BEAD MILL

SPECIFICATIONS :

Grinding Chamber Capacity: 500 ml to 500 lt

Grinding Beads Size: 0.3 mm to 5 mm

Cooling System: water/air cooled

Materials of Construction: Stainless Steel (304/316L) / High-grade alloys

HOW IT WORKS :

The MECWORKS BEAD MILL operates on the principle of wet grinding, using high-energy mechanical forces to achieve fine particle size reduction and dispersion. The process involves suspending the material in a liquid (usually referred to as the slurry) and using grinding beads (usually made of steel, glass, or zirconia) to break down larger particles into smaller, uniform sizes. Here’s a step-by-step breakdown of how the bead mill works:

Loading the Material

The process begins by loading the slurry (a mixture of the material and liquid) into the grinding chamber of the bead mill. The slurry typically contains the raw materials that need to be ground, such as pigments, chemicals, or pharmaceutical compounds, suspended in a liquid medium.

Bead Milling Process

Bead Interaction: As the beads move through the slurry, they collide with each other and with the material particles, breaking them down through impact and shear forces. The high-speed movement of the beads

continuously forces the particles against the walls of the chamber and against each other, rapidly reducing the particle size.

Control of Particle Size:

The particle size reduction is controlled through several key factors:

Speed Adjustment: The speed of the rotor or agitator can be adjusted depending on the desired particle size and the material being processed. Higher speeds generate more impact, producing finer particles.

Bead Size: The size of the grinding beads (which typically range from 0.1 mm to 5 mm, depending on the application) also affects the final particle size. Smaller beads are used for fine grinding, while larger beads are typically used for coarse grinding or to break down larger particles initially.

Flow Rate: The flow rate of the slurry through the grinding chamber can be adjusted to control the residence time of the material, which impacts the degree of particle size reduction.

Cooling System

As the grinding process generates heat due to the friction between the beads and the material, a cooling system is used to prevent overheating. Most bead mills are equipped with either an external water cooling system or air cooling to regulate the temperature and maintain consistent performance.

Discharge of Final Product

Once the material reaches the desired particle size and dispersion level, the slurry is discharged from the grinding chamber. The mill has a discharge screen or separator that prevents the grinding beads from leaving the chamber while allowing the finely ground material to exit.

Final Dispersion: The slurry is now evenly dispersed and has reached the desired consistency for its intended application.

Cleaning and Maintenance

After each batch, the bead mill is thoroughly cleaned to remove residual slurry and prevent contamination in future batches. This typically involves flushing the system with cleaning fluids and removing the grinding beads for periodic inspection or replacement.

APPLICATIONS  :

Our Bead Mill is widely used in the following industries:

Paints & Coatings: Ideal for grinding pigments, dyes, and additives for enhanced color strength and consistency.

Pharmaceuticals: Used for producing fine dispersions of pharmaceutical ingredients, ensuring high bioavailability.

Cosmetics: Ensures uniform dispersion of cosmetic ingredients, including pigments and emulsions.

Food & Beverages: Used for grinding and dispersing ingredients such as chocolate, sauces, and beverages.

Inks: Perfect for the production of high-quality ink formulations with consistent viscosity and particle size.

ADVANTAGES OF MECWORKS BEAD MILL :

Enhanced Efficiency: With the MECWORKS Bead Mill, you can achieve finer particles at a faster rate, improving overall processing time and reducing production costs.

Precision Control: The machine allows for customizable settings, giving you complete control over particle size distribution and dispersion quality.

Proven Durability: Built to withstand the rigors of industrial environments, our bead mill offers long-lasting performance with minimal maintenance.

Cost-Effective Solution: Achieve consistent, high-quality results without the need for frequent adjustments or expensive maintenance.

Eco-Friendly: The efficient cooling and low-energy consumption design reduces environmental impact while maintaining optimal performance.