How Kady's Roto-Stator Technology Can Be Used to Disperse Two Inch Chunks of Rubber Quickly

Large rubber pieces are hard to process. Natural rubber and synthetics such as SBR, NBR, and polybutadiene are elastic, tough, and slow to break down in ordinary mixers. When the feed is two-inch chunks, plants often shred first, then mix for hours, then mill again. That extra handling raises heat, solvent loss, labor, and batch variation.

Kady International's high-speed Roto-Stator mills are built for this job. The same precision rotor-stator head used across Kady lab and production mills can take two-inch rubber chunks, fracture them, wet them, and turn them into a uniform dispersion in one vessel. Tip speeds reach 9,000 feet per minute. Cycle times are often measured in minutes, not hours.

Kady International’s high-speed rotor-stator dispersion mills deliver unmatched solids loading capabilities — up to 75% clay and 65% TiO₂ — while producing superior dispersion quality in dramatically less time.

Why High Solids Loading Matters

In the coatings, paint, ink, and chemical industries, the ability to disperse higher percentages of solids directly impacts profitability. Higher solids mean less water or solvent, lower shipping costs, faster drying times, and improved product performance.

The production of additives, emulsions, and dispersions with oil requires precise mixing to achieve uniform consistency, stability, and performance in applications ranging from coatings to cosmetics. Kady International, a Scarborough, Maine-based leader in industrial mixing since 1949, offers high-speed rotor-stator dispersion mills and mixing systems that simplify these processes. Operating from a 50,000-square-foot facility, Kady’s innovative equipment, used in over 40 countries, delivers efficient, high-quality results for fluid-based applications. Their mixers streamline the creation of oil-based additives, emulsions, and dispersions, ensuring consistency and scalability for industries like paints, pharmaceuticals, and food processing.

Custom milling and mixing equipment, such as those developed by Kady International, offer significant benefits for continuous processing systems, particularly in industries that require high-efficiency and high-quality output. These mills are designed to integrate seamlessly into continuous production lines, providing a consistent, uninterrupted flow of material. By using rotor-stator technology, Kady's equipment ensures precise and uniform dispersion of solid materials into liquids, resulting in high-quality products with enhanced texture and consistency.

The production of high-quality flexographic and rotogravure inks requires precise mixing, dispersion, and homogenization to achieve consistent color, viscosity, and performance for printing applications. Kady International, a leader in industrial mixing technology since 1949, provides advanced high-speed rotor-stator dispersion mills and mixing systems that streamline the ink manufacturing process. Based in Scarborough, Maine, their 50,000-square-foot facility produces innovative mixers, including top and bottom entry batch mixers and continuous flow mills, used globally in over 40 countries. These systems ensure superior ink quality for the printing industry, particularly for flexographic and rotogravure inks used in packaging, labels, and high-end graphics.

Kady high-speed rotor-stator mills deliver superior stability in coal-water and coal-oil-water slurries through intense impact, attrition, and high-energy dispersion — often in a single step.

Kady International, based in Scarborough, Maine, has built high-speed rotor-stator dispersion mills since 1949. The company is best known for paint, ink, coatings, chemicals, and other industrial slurries. Less obvious from a first glance, but clearly part of its published record, is sludge and wastewater work—and Kady’s own applications list even asks: “Are tanks on your farm full of sludge? Just give us a call.”

That question is the right one for many livestock and fertilizer operations. Manure tanks, reception pits, and lagoons collect settled solids that steal storage volume, clog pumps, stratify nutrients, and make land application uneven. Kady’s rotor-stator (often written “roto-stator”) head does not skim sludge out of a tank the way a dredge or vacuum tanker does. It attacks the sludge itself: breaking flocs and agglomerates, releasing bound water, and turning a heavy settled mass into a more uniform, processable slurry.

Producing vibrant, consistent liquid colors for industries like paints, coatings, and inks requires rapid and precise mixing to achieve uniform pigment dispersion and stable formulations. Kady International, a Scarborough, Maine-based leader in mixing technology since 1949, offers high-speed rotor-stator dispersion mills and mixers that streamline this process. Operating from a 50,000-square-foot facility, Kady’s equipment, used in over 40 countries, delivers efficient, high-quality results for liquid color production. Their innovative systems ensure quick, uniform mixing and dispersion, meeting the demands of industries requiring superior color consistency and performance.

We Offer Custom Design Service for Vacuum Requirements

Some batches cannot run in an open tank. Solvent flashes. Air stays trapped in the film. Moisture ruins a resin. A powder clouds the room the moment it hits the liquid. For those jobs, the mixer has to hold vacuum while it still wets, disperses, and circulates.

Kady International offers custom design service for vacuum requirements. The same high-speed rotor-stator mills used for coatings, inks, adhesives, rubber solutions, and high-solids slurries can be built as sealed systems. The head, shaft, vessel, and controls are engineered so the mill keeps working under reduced pressure instead of leaking air back into the batch.

Quality Adhesives Are Made Easily with Our Mixing Process

A good adhesive is only as consistent as the mix behind it. Resins, rubbers, fillers, tackifiers, solvents, and water all have to wet out, stay suspended, and finish at a stable viscosity. When the mix is incomplete, the plant sees grit, skinning, weak bond strength, and batches that do not match the last one.

Kady International builds high-speed rotor-stator mills for that work. The same process used for coatings, inks, rubber solutions, and high-solids slurries is used for adhesives and sealants: one high-energy head, strong circulation, and a vessel set up for the formula. Quality adhesives are made more easily when wet-out, dispersion, and homogenizing happen in a single, controlled step.

Custom Gasification Plates for Injecting Gas into Liquid Systems

Some mixes need gas in the liquid, not just solids or a second liquid. Air, nitrogen, carbon dioxide, or process gas may be added to aerate a batch, strip a solvent, change density, support a reaction, or keep a slurry from settling. Dumping gas through an open pipe rarely works. Large bubbles rise, the liquid stays lean, and the mixer wastes energy chasing foam.

Kady International designs custom gasification plates for injecting gas into liquid systems. The plates work with the same high-speed rotor-stator mills used for dispersion, emulsion, cooking, aeration, and deaeration. Gas is introduced where the liquid is already moving at high velocity, so the mill can break the gas into small bubbles and fold them into the batch.

Custom Designed High Intensity Fluxing and Non-Fluxing Type Mixers

Not every mixing job is a simple slurry. Some formulas need heat so polymers soften, wet out, and flux into a uniform mass. Others must stay cooler so solvents, pigments, or heat-sensitive resins are not damaged. Kady International designs high-intensity mixers for both cases.

Kady is known for high-speed rotor-stator mills used in coatings, inks, adhesives, chemicals, and other fluid/solid work. Those mills can also be engineered as custom fluxing or non-fluxing systems. The head, vessel, drive, and temperature controls are matched to the process instead of forcing the process onto a stock machine.

Superior dispersion for high-solids paper coating formulations

In the competitive world of paper manufacturing, the quality of the coating directly determines printability, gloss, smoothness, brightness, and overall value of the final sheet. Achieving a consistent, high-solids coating color with excellent pigment dispersion is critical — and that’s exactly where Kady International rotor-stator mills excel.

Grind Pepper Seeds for Oil Extraction in a KADY Mill

Pepper seed holds oil inside a tough hull. If the seed is only cracked, solvent or press equipment works harder and leaves oil behind. If the grind is uneven, some particles are dust and some are still whole, so extraction is slow and yield swings from batch to batch.

Kady International lists this duty among its applications: grind pepper seeds for oil extraction in a KADY Mill. The mill is a high-speed rotor-stator dispersion machine. It is used to wet, fracture, and reduce solids in liquid so the next step—pressing, solvent extraction, or slurry recovery—sees a more open, uniform feed.

Phthalo Blue is one of the most widely used organic pigments in the coatings, ink, and plastics industries. Known for its intense tinting strength and excellent lightfastness, it is also notoriously difficult to disperse due to its strong tendency to form agglomerates.

Traditional mixers often require 2 to 6 hours to fully develop Phthalo Blue. With a Kady high-speed rotor-stator mill, the same pigment typically reaches full color development in just **45 minutes**.

KADY Makes Superior Salad Oil Emulsifications

Salad oil only becomes a dressing, sauce, or mayonnaise-style product when it stays mixed with water, vinegar, and egg or gum. If the droplets are too large, the bottle separates on the shelf. If the mix is overworked and overheated, flavor fades and the emulsion breaks later anyway.

Kady International has said it plainly for years: KADY mills make superior salad oil emulsifications. The claim sits with the company’s other food and oil work—mustard, flavor dispersions, and oil-in-water emulsions—because the same high-speed rotor-stator head that disperses pigments can also cut oil into a fine, stable droplet field.

The High Cost of Poor Dispersion

Pigments are often the most expensive component in paints, inks, coatings, and liquid color formulations. Traditional high-speed dissolvers and lower-shear mixers leave many pigment agglomerates intact, wasting expensive raw material. Manufacturers compensate by adding 10–30% more pigment to reach target color strength, gloss, and opacity — directly inflating costs and extending production cycles.

Making the Best Mustard with a KADY® Mill

Mustard looks simple in the jar. In the tank it is a wet grind, an emulsion, and a hydration problem at the same time. Seed must break. Water, vinegar, and oil must take up the solids. Heat and hold time have to develop flavor without cooking the batch into paste that will not pump.

Kady International has listed mustard among the foods made on a KADY® Mill for years: some of the best mustard is made in a Kady mill. The reason is the same high-speed rotor-stator process used for sauces, emulsions, and other food and chemical dispersions. One head wets the seed, cuts the particle size, and builds a stable mix.