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Maker - Product Challenge

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Changemakers

Technology Supplier WAB Group 

WAB-GROUP is a global leader in wet grinding technology, three-dimensional mixing technology, and flow chemistry. With a rich history of innovation since 1933, WAB-GROUP offers world-class solutions across various industries, including industrial paint, crop protection, ink, coatings, battery materials, life sciences, pharmaceuticals, cosmetics, and food. Their commitment to quality and progress has established them as a trusted partner worldwide.

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WAB-GROUP continuously sets new industry standards through innovation and sustainable practices. Their state-of-the-art wet grinding, mixing, and flow chemistry technologies ensure efficient and high-quality processes. With advanced facilities like the Process Technology Centre in China and the R&amp;D center in Switzerland, WAB-GROUP integrates cutting-edge solutions while maintaining environmental and social responsibility. Their global presence and dedication to excellence make them a reliable partner for sustainable technological advancements.

About Willy A. Bachofen AG

Proper mixing and homogenization are essential to achieve a reliable, efficient, and fine-quality product with precisely defined active ingredient properties. However, these processes can prove to be challenging in the pharmaceutical industry.
<h2>Achieves perfect homogenization of APIs with three-dimensional mixing</h2>
TURBULA®, a 3D shaker mixer from WAB-GROUP®, is designed for uniformly mixing powdery substances with diverse particle sizes and specific weights. It excels in handling both wet and dry components, like powder inhalers or API.  Based on the Schatz geometric theory, its distinctive three-dimensional motion incorporates rotation, translation, and inversion. It facilitates a dynamic and harmonious mixing of the API with the carrier material. This constant, rhythmic pulsing motion of the shaker container ensures exposure to a vibrant, homogeneous mixing. Available in a range of configurations to accommodate container volumes spanning from 0.1 to 55 liters, the 3D shaker mixer proves its versatility across various pharma industries, R&amp;D labs, as well as pharma production plants.

3D powder mixer for active pharmaceutical ingredients

To achieve precisely defined API properties and safe and reproducible production, rigorous implementation of hygienic and sterile automated processes is a must.
<h2>Refines wet milling with clean and sterile technology</h2>
The DYNO®-MILL MULTI LAB CIP/SIP from WAB-GROUP® is a specially designed agitator wet mill for sterile research and development, pilot, and production operations in the pharma industry. It can process low to high-viscous products with batch sizes starting from 500 ml. What is more, it comes with easily interchangeable grinding chambers from 0.3 l to 1.4 l. It can accommodate both, WAB KD agitator discs as well as the DYNO®-ACCELERATOR. The use of agitating small beads in wet milling efficiently grinds suspended particles to the low micrometer or even nanometer range, maintaining a narrow particle size distribution.

Cleaning in Place (CIP) ensures there is no direct contact between the plant operator and active pharmaceutical ingredients. Steam sterilization up to 135°C ensures plant sterility, guaranteeing a germ-free production of tablets, capsules, injectables, and vaccines.

Agitator bead mill for API

During the early stages of synthesis, generating only limited product quantities can pose a challenge, making realistic milling tests more difficult.


<h2>Formulates chemical reactions for tests in R&amp;D labs and universities</h2>
DYNO®-MILL RESEARCH LAB from WAB-GROUP® is a bead mill suitable for small batches starting from 100 ml. It enables processing in two modes: continuous passage and circulation mode. The mill can grind media from ø 0.05 - 1.0 mm to a particle size under 100 nanometers.

DYNO®-MILL RESEARCH LAB is designed for easy handling: you can detach the entire grinding section from the drive by loosening just three screws. Afterward, disassembling the grinding section requires only a few simple steps. This makes cleaning quick and convenient. Plus, the separate grinding cylinder can undergo sterilization as a whole.

Agitator bead mill for flow chemistry

Fine-grinding solid flavors to improve taste properties and integration into your food product, you need a clean flexible milling solution that can handle a large variety of materials. 
<h2>Super-fine grinding and dispersion for technology refines food and enhances flavors</h2>
DYNO®-MILL Universal Bead Mill (UBM) from WAB-GROUP® provides ultra-fine grinding and efficient dispersion solutions for a wide range of food and beverages, from laboratory-scale (DYNO®-MILL UNI LAB) to large-scale production. The mill accommodates a grinding chamber volume ranging from 0.5 to 100 l while utilizing grinding media ranging between Ø 0.2 and 2.5 mm. It serves dispersion and grinding for food refinement of chocolates, natural colorants, alternative foods, food supplements, and pet foods.  

DYNO®-MILL UBM features the DYNO®-DISC BC agitator discs, designed with grinding media channels, which ensure effective acceleration of the grinding beads along a precisely defined path. During operation, each bead channel forms two grinding circuits between agitator discs, operating in opposite directions. The closed outer contour securely retains the beads between the discs and uniformly distributes them within the active grinding chamber, giving efficient dispersion and fine grinding of food and beverage products.

Agitator bead mill for functional foods and flavors

To achieve cleaner, safer, and more efficient transformations in the pharma and chemical industry minimizing the use of hazardous solvents and reducing energy consumption is pivotal.
<h2>Reduces energy consumption with an inductively heated agitator </h2>
The WAB IMPA°CT REACTOR from WAB-GROUP® is an innovative agitator bead mill reactor in the field of flow chemistry. Featuring a horizontal reaction chamber, it is optimal for efficient mass transfer and activation of chemical reactions. An inductively heated agitator employs impact bead milling for high and uniform mechanical energy input and surface renewal of the reactants. Additionally, an induction heater arranged around the stirring elements enables direct heating of the reactants up to +160 °C. It integrates the power of three WAB technologies into one single reactor: the DYNO®-ACCELERATOR, the patented DYNO®-DISC BC, and the DYNO®-DISC KD agitator discs.  

The technology is ideal for both passage and circuit operation and can be used for liquid as well as viscous, pumpable products and heterogeneous catalysts. It is scalable to meet industry requirements from g/h up to tons/h. Due to its cooling properties, the reactor can be utilized in exothermic reactions, in addition to its application in endothermic processes.

Agitator bead mill reactor for molecular synthesis by mechanochemistry in continuous flow

To optimize qualities like particle size, distribution, solubility, and miscibility of active ingredients in agricultural chemicals, you need to be able to grind them ultra-fine.


<h2>Finely grinds particles that provide better protection of the plant against pests, fungi, and weeds</h2>
DYNO®-MILL Universal Bead Mill (UBM) from WAB-GROUP® offers dispersion and ultra-fine grinding solutions for fertilizers, fungicides, herbicides, and insecticides. The mill accommodates a grinding chamber volume spanning from 0.5 to 100 liters and employs grinding media with diameters ranging between Ø 0.2 and 2.5 mm. It efficiently grinds and disperses active ingredients to very fine particle sizes.

Featuring the DYNO®-DISC BC agitator discs with integrated grinding media channels, the DYNO®-MILL UBM ensures an acceleration of the grinding beads along a defined trajectory. In the operational phase, each channel for the beads establishes dual grinding circuits between the agitator discs, operating in opposing directions. The enclosed outer configuration secures the beads between the discs, ensuring their uniform distribution within the active grinding chamber, thereby facilitating efficient dispersion and fine grinding of active ingredients.

Bead mill for crop protection

Using nanoparticles in cosmetics requires precise control over material breakdown and distribution. You also have to keep material compatibility, temperature control, and high hygiene standards in mind.


<h2>Versatilely disperses particles in nano-cosmetic applications</h2>
DYNO®-MILL MULTI LAB (ML) from WAB-GROUP® is a flexible laboratory agitator bead mill, ideal for research and development and small-scale productions of cosmetics. It can accommodate varying grinding chamber sizes, material selection, and grinding technology. That in both, continuous and discontinuous operation. For the smallest applications, it is designed to use the finest grinding beads down to 0.1mm.

Discontinuous operation employs specially designed 0.15 l and 0.3 l grinding vessels to process low-viscosity suspensions in batch sizes of 85 ml and 170 ml, respectively. Continuous operation is suited to handle highly fluid to viscous, pumpable products. There, grinding containers of 0.15, 0.3, 0.6, and 1.4 l volumes are available to process batch sizes exceeding 500 ml. The use of high-quality ceramic components like SiC, and ZrO2 assures no metal contamination and thereby, a long service life. It offers variability with two grinding principles in one mill: the DYNO® agitator disc and the patented DYNO®-ACCELERATOR.

Flexible R&D wet agitator mill for cosmetics

For precise, efficient, and reproducible cell disruption, optimization of process parameters such as material selection, grinding media, and temperature control are important.


<h2>Employs ultra-fine grinding for cell disruption and extraction of ingredients</h2>
DYNO®-MILL MULTI LAB (ML) from WAB-GROUP® is an adaptable laboratory agitator bead mill, well-suited for small-scale productions and R&amp;D in biotechnology. Suitable in continuous and discontinuous operations, the bead mill specifically designed for smaller applications can utilize ultra-fine grinding beads as small as 0.1mm. It has adjustable grinding chamber sizes, material selection, and adaptable grinding technology. It incorporates two grinding principles in one mill: the DYNO® agitator disc and the patented DYNO®-ACCELERATOR.

Discontinuous operation utilizes grinding vessels of 0.15 l and 0.3 l to handle low-viscosity suspensions. The batches range from 85 ml to 170 ml. Continuous operation is suitable for processing highly fluid to viscous, pumpable products.  It employs grinding containers of 0.15, 0.3, 0.6, and 1.4 l to process batch sizes exceeding 500 ml. Using superior ceramic components such as SiC and ZrO2 ensures no metal contamination and an extended service life.

Flexible laboratory bead mill for vaccines

Achieving consistent homogeneity and the logistics of handling and introducing large quantities of raw materials into a high-volume mixing process of ceramics can pose a challenge.


<h2>Uniformly homogenizes bulk materials with a high-capacity</h2>
dyna-MIX® from WAB-GROUP® is a 3D shaker mixer designed for high-quality mixing of solids, liquids, and their combinations. It comes with tank volumes from 40-1000 liters. The mixer employs a hinged universal joint to mount the mixer container which creates controlled three-dimensional movements as a result of the two vertically superimposed rotations. These movements lead to a gentle, consistent, and reproducible mixing process.

The required motion paths are programmed into the PLC control module, which regulates the sequence of motion of the mixing bowl. The container-specific clamping device adapts to the loading and unloading of variable mixing bowl sizes.

High volume 3D shaker mixer for ceramics

Processing toxic chemicals requires high compliance with safety standards and a continuous overview of the protection of your operators.


<h2>Reliably disperses and finely wet grinds paints, toners, and pigments</h2>
DYNO®-MILL KD from WAB-GROUP® was the first horizontal agitator bead mill for dispersion and ultra-fine wet grinding technology. The mill offers grinding chamber volumes ranging from 0.15 to 600 liters and utilizes grinding media ranging from Ø 0.5 to 2.5 mm. It employs a wide choice of grinding media including hardened and stainless steel, hard chrome-plated stainless steel, polyurethane, and ceramic.

In the horizontal grinding chamber, the DYNO® agitator discs are symmetrically arranged on the agitator shaft and transfer kinetic energy to the grinding media. Especially in the passage mode, with optimal process parameters, these disc mills consistently achieve narrow particle size distribution in the micrometer range. It employs a cooling process by forcing the cooling water through the outer jacket, thereby enabling the processing of temperature-sensitive products like pigments and paints.

Also available as the DYNO®-MILL ECO 5 for more simple applications and smaller batch sizes.

Horizontal disc bead mill for liquid chemicals

Material heterogeneity, agglomeration, and contamination are key parameters to control when dry mixing battery powders.


<h2>Delivers high-quality homogeneous compounds</h2>
TURBULA® from WAB-GROUP® is a 3D shaker mixer specially designed for uniform mixing of powdery substances with varying particle sizes and specific weights. It can accommodate both wet and dry components or different wet ingredients.

The unique three-dimensional movement involving rotation, translation, and inversion is designed per the Schatz geometric theory. It sets the mixing container into a constantly changing, rhythmically pulsing motion, exposing the chemical product to dynamic and homogeneous mixing. Various configurations of the 3D shaker mixer can accommodate container volumes from 0.1-55 liters, making them well-suited for diverse industries from battery manufacturing, research and development, to chemical plants.

R&D shaker mixer for battery powders and chemicals

To prevent blockages, clogging, and cross-contamination coming from highly viscous materials your grinding equipment needs to be cleaned frequently. 
<h2>Grinds low fluidity products with high throughputs in the nanometer range</h2>
DYNO®-MILL ECM-AP from WAB-GROUP® is a high-efficiency agitator bead mill that features a patented grinding bead separation system. It is designed to grind the most challenging products with higher throughputs and production capacities. The self-cleaning effect of the separation system improves the driveability of highly viscous products, preventing screen clogging and reducing production downtimes for screen cleaning. It is designed to use the finest grinding beads down to 0.1mm. The uniform distribution of grinding media in the grinding chamber produces the finest and narrowest particle sizes in the nanometer range, ensuring a high grinding efficiency. It is applicable for both, pass and circulation modes. It is great for making coated and uncoated tablets.

Self-cleaning bead mill for highly viscous materials

Ensuring the quality, efficiency, and reproducibility of nanosuspensions throughout the wet grinding process is a continuous challenge, demanding strict control over various parameters like the use of high-grade materials, uniform energy input, and ideal cooling properties.
<h2>Grinds viscous products continuously in the micron and nanometer range</h2>
The DYNO®-MILL NPM from WAB-GROUP® is specially designed for continuous dispersion and wet grinding of nanosuspensions. The patented DYNO® ACCELERATORs provide powerful hydraulic movement of the grinding beads and guarantee consistent energy input for grinding thin to viscous products, in the micron and nanometer ranges. The rotating grinding media separation system facilitates the use of very small grinding media ranging from 0.05 to 0.2 mm.

The peripheral speed of the separation system ensures the safe separation of grinding media from the product. The use of high-quality ceramics like SiC, and ZrO2 provides metal-free grinding and guarantees a long service life. It is ideal for both passage and circuit operation, maintaining consistent efficiency, while achieving extremely narrow particle size distributions. It is best suited for producing construction materials like paints, toners, and cement.

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Ultra fine bead mill for nanosuspensions

To facilitate the attainment of ultrafine particles and enhance electrode properties, reactivity, and surface structure proper grinding technology and high-quality raw materials should be applied.
<h2>Offers grinding and dispersion for NMC, Li-NMC, LNMC, and NCM materials</h2>
DYNO®-MILL Universal Bead Mill (UBM) from WAB-GROUP® provides dispersion and ultra-fine grinding solutions for a wide range of battery materials from laboratory-scale to large-scale production.  The mill is scalable with a grinding chamber volume from 0.5 to 100 l while using grinding media between Ø 0.2 and 2.5 mm. It is suitable for dispersion and grinding of battery materials like anode and cathode materials, fuel cells, carbon nanotubes, multi-layer ceramic capacitors, and photovoltaic and separator materials.

It comprises the DYNO®-DISC BC agitator discs, featuring grinding media channels, which ensure efficient acceleration of the media along a precisely defined path. While in operation, each of the bead channels establishes two grinding circuits between the agitator discs, functioning in opposing directions. The closed outer contour secures the grinding beads between the agitator discs and uniformly distributes them within the active grinding chamber, for dispersion and fine grinding of battery materials.

Ultrafine bead mill for battery materials

WAB Group Technologies

WAB-GROUP's expertise is accessible through their global network of locations in Switzerland, the USA, India, China, Germany, France, and Israel. Their local teams provide comprehensive sales, service, and technical support, ensuring clients receive personalized and timely assistance. Whether you need advanced wet grinding solutions or innovative mixing technologies, WAB-GROUP's experienced professionals are ready to help optimize your processes and achieve your business goals. Contact WAB-GROUP to discover how their expertise can benefit your operations.

Connect with the experts at WAB Group

Landline telephones in the 1980s were minimalist gadgets that kept getting slimmer in the 1990s. In contrast, cell phones in the same period were bulky and cumbersome. And once they lost their charge, they turned into a giant paperweight. Then came a revolution in batteries and automation with lithium-ion battery manufacturing equipment. Mobile phones packed more power, recharged faster, and endured more recharge cycles. Above all, they were light and small, making cell phones the inseparable companions they are today. But Lithium-ion batteries power much more than phones. As a result, the world is seeing steady growth in battery manufacturing equipment and lithium-ion production lines.

Lithium-ion batteries

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

Some of the vaccines in use today were originally developed decades ago. But advances in research, expertise and vaccine development equipment provide immunizations from bacterial and viral diseases (antibodies and cell therapy) to more people every year. The Covid 19 pandemic highlights the urgent need to scale up the production of vaccines and ensure an automated as well as reproducible manufacturing environment.

Vaccines

Everything tastes like porridge, the saying goes. That may be an exaggeration, but in theory, reaction flavors could make everything taste the same. Thankfully, flavorists and chemists in the flavor industry are more inventive than that, and colorful process flavors treat our taste buds to a broad palette of sensations, flavors and aromas.

Reaction flavors

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

Ceramics are defined as inorganic and non-metallic materials. Tthey are typically brittle, hard, and elastic as well as resistant to heat and corrosion; in fact, after shaping them into the desired shape, they are heated in an oven called kiln at very high temperatures (1,000 °C to 1,600 °C). Kaolinite and aluminum oxide are the best-known examples of ceramics.

Ceramics

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.