The advantage of the three roll mill instead of ball mill

Are you still using the ball mill process? It's time to try out the three-roll mill.

It has been proved that in some applications, a Three Roll Mill can effectively replace the traditional ball milling process. Besides, it can also offer a great level of improvement in the overall throughput rate. What’s more? You will witness less amount of energy consumption and better production yield.

The three roll mill has emerged as an effective grinding as well as dispersing equipment to process high viscosity materials. As a result, the machine is widely used for grinding different types of liquid paste and paint materials, for example, plastics, pigments, inks, paints, rubber, ceramics, cosmetics, and more.

Some common issues that you can face while using the ball milling process

Speaking about a ball mill, the machine comes with a rotating cylinder-shaped shell, and that will be partially filled with grinding media. It can be metal balls or ceramic. The products that you want to be milled are inserted into the shell. After that, the machine’s cylinder will rotate on the horizontal axis. During the movement, the pieces of the grinding tool will collide against the vessel surface. The collision will produce a grinding action, and that will lower the product’s particles size.

Well, there is no doubt that ball milling machines are quite easy to operate, and they are very versatile. In fact, some designs can be used for wet and dry feeds. However, the machines come with multiple drawbacks. For example, it performs a little slower than other milling machines. As a result, the throughput will be a little low. Besides, you may also deal with issues like clogging, higher energy consumption levels, and more. Furthermore, the machines are not easy to clean.

So, do you want to optimize the material milling process? Well, you can always go for a Three Roll Mill. Even though not all the applications that you can perform using a ball mill can be carried out by the three-roll milling, but this is perfect for slurries or pastes having moderate viscosity.

Understanding the theory of operation

As the name suggests, a Three Roll Mill comes with three rollers attached to a durable iron frame. This can be installed slightly tilted and horizontally. On the other hand, the grinding effect can be achieved when the surfaces of the roller mutually press and rub against each other at different speeds. The materials that you need to mill should be placed between the center rolls and the feed. After that, the material will get transferred from the central roller to the apron roller.

Thanks to the adhesion. As the rollers move in a different direction, they create a perfect grinding action. In this machine, the rotational speed will gradually increase sequentially from one roller to another. The shear forces will develop dispersion. You can reduce the distance between the rollers to witness a huge shear, but it can lower the throughput. Once the material is ground or milled, it is scraped from the apron roller using a take-off knife.

In general, most of the roller material of the three roll mill is carefully cast from alloy cast iron. On the other hand, the surface harness will be around HS70 degrees. The roller’s diameter is very precise as well as delicate. As per the experts, using a good quality machine, you can attain a grinding fineness of 15μm.

Is the product you are using three-roller mill material?

These machines are like a classic technology that remains to be the best method for preparing very fine and smooth particle dispersions in inks, cosmetics, paints, ointments, electronic pastes, dental composites, and more. However, here are some guidelines that can help you in understanding if your product is perfect for such machines.

· As per the experts, moderately flowable and viscous materials are ideal for a three-roll mill. While using the machines, most of the applications are poured into the area between the central roller and feed roller. The material has too low a viscosity level; it can affect the product by staying on the surfaces of the rollers. The material may drip through the rolls.

· You should always remember that the materials you want to use in the machine must have the right element of stickiness to them. As a result, the material will adhere to the roller surface perfectly and will transfer smoothly between the rollers. Before using the material, it is advisable to test it using a machine.

· Another thing you should remember is that a three-roll mill can’t handle powder or any solid material. It has been seen that some manufacturers add solvent to create a good level of wetness and make the material suitable for the machine.

Understanding a sample application

Some manufacturers of high-performance ceramic composites and thermoplastic used to ball milling the resin base milling material containing the micronized silicon carbide. To obtain a decent level of dispersion of the particles, operators need to mill the slurry for a few days. After testing a three-roller mill, the manufacturers realized that they could easily cut down the milling time using the machines. After that, they started using floor-standing three-roller mill machines, and that greatly improve their production rate.

The advanced three roll mill comes with a hydraulic system that can control different parts, such as a pressure roller, discharging blade, two sides holders, and more. As a result, the system can boost up the production capacity compared to other milling processes. There is no need to go through any complex setup process, and you can enjoy higher production.

FLE brings you the best machine

With more than 20 years of experience in manufacturing three roll milling, FLE has earned a great reputation as a reliable hydraulic three roll mill producer and supplier. The machines come with the latest technology, and the users can enjoy high-line pressure and quality products without wasting much time. Each roll has an efficient cooling system. And you can check and control the roller temperature while using the machine. So, what are you waiting for? Visit the official site now, check out the models and place your order.

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This article address : The advantage of the three roll mill instead of ball mill