BACKGROUND: The current understanding and implementation of continuous mixing of non-Newtonian fluids is insufficient to ensure good mixing in many cases. In this study, the dynamic response of the continuous mixing of xanthan gum solution, which is a pseudoplastic fluid with yield stress, was quantified using a dynamic model that incorporated non-ideal flows within the mixing vessel. The model allowed for two parallel flow paths through the tank: (1) a channeling zone and (2) a mixing zone. RESULTS: Dynamic tests were made using the frequency-modulated random binary input of a brine solution with the feed to determine the magnitude of non-ideal flows. The extent of flow bypassing the mixing zone and the effective mixed volume were determined from dynamic tests and used as mixing quality criteria. We explored the effect of impeller speed, impeller type, feed flow rate through the mixing tank, fluid rheology, and feed and exit location on the degree of channeling and the fraction of fully mixed volume. Tests show that when the surface of the cavern created by impeller approaches the tank wall, the bottom of the tank, and the surface of the fluid within the mixing vessel, the percentage of non-ideal flow approached zero. CONCLUSION: This study identifies important criteria for continuous mixing vessels that will improve mixing efficiency. By applying these findings, a reduction in the extent of non-ideal flow can be achieved, which will improve the quality and control of the continuous mixing processes such as continuous high-viscosity reactor, continuous fermenter, and continuous solid-liquid mixing. (c) 2008 Society of Chemical Industry.