20 TechnicalExclusive
June 2012
The Benefits of
Twin-Shaft Mixing
By Stuart Bentley, BHS-Sonthofen
E
Everyone has a general idea what mixing means, but
describing the mixing process is not so simple. The
objective of any mixing process is to distribute and
blend the materials with different characteristics, dif-
ferent quantities as evenly as possible resulting in a
homogenous mixture.
Introducing proportional movement with the op-
timal intensity into the materials achieves effective
homogeneous mixing results. A simple one-directional
movement with inadequate acceleration of the materi-
als would obviously not achieve the same mixing re-
sults. This would be more like stirring than mixing.
The amount of relative movement that is intro-
duced is a decisive factor. Circumstances for success-
ful mixing involve distribution of all materials, and
achieving the highest probability that all recipe parti-
BHS twin-shaft batch mixers (DKX
models) are available in various
cles located in a specific position at the beginning can
be found at any random location in the mixing cham-
capacities from 48 to 700 cu yd/hr.
ber at the end of the process. This is the only way to
ensure that a consistent result is achieved every time
mixing is repeated.
Three-Part Cycle
The mixing cycle occurs
in three phases: charg-
ing the mixer, the
mixing process,
and dis-
charging.
The
sequence
in which the
individual materials to
be mixed are filled into the
mixer can have a huge impact on
the efficiency of the mixing cycle. The
mixing cycle overlaps the charging process and
the discharge cycle follows the mixing cycle. To
achieve optimum results, effective discharging meth-
ods should be taken into consideration to avoid risks
of segregation. Costs for energy and wear should be
as low as possible. Finally, it is important that the
mixing cycle takes place as quickly as possible.
In concrete production, selecting the best mixing
technology is crucial for both the quality of the con-
crete produced and the efficiency of the production
process. The optimum mixing system is one that
Twin-shaft mixers are equipped with
mixing blades on both mixing shafts
that are arranged so they follow the
pattern of an interrupted spiral.
rapidly disperses all ingredients evenly throughout
the mixing trough and completely surrounds all the
aggregate particles with the slurry cement particles.
Most concrete formulas also involve small quantities of
chemical additives which also must be evenly distrib-
uted effectively. The time required per mixing cycle as
well as the costs of energy, wear, and maintenance will
determine the economy of the concrete production.
Twin-Shaft Technology
The twin-shaft batch mixer has become a preferred
technology for concrete production in many coun-
tries. The twin-shaft mixer for concrete produc-
tion was invented at the end of the 19th century
and registered for patent by BHS-Sonthofen in
Germany. The initial reasoning was to replace
manual mixing with a shovel in which a line of
aggregate, cement, and water positioned on the
ground, was repeatedly shoveled from right to left.
This concept was later abandoned and, over a num-
ber of development stages, was replaced by today’s
highly dynamic movement process.
Today’s twin-shaft mixers are equipped with mix-
ing blades on both mixing shafts that are geometri-
cally arranged so they follow the pattern of an inter-
rupted spiral. This motions the materials to be mixed
in a screw-like pattern both along the mixing shafts
and on each shaft in opposite directions. On the
ends of both shafts the mixing blades are positioned
in a counter direction so they can transport the mix
onto the opposing shaft. This way, the materials are
constantly rotating around the mixing trough. At the

Figure 1: Materials mixed in a twin-shaft batch mixer undergo intensive three-dimen-
sional movements.
same time, the material rotating
process also takes place in an in-
ward turning spiral. This results
in an intensive three-dimensional
movement of material.
Intense Mixing
The two mixing circuits (see fig-
ures 1&2) overlap in the middle
to further increase the intensity
of the relative motion. This cre-
ates a high turbulent zone in the
middle of the mixing trough and
intensifies the mixing process. It
is possible to achieve 95% homo-
geneity with only 30 seconds of
mixing time (see figure 3). This
can be achieved with a relatively
low mixing speed of the shafts,
between 20 to 30 rpm. This low
mixing speed reduces energy
consumption, reduces wear, and
avoids stress on the particles to
be mixed.
Figure 2: The overlap of the two mixing circuits creates an intense turbulent mixing zone.
Cement is the most important
and most costly raw material in
concrete production, typically
10% of the mix design and 90% of
the cost. Only an excellent mixer
can guarantee the most efficient
use of this high-value raw mate-
rial. Various tests have shown
that a twin-shaft batch mixer
can produce concrete of a given
strength with less cement then
other mixing methods and types.
The twin-shaft mixer discharg-
ing process is accomplished along
the center of the mixer between
both mixing shafts using a rotary
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June 2012
gate that is the length of the mix-
ing trough. A major portion of the
mixed materials are discharged
through the opening created by
gravity. The remainder of the
materials is forced out by the
broad mixing blades with almost
no residue remaining. The risk of
mix segregation is therefore ex-
tremely low. The rotary discharge
gate system is also equipped with
adjustable opening positions that
increase or decrease the outflow
during discharge. Additionally,
the rotary gate system is
equipped with internal adjustable
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June 2012

ledges for sealing. This design operational requirements. For

also allows the door to be closed
without the risk of particles pre-
venting the door from closing.
The twin-shaft batch mixer is
also characterized by its relatively
high filling level compared to
other concrete mixing systems.
The benefit is that the mixing
trough can be built much more
example, ice for cooling the con-
crete and/or steam for heating is
possible. A twin-shaft mixer can
also accommodate small batches,
expecting the same mixing per-
formance and results. Concrete
formulas with course aggregate
sizes up to 7 in. can be processed.
Scientific studies have confirmed

The twin-shaft mixer is also an important

solution for unique operational requirements.
For example, ice for cooling the concrete
and/or steam for heating is possible.
Figure 3: 95% homogenous mixture in 30-sec mixing time frame

compactly which simplifies ret-
rofits and replacements of other
types of mixers. Further, due to
the smaller mixing area, the twin-
shaft has less wear than other
mixing systems which allow only
limited filling levels.
A comparison with other mixing
systems also shows advantages
toward drive power and reduced
energy consumption. Due to the
rapid mixing time, the twin-shaft
utilizes less power per batch.
Different Applications
The twin-shaft mixer is also
an important solution for unique
that self-consolidating concrete
(SCC) can also be processed
within the same 30-sec mix time
(figure 3).
The principal advantages of
the twin-shaft mixing technol-
ogy become even more evident
with larger mixing batch size and
larger machine capacity. This
places different demands on the
mixing machine. The twin-shaft
batch mixer is guaranteed to
achieve the same mixing results
within the same mixing time, re-
gardless of the size of the mixer.
This results from the precise up-
size design of the mixing tools.
In addition, the operating costs
are reduced per cubic yard as
the mixer becomes larger. The
numerous advantages of the twin-
shaft mixer demonstrate that it is
ideal for producing standard con-
crete recipes, as well as special
mixes for RCC, SCC, and UHPC.
In summary, for concrete pro-
duction that requires uniform ho-
www.PowderBulkSolids.com
mogeneous consistency at rapid
mixing rates with reduced opera-
tional costs, the twin-shaft mixer
is an ideal solution.
Stuart Bentley is mixing division
manager for the U.S. Division of
BHS-Sonthofen (Charlotte, NC). For
more information, call 704-814-7671
or visit www.bhs-sonthofen.com.
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Industry Insight
Batch processing of powders presents
unique challenges especially under cir-
cumstances where containment is critical.
Read more on page 6

Benefits of Twin-Shaft Mixing

The objective of any mixing process is
to distribute and blend the materials with
different characteristics, different quanti-
ties as evenly as possible.
Read more on page 20

T h e S o u r c e f o r D r y P r o c e s s i n g a n d B u l k H a n d l i n g Te c h n o l o g y Valves, Gates, & Airlocks

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