Emotron applications · Mixing and agitation
Intelligent control of industrial mixers and agitators
Mixers work with variable-viscosity materials, and inadequate control results in incomplete mixing, excessive energy consumption and premature equipment wear. As the official Emotron distributor in Central America, E3 Solutions automates industrial mixers and agitators in Guatemala with Emotron variable frequency drives and shaft power monitors: motor speed adapts in real time to process viscosity, and the system automatically detects when the mix reaches its optimal point.
The challenge: processing variable materials without wasting energy or damaging equipment
A mixer running at fixed speed can never respond well to a changing process. At the start of the cycle, the material is thick and the motor works at full effort; as mixing progresses, viscosity drops and the motor wastes energy unnecessarily. Worse, nobody knows exactly when mixing is complete: a fixed time is used, meaning over-mixing or under-mixing. Blades damaged by abrupt starts and stops drive up maintenance costs, and current spikes on each start deteriorate the electrical installation and shorten motor life.
- Excessive energy consumption from always running at maximum speed
- Inability to detect when the mix is truly complete
- Blade and shaft wear from abrupt starts and stops
- Risk of undetected overloads, underloads and shaft oscillations
The Emotron solution
The Emotron solution
Emotron control transforms mixer operation into an adaptive process. The FDU variable frequency drive continuously adjusts motor speed to match the actual viscosity of the mix at each moment of the cycle, reducing energy consumption considerably. The TSA softstarter eliminates mechanical jolts on starts and stops, and its integrated braking controls the stop without external brakes. The M20 shaft power monitor tracks shaft load with no additional sensors and detects, across the full speed range, when the mix reaches the optimal point, when over- or under-mixing is occurring, and whether shaft oscillation or foreign material is present — protecting both product quality and the equipment. E3 Solutions designs, installs and commissions the complete solution in Guatemala.
Recommended equipment
Recommended Emotron products for mixers
The equipment combination varies by mixer type, process viscosity and product quality requirements. These are the options we use most in mixing projects.
Emotron FDU
The FDU drive continuously adjusts motor speed to match the changing process viscosity, eliminating unnecessary consumption and maintaining mix quality at every stage of the cycle.
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Emotron TSA
The TSA softstarter protects blades and shafts with controlled starts and stops, and its built-in braking brings the agitator to a halt without external mechanical brakes.
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Emotron M20
The M20 shaft power monitor detects mixing completion, overloads, underloads and shaft oscillation with no additional sensors, alerting the operator or executing controlled stops to protect product quality.
View productKey features
Key features of mixer control
The functions that make the Emotron system a complete solution for industrial mixing and agitation.
Dynamic viscosity adaptation
The drive adjusts motor speed in real time to match the current process viscosity, with no manual adjustments or external viscosity sensors required.
Optimal mixing-point detection
The M20 shaft power monitor identifies when the mix has reached its optimal point from the load profile, eliminating fixed cycle times and ensuring product consistency.
Overload and foreign-material protection
Continuous shaft torque monitoring detects overloads, underloads and foreign objects in the mix, triggering an alarm or controlled stop to prevent equipment and product damage.
Smooth starts and stops without external brakes
Controlled starting and stopping eliminate the mechanical jolts that damage blades and shafts. The TSA softstarter's built-in braking brings the agitator to a quick, precise stop without additional components.
Benefits
Benefits of automating your mixers
The results a process plant achieves when its mixers run with Emotron control.
- Significant energy savings by matching speed to the actual process viscosity
- More consistent product quality through automatic detection of the optimal mixing point
- Less wear on blades, shafts and seals from controlled starts and stops
- Fewer unplanned stoppages through early detection of overloads and oscillations
- Elimination of external mechanical brakes in applications with the TSA softstarter
- Longer motor and electrical installation life by reducing current spikes
Resources
Learn more about motor control
8 min readVariable frequency drive vs soft starter
Compare function, cost, energy savings, and applications to choose the right equipment from the start.
Read guide
8 min readWhat is a soft starter?
What it does, how it works, and when to use a soft starter on a three-phase industrial motor — technical guide by E3 Solutions.
Read guideFAQ
Frequently asked questions about mixer control
Want to optimize your mixers or agitators?
Tell us about your mixing process and we will propose the right Emotron equipment combination, with installation and commissioning in Guatemala.