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Performance considerations in stator selection for high shear rotor-stator mixers
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7. Decision matrix
| Process condition | Typical first choice stator | Why | Typical risk if misapplied |
|---|---|---|---|
| Low viscosity fine emulsion | Fine emulsor | Highest finishing shear and droplet refinement | Fouling or overprocessing if coarse solids remain |
| General dispersion, medium viscosity | Square hole screen | Strong deagglomeration with still usable circulation | Pressure drop climbs as viscosity increases |
| Fibers, tissues, stringy solids | Slotted head | Better solids passage, lower blinding tendency | May not deliver the finest final PSD |
| Powder wet out, large viscosity contrast | Coarse or slotted | Better turnover and ingredient capture | Final particle size may stay too coarse |
| High viscosity creams/gels | Coarse or slotted plus anchor/scraper | Maintains turnover in the bulk | Fine screens can shear locally but stall bulk exchange |
| Shear sensitive emulsion | Slotted or square hole | Better balance of circulation and moderate shear | Fine screen can overshear or heat product |
| Strict CIP or difficult residues | Coarse or slotted | Easier flushing, lower blockage risk | Fine perforations may retain residue |