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What are the Functions of the Hydraulic System in a Hydraulic Triple Roller Mill? Will the Absence of a Hydraulic System Affect Its Operation?

The hydraulic system of a hydraulic triple roller mill is the core control and power execution mechanism of the entire equipment, and its role is crucial. Without the hydraulic system, the equipment would be completely unable to function normally.

Main Functions of the Hydraulic System:

Provide and Precisely Adjust Roll Pressure
This is its most basic and important function. The hydraulic system applies significant and adjustable pressure to the middle roll, pressing it against the upper and lower rolls, thereby generating strong compressive and shear forces on the material passing through the roll gap. Adjustable pressure is key to achieving the ideal grinding fineness and dispersion effect for different materials (such as coatings, inks, chocolate, etc., with varying viscosities). Manual or mechanical methods cannot achieve such massive and linear pressure adjustments.

Control Roll Gap Spacing
The hydraulic system allows for precise and smooth adjustment of the gaps between the three rolls to accommodate different feed particle sizes and desired output fineness. It is also needed to open the roll gaps during startup and shutdown.

Enable Safety Interlocks and Overload Protection

The system is equipped with safety valves (relief valves) that automatically release pressure when it exceeds the set value, protecting the rolls, bearings, and frame from mechanical overload damage.

It is typically integrated with the electrical control system to ensure the equipment can only operate under specific pressures or positions, ensuring operational safety.

Control Auxiliary Functions

  • Drive the raising and lowering of the apron to form a material pool on the rolls.
  • Provide power for auxiliary devices such as scraper mechanisms or discharge trays (for some models).
  • Drive the braking device to ensure the rolls stop quickly and smoothly during emergency or normal shutdowns.

Ensure Smooth Operation and Repeatability
The pressure provided by the hydraulic system is uniform and constant, avoiding pressure fluctuations caused by deformation or gaps in mechanical systems. This ensures consistent grinding quality for each batch of products (repeatability).

What Would Happen Without a Hydraulic System?

  • Inability to Establish Necessary Grinding Pressure: Manual or mechanical methods cannot generate sufficient and controllable pressure to effectively disperse and grind materials, resulting in failure to meet grinding fineness requirements or even complete inability to process materials.
  • Loss of Core Control Functions: Operators cannot adjust pressure and roll gaps promptly and accurately according to process requirements, rendering the equipment inflexible and capable of handling only very limited materials.
  • Serious Safety Hazards: Without overload protection, jamming or the ingress of hard objects can easily lead to catastrophic mechanical failures such as roll breakage, bearing damage, or frame deformation. Quick pressure release and roll separation in emergencies would also be impossible.
  • Basic Operations Become Impossible: For example, automatic raising and lowering of the apron would be unavailable, making feeding and operation extremely difficult.

Summary
For a hydraulic triple roller mill, the hydraulic system is not an auxiliary component but the key system that defines its functionality and realizes its value. It integrates power provision, process control, and safety protection. If the hydraulic system fails, the equipment must be shut down for maintenance. Otherwise, it will not only fail to produce qualified products but may also cause permanent damage to the equipment itself. Therefore, maintaining the stability and reliability of the hydraulic system is the primary task in ensuring the normal operation of a hydraulic triple roller mill.

The Core Difference Between Hydraulic Three Roller Mills and Conventional Three Roller Mills

The fundamental difference between hydraulic and conventional (mechanical) three roller mills lies in the method of applying and adjusting the pressure between the rollers. This directly leads to significant differences in control precision, ease of operation, safety, and application scope.

Hydraulic Three Roller Mill:

Principle: Pressure is provided by one or more hydraulic cylinders (typically located on the bearing housings of the middle or side rollers). A hydraulic power unit generates high-pressure oil, which is directed into the cylinders via control valves, pushing the rollers against each other.

Characteristics: Pressure application is smooth, uniform, and allows for precise, linear, and stepless adjustment. They are usually equipped with pressure sensors and digital displays for real-time monitoring and precise setting of roller gap pressure.

Conventional (Mechanical) Three Roller Mill:

Principle: Pressure is primarily generated by manually rotating screws that push or pull the bearing housings on the frame, bringing the rollers closer together.

Characteristics: Pressure depends on the operator's experience and feel. Adjustment is stepped and relatively coarse. Pressure is difficult to quantify, typically judged by observing the roller gap or material behavior.

Feature

Hydraulic Three Roller Mill

Conventional (Mechanical) Three Roller Mill

Control Precision

Very High. Pressure can be preset and maintained constant, ensuring excellent batch-to-batch repeatability. Ideal for high-precision dispersion and grinding.

Lower. Relies on operator skill, leading to poor repeatability and potential batch variations.

Ease of Operation

High. One-button pressurization/depressurization. Quick and easy roller gap adjustment. Low labor intensity.

Low. Manual screw adjustment is time-consuming and labor-intensive.

Safety

High. Usually equipped with overload protection. The hydraulic system can automatically relieve pressure in case of foreign objects or overpressure, protecting the rollers and machine.

Lower. Rigid mechanical structure. Hard objects can easily damage rollers, bend screws, or cause machine failure.

Function & Automation

Strong. Easily integrated with PLC control, pressure profile programming, data logging, and automated production lines.

Weak. Primarily manual operation, difficult to automate.

Maintenance & Cost

More complex, higher cost. Requires maintenance of the hydraulic system (pump, valves, seals). Higher initial investment and subsequent maintenance costs.

Simple, lower cost. Simple, robust mechanical structure, easy maintenance, and lower purchase cost.

Primary Applications

High-end, precision fields. E.g., electronic pastes, PV conductive pastes, high-end coatings/inks, lithium battery electrode slurries, cosmetics—industries with extremely high demands on fineness and consistency.

General, conventional fields. E.g., general paints, coatings, inks, chocolate, sauces—materials where ultra-high precision is not critical, or for pre-processing.

Summary:
Hydraulic three roller mills represent the direction of advancement, precision, and automation. Their core advantage is the precise, quantifiable, repeatable, and flexible control of pressure via the hydraulic system. This is key to achieving high-quality, consistent products, especially for nano-level dispersion and processing of high-solid-content materials.

Conventional three roller mills embody simplicity, durability, and economy. Their core relies on a rigid mechanical structure to provide pressure. While offering less controllability, they are often entirely sufficient for many traditional processes. Due to their price advantage and ruggedness, they remain widely used in numerous applications.

What Should be Paid Attention To When Operating a Hydraulic Triple Roll Machine?

The hydraulic triple roll machine is an efficient grinding and dispersing equipment for high-viscosity materials, widely used in the processing of pastes and viscous materials in industries such as coatings, inks, pigments, plastics, cosmetics, and rubber. To ensure normal equipment operation, safe production, and maintain good processing quality, the following key points should be noted during operation:

Pre-Start Inspection

  • Check the power circuit, switches, and control buttons for normal operation.
  • Confirm that the cooling circulation water is turned on. Starting the equipment without cooling water is strictly prohibited to prevent roller overheating and damage.
  • Secure the material container to avoid material leakage or container tipping during equipment operation, which could cause material overflow.

 

Monitoring During Operation

  • Closely monitor the temperature of the bearings at both ends of the rollers, which generally should not exceed 100°C.
  • Observe the distribution of the material on the roller surface. If the coating film is uneven, adjust the cooling water flow to correct it.
  • Thin film in the middle, thick film at both ends: Appropriately increase the cooling water flow.
  • Thin film at both ends, thick film in the middle: Appropriately reduce the cooling water flow.
  • Regularly inspect the roller surfaces. If any foreign objects are found, shut down the equipment promptly to remove them, avoiding impacts on product quality or potential safety hazards.
  • Ensure the scrapers (blades) are not pressed too tightly, and regularly add lubricant compatible with the material to reduce wear.
  • Pay close attention to the spacing between the front and rear rollers to prevent excessive tightening or even equipment jamming due to roller thermal expansion.

 

Safety and Maintenance

  • Strictly prevent metal foreign objects or hard impurities from falling between the rollers. If foreign objects enter, immediately press the emergency stop button. After the equipment comes to a complete stop, remove the foreign objects to prevent damage to the roller surfaces or core components such as gears and bearings.
  • During equipment operation, operators must not leave their posts without authorization. If temporary leave is necessary, a qualified operator must be arranged to take over supervision to ensure timely handling of emergencies.
  • After production is completed, promptly clean the roller surfaces and the surrounding work area: Use cleaning agents compatible with the material and specialized tools to remove residual material from the rollers, preventing it from drying and adhering. Organize material containers and tools to keep the equipment and work environment tidy.
  • After cleaning, turn off the equipment power, cooling circulation water system, and other auxiliary systems in sequence. Record equipment operation details (e.g., operating time, temperature, fault conditions, etc.).

 

Summary
Standardized operation and regular maintenance are key to ensuring the stable operation of the hydraulic triple roll machine and extending its service life. Operators must be familiar with the equipment structure and performance, strictly adhere to these operational points and equipment operating procedures, maintain safety awareness throughout the process, and ensure a safe, controllable production process and stable, reliable product quality.

What are the Characteristics of Hydraulic 3 Roll Milling Machine?

Hydraulic 3 roll milling machine, also known as hydraulic three-roll grinding mills or hydraulic 3 roll milling machine, are equipment primarily used for the wet grinding, dispersion, and mixing of high-viscosity and high-fineness materials. They are named after their core working components—three horizontally mounted, parallel rollers installed on the frame.

 

The hydraulic 3 roll milling machine from Zhongyi offer the following characteristics:

High-precision adjustment: Equipped with WR crownless roller technology, optional gap mode or pressure mode, automatic gap calibration, and control accuracy of up to 1 micron. The four-point pressure can be independently adjusted to meet the fine processing requirements of different materials.

 

High-quality roller material: Optional imported nano-level ceramic rollers, which are wear-resistant and solvent-resistant. The rollers are precision-ground, with a smooth surface that is easy to clean, ensuring grinding quality and efficiency.

 

User-friendly operation: Features a touch-responsive display with zero-delay response for intuitive and convenient operation. Gap calibration can be performed without disassembling the machine, significantly saving maintenance time and labor costs.

 

Diverse functionality: Optional explosion-proof function to meet safety requirements in high-risk production environments. It can also accurately display parameters such as spacing, speed, and torque curves, allowing operators to monitor equipment operation in real time.

 

High level of intelligence: Utilizing advanced pressure curve technology, it enables real-time and precise monitoring of pressure changes. Key data such as gap, pressure, speed, time, and roller temperature during the grinding process are transmitted in real time. In case of abnormalities, the system immediately provides intelligent warnings. It also features powerful data traceability, with complete historical records of every grinding and dispersion process, facilitating quality control and issue tracking.

 

Wide range of applications: As the most effective dispersion equipment for medium- to high-viscosity materials, it is widely used in material preparation and processing in electronics production, such as conductive pastes, electronic inks, and electronic packaging materials. It is also suitable for industries such as adhesives, inks and coatings, new energy, nano new materials, pharmaceuticals, and cosmetics.

 

Support for automatic feeding: Compatible with automatic feeding systems to meet the needs of automated production layouts. This reduces the complexity of manual feeding, lowers labor costs, and improves the uniformity and continuity of material supply, ensuring the stability of the grinding process.

 

Stable and efficient adaptation to large-scale production: The equipment operates stably with a low failure rate, enabling continuous long-term operation. It offers excellent grinding efficiency, quickly processing large volumes of materials, effectively improving overall production capacity, and meeting the needs of large-scale industrial production.

What is a Hydraulic triple roll mill machine?

A hydraulic triple roll mill machine is an upgraded version of the triple roll mill machine, characterized by its core use of a hydraulic system to replace traditional mechanical adjustment mechanisms. It achieves precise control over the pressure and gaps between rollers through hydraulic devices, enabling fine grinding of materials. This equipment is widely used for the dispersion and refinement processing of medium- to high-viscosity materials, such as inks, coatings, electronic pastes, and cosmetic creams.

 

Compared to mechanical triple roll mill machines, its core features lie in the advantages of hydraulic drive, which can be understood in terms of both structure and operational characteristics:

 

Precision and Stability in Pressure Adjustment
The equipment is equipped with a professional hydraulic control system that applies uniform and controllable pressure to the rollers through hydraulic cylinders. This allows for precise setting and real-time adjustment of the inter-roller pressure according to different material properties, such as viscosity and particle size, avoiding issues like uneven pressure and jamming commonly seen in mechanical adjustments. Additionally, the hydraulic system includes a pressure compensation function, which automatically offsets minor deformations of the rollers during the grinding process, ensuring consistent pressure throughout and guaranteeing uniform fineness of the processed material.

 

Automation and Convenience in Operation
Hydraulic adjustment eliminates the need for tedious manual operations, such as turning screws, and allows for quick adjustment of roller gaps via a control panel. Some models can also be equipped with automatic feeding and discharging devices, forming semi-automated or fully automated grinding production lines. Furthermore, the overload protection function of the hydraulic system effectively prevents equipment damage caused by excessively hard materials or foreign objects, enhancing operational safety and extending the service life of the equipment.

 

Combined with the previously mentioned ZYE Hydraulic triple roll mill machine, this type of equipment further integrates advantages such as high-precision control, intelligent monitoring, and suitability for large-scale production, making it a mainstream choice for industrial fine grinding.

What are the Common Problems with the Rollers of a Triple Roll Machine?

The triple roll machine is essential for achieving micron-level grinding and dispersion of materials in industries such as coatings, inks, and pigments. It plays an irreplaceable role in improving product quality. With its precision design and strictly required components, the equipment can perform micron-level grinding and dispersion consistently and stably. Unique features like online gap correction and recipe menus make operation more flexible, while multiple safety measures ensure operational safety throughout the production process. So, what problems generally occur during the use of a triple roll machine?

I. Problems with the Rollers Themselves

Roll Surface Wear:

  • Loss of Precision: Prolonged use leads to gradual wear of the roller surface, significantly reducing shear, grinding, and dispersion efficiency, and failing to achieve the required fineness (loss of micron-level precision).
  • Uneven Wear: Due to uneven material distribution, misaligned rollers, or improper feeding methods, the middle or ends of the rollers may wear unevenly, affecting the consistency of grinding across the entire roller surface.
  • Grooves/Dents: Hard impurities (such as metal chips or sand particles) or abnormal pressure may scratch the roller surface or cause local dents, directly impacting product quality and damaging the material.

Roller Deformation:

  • Bending Deformation: Under high working pressure (inter-roller pressure can reach hundreds to thousands of kilograms), uneven thermal stress, or mechanical impact, rollers with a large length-to-diameter ratio may bend slightly, resulting in uneven roller gaps and preventing uniform material passage.
  • Thermal Deformation: High-speed operation or cooling system failure can cause the rollers to overheat, leading to uneven thermal expansion and deformation.

 

Roller Corrosion/Chemical Erosion:

If the material being ground is corrosive (e.g., certain acid or alkali systems) and the roller material (such as alloy steel) lacks sufficient protection, the roller surface may experience pitting or uniform corrosion, compromising its smoothness and precision.

 

II. Mechanism Problems Directly Related to Roller Operating Precision

Failure of Gap Adjustment and Locking Mechanisms:

  • Wear of the Screw Mechanism: When the worm gear working surface of the screw mechanism wears, gaps form on the meshing surfaces of the worm wheel, increasing the lead angle of the screw. During operation, this can cause the machine to lose its self-locking capability. When the worm gear becomes loose, the two screw mechanisms may fail to synchronize during operation, accelerating roller wear.
  • Issues with Bolt Locknuts: Missing, damaged, or loose bolt locknuts can affect the machine's adjustment device, leading to adjustment failure or improper connection, rendering the machine unable to execute debugging commands.

 

Failure of Pressure Application and Compensation Mechanisms:

  • Spring Failure: After prolonged operation, the springs may experience reduced elasticity or fatigue wear. During maintenance, this can cause roller displacement, as the springs cannot keep up with the machine's operating speed, compromising the accuracy of adjustments.
  • Hydraulic/Pneumatic System Issues (for automatic pressure models): Problems such as leaks, unstable pressure, or valve malfunctions can lead to imprecise pressure control.

 

Wear of Guiding and Support Mechanisms:

  • Slide Way Wear: Worn slide ways increase operational resistance and friction, hindering normal movement. Similar to spring failure, this can reduce the parallelism between rollers. If not addressed promptly, the rollers may come into direct contact and friction, accelerating wear and ultimately reducing the machine's overall efficiency.
  • Bearing Wear or Damage: The bearings supporting both ends of the rollers withstand significant radial forces. Worn bearings can cause roller runout, axis deviation, and loss of parallelism, often accompanied by abnormal noise and overheating.

 

III. Other Related Problems Indirectly Affecting Roller Operation

Cooling System Failure:

Blockages, scaling, or insufficient water flow in the internal cooling channels of the rollers can cause overheating. This raises the material temperature, potentially altering its rheology (e.g., reducing viscosity) and affecting grinding and dispersion effectiveness.

Lubrication System Problems:

Poor lubrication in the gearbox, bearings, or other areas can lead to abnormal wear of drive gears or bearings, affecting the smooth transmission and positional accuracy of the rollers.

Doctor Blade System Issues:

Wear, deformation, or improper pressure of the discharge doctor blade can cause poor discharge, material wrapping around the rollers, and difficulties in cleaning, affecting continuous production and material yield. Worn doctor blades may also expose the metal base, which can scratch the roller surface.

The occurrence of these problems in rollers during long-term operation is influenced by factors such as material characteristics, operational standards, and equipment maintenance. Zhongyi Equipment addresses these issues by using high-quality specialized roller materials and intelligent gap compensation systems. This approach optimizes the performance and operational precision of core components from the source, effectively reducing the occurrence of the aforementioned problems and ensuring long-term, stable, and efficient operation of the equipment.

3 Roll Mill Rollers Generally Encounter the Following Issues

The triple roller mill is a core piece of equipment in industries such as coatings, inks, and pigments for achieving micron-level grinding and dispersion of materials. It plays an irreplaceable role in improving product quality. The precision design and strictly required components enable the equipment to maintain stable, continuous micron-level grinding and dispersion. Unique features such as on-line gap adjustment and recipe menu functions make operation more flexible, while multiple safety protection measures ensure operational safety throughout the production process. What issues generally arise during the use of a triple roller mill?


Problems with the Rollers Themselves
Roller Surface Wear:

  • Loss of Precision: After prolonged use, the roller surface gradually wears down, leading to a significant decrease in shearing, grinding, and dispersion efficiency, and failure to achieve the required fineness (loss of micron-level accuracy).
  • Uneven Wear: Due to uneven material distribution, non-parallel rollers, or feeding issues, the middle or ends of the rollers may wear unevenly, affecting the consistency of grinding across the entire roller surface.
  • Grooves/Dents: Hard impurities (such as metal chips or sand particles) or abnormal pressure may cause scratches or local dents on the roller surface, directly impacting product quality and damaging the material.


Roller Deformation:

  • Bending Deformation: Due to high working pressure (inter-roller pressure can reach hundreds to thousands of kilograms), uneven thermal stress, or mechanical impact, rollers with a high length-to-diameter ratio may experience slight bending, resulting in uneven gaps and failure to ensure uniform material passage.
  • Thermal Deformation: When operating at high speeds or due to cooling system failure, the roller temperature may rise, causing uneven thermal expansion and deformation.
     

Roller Corrosion/Chemical Erosion:
If the material being ground is corrosive (such as certain acid-base systems) and the roller material (e.g., alloy steel) lacks sufficient protection, the roller surface may develop pitting or uniform corrosion, compromising its smoothness and precision.

 

Mechanism Issues Directly Affecting Roller Operation Accuracy

Gap Adjustment and Locking Mechanism Failure:

  • Worm Drive Wear: When the working surfaces of the worm drive inside the screw mechanism wear down, gaps may form between the worm gear teeth, increasing the lead angle of the screw. During operation of the 3 roll mill, this can result in loss of self-locking capability. When the worm gear/worm drive becomes loose during operation, the two screw mechanisms may fail to synchronize, accelerating the wear rate of the grinding rollers.
  • Bolt Nut Issues: Missing, damaged, or loose bolt nuts can affect the adjustment mechanism of the mill, causing adjustment failure and improper connections. This prevents the mill from executing adjustment commands properly.


Pressure Application and Compensation Mechanism Failure:

  • Spring Failure: After prolonged operation of the triple roller mill, springs may experience reduced elasticity, fatigue, and wear. During maintenance, this can cause grinding rollers to shift. Springs may fail to keep up with the overall operating speed of the mill, compromising the accuracy of adjustments.
  • Hydraulic/Pneumatic System Issues (for automatic pressure models): Problems such as leaks, unstable pressure, or valve malfunctions may lead to imprecise pressure control.
     

Guide and Support Mechanism Wear:

  • Slide Way Wear: Wear on the slide ways can create resistance during operation, increasing frictional resistance and hindering normal movement. Similar to spring failure, this can reduce the parallelism between the rollers. If not addressed promptly, contact friction may occur between the rollers on both sides, accelerating tooth pattern wear and ultimately reducing the overall efficiency of the mill.
  • Bearing Wear or Damage: Bearings supporting both ends of the rollers endure significant radial forces. Bearing wear can cause roller runout, axis deviation, and compromised parallelism, potentially resulting in abnormal noise and overheating.

 

Other Related Issues Indirectly Affecting Roller Performance
Cooling System Malfunction:
Blockages, scaling, or insufficient water flow in the internal cooling channels of the rollers can cause excessive roller temperature. This may raise the material temperature and alter its rheological properties (e.g., reduced viscosity), affecting grinding and dispersion effectiveness.


Lubrication System Issues:
Poor lubrication in areas such as the gearbox or bearings can lead to abnormal wear of the drive gears or bearings, subsequently affecting the smoothness of roller transmission and positional accuracy.


Doctor Blade System Issues:
Worn, deformed, or improperly pressured doctor blades can cause poor material discharge, material buildup on the rollers, and cleaning difficulties, impacting continuous production and material yield. Worn doctor blades may also come into contact with the roller surface, scratching it.


Influenced by material characteristics, operational standards, equipment maintenance, and other factors, rollers are prone to various issues during long-term operation. ZYE Equipment employs high-quality specialized roller materials and an intelligent gap compensation system to optimize the performance and operational accuracy of core components from the source. This effectively reduces the occurrence of the aforementioned issues, ensuring long-term stable and efficient operation of the equipment.
 

Factors Affecting the Performance of Defoaming Mixers

Defoaming mixers are used to remove air bubbles from materials while achieving thorough mixing. Their effectiveness is influenced by multiple factors, which can be categorized into three main areas: equipment parameters, material characteristics, and operating methods.

Equipment-Related Factors

  • Speed and Speed Modes:Rotational speed is a core influencing factor. Generally, higher speeds generate greater centrifugal force and improve defoaming. However, excessively high speeds may cause material splashing, separation, or even equipment damage.Speed modes (e.g., constant speed, variable speed, forward/reverse switching) also matter. Switching between forward and reverse rotation helps achieve more thorough mixing and bubble removal.
  • Mixing Time:Insufficient time prevents adequate bubble removal and mixing. Excessive time may cause material overheating, degradation, or re-introduction of air, while also increasing equipment wear.
  • Eccentric Distance / Revolution Radius:Defoaming mixers typically operate in a revolution + rotation mode. The eccentric distance affects the magnitude and distribution of centrifugal force. An appropriate eccentric distance ensures uniform force application, leading to better mixing and defoaming.
  • Container Compatibility:The mixing container must fit securely with the equipment's clamping mechanism. Improper sizing can cause shaking or displacement during high-speed operation, affecting results and posing safety risks.Container material and shape also matter—for example, flat-bottomed, smooth-walled containers facilitate material movement and bubble escape.

 

Material-Related Factors

  • Material Viscosity:High-viscosity materials make bubble removal more difficult and may require higher speeds or longer mixing times. Very low-viscosity materials are prone to splashing at high speeds.
  • Solid Content:High solid content increases bubble retention in particle gaps and reduces material fluidity, making defoaming more challenging and requiring adjusted operating parameters.
  • Surface Tension:Materials with high surface tension make bubbles harder to break, possibly necessitating defoaming agents or adjusted speed and time settings.
  • Material Temperature:Temperature affects viscosity and surface tension. Higher temperatures generally reduce viscosity and ease bubble removal, but excessive heat may alter material properties—particularly for volatile or heat-sensitive materials, requiring temperature control.

 

Operation-Related Factors

  • Filling Volume:Generally, the filling volume should not exceed 70%–80% of the container's capacity. Overfilling restricts material movement and bubble escape, and may cause spills. Underfilling leads to unstable material flow during operation, reducing effectiveness.
  • Filling Method:For multi-step filling, the order and rate of addition affect mixing and defoaming. For example, adding high-viscosity material first, followed by low-viscosity material, can improve mixing. Rough handling during filling may introduce more air, increasing defoaming difficulty.
  • Environmental Factors:Ambient temperature, humidity, and dust levels can also influence results. High humidity may affect material properties, and excessive dust can contaminate the material.

Is a Higher Vacuum Pressure Always Better for Vacuum Defoaming Machines? What Level is Appropriate?

Vacuum defoaming mixers play a crucial role in material blending and bubble removal. Currently, vacuum defoaming equipment on the market can be divided into contact and non-contact types. Contact-type machines mainly utilize rotating blades combined with vacuum mixing to achieve material homogenization and defoaming, while non-contact types employ a planetary rotation method, relying on both rotation and revolution to accomplish mixing and defoaming. Compared to traditional contact-type vacuum defoaming machines, non-contact models offer advantages such as faster processing, no contamination of materials, and easier cleaning. As a result, they are increasingly favored in the market. When using vacuum defoaming mixers for material blending and bubble removal, applying vacuum is sometimes necessary. So, is a higher vacuum level always better for these machines? What level is appropriate? Let’s analyze this together.

 

What Vacuum Pressure Level is Suitable for Vacuum Defoaming Machines?  
This generally depends on the viscosity and stickiness of the material. For materials with low viscosity and low defoaming requirements, such as simple liquid mixtures or solid-liquid blends that do not require an oxygen-free environment, non-contact vacuum defoaming mixers can often achieve ideal mixing and defoaming results without vacuum—simply operating under atmospheric pressure.

 

For materials that require an oxygen-free environment and have relatively low viscosity, applying an appropriate level of vacuum is necessary for defoaming. Typically, a vacuum level of -80 to -90 kPa can achieve the desired effect.

 

For materials with higher viscosity and stickiness, where the centrifugal force generated by rotation and revolution alone is insufficient for effective defoaming, a vacuum environment is required to assist in bubble removal. In such cases, the vacuum level needs to be increased accordingly, or the rotation and revolution speeds must be further enhanced to improve defoaming performance.

 

Is a Higher Vacuum Level Always Better for Vacuum Defoaming Machines?  
Generally, a higher vacuum level indicates better sealing performance and stronger defoaming capability—this is undeniable. However, for certain specific materials, the machine’s high performance may not be advantageous. For example, when materials contain volatile substances, a high vacuum can draw these volatiles out, altering the material’s formulation and ultimately affecting its performance.

 

In some industries, such as ink production, higher vacuum levels are required for material defoaming. If the machine cannot meet this requirement, a dual-stage vacuum pump can be added to achieve a higher vacuum level.

 

As an emerging product in the market, vacuum defoaming mixers are widely used in many industries, such as conductive silver paste, silicone, cosmetics, and LED manufacturing, addressing challenges in mixing and defoaming. However, purchasing the equipment is not a one-time solution. In practical applications, it is essential to explore the most suitable operating conditions to maximize the equipment’s performance and create greater value for the enterprise.

What are the Precautions for Using a Vacuum Defoaming Machine?

When using a vacuum defoaming machine, a specialized device for efficiently removing bubbles from materials, its stable operation and operational safety rely on strict and standardized procedures. The following precautions can help operators avoid equipment malfunctions and safety risks, ensuring defoaming effectiveness and workplace safety.

 

  • When connecting the power supply, ensure that the ground wire is properly connected to minimize the risk of accidents.
  • During initial adjustments, the planetary frame of the vacuum defoaming machine should rotate clockwise from top to bottom.
  • When placing the adhesive cup into the machine base, the cup must be secured first to ensure a proper seal between the defoaming machine and the cup before operation.
  • If the material requires defoaming under vacuum conditions, first check whether the water tank of the vacuum defoaming machine is filled with water and verify that the vacuum tube's sealing performance is adequate.
  • When operating the hydraulic station of the vacuum defoaming machine, carefully observe the pressure indicators and avoid setting the pressure too high.
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