Twin Shaft Mixer Batching Plant

What Is A Twin Shaft Mixer Batching Plant?

A twin shaft mixer batching plant refers to a concrete batching plant that is equipped with a twin horizontal shaft mixer. This is a common structure of modern concrete batching plant equipment.

Twin shaft mixer plants are widely used in various infrastructure construction projects these days as it ensures uniform mixing of concrete, high production output, with a good quality mix.

A steady and reliable central mixer is the heart of the concrete batching plant and is the most crucial component of the plant. The performance of the mixer reflects the quality of concrete produced; therefore, the need for reliable and high-quality mixing equipment is essential. 

According to the working method of mixers, central mixers are classified into two types:

  • Continuous type
  • Forced batch type

The compulsory concrete mixers are further divided into two types:

  • Twin shaft concrete mixer
  • Single shaft concrete mixer

LUTON offers an extensive range of high-performance concrete mixers of different types and different capacities that comply with all the requirements for concrete mixing. Some of the mixers we provide are: 

  • Single shaft
  • Twin shaft
  • Planetary or Pan

Related: Concrete Batching Plant

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What Is A Twin Shaft Mixer?

The objective of a concrete mixer is to achieve the desired homogeneity and workability of the produced concrete mix. Mixing is the process of distributing and blending the input materials which are of different characteristics and different quantities as evenly as possible, resulting in a homogeneous mixture.

Compared with a single shaft concrete mixer with only one shaft, a twin shaft concrete mixer installs two shafts horizontally in the mixing drum.

The twin shaft mixer consists of two counter-rotating shafts. Blades are geometrically arranged on each shaft to follow the pattern of an interrupted spiral. This pattern ensures that the materials are mixed in a screw-like pattern both along the mixing shafts and in the opposite direction on each shaft.

The mixing blades are geometrically positioned on the ends of each shaft in a counter direction. In this way, they can transport the mixture on the opposite shaft and the materials are constantly rotating.

At the same time, the materials also rotate in the way of inward-turning spiral way. This results in the movement of the materials in an intensive three-dimensional movement.

The principal advantages of the twin shaft mixing technology are –

  • Larger mixing technology
  • Rapid discharge
  • Mobility – as it can be moved from one place and installed again

Which Type Of Concrete Mixer Is Used In Batching Plants?

According to the structure, concrete mixing plant equipment is divided into two main shaft planetary mixers –

  • Single shaft mixer
  • Twin shaft mixer

Among them, the twin shaft horizontal compulsory mixer is the most popular type. Most of the concrete plant enterprises use the twin shaft concrete mixer as their choice of mixing machine.

The main mixer of the concrete mixing plant is divided into – forced mixing and self-falling mixing, according to its mixing method. Currently, compulsory type mixer is the most widely used in mixing plants both at home and abroad.

Concrete mixing plant equipment can mix a variety of concretes such as – mobile, semi-dry, and dry hard. The self-falling mixer mainly mixes active concrete. At present, this type of concrete is rarely used in mixing plants.

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Three Types Of Mixers Are Widely Used In Concrete Batching Plants:

1. Twin-shaft Concrete Mixers

The twin shaft mixer is a truly impressive mixer. The mixing time offered by the twin shaft mixer is similar to the planetary mixer and durability similar to the horizontal shaft, with a very dynamic mixing action.

Modern twin shaft mixer batching plant is equipped with mixing blades on both mixing shafts that are geometrically arranged so they follow the pattern of an interrupted 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 same time, the material rotating process also takes place in an inward-turning spiral. This results in an intensive three-dimensional movement of material.

2. Single shaft concrete mixer

This type of mixer comprises a single stirring shaft, stirring blade, mixing barrel, and discharge door that is arranged in the mixing barrel. The mixing barrel is in the shape of a horizontal cylinder, which makes it easy to operate and handle the machine.

In the production of bricks and tiles, single shaft mixers are one of the most important mechanical machines. Single shaft concrete mixers are lower in production efficiency compared with twin shaft concrete mixers.

3. Planetary concrete mixers

Planetary mixers are designed to achieve high mixing performance even for the most challenging applications. It is mostly preferred for producing precast concrete products such as –

  • Low or zero slump precast concrete
  • Fiber-reinforced concrete
  • Self-compacting concrete, etc

Planetary mixers deliver the highest homogeneous mixture even in a shorter mixing time. In this mixer, as the mixer turret is rotating around the mixer center point, and at the same time, the mixing stars connected to the turret are also revolving. This allows each mixing arm to cover the whole mixer floor.

They have a reasonable mixing speed and complex motion trajectory design, which makes the mixing of different materials more forceful, more uniform, and achieve higher productivity.

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What Is The Difference Between The Planetary Mixer And The Twin Shaft Mixer In The Concrete Mixing Plant?

There are many mixing options available to mix concrete, and each offers different features and benefits. Understanding the various mixing options to match the right technology with your needs early in the selection process saves time, saves money, safeguards operational reliability, and ensures quality results.

The mixing process is the heart of the concrete production process and one of the major concerns of the manufacturers.

1. Comparison between mixing devices

The twin shaft horizontal mixers of twin shaft mixer batching plant are highly regarded for their ability to handle low volume to very high volume of concrete. Despite its relatively complex structural design, the twin shaft mixers are capable of producing large volumes of concrete with a low operational cost.

Because of the relatively straightforward design of the twin shaft mixers, it is easy to customize its configurations to accommodate specific recipe applications, producing optimized mixing outcomes even for highly-specific production requirements.

Many twin-shaft mixers are also designed keeping in mind the consistent heavy usage. They often utilize hydro-dynamic engineering and integrated oil cooling systems within the gearbox to keep the mixer running at optimal temperatures, which helps in reducing wear and extending the longevity of the equipment.

This, besides the relatively low up-front ownership cost of the equipment, makes twin shaft mixers the ideal choice for precasters who are focused on high-volume production for major precast projects.

On the other hand, the mixing blade of the planetary mixers adopts a parallelogram design structure. The name of planetary mixer comes from the mixing blades running like planets around the central point. The mixing arm is designed in a clamp-type structure to improve the utilization rate and efficiency of the blade.

2. Mixing effect comparison

In a twin shaft concrete mixer, the two mixing circuits overlap each other in the middle, which further increases the intensity of the relative motion. Due to this motion, a high turbulent zone is created in the middle of the mixing trough and intensifies the mixing process.

It is possible to accomplish 95.6% homogeneity with a mixing time of only 30 seconds. This homogeneity can be achieved even with a relatively low mixing speed of the shafts, between 20 to 30 rounds per minute.

The benefit of the low mixing speed is that it reduces energy consumption, reduces wear, and avoids stress on the particles to be mixed.

With planetary mixing movement, you can achieve more uniform mixing of the materials, high mixing efficiency, and good mixing quality. It is especially suitable for the precast concrete industry with higher requirements for homogenization as it can meet the quality requirements.

For example – cement pipes, block bricks, wall panels, PC prefabricated parts, subway segments, etc.

The requirements of precast concrete with high mixing efficiency, good mixing quality, and meeting the requirements of product homogeneity can be met by the vertical axis planetary concrete mixers.

Both the twin shaft mixer and the planetary mixer have their own features and advantages. They both play an important and irreplaceable role in the construction equipment manufacturing industry due to their unique features.

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The Difference Between Twin Shaft Concrete Mixer And Single Shaft Concrete Mixer

The compulsory concrete mixing device is divided into two forms: twin shaft concrete mixer and single shaft concrete mixer. We will look into the difference between the two types of mixers.

1. The difference in production efficiency

The twin shaft concrete mixers models comes in the JS series, ranging from JS500 to JS4000, with the corresponding production capacity from 0.5m3/h to 4m3/h each time.

On the other hand, single shaft concrete mixers come in two types, JDC350 and JDC500, with the corresponding production capacity of only 0.35m3/h and 0.5m3/h each time.

2. The difference in application scale

The scope of application of the mixer is determined by the production efficiency of the concrete mixing.

For large, medium, and small construction projects the twin shaft concrete mixer is the most suitable choice as it can be used either as a separate machine or as the mixing host of a concrete mixing plant. Whereas, for small and medium-sized construction projects the single shaft mixer is more suitable.

3. The difference in power drive system

The power drive system used in the single shaft mixer is a chain structure, while the double shaft concrete mixer adopts a sliding gear and a V-belt structure power drive system.

The structure of the double shaft mixer reduces the noise during operation and the sliding gear provides a protective function, which makes it relatively safer and more convenient.

4. The Structural difference

In the single shaft concrete mixer, there is only one mixing shaft in the mixing drum and the mixing blades are distributed on the mixing shaft.

In the double shaft concrete mixer, there are two mixing shafts of the same size in the mixing barrel, and the mixing blades are geometrically arranged and evenly distributed on each of the mixing shafts.

Therefore, it is obvious that the mixing effects of both the mixers are different, while the mixing effect of the twin shaft mixer is better than the single shaft mixer.

The above are the differences between the twin shaft concrete mixer and the single shaft concrete mixers. 

LUTON manufactures all models of twin shaft concrete mixers and single shaft concrete mixers. Contact us for more details.

Related: Mini Concrete Batching Plant 

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Why Are Twin Shaft Concrete Mixers Used In Concrete Batching Plants?

Today, the twin shaft forced concrete mixer is the preferred mixing machine for most ready-mix concrete plants. The single shaft forced concrete mixer is now rarely used. The preference for a twin shaft forced concrete mixer is due to its superior aspects of mixing principle, wear resistance, and performance advantages.

Let’s take a look at the main reasons for choosing the twin shaft forced concrete mixer as the preferred mixing machine over the single shaft forced concrete mixer.

1. The mixing principle

The mixing of the twin shaft mixer batching plant occurs in two directions – the radial direction and the axial direction. The main agitation zone of the equipment is located in the circumferential direction of the agitating body, which allows the agitation space to be fully utilized.

Since the aggregate, cement, and water are in the low-speed circumference of the agitating blade, it can achieve a uniform mixing mode in a short period of time and can achieve a good mixing effect.

2. Abrasion resistance

The mixing principle of the twin shaft mixer batching plant ensures that during the ready-mix concrete batching plant production process, most of the concrete is piled up between the two mixing shafts.

This decreases the wear between the mixing arm and the blade, and the bottom lining. The liners of the double shaft forced concrete mixers are either made of ordinary steel or wear-resistant cast iron.

3. Stirring performance

The twin shaft forced concrete mixer is equipped with a hydrostatic starter and has a high mixing efficiency. The noise from the stirring process is low, and the stirred material is directly placed at the discharge port after the mixing is complete. The discharging time is also short.

For this reason, ready mix concrete plants prefer to use a twin shaft forced concrete mixer as a mixing host instead of the single shaft forced concrete mixer.

Advantages Of Twin Shaft Mixer Batching Plant

Among the various types of concrete mixers such as the rotary mixer, the planetary mixer, and the twin-shaft mixer, the most popular is the twin-shaft mixer.

Here we will take a look at the advantages of a twin shaft mixer batching plant.

  1. It is suitable for mixing various powdery materials such as wet fly ash, cement, slag, gravel, etc.
  2. It has strong mixing capability, uniform mixing quality, and high efficiency. It has a good mixing effect for various proportions of concrete such as dry hard, semi-dry hard, and plastic.
  3. Selection for the lubricating system and the main shaft drive system is done from an imported set of original parts. Depending on demand, the hydraulic door-opening system can adjust the degree of opening of the discharge door.
  4. To avoid the agglomeration of cement on the mixing shaft of the twin shaft mixers, an anti-adhesion technology is used for the mixing shaft. The seal on the shaft end seal has a multiple sealing structure to prevent mortar from leaking and ensuring that the entire mixing system operates continuously.
  5. The cleaning system of the twin shaft concrete mixer uses a high-pressure water pump with automatic and manual controls. The water outlets are located directly above the main mixing shafts to reduce dust pollution and eliminate the agglomeration of cement.
  6. All systems, whether feeding, discharging, or water supply, are highly automated. The motor control parts are safely located in the electric box, making it safe, reliable, easy to operate, and easy to maintain.

Above are just some reasons why the twin shaft concrete mixers are preferred by many customers over the single shaft concrete mixers.

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Which Type Of Concrete Batching Plant Uses The Twin Shaft Mixer?

Because of the outstanding performance of the twin shaft concrete mixer, it is extensively used in all kinds of concrete batching plants and is the choice of mixer for most construction equipment manufacturers.

Twin shaft mixers are installed in mobile concrete batching plants, stationary concrete batching plants, dry concrete mixing plants, wet concrete mixing plants, etc. It plays a crucial role in the construction industry in producing various concrete materials.

LUTON’s Twin Shaft Mixer Batching Plant

The Luton Group is one of the most famous twin shaft mixers batching plant manufacturers in the construction industry globally.

Some of the products manufactured by the Luton Group are – single shaft mixer batching plant, twin shaft mixer batching plant, planetary mixer batching plant, pan mixer batching plant, drum mixer batching plant, horizontal shaft mixer batching plant, cone mixer batching plant, and so on.

Luton’s products are popular not only for their perfect control character, accurate proportioning, and remarkable products characteristics but also the development trend of its construction equipment.

The future of the Luton Group seems bright as it is expected to lead a dramatic change in the concrete manufacturing industry with the quality of products and new development trends in the construction industry

Luton Group, founded in 1999, specializes in the research and development and manufacturing of multiple materials and batching and mixing plants including – stabilized soil batching plant, concrete mixing station, asphalt concrete batching and mixing plant, and precast concrete assembly production line, etc.

Some of Luton’s most popular products include – stabilized precast concrete batch plant, belt conveyor, aggregate mixer, concrete pump, self-loading mixer, dry mix motor plant, crushing plant, soil batching station, asphalt concrete mixing plant, etc.

If you are looking for a suitable twin shaft mixer batching plant to meet your concrete mixing requirements, feel free to contact us. Our highly efficient team will help you choose the right mixing plant based on your requirements.

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