IKA D 80 Dissolver (tooth disc), Ø 80 mm, for T 65 digital, 0020008389

Maximum shear forces for large-scale production processes: the IKA D 80 Dissolver

In industrial process development, the demanding production of paints and coatings, chemical synthesis and food technology production plants, the efficient and homogeneous incorporation of solids into liquid media is an absolutely critical process step. When fine powders, highly binding pigments, high-molecular-weight polymeric thickeners or viscous resins are introduced into extremely large volumes of liquid, stubborn agglomerates – known as ‘fish eyes’ – inevitably form. With these agglomerates, only the outer layer is wetted, whilst the inner core remains dry and physically isolated. Conventional propeller or anchor agitators are completely inadequate for such large volumes, as they merely circulate the medium without applying the local shear forces required to mechanically break up these agglomerates. The disastrous consequences are extremely prolonged process times, defective batches, blocked filter systems and reduced product quality. It is precisely for these large-scale process engineering challenges that IKA has developed the robust, high-performance D 80 Dissolver (MPN 0020008389). This extremely robust and highly specialised high-speed mixing tool shatters stubborn powder lumps in milliseconds and guarantees you absolutely homogeneous and perfectly dispersed suspensions, even in enormous batch sizes.

The physics of extreme comminution: the dissolver principle in XXL format

The technological heart of the IKA D 80 is its precisely engineered and dynamically balanced dissolver disc (toothed disc), which boasts a gigantic diameter of 80 millimetres. Unlike conventional agitators, which are primarily designed for purely axial circulation, this massive dissolver head generates enormous local shear and impact forces at the extremely high speeds of a high-performance industrial disperser. The razor-sharp teeth on the outer edge of the heavy metal disc, which are alternately curved upwards and downwards, cut mercilessly through the liquid – often highly viscous – medium at extremely high speeds. Extreme hydrodynamic turbulence, immense shear gradients and massive cavitation forces arise at the edges of these teeth. The viscous powder-liquid mixture is accelerated radially outwards with immense kinetic energy by the fluid dynamic profile of the 80-mm disc, strikes the reactor or stainless steel vessel wall, and circulates continuously back into the high-shear zone at the rotating agitator shaft. This raw, yet precisely controlled mechanical force literally tears even the most stubborn agglomerate structures apart into their tiniest primary particles.

Superior performance for large volumes ranging from 2 to 50 litres

An outstanding and absolutely game-changing feature of the D 80 Dissolver is its precise design for genuine pilot and production scale. With a specified, enormously wide operating range from 2 litres up to a monumental 50 litres (based on the physical viscosity of water), this tool bridges the gap perfectly between scale-up research and direct, on-site industrial production. Once you have successfully developed a new, complex formulation in the laboratory, scale-up (direct scaling) is often the most critical and riskiest step in the value chain. With the massive D 80 unit, you can scale this process seamlessly, safely and reproducibly to 50-litre production batches. You can generate reliable, meaningful process data for large-scale production or directly produce market-ready pilot batches without ever having to compromise on dispersion quality, colour strength or particle size distribution.

Seamless system integration: Tailor-made for the T 65 digital industrial drive

As a high-quality original IKA accessory, the IKA D 80 Dissolver is not a universal, adaptable stand-alone product, but a highly specialised, high-performance mixing head that integrates perfectly into the existing high-end ecosystem. It was designed by engineers exclusively for use in combination with the extremely powerful and robust IKA T 65 digital industrial disperser. To safely, durably and vibration-free transfer the extreme torsional forces – at volumes of up to 50 litres and the correspondingly high speeds – from the motor to the solid dissolver disc, the D 80 mixing head is coupled directly to the solid IKA dispersing shafts. It is fully compatible with all stainless steel shafts in the S 65 series. This clever, modular design offers you the enormous economic advantage of being able to use completely different tool heads with the same expensive T 65 drive motor, which massively increases the flexibility and cost-effectiveness (Total Cost of Ownership) of your valuable pilot plant.

Uncompromising material quality and GLP/GMP compliance in continuous operation

In tough, relentless continuous industrial operation with highly abrasive pigments, sharp-edged ceramic powders, toxic chemical solvents or aggressive surfactants, an agitator must be extremely robust. The IKA D 80 Dissolver is therefore manufactured entirely from the highest-quality, corrosion-resistant stainless steel of the absolute industrial grade AISI 316L. This premium material not only ensures an outstanding service life for the agitator, even when handling highly abrasive media, but also minimises unwanted metallic abrasion (cross-contamination) in extremely sensitive samples – a factor of the utmost importance for pharmaceutical quality control, the food industry and modern semiconductor technology. The flow-optimised, hygienic design of the large 80 mm toothed disc almost completely prevents stubborn build-up of product residues in dead corners. Once the intensive dispersion process is complete, the heavy tool can be cleaned thoroughly and safely under running water, in an industrial ultrasonic bath or with highly effective solvents. With a solid and robust weight of 0.44 kg and a design approved for ambient temperatures of 5 to 40 °C, this tool impressively underlines its extremely robust, industrial character, designed for durability.

Technical data

• Tool principle: Dissolver disc (toothed disc) for highly efficient radial flow
• Disc diameter: 80 mm
• Working range (H₂O volume): 2 to 50 litres
• Compatibility (drive): Designed for the IKA T 65 digital high-performance disperser
• Compatibility (shaft): Can be used in combination with all S 65 dispersing shafts
• Material (in contact with the medium): High-quality, low-wear stainless steel (AISI 316L)
• Permissible ambient temperature: 5 to 40 °C
• Main applications: Breaking up stubborn agglomerates, powder incorporation on a production scale, high-shear dispersion
• Weight: 0.44 kg

Scope of delivery

• 1 x IKA D 80 Dissolver (toothed disc, Ø 80 mm)

(Important note: The D 80 Dissolver is a mixing head only. The essential intermediate shaft from the S 65 series and the T 65 digital drive unit are not included in the scope of delivery!)

Custom requirements & accessories

To ensure you can use this powerful tool in your production facility straight away, please check your existing system configuration. To connect the D 80 mixing head to the T 65 digital drive, you will need a suitable shaft from the S 65 series. If you do not already own a shaft, you must purchase one separately. When working with extremely large volumes of up to 50 litres and the correspondingly immense centrifugal forces, a robust, industrial-grade IKA floor or wall stand is also absolutely essential to ensure safe, vibration-free operation. Our specialist procurement service is available at any time to help you configure your scale-up and production facilities optimally.