In the field of powder engineering, milling technology directly affects particle size distribution, particle morphology, and production efficiency. As of 2025, the Air Jet Mill and the Mechanical Mill remain the two mainstream industrial systems. This paper provides a systematic comparison in terms of working principles, energy efficiency, and particle size control.
Equipment Principles Comparison
- Working Principle: Compressed air (0.7–1.0 MPa) passes through a Laval nozzle to generate supersonic airflow, causing particles to collide and fracture (typical velocity 300–500 m/s).
- Core Advantages:
- No mechanical wear (suitable for materials with Mohs hardness ≥9)
- Particle size can reach submicron levels (D50: 0.5–10 μm)
- Low-temperature milling (outlet temperature <40℃)
- Typical Types: Hammer mill, ball mill, roller mill
- Working Principle: Material is milled by mechanical forces such as impact, shear, and compression.
- Core Characteristics:
- Large throughput (up to 50 t/h per unit)
- Lower energy consumption (specific energy: 0.05–0.3 kWh/kg)
- Higher risk of thermal damage (temperature can reach 80–120℃)
Key Performance Indicators Comparison
| Parameter | Air Jet Mill | Mechanical Mill |
| Minimum Particle Size | 0.1 μm | 1 μm |
| Capacity Range | 0.1–3 t/h | 0.5–50 t/h |
| Specific Surface Area Increase | 300–500% | 100–200% |
| Noise Level | <75 dB | 85–110 dB |
| Maintenance Interval | 2000 h | 500 h |
Application Recommendations
Air Jet Mill is preferred for:
- High value-added materials (e.g., lithium battery cathode materials, pharmaceutical APIs)
- Heat-sensitive substances (e.g., enzymes, polymers)
- Ultrafine powders (D90 <5 μm)
Mechanical Mill is preferred for:
- Bulk mineral processing (e.g., calcium carbonate, quartz sand)
- Coarse grinding requirements (1 mm–100 μm)
- Cost-sensitive projects (equipment investment is 3–5 times lower)
Conclusion
Air jet mills and mechanical mills each have their own advantages:
- For ultrafine, contamination-free, and precisely controlled powders, the air jet mill is the better choice.
- For cost-efficient large-scale milling, the mechanical mill is more practical.
With over 20 years of expertise in ultrafine powder processing, Epic Powder provides integrated solutions for both air jet and mechanical milling. We customize systems for our clients to strike the best balance between purity, efficiency, and cost, helping industries achieve high-quality powder production.