Ball mills are one of the oldest milling methods in the world. It’s a simple machine that uses the impact of balls in a chamber to mill different products.
Even today, it remains a very popular grinding method. Ball Mill manufacturer India uses the simplest machines with technological support to make the entire process quick and efficient.
Working Of The Ball Mills
The construction of the ball mill is pretty simple. It has a cylindrical device that rotates on a horizontal axis. This is the chamber that also contains the milling balls.
Sometimes the milling chamber may be housed in a bigger protective vessel. The material to be grounded is fed into this chamber, and as it rotates on its axis, the cascading balls pummel the material inside.
It is an extremely easy method, which is also extremely effective in getting the results you want. Why are ball mills still so popular? The answer lies in their effectiveness.
The simple design banks on the working of the balls inside the mill
Cost of installation
Compared to other mills like pin mills or rod mills, the ball mill is a simple design requiring very little installation. High-end ball mills, including extremely efficient and very large ball mills.
However, there are plenty of options available on a more reasonable budget. The installation costs are generally quite low because of its ease of installation.
Cost of power
The ball mill does not require a lot of power. Mid-sized or small ball mills only need a little power for their operation. It is considered one of the most cost-effective milling methods.
In many industries ball mills are seen as the best in green tech. It is a mechanical way of breaking down materials that do not depend on chemicals or other additives.
In the food industry or cellulose production, mechanical ball mills are the safest and most non-polluting means of producing fine particles.
The operation of the ball mills in India requires very little energy, which adds to its benefit as green tech.
For all degrees of hardness
The ball mill can be used for any degree of hardness from very hard substances to far lighter materials. It is used to grind hard materials like feldspar or plastic.
It is equally useful in breaking down cellulose. However, we have to consider a couple of factors here density and hardness. The ball medium must be denser and harder than the material to be grounded.
A lighter medium will settle on top of the material, which would defeat the whole purpose. Similarly, a medium will have no impact force if it is softer than the material.
Cheap grinding medium
Common grinding mediums are stainless steel, chrome steel, ceramic, or rubber. None of these are expensive. One must consider integrity, density, hardness, size, and a non-corrosive composition.
There are no special workmanship or installation requirements, such as in the case of other mills.
Wet and dry grinding
The ball mill is equally useful in wet and dry grinding, unlike most other mills. Most mills only work in dry grinding. With ball mills in India, we can effectively work with wet material.
All we need is a little flowability which liquid already has. We need a little liquid to ensure that the material keeps moving in the mill. In dry materials, we use airflow to ensure that it keeps moving.
The ball mill can work with a really wide range of materials from cellulose, ceramic, chemicals, fibers, pigments, metal oxides, polymers, and more.
It can work with almost any material as long as we choose the right medium. The flexibility of picking the ball medium gives us a wide range of applications and workability.
Applicable for batch and continuous operation
The ball mill can be used for batch operations where we grind some material at a time. But it is equally applicable in continuous operation where we need a constant supply. This can be critical in manufacturing assembly lines.
The ball mill is one of the most cost-effective milling solutions. This simple design is not expensive to build or install.
There is no need for specialist installation within the mill or complicated calculations to decide how it should operate. Its energy consumption is also pretty low. This makes ball mills in India one of the most economic mills to run.