From speeding up the process to reducing power usage, there are 11 incredible ways an Inline Disperser can improve your process.
1) SPEED UP PROCESSING
Operations which use standard dispersion equipment (high speed, high-shear batch machines) can take less time when an inline disperser is added. Since the inline unit utilizes a rotor stator concept, the unit provides more shear force than even a high-speed dispersion unit, allowing faster processing times.
2) ELIMINATE ADDITIONAL EQUIPMENT
In some cases, traditional dispersion equipment can be replaced completely with an inline disperser to shorten processing time. This type of mixing equipment can also eliminate the need for extra processing steps like sifting powders, filtering out clumps, and even milling, eliminating the need for those types of equipment as well.
3) SIMPLIFIED MATERIAL HANDLING AND LESS WASTE
You can expect less wasted raw materials because of the smaller surface area of the equipment in contact with your product. The mode of processing itself guarantees that all of the ingredients are incorporated.
4) GREATER CONSISTENCY AND REPEATABILITY
The very nature of an inline dispersion operation ensures that your whole batch is guaranteed to contact the work zone through the processing cycle. It can eliminate inconsistencies from batch to batch so that there is no need to worry about uniformity. Less waste and less inconsistencies make it easier to ensure repeatability from batch to batch – you will be using every bit of your ingredients, and they will all be fully incorporated into the mixture.
5) LESS DOWNSTREAM DOWNTIME
Because the full batch is guaranteed to come into the work zone of the inline disperser, the chance of clogging downstream equipment is extremely low. There is no need to worry about lumps of undispersed powder or solids. The inline disperser takes care of that.
6) LESS POWER USAGE
The rotor stator design of the inline allows for a lower peripheral speed (around 3500 FPM instead of 5500-6000 FPM) and a compact work zone design, necessitating a less powerful motor. This can return utility savings year over year.
7) SMALL FOOTPRINT
Inline dispersers are exponentially smaller than conventional dispersion equipment. This type of mixing equipment can be squeezed into your current process – as close to your tanks as possible. They are typically low profile the actual section that houses the rotor stator itself is generally smaller than the motor that powers it.
Inline dispersers are elegantly simplistic – they can be easily cleaned after each batch. Just recirculate water, solvent or detergent rinse through the unit and it should be ready for the next batch. For thicker, more stubborn products, these units are usually easily disassembled and wiped clean. Most units feature interchangeability for the stator and even rotor part of the machine. This makes it easy for you to replace the soiled piece for a clean one without necessitating any downtime. CIP centric designs are also available on most units.
The inline disperser can be an asset for many different processes. It is an expert at incorporating powder into a fluid mixture. No more watching a hydrophobic solid or powder swirl around on the top of a batch; no “fish eyes” to worry about. Inline dispersers can be outfitted with a powder introduction port which can draw in your solid/powder and forcibly homogenize the mixture. The addition of powders and solids is no longer something to dread. In addition to efficiently incorporating powders, the inline disperser is an expert emulsifier. And this type of equipment is not only versatile in terms of processing, but they are also compact and usually portable, ensuring that adding them to other processes is no big deal. Simply roll (or lift) it over, hook it up, and start the unit.
10) EASE OF USE
Simply hook up the inlet and outlet of the inline unit to your tank, press start, and adjust the rotor speed. No other controls needed.
Inline disperser equipment components are fully housed inside the machine during operation. There is no need or opportunity to “scrape the shaft” with a spatula, and no other concerns regarding operator injury during operation. An inline disperser eliminates points of danger by housing the entirety of rotation within a housing. Really the only thing you will need to worry about is where to safely place it on the production floor so it is not a trip hazard.