By utilizing the vibration dropping method, uniform size particles close to spheres can be manufactured efficiently.

Fine particles manufacturing technology refers to a method in which small diameter nozzles are vibrated with a vibrator, and since liquid droplets are formed, they become close to perfect spheres, and particles which have narrow particle distribution can be manufactured efficiently.
For raw materials, metal compounds, alloys, organic substance ⁄ inorganic substance salts, chemicals, polymers are used, and they may be used in the state of solution, suspension, molten liquid, and dispersion liquid. Taking advantage of the features of “the particles being close to spheres” and “having a narrow particle distribution,” it is being put to practical use in various fields.

Features of the Equipment

• High Quality, High Efficiency: The particle distribution is very narrow, the particles are close to spheres, and product yield is high.
• Wide Operation Range： By changing the number of nozzles, continuous operation is possible from small to large volumes (10 ml/H - 1000 L/H), and in accordance with the physical properties of the material to be treated, the operating temperature is made wide (20 - 1500°C). This method can be applied to raw materials having a viscosity of up to about 100 cp.
• Operation is Easy： The feed pressure is only about 0.1 - 0.3 MPa so operation is easy.
• Energy Saving： Since the installation space is compact, energy saving based on low power cost, and manpower saving based on automatic operation can be aimed at.
• Design Adaptability： Designing in accordance with GMP and GLP is possible.
• Clean Operating Environment： Since it is a wet type, almost no dust is formed, and a clean operating environment can be maintained.
• By changing the nozzle, it is also possible to manufacture capsule particles.

Characteristics of the Products

• The particle distribution is very narrow and the particles are close to spheres.
• It is possible to adjust the physical properties of the particles such as for high fluidity, porousness, large surface area, surface hardness, etc.
• Owing to the uniform properties of the particles, solute properties can be maintained constant.
• By changing the thickness of the shell, sustained release can be adjusted. (in the case of capsules.)
• By uniform mixing of particles with different particle sizes, high density can be improved.

Product Specifications

• Sphericity (Ratio of major axis versus minor axis of the particles) 1.01 - 1.1.
• Particle Size: Single particle: 50 - 5000 μm Capsule: 500 - 5000 μm
• Yield (Product Percentage) 90% or above.

With our technology, manufacture of the following three main types of products is possible.

• Single Particles： Single particles made of one type of component (In certain cases, additives are added) Applications are catalyst simple substance resin, etc.
• Mixing agent： Effective components are dispersed uniformly in a binder. The solute characteristics can be maintained constant. Applications are adjustment agents for flavor, enzymes and yeast.
• Capsules： Those having a capsule structure in which the effective components are sealed into. By changing the thickness of the shell, gradual release of the effective component can be controlled. Applications are for pharmaceuticals and food.

1. Sol-Gel Method
   A method, with which a raw material in sol state is made into gel state (solidification). For instance, in case metal oxides are dissolved in nitric acid and supplied, solidification is made possible by the neutralization reaction with ammonia. The moment droplets fall from the nozzle, pre-solidification occurs in the ammonia gas, and the reaction is further promoted in an ammonia solution.
2. Melting Method
   A method, with which the raw material is supplied in a molten state, and by contacting direct or indirect with cold air or refrigerant to lower the temperature below solidification point, mainly used for metals or resin.
3. Drying Method
   Material is supplied in slurry or dispersed liquid state, and evaporated its water and dried by direct contact with warm air. The principle is the same as a spray dryer.

Chemical Industry

Catalysts, catalyst carrier, inorganic ⁄ organic substances, metal or metal alloys.

Food Industry

Flavor capsules, taste (savor) masking.

Cosmetics

Flavor capsule, Pigments.

Pharmaceuticals

Medical capsules, taste masking, control of release characteristics.

Electronic Materials

BGA (Ball Grid Array)

Environmental Industry

Capsulization of yeast and bacteria, water treatment, VCC catalyst.

Plastics Industry

Additives for injection molding, hybrid filter.

Salts of alginate, gelatin, agar-agar, cellulose sulfate, wax, thermoplastic substance, metal oxides (Si, Al, Fe, Ti, Zr, Ca, etc.) sol, PEG/PVA, polyethylene imine, polyacrylate, polyamide, polystyrene.

At present, Tsukishima Kikai is tackling the development of manufacturing equipment for functional fine particles and emulsions that are "single microns and monodisperse" in preparation for next generation material fields.