Lab 3 roller mill

Types of lab 3 roller mills

A lab 3 roller mill consists of three horizontal rods (rollers) covered with a hard material like metal, ceramic, or alloy. They all rotate at different speeds in different directions to gently crush materials and produce a homogeneous mixture. There are two main categories of lab three-roller mills:

• Generally

  A standard lab 3 roller mill has three cylindrical rollers that are usually made of stainless steel. The gap between the top roller and the bottom and middle roller is adjustable to finely crush particles. The upper roller rotates in the opposite direction of the middle and bottom rollers. This three-way rotation moves material in between the rollers as they crush and gap them. Three-roller mills are common in printing ink and paint companies.

• Products with similar functions

  Some products with similar functions to a lab 3 roller mill include the lab 5 roller mill and the 3 roller mill machine with stone rollers. The lab 5 roller mill machines are the same as three-roller mills but use five rollers instead. They are larger and better suited to scale up production in mid-sized to large industries. Like the three-roller mills, they also gap and crush material homogenously. On the other hand, the three roller mill machines with stone rollers use granite stones instead of metal. They are more durable and resilient compared to their metal counterparts. The stone roller mills are also quieter during operation. Generally, all the mills work the same way. They are used to crush and gap materials with different particle sizes and produce a uniform end product.

Specification & Maintenance

The following specifications of 3 roller mill lab help buyers understand the machine better.

• Roller material:

  The 3 roller mill's core part is the three rollers, which comprise various steel alloys. SS is a popular choice due to its anti-corrosion properties, ability to maintain hygiene, longevity, and resistance to high temperature. High-chrome alloy steel boosts the roller's durability, while wrought iron alloy steel improves its toughness, preventing breakage. Some lab mills have a chrome-plated or ceramic-coated surface to enhance their anti-corrosion and anti-abrasion ability.

• Rollers diameter/ width:

  Alibaba.com offers lab 3 roller mills with different roller diameters or widths, such as 35/40/50 mm. A larger diameter can mill more products per batch. Sometimes, they are interchangeable to suit specific product requirements.

• Speed ratio:

  This refers to the ratio of the first to the second roller's speed. The first roller's higher speed helps pull the product in and crush it. The laboratory roller mill speed varies according to the product to be processed; for example, the ratio could be 3:1 or 4:1.

• Base:

  This stands on the floor and keeps the three rollers in place. An alloy cast iron base is sturdy and prevents movement during milling. A more lightweight and mobile option is an aluminum alloy base which makes it more portable.

• Power:

  This refers to the motor power in kilowatts (kW) or horsepower. A common power specification is 2.2kW/3hp, which is enough to crush small to medium batches.

• Capacity:

  The maximum product volume this machine can handle in a day determines its capacity. It is roller diameter, speed, and torque dependent. A typical capacity is 200-500 kg/h, but there are some with a higher capacity.

Maintenance

Some of the maintenance tips for the three roller mill machine are as follows:

• The supplier will send the machine manual for its parts and how to use it. The manual will help operators learn about the machine and how to maintain it better.
• Regularly inspect the lubrication parts in the machine. They should be clean and free of any contamination. The supplier will explain the process in the manual.
• Lubricate all moving parts in the 3 roller mill and the chains as outlined in the manual. Doing so regularly minimizes abrasion and wear and keeps the machine moving smoothly.
• Use the right oil for lubrication activities that the supplier recommends. Irreparable damage and breakdown of parts may occur if the wrong oil is used.
• Set a routine maintenance schedule with a qualified technician. The schedule will ensure parts and roller mill are always in good condition for use.
• Avoid delaying repairs to damaged parts, such as the driving system, bearings, seals, and gears. Damaged parts can reduce the product’s quality and create hazards.
• For safety, teach the operators during training on how to use the 3 roller mill and carry out maintenance tasks. They should read the manual before attempting to perform any tasks.

Usage scenarios of lab 3 roller mills

The lab three roller mills are used for multiple applications in various industries. Some usage scenarios of the three roller mill in the laboratory are as follows.

• Paints and Coatings

In the paint and coating industry, the three roller mills are used to create smooth and stable paints and coatings. Pigment concentrates are broken and turned into a uniform dispersion. The viscosity of the paint and coating material is improved by using the three roller mills.

• Ink

The ink industry uses the three roller mills to work on different ink formulations, such as letterpress inks and oil inks. The mills improve the quality and stability of the inks by ensuring that the pigment particles are properly dispersed and broken down. In the lithographic industry, the mills disperse colour pigments in ink formulations. They improve the quality, vibrant colour reproduction, and stability of the inks used in prints.

• Cosmetics and Personal Care Products

In cosmetic laboratories, the three roller mills help to manufacture personal care products, such as creams, lotions, and ointments. The device ensures quality control and uniformity of the final products by emulsifying and refining the materials used in the creams and lotions.

• Food and Beverages

Food and beverage companies may use the three roller mills to refine and homogenize sauces, dressings, and emulsions. The device improves mouth feel, texture, and sensory properties of food products, such as spreadable food products and fine purees.

• Pharmaceuticals

Pharmaceutical companies use the three roller mills to refine active ingredients when manufacturing drugs and medicine. The device ensures the uniform distribution of active pharmaceutical ingredients (API) in tablets, ointments, suspensions, and creams.

• Masticatories and Pastes

Masticatories and pastes, such as chewing gum bases and adhesives, are quickly refined by the three roller mill machines. The mills ensure that the chewing gum has an optimal texture and consistency, thereby improving the consumer experience.

• Rubber and Plastic Compounds

In the rubber and plastics manufacturing industry, the three roller mills are used to compound and process rubber and plastic materials. Homogenization and dispersion are crucial when formulating materials used in these industries, and the roller mill offers just that.

How to choose lab 3 roller mills

• Desired final particle size:

  Particle size reduction systems can achieve different final particle sizes. Considering the ultimate goal is essential when determining which model is ideal for specific material processing.

• Adaptability to different materials:

  Some three-roll mills are more versatile than others. The ability to handle various viscosities, consistencies, and densities can provide greater flexibility in production.

• Production capacity:

  Higher throughput is possible with some roller mill machines than others. A three-roll mill with more excellent processing ability can reduce costs in large-scale production environments. Nevertheless, rollers with lower capacity may be more economical for small-scale production.

• Equipment footprint and design:

  Floor space utilization is vital when considering confinement in a production facility. Whether to mount it on a stand or integrate it into an existing line determines the equipment's design and dimensions.

• Operating requirements and controls:

  The skill level needed to operate the roller mill and the simplicity or intricacy of its control system are significant factors to consider. In some situations, a straightforward, easy-to-use roller mill with basic manual controls is preferable. Conversely, facilities may require an advanced three-roll mill with sophisticated touch-screen digital controls and automation integration capabilities.

• Health and safety aspects:

  Health and safety issues pertaining to equipment operation are critical. Before making a choice, it is necessary to consider factors such as whether the mill is explosion-proof, its compliance with specific industry standards, and any required extraction or containment systems.

Lab 3 roller mill FAQ

Q1: Why should one use a three roll mill machine instead of a two roll?

A1: The three roll mill offers a better-controlled dispersion than a two roll. It also has the ability to heat and cool materials, which is typically not possible in a two roll.

Q2: Can a lab 3 roller mill machine be run with an air compressor instead of a water chillera?

A2: Yes, it is possible to use an air compressor but the material will not get as cold as it would with a water chiller. Therefore, it is better to use a water chiller to keep themillsurface cooler.

Q3: What are the safety features in a lab 3 roller mill?

A3: Modern three roll mills have safety features such as guards, end plates and a safety trip pull. The safety guard covers the rolls completely and there arecend plateson the rear side of the rolls. The safety trip pull is a rope that stops the machine quickly if any emergency arises.