2. Sand mills
• Sand mills are mainly used for the wet grinding of
chemical liquid products. According to the
performance, it can be divided into a horizontal
sand mill, basket sand mill, vertical sand mill,
laboratory sand mill, etc. It is mainly composed of
a body, grinding cylinder, sand grinding disc
(lever), grinding medium, motor and feeding
pump. The speed of feeding is controlled by the
feeding pump. The grinding media of this
equipment are generally divided into zirconia
beads, glass beads, zirconium silicate beads, etc.
3.
4. Sand mills
• Sand mills, also known as bead mills or media
mills, are mechanical devices used in the field
of grinding and dispersion. They utilize
specialized grinding media, such as small
ceramic beads or glass beads, to break down
the feed material into smaller particles. Sand
mills are adept at handling a wide variety of
materials, ranging from low to high-viscosity
liquids, as well as solid particles.
5. Sand Mill
• Used mainly by the paint, ink & coating
industries for size reduction and dispersing of
pigments in liquids. Particle size reduction
upto 2 microns is possible in a single pass. The
material to be processed is pumped from the
bottom of the mill into the milling chamber
which is filled with grinding media of 3mm
dia. The media is agitated by a shaft fitted with
a number of impeller discs along its length.
6. • As the material moves upwards it is subjected
to high hydraulic & shearing forces between
the grinding media which results in fine
grinding of the material. This material then
passes through the screen which separates the
media from the process material. All mills are
povided with a jacket arrangement for cooling
the material in the grinding chamber.
7. • Working Principle: Sand mills use small
beads or media, typically ranging from 0.1mm-
3.0mm, to crush the particles or agglomerates
into finer particles. As the chamber rotates, the
grinding media are agitated by a rotating shaft
fitted with discs, spacers, or pegs. The grinding
media move at a high velocity, creating shear
forces which break down the particles.
8. • Design: It consists of a cylindrical chamber
filled with grinding media. Normally the
media is 95% zirconium beads.
• Applications: Sand mills are primarily used
for the fine grinding of paints, inks, and
coatings, and agriculture. They are capable of
producing very fine dispersions.
9. • A typical sand mill comprises a cylindrical
vessel filled with grinding media, a rotating
shaft, and an electric motor. The vessel,
usually made of stainless steel or wear-
resistant materials, houses the grinding media.
The rotating shaft, powered by the electric
motor, drives the grinding media to move
within the vessel. As a result, the product is
subjected to intense grinding and dispersion
forces.
10. • The grinding media’s movement within the
sand mill is attributed to the principle of
centrifugal motion and shear stress. As the
shaft rotates, the grinding media is forced
towards the periphery of the vessel, generating
a vortex-like motion. This motion creates high-
speed collisions and shearing forces,
effectively reducing the particle size and
promoting proper dispersion.
11. Applications of Sand Mills
• Cosmetics Industry:
In the cosmetics industry, achieving a fine
particle size is crucial for products like
foundations, face powders, and lipsticks. Sand
mills provide an efficient way to grind and
disperse pigments, allowing for better color
development and a smooth, uniform
application. By utilizing sand mills, cosmetics
industries can achieve consistent and high-
quality products to meet consumer demands.
12. • Pharmaceutical Industry:
Pharmaceutical companies are often tasked with
producing medications as suspensions, powders,
or other formulations. Sand mill machines can
effectively micronize and disperse active
pharmaceutical ingredients (APIs), ensuring
uniform distribution throughout the formulation.
This improves drug dissolution rates,
bioavailability, and ultimately, the therapeutic
efficacy of the medication.
13. • Paints and Coatings Industry:
To produce high-quality paints and coatings,
achieving a homogenous particle size is crucial.
Sand mills are widely used in this industry due to
their ability to disperse pigments, enhance color
development, and ensure a smooth and consistent
finish. Moreover, sand mill machines can handle a
wide range of pigments, including organic,
inorganic, and metallic particles, making them
indispensable within the paint and coatings
industry.
14. Advantages of Sand Mills
• 1. Enhanced Dispersion Efficiency:
Sand mills excel in achieving efficient particle
dispersion due to the intense agitation and grinding
action they generate. The combination of centrifugal
motion and shearing forces ensures that even the finest
particles are uniformly dispersed within the liquid
medium.
• 2. Wide Range of Materials:
Sand mills can effectively handle a wide range of
materials, be it low or high-viscosity liquids, solid
particles, or abrasive substances. This versatility allows
industries to process different types of feed materials
without compromising performance.
15. • 3. Scalability:
Sand mills offer excellent scalability, allowing
industries to scale up their production capacity
based on demand. With various sizes and
designs available in the market, sand mills can
accommodate different production volumes,
making them suitable for both small-scale and
large-scale operations.
16. • 4. Low Maintenance:
Modern sand mill machines are designed to
minimize downtime and reduce maintenance
requirements. With advancements in materials
and technology, wear-resistant components and
easy-to-clean designs are now prevalent,
ensuring consistent productivity and extended
machine lifespan.
17. Ball Mill
• The aim is to achieve ultrafine and nano-sized
materials for the development of innovative
products. Many techniques can be used for
synthesizing materials called high-energy
milling. Various components and machines are
used for grinding applications and that’s
where high-energy ball mill comes into play.
19. • Ball mills are commonly used for crushing and
grinding the materials into an extremely fine
form. The ball mill contains a hollow cylindrical
shell that rotates about its axis.
• A ball mill is a type of grinder used to grind or
blend materials for use in mineral dressing
processes, paints, pyrotechnics, ceramics, and
selective laser sintering. It works on the principle
of impact and attrition: size reduction is done by
impact as the balls drop from near the top of the
shell.
20. • These mills, both vertical and horizontal, have
a pump with a mechanical seal which pumps
the paint. This technology is used for the
production of high-quality paints and
varnishes. This mill grinds paint pigments,
printing inks and textile colours, in addition to
a variety of solvent or water-based varnishes.
21. • A ball mill consists of a hollow cylindrical
Container shell rotating about its axis. The axis
of the shell may be horizontal. It is partially
filled with Grinding balls. In addition to the
material or Product that is meant to be ground,
ball mills also contain a grinding material.
Ceramic balls, stainless steel balls, and flint
pieces are often used as grinding products.
22. • When this matter mills against another matter,
The result is a mill powder that can then be
used for other applications. The inner surface
of the cylindrical Container shell is usually
lined with an abrasion resistant material such
as manganese steel or rubber. The length of the
ball mill is approximately equal to its diameter.
23. Working of Ball Mill
• Materials used to grind include iron ore and ceramics
are added to the ball mill. It rotates either on its vertical
or horizontal axis and bounces around while striking
the enclosed material. The force of strikes helps to
grind materials into a fine, less-coarse medium.
• For a ball mill to operate, critical speed needs to be
achieved. The enclosed ball begins to rotate along the
inner walls of the ball mill. If it fails to reach critical
speed, it will remain stationary at the bottom where
they have no impact on the material.
24. The degree of milling in a ball mill can be
influenced by:
• The residence time of material in the mill
chamber
• The size, density, and the number of ball mill
• The nature of the ball mill (hardness of grinding
material)
• Feed rate and level in the vessel
• Rotation speed of the cylinder
25. Advantages of Ball Mill
• Produces a very fine powder – particle size
less than or equal to 10 microns
• Suitable for milling toxic materials as it can be
used in an enclosed form
• A wide range of applications
• Used for continuous operation
• Used in milling abrasive materials
26. Application of ball mill
• Used in Various Paint Manufacturing
Industries ,
• Different Dry Pigments Grinding Purpose.
• Various Red Oxide Primer Manufacturing
Industries.
• Various Dry grinding Dye Manufacturing
Industries.
• Various Minerals Manufacturing Industries.
27. Application of ball mill
For fertilizer:
• pigment,
• chemicals,
• colors.
For Pharmaceuticals:
• capsule,
• tablet,
• granule.
29. • Homogeneous dispersion of solid particles in a
liquid is typically required for various
applications in the process industry and can be
achieved by high-speed disperser mixer. For
example, in the paint industry, various color
pigments are added to the liquid solvent to
achieve a homogenous solution in the form of
paint as the final product. Such pigments,
which are solid particles, are not easily soluble
in the liquid solvent and therefore require to be
homogeneously dispersed in it.
30. • Material of Construction: Carbon Steel |
Stainless Steel
• Applications: Paints, Resins & Inks,
Adhesives
31. • High-speed dispersers can create the desired vortex
along with the rigorous turbulent flow. The solids are
charged into the vortex zone such that they are
immediately dispersed. Depending on the depth of the
vortex, the disperser blade i.e. MCD Cowl Disc can
be positioned on or off-center. As the fluid viscosity
changes, the operating speed of the cowl disc can be
varied through an external VFD to maintain the
vortex and to improve the dispersion efficiency.
High-speed disperser mixers can have one or two
dispersion impellers based on the tank geometry.
32. • High-speed disperser design needs to be carefully
developed from a mechanical perspective since
the operating speeds are generally higher ranging
from a few hundred rpm to 2,800 rpm. Such
machines need to be low on vibrations, shaft
runout, and deflection. Hence, the shafting must
be with high precision, balanced, and controlled
tuned shaft. Our efficient manufacturing
processes help us achieve these mechanical
performances.
33. • A High-speed disperser comes with optional
features and varied scope on drive arrangement
(direct, belt drive), lifting arrangement
(mechanical, hydraulic, pneumatic), safety
interlock for avoiding starting if no vessel,
VFD panel for speed adjustments and trolley
mounted tanks. Surface finishes as desired for
the wetted part can be offered to suit the
applications.
34. • variable speed Dissolver is a highly versatile
machine for the production of paints, inks,
coatings, construction chemicals etc . The
main function of this machine is for breaking
up of the aglomerates , wetting & dispersing of
pigments in liquids. Due to the variable speed
control the speed of the shaft can be varied at
different stages of the mixing process thus
saving power.
35. • Another advantage is in the hydraulic lifting
and lowering arrangement wherein the height
of the mixing shaft can be adjusted so as to
obtain a uniform product circulation & perfect
dispersion. A wide range of paints & inks can
be produced on our dissolvers without the use
of grinding media. Mixing vessels of different
capacities with heating, cooling & vacuum
arrangements are also available.
36. • The process of dispersion is carried out by the
centrally located shaft having Saw tooth
impeller & running at high speed (1000 to
1400 RPM). Reckoned for trouble-free
operations, the equipment made available in
this range is extensively used for
manufacturing plastic emulsions, solvent based
Paints and eco-friendly water based paints.
37. • High-speed Disperser is to dissolve, disperse
and mix materials with different viscosity.
Through the very high peripheral tip speed of
the toothed disc, the strong shearing, crashing
and friction forces generated between the
materials and toothed disc disperse, dissolve
and mix the materials efficiently. The large
stress forces break down the agglomerates into
the liquid or paste suspension.
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47. General Hazards in paints
• Exposure to vapours of solvents, paints and
lacquers can cause irritation and damage to
eyes and mucous membranes, to the
respiratory and digestive tracts, and to the skin.
Exposure to organic substances (toluene, n-
hexane, methyl alcohol etc.) may cause
damage to the nervous system.
