The Expert's Corner
The Expert's Corner Blog features curated content from ROSS engineers, managers, and sales reps, updated regularly, to provide customers with in-depth mixing knowledge, advice, and solutions.
Blog Posts: case studies View All
Large-scale processing of molten metal slurries with melting points above 350°F (180°C). The product is explosive with moisture, and capable of reactions with oxygen, carbon dioxide, and a variety of other elements - including nitrogen - at room temperatures.
A manufacturer of pest control products was previously batching a granular pesticide for insect larvae in small quantities using a table-top kitchen mixer. As the product line grew, it became necessary to move the process to a large-scale blender. The company visited the Ross Test & Development Center to see if a Ribbon Blender can produce a uniform blend of the granules, liquid component and powder.
A major global confectionary company approached ROSS to improve their process of manufacturing a chocolate product. They were using a kitchen-style single planetary mixer that was unable to handle the high viscosity peaks that occur during mixing. The material spikes to over 1 million centipoise and finishes around 20,000 cps.
A global cosmetic company approached ROSS with the goal of expanding their gel manufacturing capabilities. Our team at the Ross Test & Development Center conducted a pilot demonstration to evaluate an appropriate batching and mixing procedure on a 100-gallon VersaMix Multi-Shaft Mixer.
A manufacturer of plastic pipe and pipe fittings upgrades to a ROSS double planetary mixer to improve consistency and eliminate voids in their products
Ribbon Blenders consist of a U-shaped horizontal trough and an agitator made up of inner and outer helical ribbons that are pitched to move material axially and radially. This combination promotes fast and thorough blending even if the batch contains components with different shapes, sizes and densities.
A custom 6-cu.ft. ROSS Ribbon Blender/Dryer is helping to advance solar energy research. The pictured vacuum blender features an ASME-stamped hot oil jacket rated for 75 psig and 300 degrees Celsius. A 4" thick insulation with sheathing assists in temperature control.
The VersaMix has increased production, improved product consistency, and provided plenty of versatility to handle many different products. Variable frequency drives provide independent speed control for each of the three agitators
Three Roll Mills were developed over 150 years ago, yet they continue to be one of the best methods of for preparing very fine particle dispersions. This equipment is used in a wide variety of applications including paints, inks, cosmetics, ointments, gels, pastes, and other viscous materials.
A specialty manufacturer of polyurethane-based coatings and adhesives sought Ross for a major fast-paced expansion project. They supply to the sports industry where their products are applied to surfaces of tracks, gym floors, courts and playgrounds.
A major adhesives company was looking for a better way to dry a pigment formulation used for a particular urethane-based product. They had tried using different types of horizontal blenders to bring the moisture level down to 0.5% or less.
To satisfy the requirements of a manufacturer of electronic materials, Ross designed and manufactured a special PowerMix Model PDM-4 Gallon in conjunction with a Ross Discharge System.
Production rates from existing batch mix tanks were not fast enough to meet the needs of the new product line of liquid soaps at a cosmetics manufacturer, a producer of fragrances, cosmetics and toiletries. With the use of a ROSS in-line mixer-emulsifier and plate heat exchanger, batch time has been reduced from two hours to one hour and the product consistency has improved.
A major chemical manufacturing company recently ordered three Ross Model HSM-401 Inline High Shear Mixers to reduce the size of particulates in a hydrocarbon slurry.
Ross Inline High Shear Mixers are used to produce flocculants for wastewater treatment facilities all over the world.
A company that manufactures zinc coatings was using a high-speed disperser with a modified sawtooth blade to disperse the fine, dusty zinc powder into a resin based vehicle.
Ross Double Planetary Mixer with HV Blade Design Solves Problems in Mixing Ultra High Viscosity Sealants
A major manufacturer of silicone sealants was looking to make a new, highly filled, silicone sealant. The desired product has a viscosity of over 9 million centipoise and is very "sticky". This posed several problems for manufacturing the new sealant with their Double Planetary Mixer with rectangular stirrer blades.
In this technical brief we attempt to quantify the benefits of scraping the vessel walls of a Ross VersaMix. This is an important illustration as many emulsion based cosmetic creams and lotions require precise and responsive temperature control, especially in the cooling cycle, to effect the desired result.
One method of Thermoforming utilizes a male plug to assist the vacuum or pressure in forming the plastic part. These plugs have traditionally been machined from blocks of aluminum which can be expensive.
A major chemical company produces a catalyst for use in internal chemical processing. This catalyst includes a mixture of silica and metallic salts and is manufactured in a 2500 gallon reactor. The catalyst solution is 40% solids, has a specific gravity of 1.2 and a viscosity of approximately 100 cps.
Pest control in beehives is attracting renewed attention from pesticide manufacturers due to some species of mites that have become immune to commonly used pesticides. A new product consisting of vegetable shortening, granulated sugar, honey and an active ingredient is proven through laboratory tests to be effective in suppressing mite populations in beehives. The customer is looking to scale up their production of this successful formulation. In their R&D lab, a 1.5Hp single planetary mixer is being used but the machine is observed to be straining against the toughness of the dough-like mixture.
Obtaining the optimal functionality of CELLULON PX or AxCel CG-PX microfibrous cellulose requires proper activation techniques. The co-processing agents present in these microfibrous cellulose blends are xanthan gum and cellulose gum, both soluble components that need to be properly dispersed and hydrated in order to completely release the insoluble active ingredient, microfibrous cellulose, into the water phase.
ROSS VersaMix with SLIM Produces Viscous Carboxy-Methylcellulose Gels for the Pharmaceutical Industry
Carboxymethylcellulose (CMC) is a cellulose-derived water-soluble polymer, principally used as a water binder, thickening agent, suspending agent and emulsion stabilizer. Applications for CMC are in the manufacture of detergents, soaps, food products, textiles, paper coatings, drilling muds, emulsion based paints, cosmetics and pharmaceuticals.