Manufacturing

Toll Solutions’ services can be grouped into two main categories:
• Toll projects – Customer supplies all materials and packaging
• Custom products – Toll Solutions may provide some or all materials and packaging

These services are provided through the following versatile capabilities:

  • Chemical Mixing – Mixing solids and liquid – not a reaction but a solution, including compounding (adding a solid to a liquid to get a desired viscosity); making stable emulsions by adding compounds to water; with temperatures up to 150º C, from 50 gal to 5600 gal per vessel
  • High-Shear Mixing – Mixing for added stability due to particle size reduction, usually for adding stability to otherwise unstable emulsions; taking solids and dispersing them into a liquid carrier at a high rate of speed and adequate mechanical energy from specialized mixers, homogenizers, or rotor stators
  • Chemical Blending – Mixing liquid and liquid – creating a new formulation without chemical reaction, such as making emulsion using high shear and surfactants
  • Chemical Reactions – Creating new molecular entities through chemical reactions of gaseous, liquid or solid raw materials; specialization in silane and silicone chemistry, free radical polymerization
  • Dispersions – Suspending a solid in a liquid in a relatively stabilized form, through homogenization, high shear agitation, and milling
  • Emulsions – Similar to dispersions – includes a dispersion (solid and liquid) and water, with high shear mixing, including challenging emulsions comprised of silicon fluids, silica or titanium dioxide
  • Particle Size Reduction – Use mechanical means to reduce particle size in some type of carrier liquid through homogenization, milling, rotor stator or similar means, yielding higher-performance products and increasing stability; full advanced particle size analyses from sub-micron levels, as well as colorimetry, gas chromatography, and other analytical methodologies

Analytical Capabilities - Our blending services are backed by extensive analytical capabilities – both the equipment and experienced analytical chemists to take care of your requirements:

• GCs
• Particle size analyzers
• Titrations
• Brookfield Viscometers
• Colorimeter
• Moisture Analyzer
• DSC

EQUIPMENT

Processing Equipment

High Sheer equipment- Homogenizer, Ross Mixer, IKA, Kady Mill, Cowles Blades

Reactors (Explosion-proof room with foam fire suppression, Class I, Division II rated, all 304 stainless steel)

  • 3 separate 250-gallon Pilot tanks for scale up. (Mixers include high sheer cowles, twin turbine, and helical)
  • BA-1:  500-gallon mixer. Mixes up to 1,000,000 cp. Interchangeable Helical Mixer/Cowles
  • R-2: 3,300 gallon reactor, turbine agitator, pressure rated, vacuum, full overheads, internal coils and jacketed
  • R-3: 3,300 gallon reactor, turbine agitator, pressure rated, vacuum, full overheads, internal coils and jacketed

Dispersion & emulsion vessels (all 304 stainless steel)

  • M-1: 1,450 gallon with Cowles blade and sweep agitator, jacketed
  • M-3: 1,750 gallon with Cowles blade and sweep agitator, jacketed
  • M-7: 1,500 gallon vessel with Cowles blade and sweep agitator, jacketed
  • M-10: 1,520 gallon vessel, turbine agitator
  • M-11: 5,370 gallon vessel with sweep agitator, jacketed
  • M-12: 5,500 gallon vessel, turbine agitator
  • M-13: 1,850 gallon vessel, turbine agitator
  • M-20: 5,300 gallon vessel, turbine agitator, jacketed
  • M-21: 5,500 gallon vessel with Cowles blade and turbine agitator, jacketed
  • M-22: 2,800 gallon vessel, turbine agitator, jacketed
  • M-24: 5,500 gallon vessel, turbine agitator
  • M-25: 5,500 gallon vessel with Cowles blade and sweep agitator, jacketed

Supporting Equipment

Storage tanks

  • 36 stainless steel (all 304) storage tanks ranging from 5,000 gallons to 8,500 gallons.
  • All with level control, some heated and agitated.

Filtration

  • Various cartridge and bag filters