Nowak Industrial Products FAQs

Nowak Industrial Products manufactures its dispersion blades from both 304 and 316 stainless steel.

Stainless steel 304 and stainless steel 316 are strong enough to manage the high shear and immense torque of industrial mixing demands without warping or deforming. The durability of stainless steel plays a critical role in maintaining blade shape and sharp teeth for prolonged blade longevity and efficiency.

Nowak offers blades in both 304 and 316 stainless steel so customers can purchase blades best suited for their own specific applications. 304 stainless steel is the standard choice for most industries and provides reliable strength and corrosion resistance in most industrial settings. 316 stainless steel is ideal for mixing situations that require stronger corrosion resistance, such as acidic, saline, or sulfur-rich environments.

When selecting an industrial dispersion blade, operators must consider the viscosity of the material, tank size, and shear/circulation needs.

When it comes to selecting the right dispersion blade for an industrial application, there are three main factors that are used to determine the best configuration. Choosing the wrong blade can lead to inefficient mixing, inconsistent product quality, higher energy costs, and even damage to equipment.

• Viscosity of material impacts the blade size requirements. High-viscosity liquids (pastes or slurries) will require large, sturdy blades, while low-viscosity liquids function best with lighter and smaller blades that prioritize circulation over force.
• Tank size is important because it affects the flow pattern created by the dispersion blade. Blades that are too small for the tank will not effectively reach all areas of the tank. On the other hand, blades that are too large for the tank can cause excessive turbulence, which will impact mixing consistency and efficiency.
• Shear versus circulation needs depend on the desired outcome of the material being mixed. High-shear applications will need a blade engineered to generate intense shear forces to break apart particles for uniformity. Circulation-focused applications will focus more on moving large volumes to prevent settling and maintain temperature uniformity.

Perform regular maintenance and operate dispersion blades properly to extend their lifespan.

Precise operation and regular maintenance are essential for extending the lifespan of dispersion blades. Blades must undergo routine inspections to check for wear, corrosion, cracks, or dull teeth. They should be cleaned to prevent material buildup. Mixers and motors must also be properly maintained so that blades are not subjected to excessive vibration, which can cause premature failure.

The three most common types of dispersion blades are high-shear blades, rectangle-tooth blades, and high-vane blades.

• High-shear blades are designed to deliver intense mechanical force. When mixing at elevated speeds, these blades quickly tear apart agglomerates and solid particles, evenly dispersing them throughout the mixture. They typically feature a sawtooth edge to accelerate the dispersing action.
• Rectangle-tooth blades have evenly spaced rectangular teeth that are designed to deliver a strong pumping effect while generating a moderate level of shear. They are ideal for heavier or more viscous materials, where circulation is just as important as breaking up clumps. The straight tooth profile can move a substantial amount of product with less chance of clogging.
• High-vane blades deliver strong pumping action and are most effective for materials that require constant movement.

Nowak dispersion blades are designed to outperform OEM blades in quality, reliability, and availability.

Each blade is manufactured with precision to ensure uniform mixing and particle dispersion. By manufacturing every blade in-house, Nowak can offer exact sizes on demand, helping to reduce lead times and minimize production downtime. Nowak blades are competitively priced so that manufacturers do not have to sacrifice performance for affordability.

Side-entry mixers are designed to solve application challenges in tanks where traditional top-entry mixers fall short.

• Difficult Tank Geometry – Effectively achieves proper circulation in long, wide, or flat tanks.
• Dead Zones – Side-entry mixers improve uniformity by reducing dead spots and preventing stratification.
• Product Quality – Consistent mixing helps avoid inconsistent draws and maintains overall product integrity.
• Settling Of Solids – Side-entry mixes keep sludge, water, and solids adequately suspended in applications such as crude storage, fuel tanks, wastewater, and slurries.
• Retrofit Challenges – Ability to be installed on existing tanks without major modifications and costly redesigns.
• Maintenance Access – The side mounting of these mixers allows for easier servicing without having to drain the tank or deal with tall structures.
• Scalability – Multiple side-entry mixers can be added or repositioned to adapt to changing process needs.

By driving liquids sideways, side-entry mixers can reach the distant areas of uniquely shaped tanks with ease.

In wide, long, or low-profile tanks, the vertical flows created by top-entry tanks can not effectively mix the full volume and create dead zones. Dead zones occur when inadequate mixing allows fluid velocity in different areas of the tank to slow or become stagnant. This allows the material to settle or stratify and leads to product inconsistency and reduced process efficiency.

With side-entry mixers, the flow can be calibrated to sweep across the tank, including the floor and walls, and properly recirculate. Side-entry mixers can even be mounted on a swivel to allow operators to adjust the angle and target different areas of the tank as needed.

Top-entry mixers are mounted to the top of tanks and have a vertical shaft, while side-entry mixers are mounted to the sides of the tank and have a horizontal shaft.

Top-entry mixers generate a strong axial flow and are oftentimes more efficient than a side-entry mixer. However, tank specifications must be tall and narrow for top-entry mixers to work effectively, so they can only be used in specific applications.

Side-entry mixers are ideal for tanks that are too large and/or wide for a top-entry mixer. Instead of creating axial flow, side-entry mixers generate strong horizontal flows that sweep the edges and floor of the tank, making them ideal for a wide range of storage applications, such as crude oil, fuel, wastewater, and slurries.

In general, side-entry mixers are best suited for bulk movement of material.

Common side-entry mixer applications are processes that need gentle, but continuous mixing to retain uniformity, such as:

• Crude oils
• Refined hydrocarbons
• Water-based liquids
• Wastewater or industrial effluent with suspended solids
• Mineral slurries
• Large-volume food, beverage, or agricultural formulations

Side-entry mixers are typically not used for rapid emulsification, fine particle reduction, or high-rate dissolution. While they are not ideal for these processes, side-entry mixers can be used in conjunction with other types of mixers in a supporting role. They can assist with maintaining overall tank uniformity, preventing settling while in storage, and pre-mixing before more extreme dispersion processes.

Side-entry mixers minimize downtime for operators by simplifying both installation and ongoing maintenance.

When it comes to installation, side-entry mixers are mounted directly onto the sidewall of the tank. This allows the mixer to be retrofitted onto existing tanks without the need for complex structural supports or roof modifications. Because of this, side-entry mixer installation is generally much faster, reducing labor requirements and disruptions to production.

Another major advantage of side-entry mixers is accessibility. Since the mixer is mounted on the side of the tank, the key components – motor, gearbox, seal system – are located outside the tank. This allows operators to inspect, service, and replace parts as needed without having to climb to the top of tanks or drain them completely.

Tote mixers can effectively mix thick, heavy, or highly viscous liquids when configured with the proper drive system.

Nowak offers both high-torque electric and pneumatic options for medium to high viscosity mixing. Standard mixers may not have the torque or circulation ability to handle thicker products. As liquids become thicker, they create more resistance against the mixer shaft and impeller. These high-torque mixers are designed to deliver the extra turning force needed to move dense product effectively.

High-torque electric tote mixers combine a powerful electric motor with gear reduction systems to provide the necessary mixing power for proper circulation of viscous products. These types of tote mixers are commonly used for slurries, polymers, inks, and coatings, or for suspending settled particles.

Pneumatic tote mixers operate by using compressed air instead of electricity. Oftentimes, these mixers are used in hazardous environments where flammable or combustible materials are present. These mixers provide strong mixing power and perform reliably, even in challenging industrial settings.

All tote mixer shafts and impellers from Nowak are made from corrosion-resistant 316 stainless steel.

316 stainless steel is widely used for mixing equipment because it is highly durable, resistant to chemicals, and ensures long-term performance. Tote mixers are often used for applications involving acids, solvents, cleaning agents, or other corrosive materials. Lower-grade metals would deteriorate more quickly in these environments, whereas 316 stainless steel is specifically engineered to resist corrosion as well as surface damage.

Regular inspections, lubrication, cleaning, and component checks are required to ensure reliable performance and reduce the risk of operational downtime.

• Lubrication: This is the most important preventative maintenance task for prolonging the equipment’s lifespan.
  • Gearboxes: Check oil levels on a monthly basis and replace as directed by manufacturer guidelines or if contamination (like water) is detected.
  • Air Motors: These require lubrication during use, typically through an in-line lubricator using detergent-free oil.
• Impeller & Shaft Inspection: Inspect impellers and shafts on a regular basis.
  • Check for any buildup, chips, cracks, or pits on impeller blades.
  • Verify shaft straightness and alignment to prevent excessive vibration, which can lead to damaged bearings and seals.
• Seals & Bearings: Inspect seals for leaks, cracks, or brittleness on a monthly basis, especially when mixers are used for sanitary or chemical applications.
  • Worn seals must be replaced immediately to prevent contamination.
  • Bearings must be greased according to the manufacturer’s intervals.
• Cleaning & Sanitation: Clean the mixer after every use to prevent material buildup. Failure to do so can lead to overheating or mixing imbalance.

The right tote mixer depends primarily on the properties of the material being mixed and the process goals. Intermediate bulk containers (IBCs) typically have small, 6-inch openings, making the choice of impeller and mounting style critical.

• Material Properties
  • Viscosity: This is the most important factor. For low-viscosity (water-like) materials, direct-drive mixers at higher RPMs (e.g. 1,750 RPM) are efficient. For high viscosity (creams, sludges, gels) materials, gear-reduced drives provide higher torque at lower speeds.
  • Density & Solids: Heavier products or those with settling solids require more horsepower and specific impeller placement (often 1-2 propeller diameters from the bottom) to maintain suspension.
  • Chemical Compatibility: Ensure all “wetted parts” (shafts and blades) are made from non-reactive materials like 316 stainless steel to prevent corrosion or product contamination.
• Drive Type: Air vs. Electric
  • Air-Powered: Air-powered drives are ideal for hazardous or explosion-proof environments. These are lightweight (9-10 lbs.), inherently non-sparking, and stall if overloaded rather than burning out.
  • Electric: Electric drives allow for more precise speed control and are better for general-purpose mixing where electricity is readily available. These drive systems are more energy efficient than air motors but are heavier (35 lbs.) and require overload protection.
• Impeller Selection
  • Collapsible Blades: Since standard totes have 6” openings, use collapsible impellers that can fit through the bung and expand up to 20” or more once inside to provide proper axial flow and turnover.
  • Blade Placement: For a 330-gallon tote, place the blades near the bottom of the shaft. For 275-gallon totes, blades can be positioned higher.

To prevent settling or separation in IBC (Intermediate Bulk Container) totes, use active agitation to keep solids suspended and to maintain a uniform blend throughout.

Continuous or periodic mixing keeps solids suspended, maintains a consistent blend through the tote, and prevents any heavier materials from sinking to the bottom during storage or transport. Several factors, such as product viscosity, particle size, solids concentration, storage duration, and temperature conditions, influence how quickly settling happens. Depending on the product, re-agitation may need to occur right before use or may need continuous mixing to thoroughly maintain suspension.