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A high speed dispersing mixer is an industrial mixing equipment that enhances the particle size distribution and stabilizes the mixture. Usually, high-speed dispersing mixers that are available on the market have various designs according to the specific application.
Batch Dispersers
Batch dispersers are production-scale mixing units used to process batches of product at one time. The main components of batch dispersers are motors, gear-reduction units, shafts, and disperser blades. Motors in a batch disperser may vary from 5 to 20 h.p. and are selected according to the required product volume and viscosity. The gear-reduction unit controls the disperser's speed. Some products may need higher speed or lower speed, and some may require a longer time to process. The gear-reduction unit will change the speeds or processing times of the products. The width and design of the disperser blade will determine how much product will be processed and how long it will take to process according to the viscosity.
Continuous Dispersers
This type of high-speed dispersing mixer is similar to batch ones, but it can process the mixture in a concise time. It usually comes with a pumping system that feeds materials into the machine. In addition, the gearbox in the continuous disperser can offer various speed adjustments to suit different kinds of materials.
High-Flow Disperser
A high-flow disperser is a mix of a batch disperser and a continuous one. It features a high flow rate, and large blades help mix more materials at once. Moreover, a high-speed dispersing mixer also provides various speed adjustments to suit different materials. In addition, it has a motor with a higher horsepower that can handle more viscosity.
Inline Dispersers
Inline dispersers are also referred to as in-tank dispersers. When a product needs to be processed in a tank, then an inline disperser will be the right choice. The motor of an inline disperser is smaller than that of a batch or continuous one because it processes fewer volumes of products. It may also run with other mixers.
Anchor Mixers
Anchor mixers are designed specifically to handle materials with high viscosity. They are equipped with wide splayed arms that are designed to move through thick products effectively. Sometimes they work with heaters and stir kettles to melt certain materials. Anchor mixers heat kettles will do the job of mixing and heating certain products with a motor that has a higher horsepower.
Motor Power:
Typically ranges between 5 kW-25 kW. Industrial models may go higher for larger volumes.
Speed Range:
Can be as low as 0-200 rpm up to as high as 5,000-20,000 rpm or more. Higher speeds available in some models.
Mixing Capacity:
Usually between 50 liters up to several thousands of liters per hour depending on model size.
Dispersing Blades:
Common types include saw-tooth, disc, fish-tail and others; size ranges from 200mm-600mm diameter.
Workshops:
Suitable for many industries such as paint, ink, food, pharmaceutical, cosmetic, chemical, resin and more.
Power Supply:
Generally AC 380V±10% 3 phase or other specified voltage requirements.
Equipment maintenance is extremely important to keep its proper functioning, ensure safety and extend its service life. Here are some regular maintenance methods:
Check:
Always inspect the mixer to see if there are signs of any damages. Check the fastening of all components and especially the dispersing blades. Tighten and repair any problem parts in time to avoid larger faults.
Lubrication:
Apply lubricant to the gearbox, bearings and other moving parts periodically as per schedule specified in manuals. Regular lubrication helps keep good and smooth running.
Cleaning:
Clean the mixer, especially its containers and blades. Remove residues of materials thoroughly to stop cross-contamination between batches.
Adjustment:
Adjust the dispersing speed, mixing time and other parameters to match specific material characteristics as well as processing requirements. Change them according to different usage occasions.
Maintaining records:
Keep a maintenance record file. Log details like inspection results, cleaning processes, repair activities and more; This provides referenced basis for future equipment management.
Mixers with high speed are used in different industries. Here are some common usage scenarios for high-speed mixers.
Pharmaceutical Industry
Drug production needs to mix and combine different components. The components may include powders, liquids, and granules. A high-speed dispersing mixer helps to create uniform drug formulations. It also boosts the stability of drugs.
Food Industry
The high-speed dispersing mixer can combine food ingredients, additives, and flavorings. It also helps to create uniform textures and consistent flavors in food products.
Chemical Industry
High-speed mixers blend chemicals, pigments, and additives. They are also useful in formulations, coatings, and paints. The mixer boosts consistency and improves product quality.
Construction Industry
Mixing cement at high speed improves the uniformity of construction materials. High-speed mixers are ideal for blended powders, paints, coatings, and adhesives.
Cosmetic Industry
Cosmetics manufacturers use high-speed mixers to create emulsions. The mixer aids in creating stable formulations like creams, lotions, and serums.
Plastic and Polymer Industry
High-speed dispersing mixers enhance the uniform blending of plastic compounds, fillers, and additives. They improve the quality of the finished plastic products.
Grease and Lubricant Industry
High-speed mixers help blend base oils, additives, and thickening agents rapidly. They also improve the consistency, homogeneity, and performance of lubricants and greases.
Paint and Coating Industry
Mixing at high speeds creates paints and coatings that are well-blended. The mixer enhances the effectiveness and quality of coatings.
Production volume:
The typical batch sizes and production volumes that need to be processed are primary considerations when selecting a high-speed disperser. They will greatly influence the capacity and size of the dispersing mixer chosen to meet specific production needs.
Viscosity:
The viscosity of the materials to be processed should also be taken into account when selecting a dispersing mixer. If the viscosity is too high, the final product may not meet quality standards, and the mixing time may be longer.
Dispersion:
The level of dispersion required is another essential factor in selecting a dispersing mixer. A high level of dispersion is needed to achieve a homogeneous mix of particles and maximize the quality of the final product.
Motor Power:
The motor power of a high-speed disperser mixer governs its processing capacity. Too low motor power may struggle to handle batches effectively, leading to longer processing times and inadequate mixing.
Additives:
The Additives used in the formulation may also influence the choice of dispersing mixer. Some additives may require specific mixing techniques or equipment to achieve optimal dispersion and incorporation into the formulation.
Budget and ROI:
Another important consideration when selecting a dispersing mixer is budget and ROI. There are many models, sizes, and specifications of dispersing mixers on the market, which can be matched to specific needs and budget constraints.
Q1: What is the difference between dispersers and mixers?
A1: Dispersers are used for difficult tasks like breaking up lumps, making stable emulsions, and homogenizing particle sizes. They work with more power and better blades. On the other hand, mixers do general mixing jobs. They unite similar materials quickly and efficiently. While dispersers have the speed and strength to tackle tough jobs, mixers are sufficient for ordinary mixing tasks.
Q2: What are the limitations of a high-speed disperser?
A2: High-speed dispersers might not mix large amounts, work with very thick materials, or create uniform mixes as well as other devices. Dissolvers or homogenizers could be better choices for some applications.
Q3: What kind of motors do high-speed dispersers have?
A3: High-speed dispersers can have AC motors, DC motors, or brushless motors. The choice depends on the specific model and intended use.
Q4: Are high-speed dispersers easy to operate and clean?
A4: Yes, high-speed dispersers are user-friendly and designed for easy cleaning. They usually have operating controls that allow adjusting dispersing speed and time. Sanitary models come with a removable dispersing element and smooth surfaces that prevent product build-up.
