Triple Shaft Disperser & Mixer: Specifications & Price Guide 2026
Triple Shaft Disperser & Mixer: Specifications & Price Guide 2026
The ultimate engineering guide to multi-functional vacuum compounding for highly thixotropic sealants, silicone adhesives, and thermal pastes. Discover how three independent drives eliminate flow dead-zones.
In the production of silicone sealants, MS polymers, and polyurethane structural adhesives, process engineers face a severe rheological hurdle: "How do we rapidly disperse heavy solid fillers into a highly viscous, non-Newtonian polymer base without creating stagnant flow zones, generating excessive heat, or trapping air bubbles?" Standard single or dual-shaft dispersers simply cut a localized hole in the paste (cavitation), leaving the bulk of the material unmixed.
The POLYC Triple Shaft Disperser Mixer solves this by combining three independent kinematic actions within a single vacuum-sealed vessel. A central low-speed anchor frame constantly scrapes the tank walls, pushing the thick paste toward the center. Simultaneously, two independent high-speed shafts—equipped with Sawtooth Cowles discs operating at 22–28 m/s—shatter powder agglomerates instantly. This intense 3D turnover ensures molecular-level homogeneity for viscosities ranging from 100,000 to 1,000,000 cPs.
POLYC has engineered over 600 triple-shaft compounding lines globally for the adhesives, electronics, and specialty chemicals sectors, delivering Turnkey EPC solutions from pilot testing to 6,000L mass production.
POLYC Heavy-Duty Triple Shaft Mixer: Dual-pillar hydraulic lifting frame, triple drive motors, and a fully jacketed mobile vessel designed for continuous high-viscosity production.
Triple Shaft Mixer Specifications & Working Capacities
| Model Series & Class | Working Volume | Main Drives Power (kW) | Kinematics Configuration | Vacuum & Sealing | Investment Tier |
|---|---|---|---|---|---|
| 1. R&D Pilot Unit | 5L – 50L | 2.2 kW + (1.5 kW x 2) | Anchor Scraper (0-60rpm) + Twin Dispersing Discs (0-1450rpm) | -0.098 MPa; Double Mechanical Seals | Entry Lab Tier |
| 2. Commercial Production Unit | 500L – 2,000L | 15 kW + (22 kW x 2) | Heavy Anchor w/ PTFE Scrapers + Twin High-Shear Cowles Discs | -0.098 MPa; Barrier Fluid Tank (Ex-d Option) | Core Production Tier |
| 3. Multi-Functional High-Capacity | 3,000L – 6,000L | 45 kW + (55 kW x 2) | Anchor Scraper + Dispersing Disc + Inline Rotor-Stator Emulsifier | -0.098 MPa; Pressurized Mechanical Seals; CNC Balancing | Heavy Industrial Tier |
*Note: All models are dynamically balanced to ISO G2.5 standards to prevent shaft deflection at tip speeds up to 28 m/s. All shafts feature independent ABB variable frequency drives (VFD) for precise rheology control.
How to Select Your Working Head Configuration
Configuration A: Standard Triple-Shaft (Scraper + 2 Discs)
Process Profile: Highly filled silicone sealants, MS polymers, and mastics (up to 800,000 cPs) where extreme powder wetting and de-agglomeration are the primary goals.
Optimal Design: Shaft 1 drives the anchor wall scraper. Shafts 2 & 3 drive dual high-speed Cowles discs. The anchor forces the heavy paste directly into the intersecting shear zones of the two high-speed discs.
Configuration B: Multi-Action (Scraper + Disc + Emulsifier)
Process Profile: Emulsions, high-end cosmetics, and reactive resins requiring sub-micron droplet sizing alongside bulk powder dispersion.
Optimal Design: Shaft 1 drives the anchor. Shaft 2 drives a high-speed Cowles disc. Shaft 3 drives a high-shear rotor-stator homogenizer. This provides macro-mixing, powder shearing, and liquid-liquid emulsification in one vessel.
The POLYC High-Viscosity Equipment Ecosystem
Kinematics Anatomy
Close-up of the central anchor frame and dual high-speed shafts.
Dual-Pillar Hydraulic Lift
Heavy-duty gantry frame ensuring zero vibration under maximum torque load.
Hydraulic Ram Press
The required downstream extruder for discharging non-flowing 1M cPs sealants.
Turnkey Sealant Lines
Complete cleanroom engineering for high-end electronics and structural adhesives.
Engineering Architecture: Mechanics & Vacuum Controls
1. Fluid Kinematics: Breaking the Yield Stress Barrier
Ultra-high viscosity pastes have a high yield stress. When a single high-speed blade spins, it creates a narrow band of shear, while the surrounding paste solidifies and stops moving. The POLYC Triple Shaft Mixer deploys an outer anchor frame equipped with spring-loaded PTFE (Teflon) scrapers. This frame continuously shears the material off the vessel walls and forces it into the dual high-speed Cowles discs, guaranteeing 100% batch turnover.
2. Intermediate Booster Slanted Blades
Fumed silica (white carbon black) is notoriously light and tends to float on the surface of the paste, forming dry crusts. To combat this, POLYC installs auxiliary slanted/folded blades mid-way down the high-speed shafts. These blades generate a powerful downward axial vortex, violently pulling floating powders down into the lower high-shear zones.
3. Deep Vacuum Deaeration (-0.098 MPa)
Air bubbles trapped inside silicone sealants cause cartridge sputtering and degrade joint strength. The thick paste prevents bubbles from rising to the surface naturally. By sealing the domed vessel and pulling a vacuum of -0.098 MPa, the intensive mechanical folding of the anchor frame continuously exposes new surface area, ripping micro-voids and trace moisture out of the polymer matrix before curing begins.
What Factors Drive the Price of a Triple Shaft Mixer?
1. Gantry Rigidity & Machining Precision
Three massive shafts operating simultaneously in thick paste generate immense off-center torsional loads. Standard single-pillar lifts will bend. POLYC uses heavy-duty, dual-pillar hydraulic gantry frames. The cost of thick-walled hydraulic cylinders and CNC machining for perfect shaft parallelism dictates a premium price but guarantees decades of zero-vibration operation.
2. Mechanical Seals & Pressurized Barrier Tanks
Maintaining deep vacuum around three high-speed rotating shafts requires sophisticated cartridge-style double mechanical seals. Premium models include stainless steel pressurized thermosiphon barrier fluid tanks to lubricate and cool the seals, significantly increasing initial investment but preventing costly vacuum leaks.
3. Explosion-Proof (ATEX / Ex-d) Compliance
If processing solvent-borne adhesives (e.g., polyurethane with toluene), the system requires certified explosion-proof motors, sealed VFD cabinets, intrinsic safety barriers, and spark-free scraper tooling. This compliance adds essential safety overhead to the equipment cost.
4. Surface Finish (Ra ≤ 0.4 μm)
For electronic-grade thermal pastes or medical adhesives, the interior SUS316L vessel and all shafts must undergo extensive mechanical and electrolytic mirror polishing to achieve an Ra ≤ 0.4 μm, ensuring zero material hang-up and pure metal-free batches.
Why Source Your Triple Shaft Mixer from POLYC?
CNC heavy machining, shaft balancing, and assembly at POLYC's 9,000 m² Wuxi manufacturing facility.
🏭 Real Direct Factory Manufacturing
Shanghai Polyc Technology Co., Ltd. builds your heavy-duty triple shaft mixers directly inside our wholly-owned 9,000 m² production workshop in Wuxi, Jiangsu Province. Sourcing direct eliminates trading markups and connects you straight to the mechanical engineers designing your machine.
🤝 3-Year Global Warranty
Genuine POLYC systems include our 3-Year Global Warranty covering drive heads, hydraulic columns, and vessels. Critical wear parts like PTFE scrapers and mechanical seals are dispatched via priority air express within 3–5 business days.
🧪 Free Material Trials in Wuxi
Send a sample of your high-viscosity paste to our Wuxi pilot testing laboratory. Our engineers will run trials to verify the exact RPM, scraping efficiency, and vacuum degassing required before you approve the final CAD drawings.
Ready to Specify Your Triple Shaft Mixer?
Share your formulation viscosity (cPs), solid filler content, and batch size requirements with our engineering desk. We provide customized configurations, 3D layouts, and direct factory quotes within 24 hours.
Frequently Asked Questions
What is the maximum viscosity a Triple Shaft Mixer can handle?
Why do I need a Hydraulic Ram Press to discharge the tank?
Can I change the working heads on a POLYC Triple Shaft Mixer?
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