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The art of transformation

At Zanelli, mechanical design is more than just the starting point – it’s the art of transforming an industrial vision into a tangible technical solution. Every machine we build begins with a specific customer need and takes shape through a rigorous creative process focused on customization, precision, and durability. From the first CAD draft to final assembly, we work with one goal: to deliver unique, long-lasting machines that meet the highest industry standards.

In today’s fast-evolving industrial landscape, where customer requirements shift rapidly and materials evolve, mechanical design must adapt, anticipate, and innovate. It’s not just about drawing components – it’s about fully understanding the client’s needs and translating them into a coherent, efficient, and safe system.

Our Mechanical Team

Composed of experienced engineers and young designers, works in synergy with all departments: electrical, software, production, and testing. Designers stay in constant communication with those executing the processes and those in charge of final validation, ensuring every detail is refined and aligned.

This ongoing collaboration not only speeds up timelines but also encourages shared innovation. Every new machine reflects a company culture centered on collaboration and skill development. We continuously invest in training, software upgrades, structural simulations, and material research.

A real example

A client in the composites sector needed a system capable of handling highly viscous materials sensitive to temperature variations. We designed a thermoregulated mixing tank using FEM studies and dynamic simulations. The result? A 25% reduction in cycle time compared to their previous technology.

Our method’s structure:

• Advanced 3D CAD modeling for customized solutions
• In-house FEM simulations and structural testing
• Integration with electrical and software design
• Ongoing collaboration with production departments
• Process optimization during the design phase
• Selection of certified and innovative materials
• Technical documentation compliant with international standards

The result

Shorter production times, robust and tailored solutions ready to face any industrial challenge.

What’s next?

Zanelli’s mechanical design is evolving toward predictive simulation, 3D printing for functional prototyping, and deeper integration with digital systems.

For us, innovation always means blending expertise with vision.

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🔹 Want to find out how we transform a technical need into a concrete, personalized solution?
👉 Contact our designers and request a personalized consultation for your next plant.

Bring innovation to your production line.

Our State-of-the-Art Testing Laboratory and Industrial Mixers

We at Zanelli are leaders in the design and manufacture of industrial mixers and processing equipment. To ensure that our machines perfectly meet your needs, we provide our exclusive mixing testing laboratory, a key asset that, combined with our state-of-the-art mixers, allows us to offer customized mixing solutions and performance.

About Us: Continuous Innovation in Blending since 1962

Founded in 1962, Zanelli operates globally from our workshops in Collecchio, in the manufacturing heartland of Emilia. We are recognized for our innovative and reliable solutions, serving demanding sectors such as adhesives and sealants, paints and coatings. Our long history is a guarantee of Made in Italy expertise and quality.

Our Testing Laboratory: Certainty Before Production

Our mixing test laboratory cutting-edge is where your vision meets our technology. Here, we perform product mixing tests accurate by providing dedicated instrumentation during processing and for analysis of the finished product.

• Validate processing: We test machines for processing products with different viscosities, from the lowest (Paints) to extremely high ones (Special Glues, Mastics and Sealants).
• Collect technical data: We use dedicated instrumentation (temperature probes, pressure transducers, accurate analysis of absorptions and torques delivered by motors) to collect essential data, enabling us to configure machines perfectly sized for your production and economic needs with the certainty of being able to perform the correct Scale-Ups on production machinery.
• Offer customized mixing solutions: Faithful reproduction on a small scale of industrial machine characteristics enables us to define the optimal configuration for you in terms of Mixing Technology (single shaft, double shaft or Planetary System), reducing risks, start-up time and optimizing your resources.

Our Industrial Mixers available in our Laboratory: Power, Accuracy, Reliability tailored in Pilot-Plant version

Our range of industrial mixers is the result of decades of experience and continuous innovation. Each machine is designed for specific applications, ensuring maximum efficiency on all available sizes regardless of the machine model used.

In our Collecchio laboratory you can appreciate the construction quality and performance of our Pilot-Plant version products by making small production batches (from about 150 Liters) with our mixing technologies:

Silver : For Low and Medium Viscosity

Perfect for products such as varnishes, paints and inks. The line Silver, with outputs from 1.5 kW to 132 kW, is equipped with an independent rotary scraper to ensure homogeneous mixing and optimal tank cleaning. It is a versatile solution for the mixing of paints and similar products.

Mercury : For Medium and High Viscosity

Ideal for the production of adhesives, sealants, fillers and other medium- and high-viscosity products. The line Mercury takes advantage of vertically-excursing mixer shafts. These robust high viscosity mixers, available from 6 kW to 135 kW, are perfect for mixing of adhesives, sealants and other demanding applications where machine versatility becomes essential by combining power and reliability.

Tungsten : For Very High Viscosity

Designed specifically for the most extreme challenges, the line of Planetarians, with power ratings from 7.5 kW to 250 kW, is our champion in ultra-high viscosity mixers. Equipped with three independent electric motors, it handles products with very high viscosities, ensuring the power and torque needed for complex processes.

Applications and Sectors Served

Our industrial mixers Zanelli are successfully used in a wide range of industries, including:

• Adhesives and Sealants
• Paints and Coatings
• Inks
• Putties
• Chemistry
• Composite Products

Conclusion: Your Vision, Our Zanelli Technology

Our Zanelli mixing test laboratory and the advanced technology of our industrial mixers testify to our ongoing commitment to quality and innovation. The ability to provide customized mixing solutions, born from concrete tests and careful analysis of your needs, makes us the ideal partner to optimize your production processes. Choose Zanelli means choosing unparalleled reliability, performance and technical support.

Are you ready to improve your production? Contact us today to discuss your specific needs or to book a test in our lab. To stay up-to-date on the latest news from the Zanelli world, we invite you to subscribe to our newsletter!

Innovation and Vanguard in Mixing Processes

In the industrial sector,technological evolution plays an essential role in ensuring efficiency, quality and precision in production processes. Zanelli, a leading designer and manufacturer of industrial mixing machinery, has introduced cutting-edge technologies that are innovating the industry.

Zanelli ‘s advanced solutions enable it to provide customers with high-performance machinery that improves the quality of the final product while optimizing production time and costs. This article explores the latest developments in mixing technologies and their industrial applications.

Zanelli’s New Mixing Technologies.

Industries are adopting increasingly high-performance, safe and sustainable mixing processes. Zanelli has introduced several innovations in both product and process that redefine the design and capabilities of industrial mixers:

Real-Time Energy Consumption Monitoring and Recording: Metering Systems Integrated with the machinery control system to Monitor and Record the Energy Consumption (Electrical and Pneumatic) associated with each processing step

Energy-efficient mixing technologies: Designed to deliver high performance with low energy consumption, contributing to sustainability.

ISO 9001 and ISO 3834 Certifications: Zanelli’s commitment to quality and reliability is demonstrated by meeting rigorous international standards.

Direct Line to Customer Care: Unique identification via QR-Code of each machine for access to the Integrated System of Technical Documentation Consultation or simply to have Direct connection with the Service Department

On-Line Spare Parts Service: Each machine can be consulted directly through a Dedicated Customer Portal where it is possible to consult and order spare parts and manage Service requests

Sectoral Applications of Mixing Technologies.

Zanelli’s mixing systems are used in various fields, ensuring high precision, safety and efficiency.

Zanelli’s mixing systems are used in various fields, ensuring high precision, safety and efficiency.

Automotive, Aerospace, Construction, Inks, Silicones and Sealants

Innovations in blending in these areas allow:

• Superior homogeneity in pigment dispersion.
• Repeatability of Production Lots to ensure consistent quality
• Quality Control by monitoring and recording all process parameters
• Calculation of Energy Impact in order to be able to associate each Batch with the use of Energy Used for the Mixing process facilitating the Calculation of Product Carbon FootPrint.

Why Choose Zanelli?

Continuing Innovation

Zanelli invests heavily in research and development, ensuring cutting-edge technologies and high-performance machinery.

🔗 For more information on ISO 9001 and ISO 3834 standards, visit the official ISO website.

Certified Quality

Zanelli ‘s commitment to quality is demonstrated by ISO 9001 and ISO 3834 certifications, which ensure high quality standards and precision manufacturing processes.

Customized Solutions

• Customized Solutions Every industry has specific needs, and Zanelli provides customized solutions to meet each need.

Dedicated Technical Support

• Zanelli’s team offers comprehensive support, from machine selection to after-sales support.

Conclusion

Innovation in mixing technologies represents astrategic opportunity for companies that want to improve productivity, quality and sustainability. Zanelli is the trusted partner that offers innovation, reliability and high-performance machinery.

To find out how Zanelli can optimize your blending process, contact our team today!

In the world of modern industry, the mixing of very high viscosity materials requires engineering solutions that ensure uniformity, repeatability and robustness. Zanelli planetary mixers meet this need, with a system that maximizes cutting force and mechanical efficiency.

Since 1962, Zanelli has established itself as a reference in the industry through continuous innovation and customization of its machinery. Planetary mixers represent the most advanced outcome of this evolution.

Who uses Zanelli planetary mixers?

Our customers operate in industries where the quality of mixing is critical:

✔️ Structural adhesives
✔️ Sealants and fillers
✔️ Automotive and aerospace composites
✔️ Conductive pastes for electronics
✔️ High-density building materials

Zanelli caters to a highly demanding B2B audience that seeks reliability, precision and tailored solutions. Our technical team works side by side with customers to analyze each formulation and design the most suitable plant.

What makes a Zanelli planetarium unique?

Zanelli planetary mixers are distinguished by a complex and synchronized movement: the blades rotate on their own axis and simultaneously around the center of the tank ensuring the absence of dead zones. This guarantees:

✔️ Perfect homogeneity even in extremely dense materials
✔️ High mechanical action with low energy consumption
✔️ Ability to work under full vacuum and overpressure (BI) conditions or with simple exhalation-proof sealing (AI)

Zanelli’s special planetary lines:

Capacity: 1 to 1 900 liters
Power: 22 to 250 kW
Configurations: CE, UL, Atex Zone 1/21

Zanelli planetary models:

Iridium: singolo albero con pale ad alette

Molybdenum: doppio albero con pale farfalla

Steel: singolo albero farfalla

Chromium: doppio albero ad alette

Thungsten: doppio albero farfalla (top di gamma)

Zirconium: doppio albero ad alette

Each model is available in BI (vacuum/overpressure version) and AI (standard version) versions to ensure perfect dispersion and mixing based on customer needs.

Case study: industrial sealants

Un nostro cliente del settore aerospaziale necessitava di produrre un adesivo speciale con filler metallici. Grazie a un Thungsten BI da 500 L, abbiamo garantito:

✔️ Perfect filler dispersion
✔️ Repeatable cycles thanks to Unified Mixing Control 5.0
✔️ 30% reduction in processing time

Ready to take the leap?

Contact our technical team for a customized demo or come and test your product in our Test Lab.

Planetary movement of the mixing tools with butterflies TUNGHSTEN line alternatively planetary movement of tools with inclined blade type ZIRCONIUM line both lines complete with fast dispersion impeller with planetary movement and lateral rotating scraper.

ZANELLI has many years of experience in the design and construction of the TUNGHSTEN and ZIRCONIUM Mixers / Dispersersers lines, which guarantee a level of reliability, safety, respect for the environment, and very high-quality standards capable of processing products with viscosities up to about 10,000,000 cP.

The use of the double mixer group lifting column is fundamental for the robustness and reliability of the machine. This technical solution confers a high strength to the machine even in the most critical phases of the production cycle with an optimal absorption of the vibrations caused by the machining tools.

Another essential technical feature is the overlapping of the mixing tools during the various stages of the production process. This feature allows you to optimize the mixing flow, optimize the incorporation of raw materials, significantly reduce working times and, in the case of the vacuum version, speed up the extraction of air from the product. The combination of the dispersing shaft with independent motorization facilitates the dispersion phase, which is necessary during the production process. The side scraper with independent motorization, gives a considerable reduction in the working times, cleaning of the mixing tank wall and guarantees greater flexibility to the machine itself.

Various options and customizations are available in order to increasingly adapt the TUNGHSTEN and ZIRCONIUM Line Mixers / Dispersersers to the specific needs of the customer.

General features:

• Mixing/dispersing even of very high viscosity and thixotropic products in a short time with high final product quality;
• Easy replacement or adjustment of mixing tools and quick cleaning of parts in contact with the product;
• Easy use of the machine;
• Easy maintenance;
• Excellent reproducibility of batches;
• Possibility of controlling all machine parameters;
• Strength and efficiency of each single component;
• Attention to detail;
• Construction configurations as well as customized automation levels;
• Guarantee of qualified technical assistance;
• Design, compact and robust and ergonomic structure that respects aesthetics and practicality;
• High number of machines sold and operational in the world.

Recipe formulation
Recipe management with version tracking, recipe compilation and validation with different users and classification by production unit.

Production scheduling
Management of the recipe list to be produced in the day or in the week with possibility to import data from the company management softwares, production priority, recipe / machine pairing.

Production progress
Reload storage units with raw material batch tracing, display of steps to be performed on operator interfaces on board of the machine, display of containers prepared for each recipe, integration with laboratory for sample checks and corrective steps at the end of the recipe.

Historian Database for Data analysis
Display of historical production data for productivity analysis and data tracking for traceability, with details on the measured quantities, times, operators and machines associated to lot/batch numbers.

Maintenance scheduler
Management of the Maintenance Log Book and scheduling of predictive maintenance.

User Identification System
Management of single user Identification through RFID/Barcode Technology in order to trace all manual actions.

Remote Assistance
Remote Assistance through augmented reality and TeamViewer to help on-site users.

The SmartLoader dosing station is the ideal solution for managing manual liquid and powder dosing in industrial settings, ensuring maximum traceability of operations without the use of paper media. All information is recorded on databases and can be accessed at any time from any computer connected to the corporate network.

The principle of operation is simple. The built-in monitor shows the operator the recipe whose components he needs to dose, highlighting the line of the component that needs to be loaded at the time. The operator uses the barcode gun to identify the component to be dosed (code + batch, if any). The monitor shows a graphical progress bar that the operator follows to complete the required dosage, zooming in as the setpoint is approached. If the dosage has the required prescription tolerance, the operator confirms the dosage and moves on to the next one.

In this way, the operator is guided step by step through the loading of all the raw materials required for a given recipe, without having to worry about looking at the list on a sheet of paper, collecting print receipts, or marking off the steps taken. Everything is automatically recorded by the system.

WATCH THE SMART LOADER IN ACTION

Management system

The system is configured to customer requirements and can be interfaced to company management systems (+ERP option) to ensure the correct flow of information from the warehouse to production, integrating traceability with the company’s existing coding.

Alternatively, it can be supplied together with a PC (+PC option) preinstalled with SmartLoader Manager recipe management software to be connected to the corporate LAN. The same PC can manage several SmartLoader dosing stations.

SmartLoader Manager software includes:

• Creating and editing sequential dosing recipes
• Raw material management and local warehouse
• Managing users and permissions, viewing access history
• Viewing recipes in progress and production history
• Creating printable production reports

TRACKABILITY

Each raw material can be identified by barcode by cross-referencing data from the management system to verify the correctness of the material, expiration date, supplier lot. The system can return raw material consumption to the management system by automatic summing up of what was used and actually weighed.

The SmartLoader system can track the container (+CNT option) on which dosing is done and share the information with other production management software. You can then view the list of containers in the department with details of the contents of each, ready to be used in the next step.

With the +CLN option, guided cleaning cycles can be managed to ensure the cleanliness of the station, containers or dosing tools when switching between incompatible productions (polluting materials, incompatible colors, allergens,…). Each utensil (knife, sessola, …) is identified each time it is used to ensure compatibility with the current recipe and require a washing sequence.

TECHNICAL SPECIFICATIONS

The weighing station is made entirely of STAINLESS steel and integrates a scale platform with a 600×600 platform for loading bins with a maximum weight of 50Kg, which can also be supplied in an approved version with 5g resolution.

There are several options for installing scales with higher resolution (0.5g) of different sizes that can be installed at different heights to ensure maximum operator ergonomics depending on the container to be dosed. It is also possible to interface third-party scales or weighted pallet trucks with radio or wired signal.

The dosing station comes with braked wheels and handles that allow it to be moved easily during cleaning, or to move the whole station to other departments. On board it is equipped with a dedicated weighing instrument (can also be supplied with metric approval), barcode reader (wired or wireless) and fully washable touch screen panel PC.

For further details please contact us and download the full data sheet:

Zanelli is proud to announce the acquisition of two new CNC machines which have joined our metal workshop in our headquarters in Italy.

We have extended and increased our production thanks to these 2 premium tooling machines. Machines that were proudly made in Italy.

We do not compromise the quality of our products and that is the main reason why we invest in equipment that will help us assure and guarantee our quality day in and day out. We take pride in guarantying high-quality production with accurate quality control of each component we build for our machines.

These state-of-the-art CNC machines are equipped with a supervision system amplifies the potential of normal NCs, with absolute benefits in terms of production flexibility, process reliability and efficiency, monitoring of current equipment conditions with an array of sizes, in terms of reaching a wider length and depth.

Since 1962, Zanelli Mixing & Dispersing Innovations has been making all internal components to their machines in house; making Zanelli one of the top machine manufacturing companies in the world. This success begins in our metal working shop, which supplies all essential components to our equipment. We take quality very seriously and our investment in equipment shows how important it is for us.

Our planetary mixers models require attention to each small detail, strong in-depth knowledge and expertise gained in the field of process technologies which it should be constantly made available to the customer into Zanelli range of machines.

Our qualified team of technologists and engineers offers both theoretical and applicative activities. Constantly developing the know-how thanks to a significant number of trials and different outcomes experience during our many years in the mixer manufacturing market. These experts have helped solved many issues experienced, especially in the higher viscosity range of products.

Silicone Expo 2024 Europe
You are welcome to visit our booth on February 28 and 29 at RAI-Amsterdam.

Learn about the latest innovations and trends in process technology and quality control for the silicone industry at our upcoming trade show! Whether you are active in research and development (R&D) or manufacturing, this expo offers a unique opportunity to stay up-to-date on the latest technologies.

What to expect from our fair:
🙂 Showcase of advanced manufacturing processes for efficiency and quality optimization.
🙂 Demonstrations of state-of-the-art mixing techniques, improve your mixing process, improve your process time!
🙂 Interact with leading experts and professionals in the silicone industry.

Whether you are looking for opportunities to strengthen your research and development efforts or improve your manufacturing processes, this expo offers a comprehensive overview of the latest developments that can take your business to new heights.

Don’t miss the opportunity to be at the forefront of the silicone industry. Come to the ZANELLI booth and be surprised.
#silicone

Visit us in Indianapolis at the industry’s most important trade show.

You can find us at booth number 1975.