Mixing Technology Insights
Mixing Technology Insights offer a brief look into ROSS' products, process expertise and market strengths. The reports delve into how the equipment can be used to improve your process and to add to your bottom line. ROSS strives to provide its customers with up to date information covering new technology in the industrial mixing and blending industry.
Select a specific product, process or market to view a list of related Insights:
- Recommended Mixing Equipment for Filter Cake Dispersions
This bulletin describes three mixing technologies commonly utilized in the preparation of filter cake slurries: High Viscosity Dispersers, Dual-Shaft Mixers and Inline High Shear Mixers.
- Recommended Mixing Equipment for Starch Dispersions
Dispersing powdered starch into liquid is a commonly encountered mixing challenge because of its tendency to float and form lumps (“fish eyes”) if not added or agitated properly.
- Recommended Mixing Equipment for Carbomers
Carbomers are water-soluble acrylic acid polymers available in dry powder form. Acting as thickening and gelling agents, different grades of carbomers produce a wide range of viscosities for suspending insoluble ingredients and stabilizing emulsions.
- Speed up your dispersion and
- Multi-viscosity mixing in a
This bulletin provides a step-by-step look at a typical multi-shaft mixer application which demonstrates the system’s processing flexibility in terms of mixing, heating, cooling and deaerating batch material at different viscosity stages.
- How to upgrade your high speed disperser
Increased demand, product improvements, change in raw material supplier, custom orders and many other situations can cause mixing processes to outgrow the original equipment. This bulletin offers some insights into the operation of high speed dispersers and how to address specific areas of improvement using alternative mixing solutions.
- Simplified production of fine solid dispersions.
This bulletin discusses a new technology for producing stable dispersions of solids in liquid. Ultra-high shear mixers such as the ROSS PreMax utilize specially engineered rotor/stators that can deliver extremely fine particle size distributions faster and more cost-effectively than conventional milling devices.
- Ultra-high shear mixing: an
alternative to three roll milling
Certain applications that previously required three roll milling can now be processed in inline ultra-high shear mixers. Advantages include higher throughput, lower processing costs, safer operation and simpler maintenance.
- Designing high speed dispersers
for large-scale mixing processes
In addition to maintaining basic design parameters, high speed dispersers can be specially engineered to support high volume production requirements.
- Ultra-high shear mixing of
Batch and inline ultra-high shear rotor/stator mixers can effectively disperse nanoparticles into liquid. Advantages include short processing times and volume flexibility, as well as easier maintenance and lower capital cost compared to traditional milling equipment and high pressure homogenizers.
- Preparing superior quality
This bulletin discusses various mixing technologies for efficient processing of high-quality nanoparticle dispersions depending on rheology and shear requirements.
- Move your media mill process
to an ultra-high shear mixer.
Specially designed rotor/stator mixers achieve ultra-high shear conditions which often result in extremely fine dispersions of pigments and other raw materials. More than just an ordinary ‘pre-mixer’, an ultra-high shear rotor/stator device can produce results comparable to one or two passes through a media mill.
- Mixers for continuous dilution
Static mixers and rotor/stator mixers are utilized for truly continuous in-line dilution of concentrated solutions. Advantages include high throughput, low space requirement, easy installation, performance predictability and low maintenance..
- Multi-agitator mixer/reactors
Multi-agitator mixers are ideal for reaction processes that require intense mixing, high speed dissolution, emulsification, deagglomeration or heating/cooling of viscous liquids.
- Effectively disperse fibers into your viscous mix.
Many fiber-filled composites are high viscosity formulations that require efficient dispersion in a planetary mixer configuration where a number of blade designs and combinations are available. Fiber characteristics and composite rheology are the main factors evaluated in the mixer selection process.
- Best practices for safe and efficient three roll milling
The three roll mill remains to be one of the best methods for preparing very fine particle dispersions. This bulletin discusses some best practices to help users operate the three roll mill safely and efficiently.
- Mixing high solids
Mixer selection for high solids formulations depends on viscosity rather than percent solids. Regardless of solids concentration, low-viscosity mixtures can be prepared in single-shaft rotor/stator mixers or high speed dispersers. For products that undergo a high viscosity phase, multi-agitator and planetary mixing equipment are commonly employed.
- Inline mixing of gases and liquids
Efficient mixing of gases and liquids is a critical step in many chemical and biological process technologies. Static mixers and inline rotor/stator mixers are typically used in gas-liquid applications where high intensity mixing, short contact time and/or continuous processing are required.
- Shorten your dissolution time by switching to a multi-agitator mixer.
Dissolution processes can be optimized through the use of multi-agitator mixers which provide a combination of low-speed blending, high shear mixing, particle size reduction and superior heat transfer.
- High speed mixing: saw-tooth dispersers vs. rotor/stator mixers
The saw-tooth disperser and rotor/stator mixer are two of the most widely used high speed mixers yet many are unaware of the differences in their utility and operating capacities. Knowing the unique attributes of these devices is important in mixer selection and process optimization.
- Eliminate “fish eyes” in your mix.
Inefficient mixing can lead to agglomerates and “fish eyes” which are difficult to disperse once formed. Using a high shear mixer equipped for powder induction helps prevent the formation of agglomerates, maximizes yield and cuts cycle time.
- Consider the advantages and disadvantages of scrapers.
Consider the advantages and disadvantages of scrapers.
The use of scrapers in batch mixing operations helps improve product homogeneity and heat transfer efficiency. However, there are cases wherein scrapers are not recommended such as in the processing of abrasive applications or highly viscous, sticky materials.
- Double planetary mixers are ideal for low shear dispersion of viscous materials.
Viscous products possessing shear-sensitive behavior, fragile components or abrasive properties require gentle but thorough mixing. In most cases, a double planetary mixer is the best choice for processing such applications.