High Shear Mixers

Innovation in

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MORE CHOICES. FASTERPROCESSING. SUPERIOR SUPPORT.Ross manufacturers the world’s broadest line ofHigh Shear Mixers – from traditional High SpeedDispersers and single-stage Rotor/Stator Mixers tothe new generation of patented ultra-high shearX-Series* mixers.

With five plants in the USA alone, Ross standsbehind its mixers with support that no other mixermanufacturer can match.

• Fast production and delivery of new mixers

• Fast turnaround on custom designs

• Replacement parts delivered overnight from ourU.S. plants

• Trial units to evaluate our mixer on yourprocess line before you buy it

• A sophisticated test and development center,where you can test your mixer before you buy it

• Our USA-based service network is ready toprovide the fastest and most reliable service youcan find to support your Ross High Shear Mixer

*Patent No. 5,632,596

INNOVATION. SUPERIORPERFORMANCE.While other manufacturers continue to sellvirtually the same mixers they built 25 years ago,Ross is continuously introducing designimprovements and exciting new design conceptsproduced by our R&D team.

First, we perfected conventional rotor/statormixer design. Our high performance rotor/statormixers are available in sizes from benchtopthrough full-scale production, in batch and in-lineconfigurations, with a multitude of options to fine-tune performance.

We’ve also introduced a new, patented familyof mixers that have opened up a new horizon inrotor/stator mixing. Our new designs includerotor/stator mixers capable of far greater shear.

High Shear Rotor/Stator Mixers

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MORE MIXERS IN STOCK FOR FAST DELIVERYRoss maintains the world’s largestinventory of batch and in-line mixers –new and rebuilt, fully warrantied, andready to ship when you need them. Our multi-million dollar inventory is yourultimate assurance that you can have theequipment you need, when you need it.

ContentsRotor/Stator Design

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High Shear Batch Mixers Page 6

High Speed Powder InductionPage 9

High Shear In-line Mixers Page 10

High Speed DispersersPage 13

Controls, Fabrication andLaboratory Development

Page 14

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The driving force in High Shear Mixer design

Ross High Shear Rotor/Stator Mixers are available with a variety of interchangeable statorsto fine-tune such functions as particle size reduction, deagglomeration and emulsification.

The Disintegrating Head is excellent for general purpose mixing, fast particlesize reduction of larger solids, andvigorous flow.

The Slotted Head provides the mostpopular combination of high shear andefficient flow rates. It is well-suited foremulsions and many medium-viscositymixing applications.

The Large Square Hole DisintegratingHead is ideal for applications that requireextremely vigorous flow and intense shear.

The Fine Screen Head applies the highestshear rates of all single-stage High ShearMixers. It is generally used for lower-viscosity emulsions and fine dispersions.

THE CLASSIC SINGLE-STAGEROTOR/STATOR MIXERAll rotor/stator mixers are comprisedof a rotor that turns at high speedwithin a stationary stator. In a“single-stage” unit, the rotor includesa single set of four blades. As therotating blades pass each opening inthe stator, they mechanically shearparticles and droplets, and expelmaterial at high velocity into thesurrounding mix, creating intensehydraulic shear. As fast as material isexpelled, more is drawn into thebottom of the rotor/stator generator,which promotes continuous flow andfast mixing.

The Ross Rotor/Stator Mixer easilyreplaces other high speed mixers inmany applications. With the rotorturning at 3,000 -4,000 feet perminute (fpm), the generator appliesintense mechanical and hydraulicshear, and produces vigorous flow ina low-viscosity batch.

Applications Homogenization, solubilization, emulsi-fication, powder wet-out, grinding andparticle size reduction, in batch andin-line configurations. The single stagerotor/stator mixer is ideal for applica-tions that require fast particle/dropletsize reduction.

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MULTI-STAGE ROTOR/STATOR MIXERSMulti-stage rotor/stator generators include two orfour rows of rotating blades that nest inside amatching stator. The mix material enters the centerof the generator through an inlet connection andis accelerated outward by centrifugal force.During each transit through the rotor/statorgenerator, the material is subjected to a quicksuccession of increasingly intenseshearing events – until it finally exitsthe generator and iseither pipeddownstream orrecirculated foranother passthrough the mixer.

By applying aseries of shearing eventswith every pass through thegenerator, the multi-stage mixer accelerates themixing process dramatically. This action alsoproduces particles and droplets that are quitesmall – usually well below 1 micron in diameter –and extremely uniform.

LOW PROFILE X-SERIES*ROTOR/STATOR MIXERSThe rotor and stator in the X-Series generator are unique. Instead of ordinary blades in aconventional stator, the X-Series rotor and statorare comprised of many concentric rows ofintermeshing teeth. The mix material begins atthe center of the generator and moves outwardthrough radial channels cut in the rotor/statorteeth. Tolerances are extremely close, and theshear applied to the material in each pass isextraordinarily intense. The shear applied by theX-Series mixer is further intensified since thisgenerator operates at extremely high tip speeds –up to 18,000 fpm.

For the process engineer, the greatestadvantage of this rotor/stator design is its abilityto produce emulsions and dispersions thatotherwise would require a more expensivecolloid mill or homogenizer.

ApplicationsUltra-high quality dispersions and emulsions, in anin-line configuration only. X-Series units are appropriatefor applications in which sub-micron particle/dropletsize is desired to achieve the necessary productstability, visual appeal and texture – especially forcosmetics, personal care and food products.

*Patent No. 5,632,596

The low profile X-Seriesrotor/stator generatorintroduced the first quantumjump in rotor/stator designin 25 years.

A four-stage rotor/statorgenerator used in the RossQuad-Slot Mixer.

The Ross Dual Rotor/Statoris a two-stage generator

ApplicationsFine dispersions and high-quality emulsions.

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No other company in the world canmatch the selection and support that Rossoffers in High Shear Batch Mixers. Insizes from 1/2 HP to 200 HP, handlingbatches from 50 ml to more than 6,000gallons, Ross High Shear Mixersdeliver an unbeatable combination ofefficiency and flexibility.

Series 100Our Series 100 High Shear Mixers

combine economy and efficiency formixing under atmospheric conditions.Models up to 10 HP can easily be movedfrom one vessel to another on an optionalrolling hydraulic stand – accommodatinga wide range of vessel sizes.

The Ross Series 500High Shear Mixer

The Ross Series 100High Shear Mixer

Series 500Series 500 High Shear Mixers

include a mechanical seal abovethe shaft and an ANSI flange toallow the mixer to be anchoredto the top of an enclosed vessel.Suitable for either atmospheric orvacuum/pressure mixing, thesemixers are designed forapplications that require an extrameasure of protection againstcontamination. USDA-approvedsanitary designs are available.

Ross High Shear Batch Mixers

ROSS QUALITY,VERSATILITY AND VALUEHigh-efficiency explosion-proof motors are standard.

With a mechanical seal, the Series 500 High Shear Mixer is ideal for many sanitary applications.

Downthrust and circulation propellerscan be added to enhance circulation inthe vessel. Ross can also provide anunlimited variety of special tanks.

Standard shaft support bushings arebronze or glass-filled Teflon. Otheroptions include ultra-hard alloy shaftsleeves and continuously lubricatedbushing assemblies for specialapplications.

Standard material of construction isType 316 stainless steel. Optionsinclude special alloys and coatings and specially hardened steel for rotorsand stators.

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Typical ApplicationsFood

Chemicals

Textile colors

Series 500 High Shear Mixers are available in standardsizes up to 100 HP. Adurable epoxy paintfinish is standard, withstainless steel anoption for sanitaryapplications.

BATCH MIXING: FLEXIBILITY,HIGH FLOW AND FASTMIXING CYCLES

Batch High Shear Mixers can bepermanently mounted to the mix tankor suspended over the vessel with aportable lift. The mobile config-uration offers you the flexibility to usea single mixer in multiple vessels. It

also allows you to vary the position ofthe rotor/stator generator in the vesselto fine-tune the process to handle avariety of materials.

The flow through a batch rotor/statorgenerator can be as much as ten timeshigher than in a comparable in-linemixer. For many applications, thisproduces fast particle size reductionand short mixing cycles, but only if theflow pattern within the vessel isoptimized. Ross engineers will helpensure that high flow through therotor/stator generator correlates withcomplete tank turnovers – and ahomogeneous end product.

The rotor/stator generator of the batchHigh Shear Mixer is generally positioned2-3 head diameters from the bottom of thevessel, and slightly off-center. To ensureadequate suspension of heavier solids, therotor/stator generator may be located inthe center of the vessel.

With a mobile hydraulic lift, your Ross HighShear Mixer can easily be repositioned for usewith numerous vessels. Standard lift designsaccommodate mixers up to 10 HP. Ross canalso provide larger lifts for special applications.

Ross offers the unique ability to provide a High Shear Mixeras a component in a larger,multi-shaft batch mixing system.The Ross VersaMix combines the High Shear Mixer with a High Speed Disperser and aslow-speed anchor agitator.With supplemental agitation, the High Shear Mixer – which is normally limited toviscosities of approximately10,000 cps – caneffectively handle materialswell over 200,000 cps.

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100L High Shear Laboratory Mixer:1/2 HP – An economical workhorse forprocess development in the laboratory, the100L High Shear Mixer is equipped with a1/2 HP motor and variable speed drive.Speeds range from 0-10,000 rpm,handling batches from 1-20 liters. Fourinterchangeable rotor/stator heads arestandard: a Slotted Head, DisintegratingHead, Fine Screen Head and an AxialFlow Head. All wetted parts are Type 316stainless steel, and they are easilydisassembled for cleaning.

100LC High Shear Laboratory Mixer:1 HP – The most powerful and versatilerotor/stator mixer ever built for the laboratory.A power lift makes raising and lowering the mix head as easy as pushing a button. Forimproved control and lab efficiency,operation can be highly automated– with a timer, temperature probeand a powerful control packagebuilt by Ross Systems and Controls.Available with four interchangeablerotor/stator assemblies to handle anextraordinarily broad range ofbenchtop applications.

Micro High Shear Mixerattachments for batch sizesof 50-500 ml.

The Ross 100LX High Shear Mixer isdesigned for either laboratory developmentor small-scale production. It is available withyour choice of either a 1 HP or 2 HP motor.Explosion-proof motors are standard.

High Shear Lab Mixers

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Model 405SB-25 In-line SLIM – Turn-key skid-mountedsystems are also available with custom control packages andfabricated vessels. This sanitary, 25 HP In-line SLIM System wasbuilt for a personal care products manufacturer. Solids are addedusing the hopper mounted in the center of the system.

New Technology for High Speed Powder Induction

Powders like fumed silica, calcium carbonate,titanium dioxide, gums, thickeners and manypigments are notorious for driving up processingcosts. Even with a strongvortex in an open vessel,they resist wetting out andoften float on the surfacefor hours.

Ross has developed newtechnology that enablesyou to mix and wet outpowders almost instantly.Available in either a batchor in-line configuration, theSLIM (Solid/Liquid InjectionManifold) system injectssolids directly into the high shear rotor/stator,where it is immediately wetted out and dispersedinto the liquid stream.

The SLIM system accelerates the mixingprocess dramatically, while it virtually eliminatesdusting – minimizing the volume of airborneparticles released inside the plant atmosphere.

Model 505 Stainless Steel High Shear Mixer with batch SLIMsystem: 5HP – While the mixer is running, the operator simply insertsthe feed tube into a container of powder and opens the feed valve. Thevacuum created by the specially modified rotor/stator generator draws thepowder through the tube and directly into the high shear zone. Dusting and delays are eliminated.

The In-line SLIM system replaces older design concepts that reliedon an additional pump and eductor. In the In-line SLIM unit, solidsare combined with the liquid stream and instantly subjected to

intense shear – with no need to pump the solidsdownstream from the eductor to the mixer. Theresult is far greater capacity and less clogging.

The unit can be wheeled into position easily, usedto inject solids into a process stream or stationarymixing vessel, then wheeled away to start work onanother process line.

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Ross High Shear In-line Mixers

Model 703X-10 High Shear In-lineMixer: 10 HP – The smallest of the X-Seriesmixers. Its 3" rotor generates tip speeds inexcess of 11,000 fpm – and thousands ofintense shearing events with each revolution.

A Ross High Shear In-line Mixer is a versatilechoice for process lines that require frequentchangeover from one product to another. Asimple valve can divert finished productdownstream or switch instantly from one sourcevessel to another. Between-batch cleaning iseasy. Interchangeable rotor/stator generatorsprovide virtually unlimited flexibility to adapt to a variety of product recipes.

Series 400Standard single-stage and dual-stage

generators provide a cost-efficient mixingsolution for many applications.Series 400 HighShear In-lineMixers areavailable with a selection of stators,including round-and square-holedisintegratingstators, slottedstators, and fine-screen stators. Tipspeeds range fromapproximately3,000 to4,000fpm. Singlemechanicalseals are standard, anddouble mechanical seals areavailable for more demanding applications.

Series 700Series 700 High Shear Mixers are designed for

continuous operation under extreme conditions.Using multi-stage rotor/stator generators, theyimpart extraordinarily intense shear andproduce materials with sub-micronparticle/droplet sizes. WithQuad-Slot and X-Seriesrotor/stator generators, our Series 700 High ShearMixers offer many highperformance featuresincluding heavy dutyshafts andbearings,tightertolerances,extremely high tipspeeds andhigh-viscositymixingcapability.

Model 100 ILC: 1 HP – Anin-line rotor/stator generator convertsthe 100LC Laboratory High ShearMixer to an in-line mixer withexcellent versatility in the lab. Thein-line unit is available with either astandard single-stage rotor/stator ora four-stage QuadSlot design forhigher shear rates. With amechanical seal, it can operateunder vacuum or pressure.

Model 405S Sanitary High Shear In-line Mixer:5 HP – This in-line High Shear Mixer produces apharmaceutical product that requires highly predictableresults, batch after batch. All internal and external partsare stainless steel polished to a pharmaceutical finish.

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Model 400DL High Shear In-line Mixer: 1 HP – A recircu-lating system enables you to fine-tune your final particle/droplet sizeand distribution. This is particularly useful in benchtop development,since scale-up with Ross High Shear Mixers is highly predictable.

Model 405S High Shear Mixer:5HP – All Ross High Shear In-line Mixerscan be provided with a jacketed vesselto closely control batch temperatureduring recirculation. Data fromtemperature probes located in the vesselcan be fed to a Ross-designed controlsystem for automated control of acooling/heating system.

Series 700 Typical ApplicationsMayonnaise & mustard

Greases & lubricants

Cosmetic raw ingredients

Silicone elastomers

Antimicrobial agents

Silica dispersions

Series 400 Typical ApplicationsMilk & Juice fortification (calcium)

Clay slurries

Leather tanning solutions

Modified asphalt

Synthetic fuels

Model 410V High Shear Mixer with arecirculating tank: 10 HP – This High ShearMixer is oriented vertically to prevent clogging at thevessel outlet and promote complete discharge.

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Model 712XS-50 High Shear In-Line Mixer withoptional sanitary enclosure: 50 HP – Operating with tipspeeds over 11,000 fpm, X-Series High Shear Mixers produce sub-micron emulsions more quickly and cost-efficiently than any colloidmills and high pressure homogenizers in many applications. Sizesare available for lab applications through high-volume production.

Model 706X-30: 30 HP-With a new highperformance shaft bearing system, the X-SeriesHigh Shear Mixers can now handle materials ofeven greater viscosities – up to 500,000 cps.

IN-LINE MIXING: CLOSEPROCESS CONTROL, ECONOMY AND LARGE-BATCH CAPACITY

A Ross In-line High Shear Mixer offers you excellent control over your mixingprocess. Whether your system is set up forsingle-pass mixing or multiple passes withrecirculation, the mixer allows you toproduce an end-product with a predictableparticle size distribution and outstandingreproducibility. Because the in-line systemis closed, it also minimizes problemscaused by air entrapment duringprocessing.

The in-line mixing system is extremelycost-efficient, especially when mixingmaterial in large volumes. Unlike a batchmixer, which requires a high-horsepowermotor to generate adequate circulation ina large vessel, a small in-line mixer canhandle a 2,500-gallon batch as easily asit handles a 25-gallon batch. As the vesselsize increases, the energy required by the in-line mixer remains low.

High Shear In-line Mixers are self-pumping and normally mix materials up to 10,000 cps without an auxiliary pump.With a pump added, the mixer easilyhandles materials up to 200,000 cps.

Model 405SB-25: 25 HP – This skid-mounted system includesan In-Line SLIM and a 50-gallon jacketed recirculation vessel forhigh-speed powder induction. Skid-mounted systems can bewheeled from one vessel to another to accommodate a variety ofprocess lines. Ross can provide a custom-designed skid-mountedsystem, including the mixer, vessel, piping and valves, pump andcomplete controls, to meet the demands of any application.

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High Shear Mixers for High Speed Dispersion

THE ROSS PREMAX – POWERED BY THE ROSS DELTA GENERATORThis single-stage rotor/stator generator isspecially contoured to generate bothhigh shear and vigorous flow in abatch mixing environment.Designed especially for pigmentdispersions, the Delta rotor/statorgenerator is used in the RossPreMax* to produce an intensecombination of mechanical, hydraulic andcavitational shear, which results in aggressivedeagglomeration.

*Patent No. 6,000,840

Typical Applications Pigment dispersions

Automotive coatings

Dye stuffs

High performance ceramics

Plastisols

Carbon dispersions

Graphite and magnetic dispersions

Paints

Printing Inks

*Patent No. 6,000,840

ROSS HIGH SPEEDDISPERSERSare the industrystandard for durability,faster dispersion and lowmaintenance costs. Standard models include:explosion-proof, inverter duty motors; heavy dutyV-belt drives and bearings; safety switches; anair/oil hydraulic lift system with hand/footcontrols; and stainless steel wetted parts andshaft guard. Sizes range from 1/2 HP to 200 HPto handle batches from 1 to 2000 gallons.Custom designs are also available.

Ross PreMax: 30 HP – Especiallysuited for pigment dispersions, the Ross Premax produces high shear andenergetic flow in the vessel. Sizes rangefrom 5 to 250 HP, for vessels rangingfrom 2 to 2,000 gallons.

PreMax ApplicationsGrinding and particle size reduction, in a batch configuration, including: flexo,gravure and offset inks, paints, industrialcoatings, electronic inks and cosmetics.

Model 100DLC High Speed Disperser:1 HP – Fitted with an interchangeabledisperser blade, it is ideal for laboratorydispersion applications.

Ross High SpeedDisperser: 30 HP

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ROSS CONTROLS AND DATAMANAGEMENTOur controls are designed and built by RossSystems & Controls division. Whetheryou need a simple ON/OFF switch or amulti-axis, PLC-controlled control system,no other company can build controlsthat are better suited to your new mixerand your process requirements. Bychoosing a genuine Ross control system,you can save time in engineering,simplify your start-up, reduce costssubstantially, and guarantee that yourcontrol will be flexible enough toexpand efficiently as your needs change.

Ross offers a spectrum of choices to helpaccelerate your process and make it moreaccurate and consistent. Our data logging systemscan also help you manage your process moreeffectively – with the data acquisition and analysiscapabilities you need for efficient processdevelopment and tight quality control.

ROSS CUSTOM FABRICATIONWith extensive fabrication facilities in the USA and overseas, Ross is equipped to build all thecomponents your system requires. This is your bestassurance of flawless quality from start to finish,and prompt delivery.

THE ROSS TEST & DEVELOPMENT CENTERThis allows you to simulate yourprocess and test our mixer beforeyou buy it.

Using the Ross DataLinx data management system, data from eachmix cycle can be captured and downloaded to your PC in CSV(Microsoft Excel) file format for display, documentation and analysis.

Ross Controls, Fabrication and Development

Contact Ross today for detailed information on any of the

products and services we offer, orto schedule a test in the Ross Test &

Development Center, call1-800-243-ROSS in the USA,

or 631-234-0500.Fax: 631-234-0691.

E-mail: sales@mixers.com.Or visit Ross on the web:

www.highshearmixers.comwww.mixers.com

Charles Ross & Son Company710 Old Willets PathHauppauge, NY 11788-0615USA Tel.: 800-243-ROSSOverseas: 631-234-0500Fax: 631-234-0691E-mail: sales@mixers.comInternet: www.mixers.comwww.highshearmixers.com

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