining
  • Molding compounds
  • Ceramics
  • Powdered metals
  • Plastics
  • Crystalizations
  • Pharmacuticals

The Readco Continuous Processor Is Used in Processes Involving

  • Mixing
  • Reacting
  • Compounding
  • Kneading
  • Shearing
  • Encapsulating

 

Downloads:

Continuous Processor Brochure (PDF)
RK1 Lab Size Continuous Processor (PDF)

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Connect With Readco Kurimoto LLC for More Information on Our Continuous Processor

Consider utilizing a continuous mixer if you need a dependable method of mixing one or more powders with one or more liquids, with enhanced quality and increased throughput. Using this versatile piece of machinery will assist you in producing a more uniform end product while decreasing material waste and enhancing product quality.

If you need a supplier of high-quality continuous mixers, count on Readco Kurimoto LLC. Our Continuous Processor is the perfect choice for you. Contact us today to learn more about the continuous processor and how it can benefit your business.

Continuous Processor Videos

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