Run the mixer at its full RPM for optimal performance. All mixers will have a maximum speed, and assuming the power draw is within the machine’s range, this is where your high shear mixer will work most efficiently. Running your mixer too slowly will negatively affect the type of product distribution you’re seeking from your high shear operation. If your process requires more shear than what your mixer is able to produce at max RPM, consider changing the stator or jumping to the next horsepower motor.
Keep a variety of rotor stators on hand. Just as impellers come in specific shapes and sizes for their applications, rotors and stators are configurable for your mixture. By changing the rotor or stator you can increase tank turnover, shear, and emulsification capabilities.
When scaling up your processes from testing to full-scale production, it’s critical to consider more than just motor power increasing. When scaling up a rotor stator, it’s helpful to have a viscometer, rheometer, and a droplet size analyzer on hand, and to consider the geometry of the rotor stator along with power draw and shear frequency.
Make sure you’re selecting liquids with viscosity less than 5,000cps to maintain good flow in your vessel. As these viscosities increase, you may need to include ancillary mixing.