The pigments market remains a 15-billion-dollar industry and is still expected to maintain long-term growth. The world economy needs everything from trans-oxide pigments for deck stain applications to carbon black for printing ink applications to metallic-based dyes for the automobile industry. Pigment cost is the lead overall cost driver in all these application markets. For this reason, companies are always looking for new methodologies to reduce this cost in the manufacturing process.
Mixmill horizontal plow mixers and vacuum dryers have been part of the pigment industry for years, and many manufacturers have used them for their versatility to drive savings. The industry has used plow mixers as everything from dry pigment blenders to vacuum dryers to vessels capable of performing the initial mix and dispersion of the pigments. Plow mixers are multipurpose horizontal mixers and vacuum dryers that offer advantages in mix time compared to other technologies. In dry powder applications, customers have seen improvements of upwards of 600 percent in throughput speed versus ribbon blenders. This higher speed blending results in less energy consumed per pound of material produced. Processall’s pigment mixers also have a high heat transfer rate enabling them to significantly reduce the amount of time needed to dry everything from flushed materials to pigment press cakes. Finally, they can do the initial grinding and dispersing of pigment into solutions achieving particle sizes of nanometers in the unit
Processall employees have a long history of working with companies in all markets, aiding in everything from initial testing to installation to maintenance throughout the unit’s life cycle.
Processall’s plow mixing technology gives manufacturers a leg up on the competition. Below are some benefits of moving toward plow mixing technologies for pigment operations:
- The advantage of being a multipurpose plough mixer and vacuum drier
- Greater uniformity and Elimination of streaking in dry pigment blends
- Creation of a mechanically fluidized bed which reduces mix times
- Reduction in the energy required for dry pigments
- A high heat transfer rate within the vessel enables faster drying
- The vessel jacket allows different media (hot oil, steam, or tempered water) to be used depending upon the thermal sensitivity of the product
- Adjustable Pressure conditions enable both high-pressure applications and near vacuum pressures to occur during different stages of the reaction
- Ability to granulate pigment
- Mill breaks up clumps and can be used for defining particle size
- Thermal jackets to allow for optimal temperature controls
- Easy to scale up and predict mix and drying times after lab testing
- Ability to remove hazardous solvents from material
- Vessels can be further outfitted to increase versatility:
- Mechanical seals will allow the vessel to be pressurized as well as reach a low vacuum (28 Hg)
- Liquid lances allow media to be sprayed onto the substrate
- Ability to perform the reaction and the mixing and drying within one unit resulting in:
- Faster throughputs
- Reduced energy consumption
- Smaller footprint on the production floor
Current uses in the Pigment market
- Dry pigment blending
- Pigment Presscake drying
- Dispersing operations
- Grinding applications
- And many more
Processall maintains a fully equipped testing facility in Cincinnati, Ohio. It is designed to provide customers with the data they need to develop their process, evaluate equipment, scale up, and identify the necessary equipment to maintain desired production volumes. We invite all potential customers to bring their products to our test center and get a “hands-on” experience with our technology and capabilities.
We also maintain a rental fleet that customers can utilize for further testing at their facility or minimize their startup costs for a new process.
Please feel free to contact us with all your material processing questions, and our experienced industry professionals will help you find the right mixing solutions for your particular application.