The client, a high-quality resin sphere manufacturer based in Malaysia, faced challenges processing polymer materials. Resin spheres are notoriously heat-sensitive (prone to softening and clumping) and possess high toughness, making traditional ball mills or standard pin mills inefficient for achieving the required throughput and particle size distribution.
Core Requirements
- Target Fineness: d50 = 20μm.
- Production Capacity: 200kg/h.
- Material Characteristics: Strict temperature control to prevent thermal degradation or oxidation.
- Particle Morphology: Uniform particle size distribution with minimal ultra-fine dust or oversized particles.
Technical Solution: Epic Powder Turbo Mill + ITC Air Classifier for Resin Sphere Grinding and Classifying
To address the physical properties of resin, Epic Powder engineers configured the following process:
Process Workflow
- Feeding: Resin spheres enter the TSM Turbo Mill via a quantitative dosing system.
- Vortex Pulverization: The high-speed rotor generates powerful air vortices. The spheres collide and shear against each other within the airflow rather than relying solely on mechanical impact. This “air-grinding” attribute significantly reduces heat generated by friction.
- Classification: The pulverized material is carried by the airflow into the ITC Classifier. By adjusting the classification wheel speed, particles meeting the 20μm requirement are separated.
- Collection: Qualified powder is collected by a cyclone and pulse dust collector, while oversized particles return to the mill for regrinding.
Performance & Empirical Data
Following the implementation of the resin sphere grinding and classifying system, the facility achieved the following results:
- Granularity Control: The finished product d50 remained stable between 18.5μm and 21.2μm , perfectly aligning with the 20μm target.
- Capacity Achievement: Actual average throughput reached 215kg/h, exceeding the client’s 200kg/h requirement.
- Temperature Stability: With the integrated cooling system, the grinding chamber temperature stayed below 45°C, effectively preventing resin softening or “wall-sticking.”
- Automation: The PLC touch-screen interface supports one-touch start/stop, simplifying operation for the local workforce.
Conclusion
The specialized Resin Sphere Grinding and Classifying workflow developed by Epic Powder not only solved the fineness issue but also optimized material residence time through fluid dynamics design, preventing thermal degradation.