Our specialty lies in Surface Modification of the particles mechanically and giving them the desired shape so as to optimize their performance. We have successfully modified Talc Particles into Rhombus Shape or Needle like shape on Nano scale. This helped us in reducing the Oil Absorption Levels while also reducing the Particle Size. The product is first grinded to the desired particle size, then we modify the particle structure to add another performance criteria.
1. We have made Talc product for polymer industry where we have more than 49% particles below 1 Micron, 34% Particles below 0.5 Microns. Where traditionally speaking these particles will take up more space hence will increase the Oil Absorption level. This is a very negative sign for polymer industry as more oil absorption level will reduce the filler loading because the material will become viscous and will not flow properly.
On modifying the surface mechanically, we were able to reduce the Oil Absorption levels from 75 ML/ GMS to 40 ML/GMS, this drastically increased the percentage of loading in the polymer compound and added new properties to the performance to the end use products.
2. In Paints and Coating Industry there are many products available to reduce the TiO2 Content in the formulation. These products have Average Particle Distribution of 2 Microns. The concept is to have tinting strength close to TiO2 hence partially replace it as per the performance of the filler. These products also face similar problem with Oil Absorption levels.
We have reduced the Oil Absorption levels and have also reduced the Average Particle Distribution level to 1 Micron. Which gives excellent Tinting Strength in White Paint manufacturing. But as Paint is not limited to white colour, as we add colour to the formulation, this tinting strength becomes a hinderance, because to achieve the desired shade more pigment is needed to counter the white tint of TiO2.
On surface modifying the material with different aspect ratio, we were able to reach a formulation where we were able to achieve the Tinting Strength but also able to Morph the Pigment Shade, hence reducing the over all pigment addition to the formulation to achieve the desired shade.
Reducing the size of the particle can be achieved through various methods and principals. It can be either different mechanical principals or through chemical reactions.
Mechanical process keeps the integrity of the mineral intact, which is why it is preferred in the mineral industry.
Grinding material to Top Cut 10 Microns level is relatively easy. But to reduce the size further from there on becomes increasingly difficult. The material itself starts acting like shock absorber which reduces the Impact Force or Colloidal Force. This happens due to increase in number of smaller particles, which fill the empty space between the grinding media and material. This space is necessary as it keeps the momentum of the grinding media; to the levels necessary; to have the correct impact force to break the particles. As a result the particle itself becomes the problem to further grind it.
We have overcome this problem with our indigenously designed system which manages the extraction on these smaller particles before they become a problem. This helped us in manufacturing these particles in a Continuous Production Cycle rather than Batch Production Cycle which is most common.