Evaluating the Effectiveness of Lancaster Products K-Series High Shear Counter-Current Mixers in Ceramic Processing
In typical ceramic processing applications, mixing / milling is performed using processes such as ball milling, which is a lengthy and energy-intensive process, often requiring processing times as long as 12 – 24 hours.
Could you achieve similar mixing in far less time?
A Simple Study
- Mix the components of a solid state reaction system and evaluate phase composition, particle size, and homogeneity (not shown here) of the heat treated powders (calcium carbonate and titanium dioxide.)
- Compare ball milling at set increments (3,6,12, and 24 hours) with powder sampled from the K-series mixer at shorter times (30 min. or less.)
Comparable mix quality and reduction in particle size in 10 to 20 minutes of mixing in a high shear, counter-current mixer yielded similar results as 3 to 6 hours of ball milling time.
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The high-speed rotor is the primary mixing and pelletizing tool in industrial high shear mixers and in many ways, it is the most utilized part of the machine. But rotor wear is also a good leading indicator of your machine’s overall operating condition as it is a direct result of material processing. Chances are, if the rotor is worn, there is other preventative maintenance to be done.
Industrial mixers are built to run and withstand a great deal of abuse, however, regular preventive maintenance efforts can help keep your mixer running like new. The two most critical components that can affect the life of your mixer are lubrication and inspection of working tools. Below is an overview of the in-depth information provided in our full maintenance schedule available for download below.
Lubrication: Proper lubrication can encompass multiple areas on your mixer, not just the shaft seals of the mixing tool. Lubrication of all seals as well as drive gears, discharge valves and other locations where bearings are utilized is the best way to extend the life of your mixer. Automated lubrication systems on larger production mixers help maintain proper lubrication intervals, but regular visual inspection should be scheduled to assure the system is working properly.