In 2022, Edwards Agricultural Supplies wanted to scale up production of their seaweed fertiliser product quickly and easily. This was due to a skyrocketing in demand for their natural fertiliser. They knew that they needed to invest in an industrial mixer but were unsure where to start the search.
Based in Shropshire in the UK, they had previous knowledge of the reputation of KEENAN as reliable agri mixers that last for years. What they did not know was that for over 40 years KEENAN also supplied an industrial mixer or ProMix+ for mixing large scale industrial products. These mixers are also sturdy, dependable and have low running costs. They are also surprisingly easy to maintain for a trouble-free working life.
Seaweed fertiliser is a chemical free alternative to traditional fertilisers. It is becoming more popular due to environmental concerns. It is a rich source of nourishment for the land.
The sourcing of seaweed is a highly regulated environment. The seaweed is then blended with additional ingredients to produce a consistent mix. They required an industrial mixer that had the technology to produce consistent batches. They needed to regulate the weight of each ingredient and the loading order of materials. This allowed the resulting mix to be consistent no matter who was operating the industrial mixer.
Helping with the decision process
Investing in a bespoke industrial mixer is a big decision. Most projects are one-off with their own individual requirements. KEENAN can tailor a machine to any industrial application.
“We needed help in deciding on what we required and also on what we did not need. We knew the secret behind our blend and we wanted a mixer that would recreate that special receipe repeatedly. We would not compromise on mix quality. KEENAN engineers came on board to help us custom build a mixer to suit our individual needs,” says Dave Edwards.
KEENAN appointed, Michael Conroy to help design a mixer within the 6-month time frame and budget allocation.
“The most important feature the machine needed was to be completely watertight. The machine was going to mix 10,000 litres a day of a 90% liquid mix, so a fully sealed mixing machine was paramount,” says Michael Conroy, engineer and key account contact at KEENAN.
“The controller fitted to the front of the machine, clearly displays on the 8” screen, the order and weight of ingredients. This screen can be replicated on a tablet or device. It makes accurate loading easy, even if we only need to do a small batch,” says Dave Edwards.
The benefits of moving away from labour intensive methods
Moving from labour intensive manual mixing to industrial mixing has many benefits. Only one person was now required to run the mixing process. Five times the amount of batches could now be produced in the same time period. Running costs were extremely low with a saving on fuel and power requirements.
“As soon as the new mixer was installed and commissioned, the results were astonishing. Instead of mixing 2,000 litres a day, we could now mix 10,000. This really was mixing on an industrial scale,” adds Dave.
Technical components – building a unique mixer
For this project, a new rotor and shaft seal had to be used. KEENAN sourced a solution through one of their trusted suppliers, SKF Seals Division. The engineers adapted the product and created a unique solution for Edwards Agri’s project.
The body of the mixer also had to be made watertight by replacing the variable feed control door with a fixed fully sealed panel. The end parts of the body were custom built to take the new custom rotor shaft seals. The paddles which give the unique mix were fitted with the latest 6˚ paddle design.
A hinged hydraulic cover/lid was fitted to allow for integration of powdered raw material. As the building in which the mixer was housed was of limited ceiling height, a height restrictor was fitted to prevent damage. Three separate 150 mm diameter fill points were provided on the fixed section of the cover for loading liquid materials.
For emptying four hydraulic gate valves were fitted to the underside of the machine. These connected to pipework for the next stage in the production process. All hydraulic functions are centrally operated for ease of use.
Currently, the machine is powered by a PTO driven by a tractor. It can be switched to an electric motor at any stage in the future. The customer can choose either method to power their industrial mixer.
The chassis of the mixer was designed for static use (once in position)
Machine fabrication: Watertight front panel
A bespoke lid was designed and fitted to the industrial mixer