A high energetic materials (explosives/propellants) manufacturer was having some problems/concerns with their existing mechanical mixing equipment.  Though it could be operated remotely to theoretically protect workers, there was still a risk of ignition, which would be catastrophic.  There were also significant risks associated with the cleaning or the potential for improper cleaning/material transfer.  Furthermore, the mixer entrained air in the material, causing inconsistent and reduced performance of the material.  After evaluating the Hauschild SpeedMixer®, the decision to upgrade their mixing technology was easy.  The Hauschild SpeedMixer® could be operated remotely, just like their previous system and it offered some significant safety improvements.  The ability to mix in a closed, single use, conductive container with no blades virtually eliminated the risk of ignition and all the dangers that were previously associated with cleaning and material transfer.  They also noticed that the Hauschild equipment removed any entrained air and that their material properties were improved and more repeatable. 

Title: Enhancing Safety and Efficiency in High-Energy Materials Manufacturing with Hauschild SpeedMixer®

Background:
This case study explores the challenges faced by a high energetic materials manufacturer in their existing mechanical mixing equipment and how the implementation of Hauschild SpeedMixer® resolved their concerns. The manufacturer sought to improve safety, eliminate risks associated with ignition, ensure proper cleaning and material transfer, and enhance material performance consistency.

The high energetic materials manufacturer specializes in the production of explosives and propellants, where stringent safety protocols are paramount. Their existing mechanical mixing equipment, although remotely operable, posed significant risks of ignition and suboptimal material performance due to entrained air. Furthermore, the cleaning process and material transfer introduced potential hazards.

Challenges faced:
Risk of Ignition: Despite remote operation capabilities, the existing mechanical mixer still presented a risk of ignition. This posed a significant safety concern for the workers and the entire facility.

Cleaning and Material Transfer Hazards: The cleaning process and material transfer in the bladed mixing system carried inherent risks. The potential for improper cleaning or inadequate material transfer compromised product quality and safety.

Inconsistent Material Performance: The entrainment of air during mixing resulted in inconsistent material properties and reduced performance. This inconsistency affected the reliability and predictability of the manufactured explosives and propellants.

Evaluation and Decision:
Upon evaluating the Hauschild SpeedMixer®, the manufacturer Made the determination that there were numerous advantages that made upgrading their mixing technology an easy decision.

Enhanced Safety Features: The Hauschild SpeedMixer® offered significant safety improvements.  By mixing in closed, single-use, conductive containers, the risk of ignition associated with traditional mechanical mixers was eliminated. This ensured improved worker safety and helped protect the facility from potentially catastrophic events.

Eliminated Cleaning and Improved Material Transfer: With the Hauschild SpeedMixer®, the previous concerns related to cleaning and material transfer were effectively addressed.  The company determined that by mixing in a closed, single use container they could eliminate the cleaning process and transfer the material safely in the mixing container. 

Elimination of Entrained Air: One of the notable benefits observed by the manufacturer was the removal of entrained air during the mixing process. The Hauschild SpeedMixer® ensured the absence of air bubbles, resulting in improved and more repeatable material properties. This enhanced consistency and reliability in the performance of their explosives and propellants.

Conclusion:
By adopting the Hauschild SpeedMixer®, the high-energy materials manufacturer successfully addressed their concerns regarding safety, cleaning, material transfer, and material performance consistency. The company determined that the highest level of safety, efficiency, and product quality could be achieved by using Hauschild equipment for their mixing process.  This case study illustrates the significance of evaluating the risks associated with high-energy materials manufacturing so that the best equipment can be selected to mitigate risks and optimize operations.