Coatings World Suppliers Insights Q&A with Hockmeyer Equipment

Coatings World: How does Hockmeyer’s NexGen milling technology reduce processing times?

Hockmeyer: The aggressive shear zone, the rapid recirculation, and the vacuum.  This three-pronged approach attacks agglomerates and reduces milling time. 

For example, a client’s carbon black pigment milling process took approximately six hours using a horizontal mill, which significantly cut into their efficiency and profits. They were looking to reduce this processing time to turn over more batches per day. Our NexGen Vacuum Recirculation Mill reduced this processing time to approximately one hour and 45 minutes. Our machine also achieved a superior particle size distribution and surpassed color development expectations. Overall, the client enjoyed a 70% reduction in milling time and tripled their milling capacity.

Also, the compact chamber leads to efficient color change-over with minimal cleaning required compared to traditional horizontal mills. And the high flow rates achieve a tighter particle distribution (a more uniform dispersion). Plus, greater temperature and rheological control via rapid recirculation and inline jacketed cooling tubes. 

CW:  In what ways can a Vacuum Recirculation Mill help you improve your process?

Hockmeyer: Rapid-flow vacuum milling is meant to improve efficiency and increase profits by cutting down process times, increasing yields, and preventing air entrapment. It allows faster particle size reduction and deagglomeration without the problems caused by air bubbles in the feedstock.

It makes a significant difference if the feedstock is vacuumed into the mill rather than pumped in. Since a pump pushes the pre-mix and whatever air is contained within it, through the media field, the air bubbles remain in the mix and prevent effective particle dispersion as they act as a cushion between the media and the particles. Plus, micro air bubbles can create volumetric filling issues. 

In contrast, when a liquid containing air bubbles is pulled through a vacuum, the bubbles inside the agglomerates will expand, causing them to push the particles apart. The air then separates from the solids and begins to collect in the mill’s upper chamber. Once enough air gathers, it is intermittently released by the mill, returning to the supply tank and quickly rising to the top, where it is expelled. Thanks to this process, the air trapped inside agglomerates is effectively removed, resulting in improved wetting with liquids and resins.  

That’s not all…. The NexGen mill also has nano-milling capability and proven excellence in processing printing inks, conductive inks, agrochemicals, coatings, pharmaceuticals, electronics, and energy components to nanoparticle sizes. 

This mill is also designed with portability in mind and can work even in tight-fitting spaces. It can hook up to any tank, whether portable or permanent, allowing you to customize it to fit in exactly where you need it most. 

Finally, the NEXGEN™ Vacuum Recirculation Mill features an ergonomic design and comes with automated digital controls, allowing for remote monitoring and controlling of the mill and formula management, as well as multiple standard safety features. These features make the mill a great choice not just for the profitability of your business, but also for the safety of your team members.

Along these lines, we recently launched the Hockmeyer Integrated Process System [HIPS]. This platform combines the NexGen vacuum rotor stator and the NexGen vacuum mill for airless premix and milling processes, with the option of a powder feed system, for ultra-efficient processing.

The innovative system incorporates features to enhance performance and outperform traditional systems. Some of the advancements include control systems that help predict solutions to common problems. It provides a statistical analysis of the process under existing conditions, including temperature, flow, and amps. Much of the information is captured with Automated Process Control III, the most advanced version of HIPS controls, which gathers data at set points. However, some data gathering must still be done on external devices such as particle analyzers, spectrophotometers, and gloss meters, since reliable in-line units are not commercially available. Although making these initial readings is cumbersome, once integrated into the APC-III, they become part of the system’s history, and as the data grows, predictability and effective problem-solving become possible. As new instruments for in-line readings become available, they can be incorporated into the APC-III. 

The APCIII features programmable setpoints for process control, enabling control via time and temperature, as well as automated ball valves for regulating flow and vacuum. Integrated failsafe alarms based on kW, amp draw, temperature setpoints, and also alerting operators of recommended PM scheduling based on processing time. 

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CW: What types of testing and training does Hockmeyer offer its customers?

Hockmeyer: We offer a comprehensive range of support services to help our clients maximize the performance of their Hockmeyer machines and resolve any issues quickly and easily. Also, choosing the right equipment for specific processes can be challenging; so, our testing lab enables prospective customers to try out laboratory, pilot, and production units of most of our models, ensuring they select the appropriate tool for their needs. And this initial testing is offered at no cost. 

CW: How does Hockmeyer support its customers regarding parts and services?

Hockmeyer: When equipment needs to be repaired, it costs our clients valuable time and money. To quickly assist customers, we keep a wide variety of replacement parts in stock for immediate overnight shipping. Additionally, our experienced customer service technicians are available to provide their expertise, ensuring the equipment operates at maximum efficiency. 

CW: In what ways does Hockmeyer support its customers in replacing parts?

Hockmeyer: We know that a Hockmeyer machine is a significant investment that requires ongoing care and maintenance if it is to last. So, we offer an equipment support program to identify and address minor issues before they escalate into larger problems. Our support program includes a post-installation assessment, equipment inspection, evaluation of wear patterns, operator refresher training, and more. Tailored to each customer’s needs.