EXAKT 80 Three-Roll Mill (Basic Model)

Overview

The EXAKT 80 Three-Roll Mill is a precision-engineered dispersion and particle size reduction system designed for laboratory-scale processing of soft, paste-like, and highly viscous materials. Operating on the principle of shear-induced comminution between three horizontally aligned, counter-rotating rolls, it delivers controlled mechanical energy input to deagglomerate, homogenize, and refine suspensions—particularly in pigment dispersions, battery electrode slurries, cosmetic pastes, pharmaceutical ointments, and advanced ceramic formulations. Unlike high-energy impact mills, the EXAKT 80 applies laminar shear stress in a defined gap geometry, enabling reproducible sub-micron particle size distribution (PSD) control without thermal degradation or excessive solvent evaporation. Its compact desktop footprint (635 × 400 × 560 mm) integrates seamlessly into ISO-classified cleanrooms, QC labs, and R&D pilot lines where space efficiency and process traceability are critical.

Key Features

• Dual-speed or continuously variable drive system (0.3 / 0.45 kW) with precise speed ratio control (3.3 : 1.8 : 1) to optimize shear gradient and residence time.
• “One-point adjustable gap” mechanism enabling smooth, repeatable roll-to-roll spacing adjustment—critical for consistent film thickness and final particle size targeting (≤1 µm achievable under optimized conditions).
• Universal blade system featuring spring-tensioned mounting and adjustable outlet width, ensuring uniform material scraping and minimal dead volume; PFA-coated variants available for aggressive solvents or ultra-high-purity applications.
• Hard-chromed stainless steel and chemically oxidized alumina roll surfaces provide exceptional wear resistance, corrosion immunity, and low surface energy—minimizing material adhesion and cross-contamination.
• Integrated safety architecture: stainless steel feed hopper with hand guard, drip-proof tray with quick-release design, emergency stop button, electronic dynamic braking, and CE compliance per Machinery Directive 2006/42/EC.
• Optional roll temperature control (–20 °C to +100 °C) via integrated cooling/heating channels—enabling thermosensitive formulation processing and rheological stabilization during milling.

Sample Compatibility & Compliance

The EXAKT 80 is validated for use with soft, non-abrasive, and moderately abrasive pastes—including organic pigments, lithium-ion cathode slurries (NMC, LFP), silicone-based adhesives, UV-curable resins, and hydrophilic polymer gels. Feed particle size range (5–180 µm) accommodates pre-mixed agglomerates, while final output consistently achieves ≤1 µm median particle size (d₅₀) under optimized throughput (0.02–45 L/h). All wetted parts comply with EU Regulation (EC) No. 1935/2004 for food-contact materials and USP Class VI biocompatibility standards. Optional ATEX-certified configurations (II 2G Ex db IIB T4 Gb / II 2D Ex tb IIIC T135°C Db) meet IEC 60079-0 and -1 requirements for operation in Zone 1/21 hazardous environments.

Software & Data Management

While the EXAKT 80 Basic Model operates via analog controls, its modular architecture supports integration with external PLC-based monitoring systems (e.g., Siemens S7 or Allen-Bradley CompactLogix) via 4–20 mA analog I/O and digital relay interfaces. Process parameters—including roll speed, gap setting (via calibrated micrometer scale), inlet temperature, and throughput rate—are manually logged per GLP/GMP batch record protocols. For full digital traceability, EXAKT offers the optional EXAKT Connect module, providing USB/RS-485 connectivity, real-time parameter logging, audit trail generation compliant with FDA 21 CFR Part 11, and export to CSV or LIMS-compatible formats.

Applications

• Electrode slurry refinement for lithium-ion and solid-state batteries—ensuring uniform conductive network formation and minimizing electrode porosity variation.
• Pigment and dye dispersion in automotive coatings and inkjet inks—achieving narrow PSD and eliminating haze-causing aggregates.
• Pharmaceutical topical formulation development—homogenizing active pharmaceutical ingredients (APIs) within oleaginous bases under low-shear, low-temperature conditions.
• Nanocomposite masterbatch preparation—exfoliating layered silicates or carbon nanotubes in polymer melts without filler re-agglomeration.
• High-performance ceramic green tape casting—controlling particle packing density and binder distribution prior to sintering.

FAQ

What is the minimum and maximum throughput capacity of the EXAKT 80?
The unit supports a continuous throughput range of 0.02 to 45 liters per hour, dependent on material viscosity, roll gap setting, and speed ratio configuration.
Can the EXAKT 80 process aqueous or solvent-based systems?
Yes—wetted components are chemically resistant to water, alcohols, ketones, esters, and chlorinated solvents; PFA-coated blade options extend compatibility to strong acids and fluorinated media.
Is roll temperature control standard or optional?
Roll heating/cooling is optional but factory-integrated; standard capability covers –20 °C to +80 °C using external chiller/heater units; extended range to +100 °C is available upon specification.
Does the EXAKT 80 meet regulatory requirements for pharmaceutical manufacturing?
The base configuration complies with ISO 14644-1 Class 5 cleanroom compatibility and supports GMP-aligned documentation practices; full 21 CFR Part 11 compliance requires the EXAKT Connect digital interface module.
Are ceramic roll or blade options available?
Ceramic blades are compatible with the universal blade mount (standard on EXAKT 50/80 series); alumina-coated rolls are standard, while fully ceramic (Al₂O₃) rolls are available as a custom engineering option for extreme wear applications.