For decades, process engineers in chemical, pharmaceutical, biotechnology, food and related industries have faced a recurring frustration when trying to answer the real questions about their processes, such as:

• How quickly my solids dissolve?

• What drop size distribution can I expect in this emulsion?

• Does my gas-liquid system achieve the required mass transfer rate?

When selecting tools for these tasks, engineers faced a painful choice between two insufficient options:

1. traditional Computational Fluid Dynamics (CFD) software, and

2. empirical correlations developed based on experimental studies conducted under narrowly defined sets of conditions.

While CFD tools excel at calculating fluid dynamics variables, they fall short of addressing the real questions related to process characteristics.

Empirical correlations, on the other hand, tend to lose accuracy when applied outside the bounds of experimentally studied conditions—even marginally. More critically, their range of applicability is often difficult to define with confidence.

VisiMix was created precisely to address this gap. It is not another CFD package or a compendium of empirical formulae. Instead, it is a suite of desktop simulation tools built by engineers for engineers, with the explicit mission of providing quantitative, reliable, and usable answers about mixing processes.

Why Engineers Struggle with Traditional CFD Approach?

CFD tend to focus on spatial profiles of fluid velocity and pressure, and turbulence energy and dissipation rate. While these variables are valuable in aerospace or automotive industries, they are not the real end-goals for process engineers. What matters in a production plant is:

• Mixing and circulation times

• Dissolution and suspension efficiency

• Emulsion and dispersion stability

• Heat and mass transfer rates

• Chemical reaction outcomes under actual mixing conditions

• Circulation, shear, and oxygen availability required for optimal cell growth

Unfortunately, conventional CFD packages leave the burden of interpreting these fluid-dynamics outputs to the user, often forcing engineers to rely on narrow, empirical correlations that may not apply outside a limited range of conditions.

The result? After spending weeks setting up 3D models and repeatedly adjusting them to accommodate even minor design changes, engineers are often left with no actionable insights—or forced to rely on guesswork. Neither outcome is acceptable in high-stakes, process-intensive industries.

The VisiMix Difference – Process Characteristics

VisiMix offers a fundamentally different approach: it focuses directly on process characteristics rather than on raw hydrodynamic variables. This shift makes all the difference.

1. Proprietary Knowledge Base

   • VisiMix is powered by a unique knowledge base built on a network of interconnected physical models, developed and validated over more than 30 years. These models encompass all key phenomena encountered by process engineers working with mixing equipment.

   • This knowledge base operates in two stages.

1. It first links input design and process data to selected fluid dynamics variables.

2. Then, it connects these fluid dynamics variables directly to process outcomes—such as mixing times, dissolution rates, or emulsion droplet sizes.

1. • This knowledge base represents decades of experimental research, industrial feedback, and proprietary models—tested and refined against real-world data.

2. User-Centered Algorithms and Formats

   • Instead of requiring a full 3D CAD model, engineers only enter a concise set of practical parameters: tank geometry, impeller type, speed, and fluid properties.

   • Proprietary algorithms instantly deliver mean process characteristics for all critical zones of the vessel, without unnecessary complexity.

   • The results are formatted into clear tables, plots, and even animations.

3. Reliability

   • As VisiMix simulations are based on robust physical models, their range of applicability is clearly defined. Built-in constraints and safety checks are automatically triggered when conditions fall outside this range, preventing invalid simulations.

   • Output is quantitatively accurate for effective mixing and at least qualitatively accurate for less effective regimes—always making clear distinctions between the two.

4. Advanced Features

   • Scale Up/Down: Transfer validated results from lab to plant scale—or vice versa —without losing process fidelity.

   • Process Analysis: Compare multiple tank designs, scales, or operating conditions for the same process side by side.

   • Sensitivity Analysis: Evaluate the effect of a single parameter (e.g., impeller speed) while keeping all other input parameters constant.

5. Short Learning Curve

   • Intuitive and process-oriented user’s interface can be rapidly mastered.

   • The configuration and display sequence of the input menus are designed from a process engineer’s perspective.

   • Every input requested is directly relevant to the task at hand, and no unnecessary information is ever required

Faster Process Development and More

• Faster Process Development: Rapid simulation cycles allow you to test design alternatives in minutes instead of weeks.

• Confidence in Decisions: Engineers can base scale-up, optimization, or troubleshooting decisions on well-verified models instead of guesswork.

• Recognition as Experts: Clear, actionable results make it easier to communicate insights with managers and colleagues.

• Reduced Risk: Built-in safety constraints and inherently safer design principles minimize costly errors and prevent dangerous operating conditions.

• Career Growth and Organizational Value: Delivering faster, more reliable process solutions enhances both personal reputation and company performance.

Applications Across Industries

VisiMix covers a wide range of unit operations and industrial needs, including:

• Single-phase liquids: neutralization, synthesis, heating, cooling, blending

• Liquid-liquid systems: emulsions, solvent extraction, polymerization

• Solid-liquid systems: dissolution, crystallization, suspension polymerization, leaching, and cell culture processes

• Gas-liquid systems: aeration, oxidation, stripping, fermentation

This breadth ensures that whether you are in pharma, biotech, food engineering, or chemicals, VisiMix can model the processes central to your work.

Visimix – A Software Made for Engineers

Engineers who have struggled with CFD or empirical methods often come to a simple realization: what they need are process answers, rather than fluid-dynamics puzzles or unreliable empirical correlations.

VisiMix is designed to deliver exactly that. It provides an intuitive, reliable, and proven framework for understanding, designing, and optimizing mixing systems—without unnecessary complexity.

If you have ever asked yourself “Why can’t my current tools give me a clear answer about mixing?”, then VisiMix is the solution you have been waiting for.

It is more than software—it is a practical engineering partner that turns the complexity of mixing into clarity, speed, and confidence.