Efficient Innovations Individual Solutions to Turn-key Plants

Editor: Ahlam Rais

Diverse individual solutions will be presented by Netzsch along with skids and complete plants in a 3D virtual reality system at Achema 2018. Visitors can also stop by and learn why the firm sees the combination of an Epsilon inline disperser and a Neos high-performance grinding system as the ideal universal solution for processing printing inks.

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The combination of an Epsilon inline disperser and a Neos high-performance grinding system is the ideal universal solution for processing printing inks.
The combination of an Epsilon inline disperser and a Neos high-performance grinding system is the ideal universal solution for processing printing inks.
(Source: Netzsch Trockenmahltechnik)

The most intensive pre-dispersion or pre-crushing can be realized in an agitator bead mill. First, however, a suspension must be prepared. This means solids must be added to a mixture of various liquid formulation components. Ideally, this step should be automatic and emission-free. Wetting of the solid surfaces is also necessary only then will a homogeneous pumpable suspension be created, states the firm.

An agitator bead mill is not suitable for this task.

And, for the majority of products, pre-crushing is not necessary. Depending on the product properties, various dispersion machines, such as dissolvers, rotor-stator systems or inline dispersers, like the –Mix und Epsilon for example, are suitable for dosing and wetting the solids with a mixture of liquid formulation components, pre-dispersion, homogenization and deaeration of suspensions.

In one step, the Epsilon inline disperser universally handles dosing, wetting, pre-dispersion, homogenization and deaeration of solids in a dispersion medium for a wide variety of products, claims the company.

Since there are no narrow gaps or static elements inside the machine, through which the product must be pumped, efficient dispersion is possible with low energy input and thus minimal product warming, even for shear-sensitive products.

According to the firm, the process housing and powder feed of the inline disperser are designed such that, when necessary, they can be cleaned quickly. Even complete emptying of the machine is effortless. This is an important point for frequent product changes during which contamination must be avoided. The machine is characterized by a relatively small footprint as well as safe and easy handling during operation, cleaning and maintenance. In addition, depending on the bulk properties of the powder, the inline disperser can be operated with a variety of feeders for powders or solids.

The powder can be fed into the machine, for example, from a bag discharge station, Big Bag, silo or, for light powder such as silica, via suction lance. For a machine with an installed motor power of 30 kw, the typical powder feed rates are approx. 50-300 kg/h via suction lance and up to 10,000 kg/h via Big Bag, sack chute and silo.

4 Pros for Ideal Individual Solutions

In addition to pre-dispersion, selection of the right grinding system and the optimum operating parameters is crucial to the efficiency and output capacity of a wet grinding process. Depending on the product requirements, there are four different grinding systems from the firm that can be employed.

The Discus disk grinding system is primarily used for dispersion tasks in single and multi-pass operation. The new Macro peg system was designed for a high power requirement for single and multi-pass operation. The Zeta high-performance grinding system or the newly-developed Neos system can be used for processes in circulation mode. So, whatever the product specifications and grinding bead size requirements, the ideal grinding system is always available from the organisation.

According to the company, all grinding systems are equipped with a highly-efficient cooling system. In addition, the standard grinding chamber liner is made of Ceramc, a highly wear-resistant ceramic material. The excellent cooling properties and wear resistance allow for the highest power input and therefore maximum production output is possible. At the same time, the systems have extremely long lifetimes and thus minimal downtimes and low maintenance requirements, adds the firm.

Alpha Lab Zeta RS

The laboratory agitator bead mill is claimed to be the first laboratory machine that can be equipped with a screen-free, separately-driven, open, dynamic classifier system (SDC) for the separation of grinding media with a diameter of 0.03 – 0.3 mm. This means that a scale-up-capable solution for small product batches is now available for development work on the nanometer scale.

In addition to the Zeta RS grinding system, other grinding systems, such as the Discus, Zeta or Neos can be employed. Switching grinding systems, which are available in various materials and grinding chamber sizes, is fast and straightforward. When designing the machine stand for the Alpha Lab Zeta RS, special attention was given to user friendliness and ergonomics, explains the company.

The grinding chamber of the Alpha Lab Zeta RS can be swiveled, so very little effort is required to fill with grinding media, empty the grinding system with minimal hold-up and discharge the grinding beads after the test. The configuration was changed in order to optimise handling of the swivel mechanism.

The complete system for supplying the mechanical seal with barrier fluid is easily accessible. This means less time and effort are required to change the barrier fluid when changing products frequently.

The machine control system has a plain, clearly-arranged design. Standard with the new laboratory agitator bead mill is the interface required to access the firm’s Connect, the database-centered tool that is controlled via a web browser.

Maximum Production Output and Efficiency

An ergonomic machine design facilitates faster cleaning with less solvent. The efficiency of the dispersing and grinding system results in energy savings and less wear, which leads to less maintenance and shorter downtimes, thus saving costs and leading to higher production output.

The company always offers the ideal combination of predispersion and wet grinding based on the particular product requirements, states the firm. The potential for savings, which is enormous in some cases, as well as the potential increase in product output can be discussed as a function of product characteristics and identified and calculated through trials in the Applications Lab.

Depending on the initial situation, it is possible to increase production output by more than 100 %, while also realizing savings in specific energy consumption or through raw material conservation. This also facilitates more cost-effective production.

Netzsch Trockenmahltechnik

Hall 6.0, Stand B6

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