Solid-liquid mixing system for stabilizing the dispersion quality of resin materials.
Dispersion is not determined by the equipment. It is determined by the process design of the resin dispersion system.
In the manufacturing of resin materials, dispersion quality affects product performance and appearance quality. Particularly in formulations containing fillers, dispersion unevenness and agglomeration are likely to occur, leading to issues with strength, functional characteristics, and appearance defects. Additionally, in high-viscosity systems, poor mixing and viscosity variations can easily arise, making it challenging to ensure quality. Furthermore, during scale-up, reproducing dispersion conditions can be difficult, resulting in cases where quality is not stable during mass production. Shibuya Kogyo's inline solid-liquid mixing and dispersion system designs the dispersion process throughout the entire process according to the characteristics of the resin and fillers. It optimizes everything from powder supply to dispersion, formulation, and CIP cleaning in a consistent manner, achieving uniform dispersion while suppressing dispersion unevenness and agglomeration. It establishes optimal dispersion conditions based on material properties and viscosity conditions, stabilizing reproducible quality. For those struggling with dispersion unevenness or viscosity variations in resin materials, we propose optimal dispersion processes tailored to material properties and process conditions. Please consult us about your current challenges. We also accommodate dispersion of not only fillers but also nanoparticles and functional materials. For details on electronic material dispersion, please refer to the related links.
basic information
The inline solid-liquid mixing and dispersion system is designed for a seamless process from powder supply to dispersion, blending, and CIP cleaning. It optimizes dispersion energy, input conditions, and fluid design according to the particle size, shape, and content of the filler, suppressing dispersion unevenness and undispersed materials. It accommodates high-viscosity materials and high-fill formulations, achieving both uniform dispersion and stable workability. Dispersion conditions are established based on viscosity characteristics and formulation conditions, reducing variations in appearance quality and functional properties. It can support both continuous and batch processes. Additionally, it flexibly responds to material lot differences and formulation changes, maintaining stable quality. It also supports integration with higher-level production management systems and data logging, aiding in the stable operation of mass production lines.
Price information
It varies depending on the specifications.
Delivery Time
Model number/Brand name
Inline solid-liquid mixing system for resin materials
Applications/Examples of results
- Fillers are not evenly dispersed, leading to the formation of lumps. - Appearance defects (color unevenness, foreign substances) occur due to uneven dispersion. - Strength and functional characteristics are unstable due to insufficient dispersion. - High filler content increases viscosity, making mixing difficult. - Viscosity variations reduce processability and coating properties. - Quality is unstable due to sedimentation and separation. - Product performance varies due to differences in dispersion conditions. - Research conditions cannot be reproduced during scale-up. - Quality fluctuates due to material lot differences and formulation changes. - Long dispersion times do not improve productivity.
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| Inline solid-liquid mixing dispersion system |
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What are the causes and countermeasures for quality variation in dispersed engineering? An explanation of design points to prevent instability in particle size distribution and reduced reproducibility.
In dispersion processes, issues such as unstable particle size distribution and quality variation between batches occur in many settings. These quality variations are caused not only by equipment performance but also by variations in dispersion conditions, flow states, and process design. For example, when shear energy is uneven, differences arise in the disintegration state of particles, leading to a wider particle size distribution and residual agglomeration. Additionally, in batch processing, variations in mixing uniformity and residence time can cause fluctuations in dispersion state between batches, making it difficult to ensure reproducibility. Particularly in high-viscosity systems or high solid content slurries, even slight variations in conditions can significantly impact quality. To suppress quality variations, it is crucial to design processes that maintain consistent dispersion energy and flow conditions. By stabilizing conditions, as in inline continuous processing, it becomes possible to reduce inter-batch differences and achieve stable dispersion quality. Furthermore, in dispersion processes, not only the performance of the equipment itself but also operating conditions such as input order, residence time, and flow control greatly affect quality. Inline continuous processing makes it easier to maintain these conditions consistently, ensuring stable dispersion even in high-viscosity slurries. By designing the entire process, it is possible to fundamentally suppress quality variations.
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What is decentralized process design? Key points for stabilizing quality.
In dispersion engineering, stable quality cannot be achieved solely based on the performance of the equipment. What is important is the overall design of the process, taking into account material properties and process conditions. This is referred to as dispersion process design. Dispersion quality is determined not only by the strength of shear but also by multiple factors such as flow state, residence time, and method of input. If these conditions are not properly designed, localized agglomeration or variation can occur, making it difficult to maintain stable quality. For example, poor wetting during powder input or the occurrence of stagnant areas due to flow bias can lead to clumping or dispersion issues. Additionally, even if the shear energy is sufficient, if it does not act uniformly on all particles, differences in dispersion state will arise. Therefore, in dispersion processes, it is crucial to design "flow," "shear," and "processing time" as an integrated system. This allows for all particles to receive the same dispersion history, achieving uniform and highly reproducible dispersion quality. In particular, inline continuous processing has the advantage of maintaining consistent conditions within the flow, making it easier to ensure reproducibility in process design. Dispersion process design is a key concept for stabilizing quality and successfully scaling up.
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Distributors
Our company is headquartered in Kanazawa City, Ishikawa Prefecture, and has sales offices and factories both within and outside the prefecture. We focus on the bottling business, which involves filling beverages and other products, and we are expanding into various fields such as solid-liquid mixing and dispersion systems, laser processing machines (including fiber lasers and CO2 lasers), and semiconductor assembly equipment (such as taping machines, multifunctional test handlers, ball mount machines, and bonders). Please feel free to contact us if you have any inquiries.