Customization of Top Entry Mills
We are known for our top entry and bottom entry industrial mills, these mills can be designed to work with your current tanks or we can supply tanks that are built for our specific mills. As stated earlier, our engineers will work with you every step of the way to ensure you are getting a product that fits your application perfectly. We offer five different models of our KADY Top Entry line, each with a different operating volume, rotor speed, and horsepower.
If your application requires dispersion, look no further than KADYs top entry mills. These mixers are excellent for dispersing solid materials into liquid in a uniform way; dispersion is a common way to deagglomerate or dissolve certain solids into liquids. Our dispersion machines work by utilizing energy transfer with the primary forces being shear, impact and impingement.
- The heart of the dispersion unit is the rotor. It acts much like a centrifugal pump and is the dominant force of the machine. Its function is to accelerate the particles in a liquid stream and force them at high pressure into the stator wall. The rotor tip speed reaching 9000 ft./min., the rotor slots are cut tangentially into the rim, opposite the flow or rotation of the batch, and serves also as a pump, to re-circulate the complete batch within the vessel.
- Working in conjunction with the rotor is the stator. The stator is a fixed closed circle surrounding the rotor. The clearance between them serves as a barrier for the rapid impact and impingement of the particles. It has slots cut through at an angle to help promote flow.
- Two propellers, one working just above the rotor, the other working just below, are designed to force feed the rotor. Although the lower propeller is generally a flat blade type, the upper propeller, is modified to suit the product's requirements.
- Upper props commonly used are, flat blade type, marine, (like those found on boats) or flat blades with either a ring around them or tips on the end of the blades...all designed to help achieve a specific flow pattern.
- Head plates fit against the top and bottom of the stator and act to sandwich the slots thus concentrating the force of the material through the slot only and to help avoid "spill-over". Head mounted baffle(s) are also provided to control the flow pattern.
Design and Engineering Support
KADY engineers collaborate with your team to translate process goals into a reliable mill solution. We provide CAD reviews, material compatibility guidance, and process modeling to ensure the selected rotor, stator, and propeller configuration will meet your dispersion, emulsifying, or homogenizing needs. Early-stage engineering includes recommendations for head plates, baffles, and feed-prop arrangements to prevent spill-over and optimize flow patterns for uniform particle size reduction.
Customization and Tank Integration
Top-entry mills are often integrated with existing vessels or supplied with matched tanks built to KADY tolerances. We offer custom shaft lengths, flanged mounts, and tank-adaptation kits so mills fit your footprint and piping layout. Options include seismic-rated supports, explosion-venting considerations, and multiple inlet/outlet locations; these customizations reduce retrofit complexity and minimize civil or structural changes at installation.
Dispersion Technology and Process Optimization
The rotor-stator interface is the heart of KADY dispersion units, delivering shear, impact, and impingement needed to deagglomerate solids and disperse them uniformly into liquids. We optimize rotor tip speed, slot geometry and stator clearance for the material system, adjusting rotor rpm and slot tangency to balance throughput and fineness of grind. Two-stage flow control using upper and lower propellers ensures positive feed to the rotor even in high-solids slurries.
Installation, Commissioning, and Performance Validation
KADY supports installation and startup to validate mechanical alignment, electrical integration, and process parameters. Commissioning includes rotor/stator clearance checks, vibration and temperature monitoring, and first-batch production trials to confirm dispersion targets. We document baseline performance and provide operators with start-up and troubleshooting guidance so your team can reproduce results consistently.
Maintenance, Spare Parts, and Upgrades
Planned maintenance greatly extends tool life and minimizes downtime. KADY offers spare rotor and stator sets, head plates, propeller options, and consumable wear parts, Upgrade paths include hardened or coated rotors for abrasive media, alternative alloy stators for corrosion resistance, and retrofits to accommodate different feed geometries as your process evolves.
Frequently Asked Questions
What Operating Volume and horsepower Should I Choose for High-Solids Pigment Dispersions?
Choose a model whose recommended operating volume overlaps your batch size and whose energy input supports the shear and impact level required for pigment and particle deagglomeration; request an engineering review for a precise match.
Can KADY Mills be Retrofitted into Existing Tanks?
Yes, we offer flange adapters, shaft-length variations, and tank-mounting kits to integrate mills into many existing vessels.
Do You Provide On-Site Startup and Operator Training?
Yes, KADY offers operator training to ensure consistent production and safe operation.
Our knowledgeable engineers understand the differences of each application and which machine would be best for you and yours. We carry an extensive line of products that are excellent for dispersing, emulsifying, homogenizing, milling, mixing, cooking, and other applications.
So if you are unsure what product you require, do not hesitate to call our friendly staff and we will work with you to diagnose your specific need and suggest a solution that is tailor made for you based on your specifications. We have over 60 years of experience in the industry and we want to go to work for you.