Intensive Disperser Mixer

An intensive disperser is equipment that applies high shear forces to mix, disperse solids into liquids, break down agglomerates, emulsify immiscible phases, and more. It typically features a rotor or impeller (sometimes a rotor-stator) that rotates at high speed within a fluid, creating turbulence, vortices, and flows that efficiently disperse particles.

• Dispersion of powders (polymers, pigments, additives) into liquids.
• Emulsification of oil in water or of immiscible phases.
• Homogenization to achieve a uniform texture of creams, varnishes, paints, cosmetics, etc.
• Preparation of suspensions or high-viscosity masses.

• Intensive dispersers generate much higher shear forces than simple agitators, allowing them to break down clumps, distribute hard-to-wet particles, or emulsify phases that slow agitators cannot handle.
• Agitators are good for maintaining homogeneous mixtures or for low-viscosity liquids, but for materials with high solids content or high viscosities, the disperser is far more effective.

• Highly viscous products can hinder flow around the impeller, creating “dead zones” where proper mixing does not occur.
• If the material is very “rigid” or sticky, the flow may not penetrate the entire volume.
• When used in very small batches or in containers that are too large relative to a small impeller, efficiency can decrease.
• Temperature control is critical — heat generated by shear can alter product properties or damage sensitive components.

Some factors to consider:

• Material viscosity and solids content; the higher the viscosity or solids, the more power or a special impeller will be required.
• Type of particles or powder (size, ease of wetting, tendency to form clumps).
• Batch volume / tank capacity.
• Temperature requirements (if the product is sensitive).
• Ease of cleaning, maintenance, and replacement of wear parts (blades, seals, bearings).

Some recommended practices:

• Regularly check the balance and alignment of the impeller/shaft to avoid vibrations.
• Periodic lubrication of bearings, joints, and rotating parts.
• Constant cleaning of blades, rotor, stator, and contact parts to prevent residue buildup that impairs dispersion.
• Replacement of wear parts (blades, seals) according to the manufacturer’s recommendation or when excessive wear is observed.

It depends greatly on the application:

• The impeller rotation speed, blade diameter, and material viscosity directly influence power consumption.
• There is a trade-off: operating at very high speed generates more shear (better dispersion) but also more heat and higher consumption. It is important to adjust to optimize.

Yes — some recommended practices:

• Protect the shaft/impeller to avoid accidental contact (safety guard).
• Never operate with the blade out of the liquid or container without adequate content — this can cause excessive vibration and damage the equipment.
• Use the rotor or rotor-stator according to specifications to avoid operating in a regime for which the machine was not designed.
• Monitor temperature, noise, and vibration — signs of malfunction or wear.

This depends on several factors, such as:

• Type of powder or solid (ease of wetting, particle size)
• Initial viscosity of the system
• Liquid-to-solid ratio
• Power and type of disperser (impeller diameter, rotation speed, rotor-stator, etc.)

Frequently, initial test batches are performed to determine the ideal time for a specific formulation.

Yes, but with some adaptations:

• Some characteristics do not scale linearly (e.g., heat dissipation, shear efficiency per blade area vs. tank volume).
• It may be necessary to adjust the impeller, speed, tank size, or use multiple dispersers or auxiliary rotors.
• Pilot tests are useful to calibrate for commercial scale.