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When liquids start acting more like solids, your standard mixing tools are going to fail. This is where the Sigma Mixer comes in. It is widely known as the top choice for handling very thick, sticky materials.
In the big world of industrial mixing, thickness—or viscosity—is what separates the easy jobs from the hard ones. Standard stirrers and ribbon blenders are great for things that flow easily. For example, Karvil makes excellent horizontal mixers that handle flour or dry powders without any trouble. But those machines meet their match when they face materials that just refuse to move. We are talking about substances with a thickness level that goes way above 500,000 centipoise (cP). These are materials like the base for chewing gum, heavy silicone sealants, stiff doughs, and even fuel for rockets.
If you try to put these "almost solid" fluids into a regular mixer, it is a recipe for a bad day. You will likely burn out the motors, break the metal shafts, or end up with a product that isn't mixed well. You might find lumps of unmixed powder hiding inside the batch, which means the product is ruined.
This is exactly why the Sigma Mixer exists. Some people call it a Z-Blade Mixer or a Kneader. It is built to beat the toughest mixing challenges. This machine does not just "stir" the pot. It cuts, kneads, folds, and stretches the material until it is perfect.
Karvil has sent equipment to more than 50 countries and regions all over Europe and the Americas. Because of this, Karvil has built a strong name as a world leader in heavy-duty mixing solutions. From making food to helping with space engineering, our custom-built mixers are running production lines all around the globe. This guide is going to take a deep look at how the Sigma Mixer works, why safety is so important, and how you can set it up for your needs.
To really get why the Sigma Mixer is the standard tool for thick materials, we have to look inside the mixing tank. Unlike vertical mixers that use a single spinning stick, the Sigma Mixer uses a tank shaped like a "W" that lies on its side. Inside this tank, there are two heavy-duty Z-shaped blades.
The real secret here is the shape and the movement. The two blades do not move in the exact same way. They usually spin at different speeds. A common setup is a 3:2 ratio or a 2:1 ratio.
l Blade 1 (The Fast One): This blade spins quickly. Its job is to pull the material away from the walls of the tank and fold it over on top of itself.
l Blade 2 (The Slow One): This blade turns more slowly. It squeezes the material and pushes it back toward the fast blade.
This difference in speed creates a very strong shear force. As the material gets squeezed between the metal blades and the walls of the tank, it gets stretched out and folded over and over again. This is super important for materials like rubber or gum base. If you just stirred these materials, they would bounce back because they are elastic. But the Z-Blade breaks that elasticity so the ingredients can actually mix together.
Depending on what kind of material you are making, you might need to choose between two different ways the blades can be arranged:
l Tangential Design: In this setup, the blades do not touch each other at all. This gives the strongest cutting force. It is the best choice for the stiffest materials, like rubber compounds or very heavy glues.
l Overlapping Design: In this setup, the blades cross over each other's path, but they still do not touch. This is better for moving the material around the tank. It is ideal for materials that need to be very smooth and uniform.
At Karvil, we know that machines with this much power come with risks. That is why safety and following the rules are not just extra features; they are a core part of how we build things. Our machines are made to meet the strict safety rules of our customers all over the world, especially in Europe and North America.
We have a strict policy that we call "Zero Access" while the machine is running. We want to make sure no one gets hurt.
l Emergency Interlocks: All of our mixers have a system where if you open the lid, the machine stops immediately. The second the mixing tank lid is lifted, the power to the motor is cut. This stops the blades instantly so no one can get injured.
l Covered Moving Parts: All the parts that move the blades—like gears, belts, and chains—are completely covered in a protective box. This keeps workers from accidentally touching moving parts. We follow strict international safety rules to make sure of this.
We promise quality, and we have the papers to prove it.
l CE Marking: Our machines follow the safety, health, and environmental rules required by the European Union.
l ATEX Certification: For our customers who work with chemicals, explosives, or glues, we offer ATEX-certified explosion-proof models. This is extremely important when you are mixing materials that could catch fire or explode. You need to be sure that no sparks will happen.
For our customers in the food industry—those making chewing gum, protein bars, and other treats—being clean is the most important thing.
l Clean Design: All the parts of the machine that touch the food are polished until they shine like a mirror. This gets rid of any tiny cracks where bacteria could hide.
l Following the Law: The materials we use to build our machines have passed the EU Food Contact Material (FCM) test. We strictly follow the (EC) No.1935/2004 regulations. When you choose Karvil, you are choosing a machine that guarantees your food products will be safe and pure.
The Sigma Mixer is a versatile tool, but it is also a specialist. It is the best tool for specific jobs. Drawing from Karvil’s long history of building custom solutions for over 50 countries, here are the areas where our Z-Blade mixers really shine:
Making candy and snacks is actually very hard on machines.
l Chewing Gum: The base for gum is tough and stretchy. The Z-Blade’s cutting power softens this base. This allows the sugar and flavors to mix in evenly. If you don't do this right, you get "hot spots" where the flavor is ruined by heat.
l Protein Bars: The health food market is growing fast. Manufacturers need mixers that can handle dense, sticky protein doughs. Our sanitary designs make sure there is zero contamination for these expensive products.
l A Note on Powders: For clients who need to mix the dry ingredients first (like flour, additives, or ice cream powder), Karvil also provides specialized Horizontal Ribbon Blenders. This means we can offer a solution for your entire production line.
l Silicone Sealants & Hot Melts: These industries need to mix things under a vacuum to get all the air bubbles out. Karvil’s vacuum-rated tanks make sure you end up with a bubble-free, solid product.
l Using Planetary Mixers: While Sigma mixers handle the heaviest sealants, Karvil also makes Planetary Mixers. These are great for dental materials, battery mixes, and sealants that aren't quite as thick. This ensures we have the right tool for every level of thickness.
When safety is on the line, you cannot afford for things to break.
l Explosives & Rocket Fuel: This is a very special field where Karvil’s careful engineering stands out. Both our Sigma Mixers and Planetary Mixers are used in the aerospace and defense sectors. They are used for mixing solid rocket fuel and other energetic materials. Our ATEX explosion-proof designs are standard here. This ensures that highly sensitive compounds are processed safely.
Choosing a Heavy Duty Z-Blade Mixer is all about setting up the machine to fit your specific work. Karvil offers many ways to customize your machine based on our decades of experience in the industry.
How do you get a sticky, non-flowing material out of the mixer when it is done? This is often the hardest part.
l Hydraulic Tilt Discharge: This is like a dump truck. The whole mixing tank tilts over to dump the product out. This is best for batch processes where the product comes out in a big chunk (like explosive doughs or food products).
l Screw Extruder Discharge: This is the best choice for silicone sealants and glues. There is a screw at the bottom of the tank. When mixing is done, the screw turns and pushes the material out through a hole. This can connect directly to your packaging line.
l Stainless Steel (SUS304 / SUS316L): This is mandatory for food and corrosive chemical applications. As we mentioned before, our stainless steel meets EC 1935/2004 standards.
l Wear-Resistant Coatings: If you are mixing materials that act like sandpaper (like certain ceramics or brake linings), we can put a special hard coating on the blades and the tank to stop them from wearing down.
l Heating: We can use steam or hot oil jackets to keep the tank warm. This is needed for hot melt adhesives so they stay liquid.
l Cooling: We can use water circulation jackets to keep the tank cool. This is critical for rubber and explosives. The friction from mixing creates a lot of heat, and if it gets too hot, it could be dangerous or ruin the product.
At Karvil, we believe that selling a machine is just the start of our relationship. We are committed to making sure your equipment runs smoothly for tens of years.
Full Warranty & Lifetime Help We provide a standard one-year warranty on all our equipment. But our promise goes much further than that. We offer lifetime technical consulting services. It does not matter if you bought your mixer yesterday or ten years ago, our team is ready to help you.
Global Remote Assistance We understand that buying a machine from another country can feel scary. To support our clients in over 50 countries, we do the following:
l Documentation: Every machine comes with a complete Operation Manual and Circuit Diagrams in English. This ensures your local engineers have everything they need to understand the machine.
l Remote Engineering Support: Our professional engineers are available to help you remotely. We can troubleshoot problems and give technical advice over the internet. This ensures that the distance between us never stops your production.
The Sigma Mixer is the heart of your heavy-duty production line. It does not matter if you are making a new protein bar recipe, manufacturing silicone sealants, or processing critical fuel for rockets. The difference between success and your line stopping lies in the quality of your equipment.
With a presence that covers Europe, the Americas, and beyond, Karvil brings a huge amount of experience from different industries to your factory floor. From certified food safety to ATEX explosion-proof engineering, we customize every detail to meet your local laws and your production goals.
Do not let high thickness slow you down. Contact Karvil today to talk about your specific mixing needs.
A: Yes, absolutely. We specialize in clean designs for the food industry. Our mixers are built with high-grade stainless steel (SUS304/316L). We polish them to a mirror finish. This prevents bacteria from growing. Most importantly, our product materials have passed the EU food contact material test and strictly comply with (EC) No.1935/2004 regulations. This makes them safe for making chewing gum, dough, and protein bars.
A: Yes, we support clients in over 50 countries. We provide full English operation manuals and detailed electrical circuit diagrams with every machine. Also, our professional engineers offer lifetime remote technical support. They will guide you through installation, operation, and fixing any problems. This ensures your production never stops.
A: Safety is our top priority. For dangerous environments, we provide ATEX-certified explosion-proof motors and control panels. Mechanically, our machines feature strict safety locks. For example, if the lid opens, there is an emergency stop. We also have fully enclosed transmission systems to protect operators from moving parts. We have a lot of experience serving the explosives and aerospace sectors (rocket propellants) where safety is critical.
