To understand how high shear mixers can do this and how they could benefit your mixing process, it is useful to understand how these mixers work.
What is a High Shear Mixer?
Shear means to cut. A high shear mixer utilises specialised rotor/stator technology to generate extremely high shear rates.
- Rapid intake – The rotor creates a powerful suction effect that continuously draws materials into the high shear workhead.
- Initial Shear – Centrifugal force then drives materials towards the periphery of the workhead where they are subjected to a milling action in the precision machined clearance between the ends of the rotor blades and inner wall of stator.
- Hydraulic Shear – This is followed by intense high shear as the materials are forced, at high velocity, out through the perforations in the stator and circulated into the main body of the mix.
- Complete processing – The materials expelled from the head are projected radially at high speed towards the sides of the mixing vessel. At the same time, fresh material is continually drawn into the workhead maintaining the mixing cycle. The effect of the horizontal (radial) expulsion and suction into the head is to set up a circulation pattern that minimizes aeration caused by the disturbance of the liquid’s surface.
Unlike low shear devices such as stirrers and agitators, high shear mixers actively process the materials in the mix, enabling faster and more consistent results.
How are High Shear Mixers used in the Chemical Industry?
Chemical processing demands consistency under abrasive, high viscosity and reactive conditions. Many chemical formulations are now increasingly complex and as such require a piece of mixing equipment that can complete multiple mixing operations.
High Shear mixers can:
- Accelerate reaction rates
- Create stable emulsions and small particle sizes, every batch
- Maximise yield of active ingredients in chemical suspensions
- Handle high viscosity mixes and effortless blend liquids of varying viscosities
- Ultra fine, uniform dispersion of pigments
- Increase production capacity without adding shifts or staff
- Achieve results in R&D that can easily be replicated at full production scale
For more information on specific chemical applications, read Silverson Machines chemical mixing guides.
Choosing the right mixing solution
Why choose a Silverson high shear mixer over other high shear mixers available on the market?
- Experience – In 2026 Silverson Machines turns 80. We’ve 80 years of experience, technical knowledge and application know how to help assist our customers when helping them solve their mixing problems.
- Precision and Quality – Silverson High Shear mixers have the tightest shear gap in the industry. If you think of a pair of scissors, a pair with blades close to one another will cut the paper much more efficiently than a pair which has a larger gap. The same applies to high shear mixers. This tight tolerance between the rotor and the stator also allows for more accurate scale-up.
- Trusted by Multinationals – Because of the tight shear gap, Silverson mixers can be relied upon for batch-to-batch consistency, in terms of quality and timings. Looser tolerances means that batch times can vary, even a five minute variation can have a knock on effect and could consequently end up with fewer batches being produced in a working day. With Silverson, results can be replicated time after time.
- Versatility – Silverson Machines offers the widest capacity range from a single manufacturer, with mixers suitable for processing batches of 1ml up to 30,000 litres. Within our range there are many options suitable for chemical processing, including ATEX approved models and models suitable for aggressive chemical service. A comprehensive range of workheads and screens is available for all Silverson high shear mixers, allowing them to be used for multiple mixing operations.
- Worldwide support – with offices, representatives and agents in over 60 countries, there is always support nearby.
Try it for yourself
For nearly eighty years, Silverson Machines has worked closely with chemical manufacturers to solve their mixing problems. We are confident that high shear mixing can revolutionise your mixing process, so put us to the test! Get in touch today to arrange a trial and see the results for yourself.
You can view the entire range of Silverson High Shear Mixing equipment on the Silverson website.
