EXAKT 80S Surface-Polished Three-Roll Mill

Overview

The EXAKT 80S Surface-Polished Three-Roll Mill is a precision-engineered laboratory-scale dispersion and particle size reduction system designed for consistent, reproducible micronization of soft, viscous, or heat-sensitive materials. Based on the Couette flow principle, it subjects material to high-shear deformation between three horizontally aligned, counter-rotating rolls operating at precisely controlled speed ratios (9:3:1). The surface-polished configuration—optimized for final fineness in the 1–9 µm range—employs enhanced surface finish on roll exteriors and refined gap control mechanics to minimize edge effects and improve laminar flow stability. Its compact desktop footprint (625 × 420 × 470 mm) enables seamless integration into QC labs, R&D cleanrooms, and pilot-scale formulation suites without requiring dedicated floor space or structural reinforcement.

Key Features

• Surface-polished roll geometry engineered for sub-10 µm particle size distribution (PSD) consistency and reduced agglomeration risk.
• Dual-speed motor option (1.0 / 1.5 kW) with variable-frequency drive (VFD) capability ensures torque stability across full speed range—critical for processing high-viscosity pastes or thermally labile suspensions.
• Patented EXAKT pre-tensioned roll alignment system maintains constant inter-roll gap during operation, eliminating drift-induced PSD variability.
• Manual gap adjustment with calibrated pointer-and-scale indicator enables repeatable, traceable setting (resolution ±5 µm) without digital instrumentation.
• Modular roll material selection—including hard-chrome stainless steel, anodized aluminum, silicon carbide, and zirconia (250 mm variant)—supports compatibility with abrasive, corrosive, or food-grade formulations.
• Universal blade holder with quick-release mechanism accommodates stainless steel, engineering plastic (POM), aluminum oxide, or zirconia blades; optional PFA coating enhances non-stick performance and simplifies cleaning validation.
• Integrated safety architecture includes magnetic hopper switch, roll-gap guard, splash-resistant tray with safety interlock, and IP54-rated enclosure for routine wet-cleaning compliance.

Sample Compatibility & Compliance

The EXAKT 80S is validated for soft, paste-like, or semi-solid matrices including pigment dispersions, pharmaceutical ointments, cosmetic emulsions, conductive inks, battery slurries, and food-grade pastes. Its design conforms to ISO 13850 (safety of machinery – emergency stop function) and supports GMP/GLP-aligned workflows through mechanical traceability (gap setting, speed, temperature), absence of software-based data logging (reducing 21 CFR Part 11 validation burden), and compatibility with ATEX Zone 22 certification (optional). All wetted surfaces meet FDA 21 CFR 177.2400 (food-contact plastics) when specified with PFA-coated components and non-metallic blades. Cleaning protocols are fully documented per ASTM E3179 (cleaning validation for lab equipment).

Software & Data Management

The 80S operates as a deterministic mechanical system with no embedded firmware or cloud connectivity. Process parameters—roll speed (single/dual), gap setting, and optional coolant temperature—are manually set and recorded externally. This architecture eliminates cybersecurity exposure and simplifies audit readiness for regulated environments. For laboratories requiring electronic batch records, EXAKT provides standardized parameter log sheets compatible with LIMS integration via manual entry or barcode-scanned SOP templates. Optional VFD units include analog 0–10 V output for external PLC monitoring of motor load and thermal status.

Applications

• Pharmaceutical: Homogenization of topical gels and transdermal patches; dispersion of nanostructured lipid carriers (NLCs) and microemulsions.
• Electronics: Production of uniform silver/carbon conductive inks for printed electronics and flexible PCBs.
• Coatings & Inks: Stabilization of organic pigment dispersions in UV-curable resins and water-based acrylic systems.
• Food Science: Refinement of chocolate masses, nut butters, and functional ingredient suspensions under low-thermal-stress conditions.
• Advanced Materials: Deagglomeration of graphene oxide, MXene, or ceramic nanoparticle suspensions prior to film casting or electrode slurry preparation.

FAQ

What is the minimum achievable particle size with the 80S Surface-Polished model?
The system achieves a median particle size (D50) of 1–9 µm under optimized feed conditions (5–180 µm input, viscosity ≤ 50 Pa·s, temperature-controlled operation); sub-micron refinement requires downstream ultrasonication or bead milling.
Can the 80S process materials requiring inert atmosphere handling?
Yes—optional sealed hopper with glove port and nitrogen purge fitting is available for oxygen- or moisture-sensitive formulations.
Is temperature control limited to cooling, or does it support heating?
Rolls support bidirectional thermal regulation from ambient to +80 °C standard; +100 °C heating capability is available with custom heat-transfer fluid loop design.
How is gap calibration verified during routine maintenance?
A certified feeler gauge set (0.005–0.100 mm) and EXAKT-supplied calibration certificate accompany each unit; annual verification is recommended per ISO/IEC 17025 guidelines.
Does the PFA-coated blade holder comply with EU Regulation (EC) No 1935/2004 for food contact?
Yes—the PFA coating meets full migration limits (<0.01 mg/kg food simulant) and is listed under EU Plastics Regulation (EU) No 10/2011 Annex I, substance #100001.