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John R Boone has supplied a horizontal Delta Blade mixer to cementitious product manufacturer F Ball, to provide high-speed mixing with low power consumption.

The process comprises weigh hoppers that feed the Boone mixer, discharging via a bomb door to an under hopper that feeds a packaging and palletisation line beneath; a process that requires good control and a short mixing cycle to achieve the total batch time of less than two minutes for a 2 tonne mix.

F Ball, a producer of flooring adhesives, levelling products and grouts, installed its first mixer from Boone in the 1990s and so began a relationship that has lead to its latest purchase of a Boone horizontal Delta Blade mixer for high-speed production in its new powder mixing plant.

The new plant is designed to produce up to 30 tonnes of blended material per hour.

At any time there may be as many as six batches within the process: one in each of the two weigh hoppers, containing the bulk materials (sand, cement) together with additives such as flow promoters and set retarders; a further batch in the mixer, mixed material in the underhopper and two further batches within the packing and palletisation line.

A key objective for the plant was that it would have as small an environmental impact as possible, and a vital part of that objective was to minimise the energy used, for example by the use of gravity fed rather than mechanically conveyed processes and making every element of the process as energy efficient as it could be.

Boone’s Delta Blade is a plough-type mixer, with a precisely engineered blade shape that uses the principles of high agitator speeds to radially and axially accelerate the product formulation in a short criss-cross pattern within the mixer shell.

According to Boone, the machine produces higher levels of shear with lower power consumption than more conventional mixers, meaning that batches are mixed quickly, thoroughly and homogenously using minimum energy, reducing its carbon footprint.

Since its installation more than two years ago, a further benefit has been noted – due to its efficient mixing action and despite the abrasive nature of the materials in use, no wear parts have needed replacing.

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