Dispersers play a central role in the dispersion of solids and liquids. Precise selection is essential to maximize color intensity and opacity. Modern devices, such as the IKA model, can reduce energy consumption by up to 90 %. They enable a uniform emulsion, homogenizing the product as a suspension or paste.
Production benefits from shorter process times and resource conservation. MedSolut AG offers a wide range of options for different applications to find the right disperser.
Important findings
- Dispersers increase energy efficiency by up to 90
- Uniform distribution of solids contributes to better product quality
- Devices from IKA offer a wide range of applications
- Suspensions can be mixed faster and more gently
- Every emulsion requires careful machine selection
- The right technology saves operating costs and time
Basics: What is dispersion all about?
Dispersers have played a central role in industrial production since the 1930s. They are used to mix and disperse particles as finely as possible. The effectiveness depends on the viscosity, the speed of rotation and the radius. The shear force, calculated by F = 6 × η × ω × r, enables precise adaptation to the medium. A higher shear force shortens the dispersion time, but can damage sensitive particles.
Modern inline dispersers use focused energy. Systems from ystral concentrate their comminution-effective zone. A short cycle often enables the combination of different phases or the homogenization of solid-liquid systems. Powder and liquid are swirled together in the container, which promotes dispersion and improves the result. The aim is to break phase boundaries quickly and distribute them evenly.
Mixing and homogenization process
The efficient combination of different components is crucial in the manufacture of paints, coatings and other products. Inline solutions feed solids continuously and distribute them evenly in the container. This reduces energy costs through short process times and high shear force.
How shredding energy influences the phase boundaries
The adjustable speed directly influences the performance of the disperser. The snap-in mode allows the energy supply to be adjusted selectively, which increases particle size reduction. Fast break-up of the ingredients minimizes the time required for emulsification. Individual adjustments in power and speed enable smooth operation and rapid achievement of the desired fineness level, even with high viscosity.
Disperser: design and functional principle
A disperser is characterized by a compact design that makes it possible to effectively apply shear forces to the substance in liquid form. This machine, often referred to as an Ultra-Turrax, increases efficiency in the production of suspensions. It crushes particulate components and distributes them evenly in a liquid. The aim is to break up lumpy powders completely.
The process is continuous and creates stable suspensions and emulsions. This enables fast production processes, particularly in the paint industry. Optimized processes reduce energy requirements and costs by up to 90 %. This is a significant advance on traditional dissolver technology, which has seen little innovation since the 1930s.
The internal structure of such systems ensures an extremely large specific liquid surface area. This leads to excellent mixing. Short residence times significantly reduce energy consumption, while the product remains consistently homogeneous. The high volume-specific output enables a significantly better performance yield.
- Less production time thanks to intensive shear gap
- Reduced production costs thanks to modern approach
- Greater system efficiency thanks to flexible integration
| Technology | Volume-specific output | Savings potential |
|---|---|---|
| Classic dissolver | Limited | Low |
| Inline disperser | Up to 30,000 times higher | Up to 90 % |
Inline dispersers, IKA and Ystral: possible applications on a laboratory scale
Modern small-scale systems enable laboratories to develop innovative formulations. They strive for a stable, homogeneous result. An inline design enables targeted work by quickly distributing particles and shortening process steps. Ekato Systems has developed a concept for larger markets that began with 100-liter systems. Later tests on 1000-litre scales confirmed the improvement in dispersing the product and minimized scale-up effects.
When emulsifying or suspending, speed control is crucial. An adjustable vacuum facilitates the introduction of powders. This allows substances to dissolve or chemically combine with each other and homogenize more easily. A dispersing machine with interchangeable modules makes it possible to adapt to different batch sizes. As a result, the end result remains homogeneous and process-stable.
Modular design for different batch sizes
Devices from IKA and Ystral are adaptable for different volumes. Laboratories can emulsify or suspend to ensure reproducibility. Quickly dissolving or chemically combining ingredients creates a safe process. Important factors in a short process are
- Receiving and mixing components
- Required stirring and homogenizing power
- Required vacuum values
Energy efficiency and speed-dependent operation
The energy requirement depends on viscosity and flow behavior. Ystral Coflow allows throughputs of up to 13,500 kg/h, which enables fast work compared to batch processes. This technology shortens production times and disperses the product gently. A small contact surface supports cleaning and increases overall efficiency. This saves costs and optimizes processes.
Production of suspensions and emulsions in containers
The manufacture of emulsified products in large-volume processes is regarded as the epitome of efficient production. In the food industry, large containers are used to mix liquid components evenly. This operation requires precise processes to ensure that particles remain consistently dispersed.
SeFluid high-speed dispersers have outputs of 4 to 110 kW. The process allows a high speed of up to 1500 rpm, whereby liquid formulated substances are quickly homogenized. The systems are suitably equipped and can be used on a laboratory scale before larger quantities are produced.
Typical performance data includes:
- Maximum speeds up to 2930 rpm
- Linear speed of over 20 m/s
- Batch capacities between 200 and 7000 liters
- Automation for shorter mixing times and lower labor costs
The short mixing times save energy and ensure the best results in fine distribution. An automated control system keeps the process under control and minimizes manual intervention, which keeps the quality continuously stable. Paint or lacquer manufacturers benefit from this, as do cosmeticsand chemical companies with higher throughput.
How liquid droplets and solid particles are distributed as evenly as possible
The targeted application of shear forces prevents coarse agglomerates and promotes a high-quality suspension. Fine particles are distributed evenly, which increases shelf life. A well-founded process design enables the use of large containers without compromising on product quality. The result is a stable emulsion that is valued in various industries.
Manufacturers such as IKA and Ystral have developed similar dispersing solutions that adapt to different viscosities. Their flexible concepts have enabled extensive testing in practical laboratories. This results in stable products that meet even the highest requirements in the paints, adhesives and cosmetics sectors. Many users emphasize the short set-up time and low-maintenance design, which makes the production process run smoothly. An intelligent process flow is essential to sustainably increase efficiency and product quality.
Reliable measurements accompany every step to ensure consistent quality. Users benefit from colors, stable consistencies and long-lasting products. Manufacturers increase their competitiveness and deliver quantities without compromising on process reliability.
Mixing and dispersing in practice
Mixing and dispersing is becoming increasingly important in practice when it comes to high-quality products. A suitable design facilitates the mixing of different substances. This makes a process particularly effective in areas such as cosmetics.
The disperse phase plays a central role here. It attempts to create the smallest possible interface. This is crucial for the quality of the products.
Products benefit if they can form a small interface. An emulsifier stabilizes the phase boundaries and serves as a barrier. It prevents agglomeration and ensures a fine distribution.
Optimized processes reduce production costs by up to 90 %. Inline dispersing technologies increase the specific liquid surface area many times over. They minimize production times considerably.
- System efficiency is increased by 60 to 100 % thanks to twin-tank concepts.
- Particle sizes are usually less than 1 mm.
- Time savings of up to 94 % are possible with pigment pastes.
| The process | Energy reduction | Time saving | Further advantages |
|---|---|---|---|
| Inline disperser | up to 90 % | up to 94 % | High volume-specific output |
| Jet mixer | less than one third | up to 90 % | Vertical circulation |
| Batch disperser | - | - | Ideal for dissolving solid prills |
Criteria for the right product in paint and varnish production
The choice of dispersing system depends on energy requirements and particle properties. Primary particles can only be broken down by grinding, while aggregates and agglomerates are effectively dissolved by dispersing tools. Pigments in paints and coatings benefit from finenesses below 5 µm.
The distribution of solid particles into equally sized particles promotes homogenization. The introduction of rotating parts in the rotor-stator principle significantly increases the shearing effect. When processing powder, a short process time enables efficient work. A rising temperature indicates the degree of dispersion achieved.
Dispersers keep viscosities in check. Emulsifiers and stabilizers ensure the stability of the end product. A 110 kW dissolver only needs 10 minutes to process 2000 kg. This results in energy consumption of less than half a cent per kilogram, which guarantees high product quality.
| Particle type | Dispersible | Processing method |
|---|---|---|
| Primary particles | No | Grinding |
| Aggregates | No | Grinding only |
| Agglomerates | Yes | Dispersing |
Range of applications in food, cosmetics and more
Dispersers are not only at home in the paint and coatings industry. INOXPA offers customized solutions for the food, cosmeticsand pharmaceutical industries. A high shear gradient enables the clean processing of powder. This results in a finely distributed structure. The modular systems offer flexible adaptation to different batch sizes. This leaves sufficient free headroom for process adjustments - a sign of modern technology.
INOXPA specializes in strictly regulated sectors such as pharmaceuticals and biotechnology. High-quality components, IQ/OQ protocols and certified processes guarantee hygiene. Mixing unitswith automated control loops are used in 600-liter reactors for shampoos. Lastly, the company relies on technological pilot systems for product tests for creams or gels.
Dissolving substances into each other or chemically combining them
Hair care products, ointments or beverage bases are efficiently processed using active ingredients with the right interfacial tension. This enables a controlled break-up of structures and leads to optimum results.
Ensure a homogeneous phase through homogenization
Homogenization stabilizes the end result. Systems with double mixing cones prove their worth with solid raw materials such as proteins. The disperser optimally combines substances to ensure precise dosing. The result is a uniform, stable phase.
Find laboratory dispersers now: Focus on processing and process system
A laboratory disperser stabilizes boundary surfaces through comminution-effective energy that is designed for uniform results. The processing of fine mixtures requires precise interaction between the dispersing process and the processing system. Dunn Labortechnik, founded in October 1982, has a team of around 20 employees, including five scientists. The company celebrated its 36th anniversary in 2018 and offers solutions for various sectors such as universities, clinics, routine laboratories, research institutes and industry.
Snapin mode and continuous processes
Snap-in mode enables quick changeovers when changing batches. Continuous processes extend the range of applications by crushing particles within a short time. The use of a suitable disperser increases the efficiency of dispersion. An effective dispersing agent stabilizes the system while different batch sizes are processed.
Finely dispersed thanks to the rotor-stator principle
The rotor-stator principle ensures fine distribution, which keeps the particle size stable. The forces generated make the dispersion process extremely effective and enable homogeneous mixtures. This method is versatile and can be used when high quality and consistent viscosity are required. The key lies in adjusting the parameters to achieve optimum flow properties.
Conclusion
Modern dispersing technology plays a central role in numerous sectors. In the paper industry, a suitable disperser enables a significant increase in web strength and smoothness. Disc dispersers operate at impressive rotational speeds, while rotor-stator systems ensure efficient dispersion through strong shear forces. Inline solutions are ideal for high throughputs by providing a continuous process.
Professional systems, such as those from ika, guarantee consistent results at every stage. The final product benefits from improved quality as particles are evenly distributed and air inclusions are minimized. The decisive factors here are the type of material, production quantity and degree of automation. Ystral technologies are also used, especially when processing up to 80 percent solids concentrations.
Reliable systems make a significant contribution to reducing time and energy losses. Maintenance costs are reduced when processes are optimized. Many manufacturers also offer training programs to familiarize personnel with the latest technology. These measures lead to stable production conditions and improved results in laboratory and industrial processes.
Inline dispersers are specially designed for processing large quantities of material. They ensure homogenization in continuous processes without stagnation of the final material. This leads to a reduction in costs and downtimes. The rotor-stator principle can be individually adapted to achieve precise fineness.
A twin-tank system from Ystral supports the processing of poorly soluble powders. The alternating use of the tanks stabilizes throughput. The food industry benefits in particular from the production of milk alternatives or mayonnaise. This minimizes waiting times and speeds up processes considerably.
Are you looking for a suitable disperser? Discover our extensive range here. Sound advice is crucial for selecting the right model and efficiently implementing future projects. A careful investment ensures convincing results in the long term.
Long-term returns increase when the dispersion unit is used optimally and downtime is minimized. Regular cleaning and testing ensure consistent results. In many industries, investing in modern technology offers a clear competitive advantage as it enables high-quality applications with less effort.
FAQ
What is dispersion all about?
In the paint and coatings industry, dispersion aims to mix solids and liquids to create a homogeneous phase. Specialized machines ensure that the product is evenly distributed. This increases efficiency and quality during production.
Which dispersers are suitable for mixing and dispersing on a laboratory scale?
Dispersers from manufacturers such as IKA or Ystral are often used in laboratories. An inline disperser enables continuous mixing and dispersing, often in modular designs for different batch sizes. Such devices work in snap-in mode to introduce powder efficiently. Thanks to inline technology, processes can be precisely controlled on a laboratory scale.
How are suspensions and emulsions produced homogeneously?
When producing suspensions and emulsions, it is crucial to distribute the disperse phase evenly. By emulsifying or suspending, the substances can dissolve into each other or combine chemically. A stable suspension is essential for suspensions. Only thorough emulsification can produce homogeneous suspensions and emulsions. This creates a uniform structure without components separating.
What are the advantages of a dispersing machine for cosmetics and food?
Dispersing machines are essential in the cosmetics and food industries as they produce mixtures. High-quality dispersing tools create a strong shear gradient to fully process powders. This leads to an even distribution of the solid particles.
How does an Ultra-Turrax support homogenization at high shear forces?
The Ultra-Turrax uses the rotor-stator principle to generate intensive comminution efficiency. The rotating parts generate a strong shearing effect, which is helpful when homogenizing mixtures. Suitable emulsifiers and stabilizers prevent the phases from separating.
What is the importance of a vacuum when dispersing a liquid suspension?
A vacuum can help to minimize unwanted air inclusions in the liquid. This stabilizes the suspension and facilitates operation. The method is particularly suitable for reducing foaming and optimizing the end result.
How do you achieve the best results when dispersing liquid media?
A precisely set speed is crucial for the best results. High-quality components are also important for effective dispersion of liquid substances. Forming a small interface is essential to prevent clumping.
Why is interfacial tension so important in a finely dispersed dispersion?
The interfacial tension influences the distribution of the components in the final mixture. The range of applications can be extended by adjusting the parameters in modern processing plants. Experiments make it possible to optimize the technology and achieve stable results.
How can different phases be homogenized efficiently?
Powerful dispersing processes are used to homogenize different phases. The medium is strongly swirled to distribute the components evenly and reduce the particle size. This minimizes segregation and results in a stable end product.
What role does the container play when working with dispersers in modern dispersing technology?
A suitable container is crucial for dispersers to perform at their best. Modern dispersing technology takes into account the shape, size and material of the container to ensure uniform mixing. This allows both small and large batches to be processed efficiently.
