澁谷工業 Official site

Shibuya Kogyo Co., Ltd. will exhibit at "POWTEX 2026 (46th International Powder Technology Exhibition)" held at Tokyo Big Sight from November 25 (Wednesday) to 27 (Friday), 2026. We propose solid-liquid mixing and dispersion systems that consider the entire manufacturing process, from powder and liquid supply to mixing, dispersion, and transfer. 【Main Introduction Content】 ■ Solid-liquid Mixing and Dispersion Systems - Process design from powder supply to mixing, dispersion, and transfer - Selection of methods such as batch and inline according to material characteristics - Support for high-viscosity and high-solid-content slurries - Live demonstration of mixing equipment (continuous kneader) - Introduction of a hybrid system for inline batch processing - Comprehensive support from lab testing to scale-up and mass production equipment 【For Those Facing These Challenges】 - Want to improve clumping and agglomeration during powder feeding - Want to reduce dispersion unevenness and quality variation in slurries - Want to review mixing and transfer processes for high-viscosity materials - Want to reproduce lab dispersion quality in mass production You can consult us not only about the selection of individual equipment but also about the optimization of the entire process and scale-up. Please feel free to visit our booth (3-H67).

In low bulk density powders and fine powders, issues such as "unstable supply," "pulsation," and "bridging without falling" frequently occur. Particularly with CNTs, carbon black, and flake powders, the particles tend to entangle easily and have low flowability, making stable quantitative supply difficult with conventional powder feeding methods. When powder supply becomes unstable, instantaneous concentration fluctuations occur, significantly affecting the dispersion quality, viscosity, and conductivity in subsequent processes. In practice, even problems that appear to be "poor dispersion" often have their causes on the powder supply side. Moreover, in low bulk density powders, bridging, rat-holing, and supply pulsations due to air entrapment are likely to occur within the hopper, and simply relying on feeder capacity may not resolve these issues. To achieve stable supply, it is crucial to design the entire process, including hopper design, supply methods, transport conditions, and feeding methods, according to the characteristics of the powder. Our company offers a solid-liquid mixing process that includes quantitative supply using loss-in-weight feeders and integration with inline dispersion devices. By designing the entire process from powder supply to dispersion as a cohesive unit, we support the establishment of stable manufacturing conditions even for high-performance materials.

In dispersion processes, the variation in quality is one of the significant challenges. Even when processing under the same equipment and conditions, it is not uncommon for the dispersion state to differ from batch to batch. The main factor behind this is the variability in the dispersion history experienced by the particles. In batch processing, the shear and residence time experienced by each particle differ depending on their position and flow state within the tank. As a result, there is a mixture of sufficiently dispersed particles and undispersed particles, leading to variations in quality. This tendency becomes particularly pronounced under high viscosity or high solid content conditions. On the other hand, in continuous processing, particles pass through a consistent processing area, receiving nearly the same dispersion conditions. Because shear energy and residence time can be controlled consistently, the variability in dispersion history is minimized, resulting in a uniform and highly reproducible dispersion state. Moreover, continuous processing is advantageous during scale-up. By adjusting the flow rate, it becomes easier to replicate similar dispersion quality from the lab to mass production. This helps reduce the risk of quality fluctuations during the transition from development to mass production. What is crucial in dispersion processes is to provide the same processing history to all particles. Continuous processing easily meets this condition and is an effective method for stabilizing quality and ensuring reproducibility.

In the dispersion process, it is not "how much to mix" but "how much energy to provide" that determines the quality of dispersion. The key factor here is dispersion energy. Dispersion energy refers to the amount of energy applied to break down the agglomeration of particles and achieve a uniform state. When dispersion is insufficient, it is often due to a lack of energy. Even if it appears to be mixed, the agglomeration between particles may not be resolved, leading to variations in quality and performance degradation. Dispersion energy is determined not only by the strength of the shear force but also by the duration of its application. In other words, it is important to consider it as "strength × time." In batch processing, this energy can vary for each particle, making it easier for differences in dispersion states to occur. On the other hand, in inline continuous processing, particles are subjected to the same shear conditions within a consistent flow, allowing for uniform application of dispersion energy. This results in a consistent dispersion state for each particle, achieving stable quality. In the dispersion process, it is crucial to provide the necessary dispersion energy to all particles without excess or deficiency. Therefore, process design that includes flow, shear, and processing time is essential.

In the manufacturing process of battery material slurry, it is important to uniformly disperse multiple materials such as conductive materials, active substances, and binders. However, on-site challenges arise, including the residual aggregation of conductive materials, variations in particle size distribution, and instability in coating properties. These issues stem from differences in dispersion behavior due to material characteristics. In particular, carbon-based conductive materials are prone to aggregation and can form a network structure if insufficient shear is applied, leading to poor dispersion. Additionally, battery material slurries often have high solid content and high viscosity, which can lead to reduced fluidity and make it difficult for dispersion energy to be transmitted uniformly. Furthermore, poor wetting during powder addition and differences in mixing order can also affect the dispersion state and final quality. Even if dispersion can be achieved without issues in the lab, variations in flow conditions and shear history during mass production may prevent the reproduction of similar quality. To resolve these challenges, it is crucial to design dispersion conditions tailored to the characteristics of the materials and to optimize the entire process, including flow, shear, and residence time. In inline continuous processing, particles are treated under consistent conditions, which helps to minimize variations in dispersion history and achieve uniform and reproducible quality. The design of the dispersion process plays a vital role in stabilizing battery performance.