Inline Disperser | 11 Ways an ILD Can Improve Your Process
Overview
An inline disperser processes inline or batch applications extremely efficiently. The product is drawn in through the inlet and sheared between the teeth of the rotor, dispersing and mixing at the same time. An inline disperser can come in various configurations: single stage, dual stage, or more. Different sized stators and rotors are also available.
Inline dispersers are compact compared to typical post-mount dispersing/mixing units. In addition, they are efficient in the processing of chemicals, foods, pharmaceuticals, cosmetics, and many other related applications. Preparing homogenous suspensions, solutions, and emulsions is relatively quick and easy.
Is an inline disperser a fit for your operation? From speeding up processes to reducing power usage, here are 11 incredible ways an inline disperser (ILD) improves a manufacturing process:
1. Speeds Up Processing
Standard dispersion equipment (high-speed, high-shear batch machines) take less time when an inline disperser is added to the process. The inline unit’s rotor-stator concept provides more shear force than a high-speed dispersion unit, allowing faster processing times.
2. Eliminates Additional Equipment
An inline disperser can eliminate extra processing steps like sifting powders, filtering out clumps, and milling – making that equipment obsolete. In some cases, an inline disperser can completely replace traditional dispersion equipment.
3. Simplifies Material Handling & Minimizes Waste
You can expect less wasted raw materials because of the smaller surface area of the equipment in contact with your product. All ingredients will incorporate due to the mode of the processing itself.
4. Provides Greater Consistency & 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 fewer inconsistencies make it easier to ensure repeatability – you will be using every bit of your ingredients and they will all be fully incorporated into the mixture.
5. Decreases 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. Reduces Power Usage
The rotor-stator design of the inline allows for 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. Decreases Footprint
Inline dispersers are typically smaller than conventional dispersion equipment. This type of mixing equipment can spatially fit into your current process and as close to your tanks as possible. They are typically low profile and the section that houses the rotor-stator itself is often smaller than the motor that powers it.
8. Improves Ease of Cleaning
Inline dispersers are elegantly simplistic and easy to clean 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, easily disassemble the unit to wipe 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.
9. Adds Versatility
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). Outfit inline dispersers with a powder introduction port to draw in solids or powder to 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) over, hook it up, and start the unit.
10. Improves 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.
11. Enhances Operator Safety
Inline disperser equipment components are housed fully inside the machine during operation. There is no need 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. Just be sure to find a safe place on the production floor to avoid a trip hazard.
Summary
It is clear an inline disperser has many benefits, but is it something that will fit into your operation? This often depends the size/scope of the process, the application, etc. The best way to figure out if an inline disperser makes sense is to contact an expert. Whether it be Schold or someone else, choose a company that will customize a unit specific to your application. There are many ways an inline disperser can be configured and you want to assure you have the correct one to maximize efficiency and minimize cost.
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