Fabricating a mixing tank isn’t just about welding metal into a vessel—it’s about engineering a system that delivers consistent blending, hygienic performance, process efficiency, and durability. Whether used in food, pharmaceuticals, chemicals, or dairy, the success of a mixing tank depends on several critical design and fabrication considerations.
1. Understand Your Application & Product Characteristics
What are you mixing?
Liquids, powders, viscous slurries, emulsions—or all of them?
Are your materials shear-sensitive?
This determines the type of agitator and speed you’ll need.
Will the process require heating or cooling?
Thermal control features like jacketed walls or internal coils become crucial in these cases.
Example: A dairy culture tank requires gentle agitation with tight thermal control to maintain optimal fermentation temperature.
2. Choose the Right Material of Construction (MOC)
Stainless Steel (SS304/SS316): Preferred for hygienic applications in food, pharma, and beverage industries
Mild Steel (MS) or Hastelloy, FRP-lined tanks: Ideal for harsh chemicals or corrosive environments
Prioritize cleanability, corrosion resistance, and product compatibility when selecting the MOC.
3. Agitator Type & Mixing Speed
Select from propeller, paddle, anchor, turbine, or high-shear mixers based on:
Viscosity of the ingredients
Blending speed and force required
Whether you’re suspending solids or creating emulsions
Use Variable Frequency Drives (VFDs) for adjustable speed control.
Example: A cosmetic lotion tank may require high-shear mixing with a turbine agitator to ensure emulsion stability.
4. Hygiene and Cleanability Standards
Especially critical for pharmaceutical and food-grade tanks:
Integrate CIP (Clean-in-Place) and SIP (Steam-in-Place) systems
Use electropolished interiors (Ra ≤ 0.8 µm) to minimize microbial contamination
Eliminate dead zones, crevices, or weld gaps
5. Thermal Control Features
Incorporate:
Jacketed walls, dimple jackets, or internal coils for heating/cooling
Circulation systems (e.g., steam, hot water, glycol)
Insulation and thermal sensors to maintain temperature stability
Example: A fermentation tank for biotechnology may require precise thermal control with glycol jackets and PID-regulated feedback loops.
6. Tank Geometry & Capacity
Tank shape and volume directly impact mixing dynamics:
Conical, cylindrical, or flat-bottom—each shapes flow differently
Maintain an optimal height-to-diameter ratio for even blending
Size should match both current batch sizes and future scalability
7. Instrumentation and Automation
Integrate sensors for level, temperature, pH, and RPM
Interface with PLC/SCADA systems for real-time control and monitoring
Enable batch traceability, recipe control, and data logging
8. Compliance, Safety & Certifications
Ensure adherence to relevant regulations:
ASME, FDA, GMP, EHEDG, ATEX, and more
PED or IS 2825 for pressure-rated tanks
Include vent filters, rupture disks, grounding, and safety interlocks