COST BENEFITS OF ULTRASONIC BLENDING

Traditional blending is slow, energy-hungry, and expensive. Blendtek’s ultrasonic technology delivers major cost savings, higher capacity, and greater flexibility – without heavy infrastructure or long blend cycles.

Increased Production Capacity

  • Each unit blends up to 12 MT per hour.
  • Multiple units in series further increase capacity.
  • No need to duplicate (“mirror”) plant infrastructure.
  • Customers have even reported lower insurance premiums by removing gas boilers from site.

Batch Flexibility

  • Extremely low minimum batch quantities.
  • No heating elements or agitator restrictions.
  • Compatible even with simple IBC tanks.
  • Failed batches can be re-blended instantly – no reheating required.

Speed & Just-in-Time Production

  • Faster blends enable lower stock inventories.
  • Slow movers and niche products can be made to order.
  • Prevents overproduction caused by minimum batch requirements.
  • Cold blending means filling can start immediately – no cooling delays

"Traditional blending requires heating tanks to 50–60 °C, stirring for hours, and then cooling – often taking a full day. Blendtek eliminates these steps, cutting both energy and time by over 90%"

Space & Layout Advantages

  • Mobile units = easy to move and reposition.
  • Can also be installed permanently.
  • One tank can handle blending, storage, and filling.
  • Easily scalable: from single units to turnkey solutions.

Operational Efficiency

  • Cold process prevents oxidation.
  • No polymer degradation thanks to extremely short Residence Time Distribution (RTD).
  • Reduced downtime between blends.
  • Easily flushable = quick product changeovers.

Cost Saving Credentials

As well as time and environmental advantages, the Blendtek solution provides businesses with considerable and multiple cost saving benefits:

  • Typically over 90% reduction in blend energy costs.
  • Faster, smaller runs = fewer labor hours.
  • Less risk of off-spec batches.
  • Use of thinner, lower-cost tanks is possible.
  • Eligible for sustainability grants and green investment allowances in many regions.

Energy & Cost Comparison

Case Study: 5,722 kg UTTO Blend

This cost comparison is based on a real blend study using the Blendtek ultrasonic unit versus a traditional batch blending process. To ensure accuracy, the analysis focuses only on the variable energy inputs for heating and mixing.

Shared inputs – such as base oil pumps, additive pumps, and hotboxes – are excluded, as these are identical for both methods. By isolating the variable consumption, the comparison provides a clear and fair view of process efficiency.

  • Traditional batch blending: 127.5 kWh, ~70–80 min.
  • Blendtek ultrasound blending: 3.4 kWh, 34 min.


➡ Energy savings of 124 kWh on a single batch = ~£5.10 per tonne (UK energy price basis).
➡ Equivalent CO₂ savings: 4.9 kg per tonne.
➡ Process time reduced by 60%.

The Bottom Line

Blendtek helps you:

  • Cut cost per litre of production.
  • Increase plant capacity without new staff or infrastructure.
  • Achieve sustainability targets while improving profitability.


👉 Contact us today to calculate your ROI with Blendtek.