Mixing is among the most utilized and significant steps in the production of items in an industrial numerical sense. While this includes the mixing of powders with liquids when producing such products as; adhesives, pesticides, paints, battery chemicals, etc., simply stirring it with a stick will not yield satisfactory results. It takes specialized mixing equipment capable of breaking up lumps and distributing them evenly throughout the entire volume of mixed material.

To accomplish the mixing of any of the above products, there are typically three groups of equipment that play a significant role; high speed agitator disperser (the piece of equipment that replicates the action of stirring a pot with a wooden spoon), the tank that the high speed agitator disperser is mounted on, and for ultra-fine mixing, the bead mill. Next, we will go through the process of selecting the best equipment and manufacturing partners for the job.

The high-velocity / high-speed / high-tear / agitator disperser is essential for producing an even mix of one solid powder mixed into a liquid vehicle; this first step is called "dispersion". The intent of the dispersion process is to wet out the solid and break it into small fragments or clumps.

A high-speed agitator disperser is engineered to accomplish this task. It is easy to identify; it resembles a very large drill press and features a saw-toothed blade (not tapered like a drill bit), which maintains the same outside diameter as the inside of the bowl, and the total length of the blade is what actually creates the shape of the vortex (or tornado) action required to mix both the solid powder and the liquid vehicle.

When the blades rotate at a very fast speed, the vortex action that develops will pull the solid down into the blade, and the high-energy caused by the spinning blades will disintegrate clumps of solid powder into much smaller particles, and allow for them to become uniformly suspended throughout the liquid vehicle.

Essentially, the high-speed agitator disperser is the workhorse of any production plant. Every preparation of any pre-mixed liquid product goes through the high speed agitator disperser during its production. If there is any downside to this significant manufacturing piece(s), it would be that if the pre-mix is not “properly” mixed (or dispersed), the further grinding operations may take much longer and ultimately cost significantly more than the mixer itself. As such, it is imperative that when searching for a disperser, you obtain one with an adjustable variable-speed design and an adjustable hydraulic lift, so you can use that specific machine for several different sized batches of product.

The Importance of Agitator Tank Manufacturer

To make sure dispersers can mix properly, they require an agitator tank. An agitator tank is more than just a bucket; it is a specially designed tank made for use within a manufacturing facility. Finding an experienced agitator tank manufacturer is very important because of the safety and efficiency concerned with the manufacturing process.

What does a manufacturer’s experience mean?

Material Quality: Generally, the agitator tank will require a higher quality of material to ensure that it does not rust or have any chance of contamination. In most cases, the agitator tank will be designed using high-grade stainless steel.

Jacketed Cooling: Mixing solutions will create heat; therefore, a quality manufacturer will produce an agitator tank with “jacketed” constructions that use double walls with cold water running between them, thereby cooling the mixing solution.

Don’t Forget: Quality Manufacturing = Durable Agitator Tank

The durability of an agitator tank is extremely important, as these tanks will experience a lot of vibration and pressure during operation. If you go with a cheap manufacturer, you run the risk of having an agitator tank crack or leak with a potential for hazardous spills or incidents occurring due to cheap workmanship.

A dyno mill will finish your product once your high speed disperser is complete, and you have a homogenized mixture. This means your mixture is smooth and free from lumps; however, the material has likely not been ground down to a particle size suitable for high quality applications (i.e. glossy car paint) at this point. To reduce the size of the particles from their current state to a nano particle size, you should use a bead mill, which is commonly referred to in the industry as a "dyno mill."

When looking for a dyno mill manufacturer (or another similar style horizontal bead mill manufacturer) who produces machines that will produce a finished product by grinding the pre-mixed material you have created into a perfect product, consider locating a supplier that provides wear resistant internal components. The internal components of these mills are subjected to damage and wear, so choosing a supplier that provides high quality and long lasting wear components will be beneficial to your overall maintenance costs.

Conclusion

Setting up a production line is about connecting the right pieces of the puzzle. You start with a robust High Speed Agitator Disperser to get a good pre-mix. You ensure safety and temperature control by working with a top-quality Agitator tank manufacturer. Finally, for that ultra-fine finish, you rely on the precision engineering of a dyno mill manufacturer.

When these three elements work together, you get a production line that is efficient, safe, and produces a high-quality product every single time.