Pre-mixing dispersion of MLCC materials with the corn mill "MKO".
Contributes to improving dispersion efficiency and reproducibility in the pre-mixing process before bead milling.
In the manufacturing of MLCC (Multilayer Ceramic Capacitor) materials, premixing, which is the preliminary process for fine dispersion using a bead mill, is a crucial step that influences the subsequent dispersion quality and productivity. If the premixing is insufficient, coarse agglomerates may remain, leading to increased load on the bead mill, longer processing times, and variations in dispersion quality. The cone mill "MKO" is an inline cone mill that performs uniform premixing while efficiently breaking down coarse agglomerates due to the high shear forces generated between the rotor and stator. By stabilizing the slurry state before it is fed into the bead mill, it contributes to improved processing efficiency and reproducibility in subsequent steps. It has a proven track record of adoption in the pre-bead mill processes of MLCC manufacturers and accommodates a wide range of applications, including ceramic slurries, electronic materials, high solid content slurries, and functional materials. We offer not just equipment proposals, but also process designs that consider everything from premixing to subsequent processes.
basic information
【Processing Method】 Inline Continuous Cone Mill 【Features】 - High shear processing due to rotor/stator structure - Simultaneous disintegration of coarse agglomerates and uniform premixing - Forms a suitable slurry state for the pre-process of bead mills - Stable quality and high reproducibility through continuous processing - Compatible with high viscosity and high solid content slurries - Supports circulation operation, allowing for customizable processing conditions - Designed for easy disassembly and cleaning, considering maintenance 【Product Lineup】 A wide range of models from lab machines for research and development to production machines. We propose suitable models based on processing volume and material characteristics. 【Compatible Materials】 Ceramic materials for MLCC, electronic material slurries, various inorganic materials, pigments, functional materials, high solid content slurries, etc. *Processing capacity and specifications vary depending on material characteristics, viscosity, particle size, and model.
Price information
It varies depending on the specifications.
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Model number/Brand name
Finishing Distribution System MKO
Applications/Examples of results
- Pre-mixing of ceramic slurry for MLCC - Electronic materials slurry - Ceramic materials - Pigment and inorganic filler dispersion - High solid content slurry - Functional materials - Battery materials slurry - Chemicals and fine chemicals [Introduction Achievements] There are successful implementations as pre-mixing equipment before the bead mill process in MLCC manufacturers. By breaking down coarse aggregates and achieving uniform pre-mixing, it contributes to improving processing efficiency and stabilizing dispersion quality in the subsequent bead mill process.
Detailed information
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The world-renowned IKA Group and Shibuya Kogyo have been collaborating on business and technology since 2010, working together on inline continuous dispersion systems.
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Inline solid-liquid mixing pilot plant. It achieves stable dispersion while suppressing agglomeration through continuous mixing. It supports space-saving and short processing times, allowing for consistent scale-up considerations from research and development to mass production.
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It is a small experimental device that can be used on a tabletop. It can be utilized in the early stages of process evaluation.
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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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What are the causes of dispersion troubles? An explanation of the reasons for aggregation, sedimentation, and variation, as well as design points to reconsider in the dispersion process.
In dispersion engineering, issues such as unresolved agglomeration, sedimentation, and unstable particle size distribution occur frequently at many sites. These problems are caused not only by the performance of the equipment but also by inconsistencies in particle characteristics, dispersion conditions, and process design. For example, when there is insufficient dispersion energy, particles do not break down to primary particles, and agglomeration remains. Additionally, if the shear conditions or flow state are not appropriate, uniform dispersion cannot be achieved, leading to sedimentation and variations in quality. Particularly in high-viscosity systems or high solid content slurries, even slight differences in conditions can significantly impact the results. Furthermore, in batch processing, variations in mixing uniformity and residence time make it difficult to ensure reproducibility. To resolve these dispersion issues, it is important to optimize the entire process, including particle characteristics, dispersion energy, and flow design, rather than simply changing the equipment. By maintaining consistent conditions, as in inline continuous processing, stable dispersion quality and reproducibility can be achieved.
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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.