High-speed mixers are rotor/stator mixers for more challenging solid-liquid dispersions and emulsions, and these high-speed dispersers cannot handle adequately. The typical feature of this type of mixing device is that a four-blade rotor rotates at a high speed in a stationary stator. When the blade rotates, the material is continuously drawn into the mixing head, and the gas is discharged at a high speed through the opening of the stator. The resulting hydraulic shear can promote rapid homogenization, depolymerization and emulsification. The typical rotor tip speed is 3000 to 4000 feet per minute.

Due to the limitation of the stator, the mixer provides a higher shear speed, but the pumping capacity is less than that of the open disc-type serrated vane disperser. For the same reason, its viscosity limit is also low-about 10,000 to 20,000 centipoise.

Another difference is that the rotor/stator mixer has both a structure that can be used for mass production and a structure that can be used for on-line (continuous) production. The performance of the online high-shear mixer is similar to that of a centrifugal pump. It cannot automatically start self-priming, and requires static pressure (gravity feeding) or positive pressure (pump feeding) to add materials to the stirred tank. In most cases, when the agitator is usually located on the ground or on a platform below the level of the recirculation tank, the product can be delivered to the rotor/stator assembly by gravity. Standard in-line mixers can easily move flowing products, even with a viscosity as high as about 10,000 centipoise, depending on the shear thinning characteristics of the formulation. Using auxiliary pumps, medium viscosity coatings, premixes and intermediates can all be processed in a high-shear mixer. For large stirred tanks (> 500 gallons), compared with batch rotor/stator mixers or other high-speed mixers that require high-power motor drive and relatively large blades to generate enough circulation to enter from the top, the in-line structure is often more practical. On the other hand, the online high-shear mixer can circulate the product through a 2500-gallon mixing tank, just as easily as in a 25-gallon mixing tank. In fact, with suitable pipelines, one in-line mixer can serve multiple batch tanks of different specifications at the same time. The typical installation method is to use a simple valve to flow directly to the downstream finished product area or to switch from one raw material source to another instantaneously.

When it is necessary to quickly add large quantities of powder to the liquid, or when it takes a long time for the hard-to-disperse solids to be completely added, it is necessary to consider a high-shear mixer with a built-in device that can add the powder below the liquid surface . Although the ejector-based powder injection system can effectively remove floating solids and provide more precise control during the mixing process, it is often affected by clogging and intensive equipment maintenance. In addition, these systems require experienced operators to handle frequently encountered difficult tasks, namely the performance balance of three independent devices in series: ejector, pump, and agitator. The high-shear mixer with powder injection integral structure is more reliable and easier to operate.