Pilot Scale Blender

Consistent results between pilot and production blending are achieved by keeping the mixing principles, equipment design, and key process parameters aligned as you scale up. Matcon blending equipment supports this by using the same design principles in its Pilot Scale Blender and production-scale IBC systems, making it easier to transfer process parameters from development to large-scale manufacture.

Factors such as rotation speed, blend time, fill level, and tip speed must be controlled so the mixing forces remain relative across different IBC sizes. NIR monitoring also helps confirm when homogeneity is reached at both pilot and production scale, reducing guesswork and preventing over-mixing.

Using an IBC blender at pilot scale gives manufacturers a practical way to develop, test and refine powder recipes with the same core blending principles used in production.

The Matcon pilot blender can handle low-volume, high-value batches efficiently while supporting proof of concept, recipe development and future scale-up. Because the IBC itself is the blending vessel, the process stays contained, batch changeovers are fast, and cleaning downtime is reduced, which helps improve productivity in R&D and pilot environments.

Optimising the fill level in a pilot scale IBC blender involves matching the batch volume to the powder’s flow behaviour and the mixing action needed to achieve a uniform blend. Matcon blending equipment is designed to handle varied batch sizes, and tumble blending is well suited to lower fill levels, which gives manufacturers more flexibility than many other blender types.

The ideal fill level is established through trials using the actual powder, while also adjusting rotation speed and blend time to suit whether the material is free-flowing, friable or more cohesive. NIR can then be used to confirm when homogeneity is reached, helping avoid under-filling, over-processing or unnecessary blend time.