How is blend uniformity measured and validated?
Blend times can be further optimised by integrating Near Infrared (NIR) technology, which continuously monitors blend homogeneity in real time. This means you see exactly when the blend reaches the required uniformity, so you can stop the cycle at the optimum point. As a result, blend times are reduced, energy use is minimised and the risk of over‑mixing is removed – all without the need for invasive manual sampling, lab delays or opening the IBC. This delivers a faster, more controlled and fully documented blending process.
Batch volume flexibility is achievable with IBCs ranging from 500L to 3,300L and the ability to fill IBCs at 20% of capacity.
What shear levels occur during blending and how do they affect sensitive ingredients?
Matcon blending equipment typically operates at low rotational speeds of around 5 to 25 rpm, creating a gentle mixing action that is well-suited to friable materials and ingredients that are prone to particle breakage. This lower shear helps protect sensitive ingredients by reducing attrition, preserving particle structure and supporting blend uniformity without overworking the product.
Where a recipe includes cohesive powders, liquid additions or agglomerates, the Matcon IBC Blender can be fitted with an Intensifier that adds controlled high shear using an 8‑bladed shaft running from 500 to 3000 rpm. This means Matcon blending equipment can be matched to the needs of the recipe, using gentle shear for delicate products and targeted high shear only where faster dispersion, lump removal or liquid incorporation is needed.
