Customer Background
A medium-sized daily chemical manufacturer located in the UAE, with a main product portfolio covering household liquid detergents, surface cleaners, and automotive care fluids. Established in 2015, the factory primarily supplies the local Middle Eastern market and fulfills export orders to parts of Africa. As order volumes have grown year by year, its existing mixing equipment has been plagued by low mixing efficiency, poor batch-to-batch stability, and excessive tank height that complicates operations. An equipment upgrade for the core mixing section has thus become an urgent priority.
Challenges Faced
The customer’s existing 1,000 L mixing tank presented the following pain points:
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Space constraints. The factory workshop is an early-standard facility with a clear height of only 2.8 m. The old tank stood 1.9 m tall, leaving insufficient overhead clearance. Operators had to climb ladders for charging and cleaning, creating safety hazards, and there was no room to install auxiliary top-mounted devices.
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Inadequate dispersion performance. The original unit ran at only 960 RPM. When formulating high-viscosity car wax liquids, powdered raw materials such as fumed silica and polyethylene wax powder frequently agglomerated, requiring an additional colloid mill pass to meet product specifications. This added about 40 minutes to each batch cycle.
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Residue and cleaning issues. The inner wall of the old tank was not polished. Surfactants in the detergents tended to adhere to the wall, necessitating large amounts of rinse water between product changeovers, generating substantial wastewater. Residual buildup also compromised the purity of subsequent batches.
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High energy consumption. The original equipment used a 15 kW motor, but its effective power utilization was low. With three batches per day, monthly electricity costs were significant.
Solution Provided
After comparing multiple Chinese and European suppliers, the customer ultimately selected our JYMT-1000 high-speed mixing tank as the replacement. To address the customer’s pain points, we offered the following customized features:
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Height: The JYMT-1000 was designed with a strict overall height of 1,480 mm—420 mm lower than the old unit. This provided ample clearance between the tank top and the workshop beams, while the feed opening was lowered to chest level, enabling charging and inspection without a ladder.
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Agitation: Equipped with an 11 kW motor and a 2,800 RPM high-speed drive via a belt speed-increasing design, the agitator tip speed reached 11.5 m/s, generating strong shear force that effectively broke up powder agglomerates.
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Surface finish: The inner shell was mirror-polished to a surface roughness of Ra ≤ 0.4 μm, minimizing material adhesion. Combined with a flanged, pressureless lid that opens quickly, this facilitated CIP spray-ball coverage of the entire inner surface.
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Monitoring: A magnetic flap level gauge was installed, allowing operators to read liquid levels directly from the floor without climbing, greatly improving daily operational convenience.
Implementation and Results
The equipment was installed and commissioned in November 2025. After three consecutive months of production tracking, the customer reported the following key improvements:
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Mixing time for car wax liquids was reduced from 55 minutes per batch to 28 minutes per batch.
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Powder dispersion fineness, measured by a scraper fineness gauge, improved from ≤ 80 μm (which also required a colloid mill pass) to directly achieving ≤ 35 μm without post-processing.
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Cleaning water consumption per batch dropped from approximately 120 L to about 40 L, thanks to significantly reduced wall adhesion.
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Total cycle time per batch (including cleaning) was compressed from about 130 minutes to roughly 72 minutes.
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Based on an 8‑hour working day, daily production capacity increased from 3 batches to 5 batches.
Customer Feedback
In an email reply, the factory’s production manager stated that what impressed them most about the JYMT-1000 was that the reduced height did not compromise mixing performance—the 2,800 RPM dispersion capability far exceeded expectations. The consistency of fineness in their automotive care fluid batches has improved markedly, and customer complaint rates have dropped significantly. At the same time, the polished inner wall makes cleaning remarkably easy, which is a major advantage for a production line that frequently switches between different detergent formulations.
Follow-up Cooperation
Based on the performance of the first two units, the customer has confirmed an additional order for 3 more identical mixing tanks for their expanding second workshop. In addition, the customer plans to convert one of the units into a jacketed heating version for temperature compensation when producing high-viscosity liquid wax in winter. Our technical team is currently working on the jacket design drawings in coordination with the customer.
Post time: Jul-17-2026