Case Studies of Distributed Engineering Failures | Why Can't We Resolve Issues with Dama and Quality Variability? Common Causes and Countermeasures.
In dispersion engineering, challenges such as "clumps persist regardless of how many times conditions are changed" and "variability in particle size distribution does not improve" occur in many settings. In one case, the cause of poor dispersion was attributed to equipment performance, leading to responses such as increasing rotation speed and extending processing time. However, the persistence of clumps and variability in quality were not resolved, and rather, new problems arose, such as particle fragmentation due to excessive shear.
Behind such failures lies the misconception that "dispersion = just apply strong shear." In reality, if clumps are formed in the initial stage due to poor wetting or uneven flow when the powder is introduced, it is difficult to completely resolve them by applying strong shear in subsequent processes. Additionally, in batch processing, variations in flow and residence time lead to different dispersion histories for each particle, making it impossible to ensure reproducibility of quality.
To address this issue, it is crucial to review the entire process, including not just changes in equipment conditions but also the steps from powder introduction to dispersion. By adopting configurations that apply shear simultaneously with powder introduction and implementing inline continuous processing that maintains consistent flow and dispersion conditions, it is possible to suppress initial clumps and achieve stable dispersion quality. Improving poor dispersion requires optimization of the entire process, not just the equipment alone.

Inquiry about this news
Contact Us OnlineMore Details & Registration
Details & Registration
Related Links
Many issues with poor dispersion are caused not by the equipment but by the process design. Our company offers a process that is designed as a whole, from powder input to dispersion, to prevent clumping and variability in advance. We support problem-solving with consistent engineering from lab validation to mass production.





