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An industrial disperser is a blending device that breaks down clustered particles in a matter to make them homogeneously spread throughout the fluid. Here are some common types of industrial dispersers:
High-Speed Dispersers
High-speed dispersers are mixing machines that are widely used to mix fluids of different densities and resistances. Usually, they feature a robust motor driving a disc-shaped blade, which is submerged in a matter to be mixed. The blades' size and shape vary, adjusting the dispersers to work with diverse applications. When the motor rotates the blade at higher speeds, they create shearing forces that break down clustered particles, pushing them to spread throughout the liquid. High-speed dispersers are suitable for dealing with matters that require rapid mixing, homogenization, and dispersion of particles. They work well in various industries, such as paints, coatings, inks, and food processing.
Ultrasonic Dispersers
Ultrasonic dispersers use ultrasound waves to disperse and mix particles in a liquid suspension. The device works by creating cavitation, a pulsation phenomenon where periodic pressure changes lead to the formation of bubbles. The bubbles grow and eventually collapse, releasing energy bursts. This energy breaks down agglomerated particles and disperses them into the liquid medium. Ultrasonic dispersers are appropriate for various applications in different industries. For example, they are used to break down tough agglomerates and minerals in the manufacturing of nano-ceramic and nano-filler dispersion.
Vacuum Dispersers
A vacuum disperser is a mixer machine that operates under vacuum pressure. The machine features a dispersing blade and a mixing vessel. When the vessel is under vacuum, smaller air bubbles are drawn into the vessel, and the blade starts to rapidly rotate. The circumferential speed and the high shear forces generated by the rapidly rotating blade break down particle agglomerates, leading to fine and uniform dispersion. One major application of vacuum dispersers is in the degassing and dispersion of adhesive mixtures and compounds used in the electronic and automotive industries. They are also used in coatings, paints, and inks that easily form air bubbles.
Colloid Mills
Colloid mills are industrial machines that finely disperse liquids and solids to create stable emulsions, suspensions, and homogenates. The mills utilize shearing, grinding, and hydraulic forces to break down agglomerated particles in a mixture by passing them through narrow gaps. This leads to the creation of a uniform, smooth liquid matter. The particle size reduction mechanism and the stability achieved after processing make colloid mills suitable for various applications. For example, they can be used in food processing to produce sauces, purees, and emulsified dressings. Also, in pharmaceutical industries, colloid mills work to produce ointments, creams, and lotions.
Power of industrial dispersers
Industrial disperser mixers are generally available in power ratings range of around 5 KW to over 500 KW, depending upon the specific application and model. Larger power ratings produces greater torque, permitting the machine to mix high-viscosity material deeply. For example, a typical model has a power rating of 15 KW, which is adequate for moderately-sized batches and viscous liquids.
The diameter of the disperser blades
A disperser blade's diameter ranges from about 50 mm to over 600 mm. The disperser blades are placed on an axle and rotated rapidly to cut, shear, and mix the raw materials in the container.
The number of disperser blades
A disperser usually has 2 to 6 blade assemblies. Each assembly has 3 to 5 blades. More blades generally produce better mixing for liquid and solid materials.
The height of disperser blades from the bottom of the container
Disperser blades are generally located from about 50 mm to 100 mm above the bottom of the container. This positioning allows easy circulation of the material and prevents wearing out of the blade.
Speed of disperser
Industrial dispersers generally operate at a speed of around 500 RPM to over 5000 RPM. Different models have different speeds. Some models have a variable speed. The motor rotates the axle, and then the blades cut and stir the material. Higher speeds are suitable for low-viscosity materials like water, whereas lower revolutions are better for high-viscous and dense liquids.
Proper maintenance is essential for smooth and efficient working and long operational life.
Regular cleaning
Clean all parts of the industrial disperser regularly. Stuck material and dirt can reduce efficiency and shorten the lifetimes of parts.
Lubrication
Industrial dispersers have bearings and moving parts. They should be greased or oiled regularly, as recommended by the manufacturer. Do not over-lubricate, as it can attract dust and dirt.
Check fasteners
The nuts, bolts, and other fasteners should be checked regularly and tightened if needed. The vibrating motion can loosen fasteners over time, which can affect the performance and safety of the disperser.
Replace the blade
The blades wear out over time. Inspect them periodically and replace them if there is uneven damage or a more significant decrease in the mixing efficiency.
Electrical connections
Check the electrical connections periodically and ensure there are no loose connections. Check the cables and ensure they are not cracked or damaged.
Food and beverage industry: emulsification and production of sauces
Industrial dispersers are widely used in the food and beverage industry to deal with food materials with different viscosity and densities, such as oil and water mixing, fruit and vegetable juice extraction, etc. For example, making sauces such as mayonnaise requires an industrial emulsifier to maintain stability and avoid separating the oil and water components. Industrial emulsifiers are also used in manufacturing processed food like ice cream and bakery products. They can improve products' texture, mouthfeel, viscosity, and stability.
Pharmaceutical industry: solid-liquid dispersions and emulsions forming
Pharmaceuticals require precise parameters and controlled procedures. Industrial emulsifiers in the pharmaceutical industry can form solid-liquid dispersions and emulsions, as well as drugs, antibiotics, and vaccines. They can improve the stability and bioavailability of drugs and ensure the exact dosage and safety of patients.
Chemical industry: preparation of paints and coatings
Industrial dispersers play a significant role in the chemical industry. They are used to prepare paints and coatings, ensuring products' uniformity, stability, and quality. Industrial dispersers can disperse pigment agglomerates, enhance pigment wetting, achieve optimal grinding effects, and improve coating adhesion to substrates.Industrial dispersers can also emulsify and disperse petrochemical products. For example, industrial dispersers are used to prepare detergents such as laundry detergent and dish detergent. They can stabilize the emulsion system, disperse active components, and enhance the product's cleaning ability and stability.
Cosmetic industry: emulsification and stabilisation of cosmetic products
Industrial dispersers are also used in the cosmetic industry to emulsify and stabilise cosmetic products. For example, foundation, cream, lotion, etc. Industrial dispersers can ensure that the cosmetic products are well-blended, evenly distributed, and stable for a long time. In addition, Industrial dispersers can deal with different raw material characteristics, such as pigments, fillers, oils, and surfactants, to improve processing efficiency and product quality.
For starters, buyers will need to establish the capacity of the disperser they need. If they handle vast batches of material, a large-scale industrial disperser could be an excellent fit. Alternatively, smaller ones would work for those dealing with small batches.
Next, buyers should evaluate the design of the disperser they are looking to buy. Different models exist out there, with each having its unique capability. An open-type disperser would do for those whose tasks require frequent material sampling. A closed-type one would suit better for those who prioritize containment and security. An anchor-type disperser works for those handling viscous materials, while a turbine would suit better for those dealing with low-viscosity fluids.
Consider the material of construction. Stainless steel dispersers work for those in industries that require high levels of hygiene, such as the food and pharmaceutical industries. Low-carbon steel would work for industries that don't have high-standard requirements.
Also, buyers should consider the rotor design and speed. Various dispersers can rotate at different speeds. They may also have variable speed settings to give operators more control over the dispersing process.
Finally, buyers should consider model compatibility. Some dispersers come with interchangeable rotors that suit different applications. Also, check whether the disperser can connect to other devices such as sieves and filters for more efficacy.
Q1: What is the difference between a disperser and a stirrer?
A1: Dispersers differ from stirrers in that they use high shear force to break up particles while homogenizing the mixture. Dispersers also have the goal of achieving uniformity rather than just mixing.
Q2: Do industrial dispersers have motors?
A2: Typically, an industrial disperser will have a motor. The job of the motor is to provide power to the dispersing tool or blade. Motors used in industrial-grade machines are usually heavy-duty so that they can ensure proper dispersion.
Q3: Are industrial dispersers portable?
A3: Some industrial dispersers are portable, allowing for easy transfer between batches or containers. However, many are fixed or stationary because they have to be aligned with a pump for the whole system to work.
Q4: Can industrial dispersers be repaired?
A4: Often, industrial machinery can be repaired unless it is extensively damaged or worn. Manufacturers will make replacement parts readily available so that businesses can get them repaired with little downtime.
