Custom Alumina Sand Mill Agitator Disc with Precision Bore and Disc Geometry

ADCERAX supplies alumina sand mill agitator discs from approximately 50 mm to 400 mm outer diameter with customized bore, keyway and disc geometry. Both standard sizes and drawing-based alumina agitator discs for sand mills are available to match existing bead mill designs.

Catalog No. AT-SM-001
Material ≥95% to 99.5% Al₂O₃
Diameter Range Ø40mm to Ø180mm
Surface Flatness Tolerance ≤0.02mm
Recommended service temperature Up to 1200–1300 °C in wet grinding systems
24H Standard Dispatch
Small Batch Support OEM
Factory Direct
Expert Engineering Support

Alumina Sand Mill Agitator Disc is a high-density alumina ceramic disc mounted on the shaft of a disc-type horizontal sand mill or bead mill to transfer energy from the motor to the grinding media and slurry. Its slots, holes and disc profile control the flow pattern and energy distribution inside the grinding chamber, so it directly affects grinding efficiency, particle size distribution and temperature rise.

Alumina Sand Mill Agitator Disc Benefits

  • Disc geometry optimized for wet grinding
    Flow channels and port patterns are tailored to bead mill hydraulics, supporting stable circulation and uniform energy distribution across the grinding chamber.

  • High-density alumina body for extended wear life
    The alumina ceramic disc combines high hardness with fine microstructure, providing long service life in abrasive pigment, filler and battery slurry systems.

  • Low contamination compared with metal agitator discs
    The alumina sand mill agitator disc minimizes metal pickup in sensitive formulations such as white coatings, high-purity pigments and lithium battery slurry.

  • Tight dimensional tolerances for smooth operation
    Critical dimensions such as bore, keyway and reference faces are machined to tight tolerances, supporting balanced rotation and low vibration at operating speed.

  • Compatible with existing sand mill and bead mill platforms
    The disc can be produced as a direct replacement for original agitator disc designs, so plant engineers can upgrade to alumina ceramic parts without changing the mill configuration.

 

Alumina Sand Mill Agitator Disc Properties

Property Unit 99.5% Al₂O₃ 99.6% Al₂O₃ 99.7% Al₂O₃ 99.8% Al₂O₃ 99.9% Al₂O₃ 99.99% Al₂O₃
Alumina content % 99.5 99.6 99.7 99.8 99.9 99.99
Density g/cm³ 3.89 3.91 3.92 3.93 3.94 3.98
Open porosity % 0
Color Ivory Ivory Ivory Ivory Ivory Ivory
Water absorption % 0 0 0 0 0
Young’s modulus (Elastic modulus) GPa 375 356 357 358 359 362
Shear modulus GPa 152
Bulk modulus GPa 228
Poisson’s ratio 0.22
Compressive strength MPa 2600 2552 2554 2556 2558 2570
Flexural strength MPa 379 312 313 314 315 320
Fracture toughness MPa·m¹ᐟ² 4
Hardness GPa 14.1 (≈1440 kg/mm²) 23 24 25 26 30
Thermal conductivity W/m·K 35 32–37 33–38 34–39 35–40 36–42
Thermal shock resistance ΔT °C 222 223 224 225 228
Maximum use temperature (no load) °C ≤1750 1755 1760 1765 1770 1800
Coefficient of thermal expansion 10⁻⁶/°C 8.4
Specific heat J/kg·K 880
Volume resistivity Ω·cm >1×10¹⁴ >1×10¹⁴ >1×10¹⁴ >1×10¹⁴ >1×10¹⁴ >1×10¹⁴
Dielectric constant (relative permittivity) 9.8 9.83 9.84 9.85 9.86 9.92
Dielectric strength kV/mm 16.9 23.2 23.4 23.6 23.8 24
Dissipation factor (loss factor @ 1 kHz) 0.0002

 

Alumina Sand Mill Agitator Disc Specifications

Alumina Ceramic Disc
Item No. Outer Diameter(mm) Inner Diameter  (mm) Height (mm) Purity
AT-SM-001 90 30 26 95%-99%
AT-SM-002 90 36 24 95%-99%
AT-SM-003 100 45 30 95%-99%
AT-SM-004 140 80 45 95%-99%
AT-SM-005 165 85 50 95%-99%

 

Alumina Agitator Disc For Sand Mill Packaging

  • Each alumina sand mill agitator disc is wrapped in soft protective material to protect the ceramic surfaces and machined hub from impact.

Alumina Agitator Disc For Sand Mill Packaging

Applications of Alumina Sand Mill Agitator Disc

  • Industrial Paint and Coating Production

    ✅Key Advantages

    1. Stable particle size control
    Alumina sand mill agitator disc maintains consistent grinding conditions, supporting narrow particle size distribution in architectural and industrial coatings.

    2. Reduced color shift and contamination
    The ceramic disc helps reduce metal contamination compared with steel agitator discs, which is important for light-colored and sensitive paint systems.

    3. Longer maintenance intervals
    High wear resistance of the alumina disc supports longer campaigns between planned shutdowns in multi-shift coating plants.

    ✅ Problem Solved

    A mid-size coating plant running a disc-type sand mill on high-solids enamel reported frequent agitator disc wear with metal parts, requiring replacement every 3–4 months. After switching to an alumina sand mill agitator disc, the disc replacement interval extended to about 8–10 months while maintaining target particle size. The plant reduced unplanned downtime hours per year and lowered the combined cost of spares and maintenance labor across several coating lines.

  • Printing Ink and Pigment Dispersion

    ✅Key Advantages

    1. Improved fine grinding of pigments
    Alumina ceramic agitator disc provides uniform energy transfer to small grinding media, supporting fine pigment dispersion for packaging and publication inks.

    2. Clean dispersion for high-strength color concentrates
    Low contamination helps maintain color strength and shade stability in high-concentration pigment pastes and masterbatches.

    3. Consistent performance across production batches
    Stable disc geometry and wear behavior support reproducible mill performance from batch to batch in high-throughput ink plants.

    ✅ Problem Solved

    A printing ink manufacturer using a horizontal bead mill for pigment concentrates experienced variable ΔE color differences and had to adjust dispersion time frequently. After replacing the original metal disc with an alumina sand mill agitator disc and matching disc geometry to the mill chamber, the company reported more stable grinding times and reduced rework rate on critical color shades, which improved line scheduling and delivery performance.

  • Lithium Battery Slurry and Functional Material Slurries

    ✅  Key Advantages

    1. Low metal contamination for electrochemical systems
    Alumina sand mill agitator disc reduces metal ion contamination risk in cathode and anode slurry preparation compared with metallic agitator discs.

    2. Compatibility with ceramic-lined grinding chambers
    The disc works with ceramic grinding chambers and high-density beads to support consistent slurry properties over long production runs.

    3. Good mechanical strength under high energy density
    High-strength alumina ceramic disc tolerates high tip speed and high energy input used in modern battery slurry bead mills.

    ✅  Problem Solved

    A battery material producer operating high-energy bead mills for cathode slurry reported concerns over metallic impurities from wear parts affecting downstream cell performance. By converting the grinding chamber to ceramic lining and installing alumina ceramic agitator discs, the plant reduced total metallic wear debris in the slurry and improved stability of slurry rheology during continuous operation, while keeping maintenance intervals aligned with planned shutdowns.

 

Alumina Sand Mill Agitator Disc Usage Instructions

  • Installation

    1. Check the shaft, keyway and hub surfaces for damage, burrs or contamination before mounting the alumina sand mill agitator disc.
    2. Align the disc bore and keyway carefully with the shaft key, and slide the disc gently into position without applying impact to the ceramic edges.
    3. Follow the original equipment tightening sequence for hub clamps, nuts or locking elements to secure the disc in its final position.
    4. Verify disc stack spacing and total length against the mill drawing so that clearances in the grinding chamber are maintained.

  • Operation

    1. Start the sand mill according to the manufacturer’s procedure, ensuring slurry is present in the chamber before the agitator reaches normal speed.
    2. Monitor vibration, noise and power draw after installing a new alumina ceramic agitator disc; unusual changes may indicate misalignment or foreign matter.
    3. Use grinding media size and filling ratio recommended for disc-type sand mills to avoid overloading the alumina disc surface.

  • Storage

    1. Store spare alumina sand mill agitator discs in dry indoor conditions, away from direct sunlight and strong temperature fluctuations.
    2. Keep discs in their original packaging or on padded racks to avoid contact between ceramic parts and metal shelves.
    3. Label storage locations with disc size, alumina grade and matching mill model to support fast and correct selection during maintenance.

  • Cleaning

    1. Clean used discs with compatible cleaning agents that do not attack alumina ceramic or corrode any metallic hub inserts.
    2. Avoid impact tools and sharp metal scrapers on the disc surface; use soft brushes or plastic tools to remove residues.
    3. Rinse and dry discs thoroughly if they are removed for inspection and will be reused.

  • Precautions and Common Misuse Points

    1. Do not hammer or force the alumina disc onto the shaft; use gradual and aligned mounting to avoid microcracks.
    2. Do not mix discs from different designs or thicknesses in a single stack unless the configuration is verified by engineering.
    3. Avoid running the mill with insufficient slurry or media, because dry running increases stress on the alumina ceramic disc and other components.

  • Three typical user issues and handling tips

    1. Issue: Disc cracking at hub after installation
    Likely cause: Misalignment or excessive force during mounting.
    Handling: Inspect shaft and keyway, verify tolerances and use controlled mounting tools; replace any disc with visible cracks.

    2. Issue: Higher vibration with new alumina agitator disc
    Likely cause: Incorrect disc orientation, tolerance mismatch or imbalance.
    Handling: Check bore and keyway fit, confirm disc stack order and orientation, and perform static balance check if required.

    3. Issue: Slurry performance changes after switching from metal disc
    Likely cause: Different flow pattern or energy input.
    Handling: Adjust media size, filling ratio or mill speed step by step and record settings until target particle size and rheology are reached.

FAQ – Alumina Sand Mill Agitator Disc

  1. Q: What is an alumina sand mill agitator disc used for?
    A: An alumina sand mill agitator disc is used in disc-type horizontal sand mills and bead mills to transfer energy from the shaft to the grinding media and slurry, supporting efficient wet grinding of coatings, inks, pigments, battery slurry and other suspensions.
  2. Q: How does alumina ceramic agitator disc compare with metal agitator disc?
    A: Compared with metal agitator discs, an alumina ceramic agitator disc offers lower metal contamination and higher wear resistance in abrasive slurries, while maintaining comparable energy transfer when the disc geometry is properly matched to the mill design.
  3. Q: Can the alumina sand mill agitator disc be used as a direct replacement in my existing bead mill?
    A: In many cases, the alumina sand mill agitator disc can be produced as a direct replacement by matching outer diameter, bore, keyway, thickness and disc profile to the original design, based on drawings or measured samples from your current disc.
  4. Q: What information is needed to design a custom alumina agitator disc for sand mill?
    A: Typical information includes mill model, disc stack drawing, shaft diameter and keyway, required outer diameter and thickness, disc spacing and any special flow channel features; photos and worn disc samples can also help define the alumina ceramic agitator disc.
  5. Q: How long does an alumina sand mill agitator disc usually last in production?
    A: Service life depends on slurry abrasiveness, media type, mill speed and operating conditions; in many coating and ink applications the alumina disc can provide significantly longer life than metal discs under similar conditions, which should be verified through plant trials.
  6. Q: Are there size limitations for alumina sand mill agitator disc manufacturing?
    A: Practical size ranges depend on the ceramic forming process and kiln capacity, but alumina sand mill agitator discs for laboratory mills up to large industrial mills can typically be supplied when thickness and diameter are designed within mechanical limits.

Alumina Sand Mill Agitator Disc Reviews

  • ⭐️⭐️⭐️⭐️⭐️
    After replacing the original metal parts with an alumina sand mill agitator disc from ADCERAX, our coating line reduced unplanned downtime and achieved more stable particle size in high-solids systems.
    -- Michael R., Maintenance Manager, EuroCoat Industries
  • ⭐️⭐️⭐️⭐️⭐️
    The custom alumina ceramic agitator disc that ADCERAX supplied matched our bead mill shaft and chamber exactly, so installation during shutdown was straightforward and the mill restarted on schedule.
    -- Hana K., Process Engineer, Nippo Ink Solutions
  • ⭐️⭐️⭐️⭐️⭐️
    We use alumina sand mill agitator discs together with zirconia beads in our lithium battery slurry mills. The parts from the ADCERAX factory have shown consistent quality and predictable wear behavior across multiple batches.
    -- Daniel L., Production Supervisor, PowerCell Materials
  • ⭐️⭐️⭐️⭐️⭐️
    Our service team maintains sand mills for several regional customers and now keeps alumina ceramic agitator discs in stock. The discs provide a convenient upgrade option when clients ask for longer life and lower contamination in their grinding systems.
    -- Laura S., Service Director, ProGrind Equipment Services
customize size

Custom Alumina Sand Mill Agitator Disc

ADCERAX provides customization for alumina sand mill agitator disc so that the disc geometry, dimensions and interface details match your specific bead mill shaft and chamber design.

1. Disc dimensions

  • Outer diameter, inner bore diameter and disc thickness
  • Tolerance options for bore and critical faces (for example, ±0.02–0.05 mm depending on size)

2. Hub and shaft connection

  • Straight bore, keyed bore, spline bore or clamping hub interface
  • Keyway width and depth, flat sections or drive pins

3. Disc geometry and openings

  • Number and shape of pumping slots or ports
  • Front and rear face profiles for flow guidance
  • Disc spacing and stack configuration along the shaft

4. Material and grade options

  • 95% alumina or higher alumina grades for different abrasion and contamination requirements
  • Optional surface finish on media-contact areas

5. Quality and inspection details

  • Dimensional inspection points and reports
  • Static balance or balance-ready requirements

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