Process / Product quality benefits
- Elimination of pigment rub-out and colour shift during production
- Fine pigment dispersion below approximately 10 µm
- Homogeneous coating structure and smooth surface finish
- Significantly faster processing times
Previously unsuccessful methods
Before implementing the Fristam solution, the customer used a bottom-entry tank blender to disperse pigments within the water-based coating. The process took hours, and multiple recirculation’s and the product still wasn’t satisfactory.
While the bottom-entry mixer provided general circulation, it delivered limited localised shear energy which led to partially broken pigment clusters, uneven colour development and settling within the wet film.
These effects commonly appear as rub-out, colour variation, reduced surface smoothness and inconsistent finish quality on coated substrates.
Fristam’s solution
Fristam implemented a Fristam FS shear blender with a 3532 rotor stator configuration. The blenders rotor-stator shearing action applies intensive mechanical energy with tight clearances and high tip speeds, enabling efficient deagglomeration of pigment particles and production of highly homogeneous multiphase products.
Trial Set-Up
1. Water-based paint was recirculated through the Fristam FS shear blender to apply controlled high-shear dispersion.
2. The product passed through the shear stage three times to achieve the required pigment deagglomeration and particle size reduction.
3. Following high-shear processing, rub-out in the coated film was eliminated and the paint exhibited full homogeneity with a smooth coated surface.
4. Colour paste was then introduced into the base paint using an inline introduction valve, rapidly producing a homogeneous coloured coating.
5. The Fristam FS Shear Blender ensured the colour paste was dispersed evenly in the paint mix.
A successful outcome with Fristam FS Shear Blender
High-shear recirculation through the Fristam FS shear blender eliminated pigment rub-out, produced a homogeneous coating and delivered a smooth surface finish on coated test boards. The process was significantly faster than the previous method of bottom entry mixing. The customer purchased the trial unit immediately, so impressed by the speed, easy integration into their existing process and the end quality of the product.
Sustainability benefits
- Reduced raw material and final batch waste
- Faster process = more energy efficient
- Allowed the manufacturer to keep the majority of their equipment and simply modify what they had, reducing environmental impact of purchasing new equipment
Financial benefits
- Less energy used during production due to shorter process times
- Batches no longer scrapped due to poor quality
- Integration into the current process simple – minimal expense to modify
Other benefits
- Less stress on operators and quality control to monitor the products end quality