Process / Product quality benefits
- Uniform dispersion of ultrafine graphite
- Stable and consistent lubricant formulation
- Elimination of agglomerates and uneven distribution
- Repeatable mixing performance
Customer brief
The customer required a mixing solution capable of dispersing: 480 kg (1,058 lbs) of ultrafine graphite powder into 1,340 kg (2,955 lbs) of base oil – with a viscosity of 460 cSt, in temperatures up to 55 °C (131 °F).
They required:
- Homogeneous and stable dispersion
- Prevention of agglomeration, floating and sedimentation
- Repeatable process performance for production scale
- Reduced risk in developing a new lubricant formulation
Fristam’s solution
Fristam supplied a custom Powder Mixer PM 03 skid, configured for this application:
- FSP 3532 (15 kW / 20 HP) for high-viscosity fluid handling and mixing
- FZ 22 (11 kW / 15 HP) for controlled powder induction
- Industrial skid-mounted design for non-hygienic environments
- Operation capability at 55 °C (131 °F)
This solution combined controlled powder induction with robust mixing performance, enabling efficient processing of abrasive graphite particles.
Trial Set-Up
Trials were conducted at the Fristam facility using the customer’s materials.
1. Liquid Recirculation
Base oil was circulated to establish stable flow conditions.
2. Powder Induction
Graphite powder was introduced via suction, ensuring immediate wetting and controlled feeding.
3. Mixing and Dispersion
The system processed the mixture under controlled conditions, overcoming challenges associated with viscosity and powder behaviour.
4. Validation
Trials confirmed consistent, homogeneous dispersion, enabling confident scale-up.
A successful outcome with the Fristam Powder Mixer
Following installation, the customer achieved:
- Reliable dispersion of ultrafine graphite in high-viscosity oil
- Homogeneous, stable and repeatable product quality
- Elimination of previous mixing inconsistencies
- Readiness for commercial product launch
The success of the project also demonstrated that:
- Live trials are critical when no established process exists
- Effective powder induction is key to controlling difficult materials like graphite
- Specialised mixing technology is required for high-viscosity and abrasive applications
- Proven performance supports scale-up and multi-site implementation, with further deployment under consideration at the customer’s Germany facility
Financial benefits
- Reduced risk of batch failure and material waste
- Faster product development and time-to-market
- Lower rework and process inefficiencies
Operational Benefits
- Compact skid design for easy integration
- Straightforward operation for production teams
- Scalable solution for future product expansion