Direct Feeding Without Pre-Cutting
Integrated cutting and dissolving allows full-size polymer blocks to be fed directly, reducing pre-processing, manual handling, production time, and operating costs.
What Is a VI/VM Dissolving System?
A VI/VM Dissolving System is an automated equipment unit designed to process solid or high-viscosity polymer additives into pumpable and measurable liquid additives. It is widely used in lubricant, grease, and fine chemical production. Through heating, agitation, high-speed shearing, and recirculation, the system dissolves and disperses block, flake, or powdered polymers, viscosity index improvers (VI Improvers), and viscosity modifiers (VM) in base oil or other liquid media, producing a uniform and stable additive solution for downstream batching, blending, and transfer.
BJVP VI/VM Dissolving Systems are engineered according to material properties, formulation requirements, and production capacity. Automated controls can be integrated to manage feeding, dissolving, recirculation, and material transfer for stable and consistent operation.
Integrated High-Speed Dissolving System
Large polymer blocks can be fed directly without pre-cutting for efficient dissolving.
Advantages of the BJVP High-Speed Dissolving System
No pre-cutting required, with dual shearing and heated recirculation for efficient dissolving and homogenization of polymer and VI/VM additives.
Dual Shearing for Faster Dissolving
A bottom high-speed shear unit and an inline high-shear mixer create a dual-shear recirculation loop to accelerate the breakup, dispersion, and dissolving of polymer blocks and additives.
Heating and Temperature Control
The dissolving tank features external heating coils and temperature control, with hot oil or steam heating options. Heated recirculation shearing improves dissolving efficiency.
High Batch Processing Capacity
The system can process approximately 10–20 tons of wet polymer gel per batch, with a typical cycle time of 4–8 hours depending on material properties and process requirements.
Accurate Dosing and Consistent Formulation
Base oil weighing and dosing systems provide accurate material addition, supporting stable downstream batching, blending, and product quality.
Skid-Mounted Integrated Design
The system integrates the dissolving tank, shear equipment, dosing system, loading lift, discharge pump, and control system in a skid-mounted package for easier installation and commissioning.
High-Shear Pump for VI Dissolving
The High-Shear Pump is a key component of the BJVP High-Speed Dissolving System, designed for material recirculation, high-speed shearing, breakup, and dispersion. High-speed rotation generates strong shear forces to break down and disperse polymers, VI/VM improvers, and other solid or high-viscosity additives, accelerating the dissolving process and promoting uniform mixing.
The inline high-shear pump works together with the bottom high-speed shear unit to create a continuous recirculation loop. Repeated exposure to the high-shear zone improves dissolving efficiency and material uniformity. Combined with heating and temperature control, the system can reduce dissolving time and reliably process high-viscosity polymer additives for lubricant, grease, and chemical applications.
Top-Entry Agitated Dissolving System
The Top-Entry Agitated Dissolving System consists of a polymer cutter, lifting system, conveyor, agitated tank, and fume recovery system. It dissolves materials through block cutting, conveying, and top-entry agitation. A typical process is: Lift → Conveyor → Polymer Cutter → Agitated Tank. The system can be equipped with BJVP’s proprietary VI Dissolving Control System for centralized process control. Its stable operation and efficient material handling help reduce raw material losses, manual handling, and energy consumption.
Traditional top-entry agitation has a lower equipment cost, but the process flow is longer and solid materials require more time for conveying. In hot and humid environments, polymer blocks or powder can also become sticky and form agglomerates again, which can affect overall processing efficiency.
The integrated High-Speed Dissolving System combines cutting, shearing, heating, and agitation in one unit. Solid or powdered materials can be fed directly into the equipment without additional cutting and conveying. High-speed shearing and heated recirculation accelerate dissolving, reduce the risk of secondary agglomeration, minimize manual handling, and improve production efficiency and operating stability, particularly in hot and humid environments.
VI Polymer Cutting and Conveying System
VI polymer cutting, crushing, and conveying solutions for continuous feeding into downstream dissolving processes.
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Automatic VI Polymer Cutting and Conveying System
Automatically cuts and continuously conveys VI polymer material for stable feeding into downstream dissolving processes.
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VI Polymer Cutting and Conveying System
Combines polymer cutting and conveying for continuous feeding and stable material transfer to downstream dissolving equipment.
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VI Powder Polymer Crushing Conveyor
Crushes and conveys powdered VI polymer to provide more uniform particle size for efficient downstream dissolving.
Automatic VI Polymer Crushing and Conveying System
The VI polymer crusher automatically breaks large polymer blocks into smaller pieces for downstream dissolving, helping accelerate the process and improve dissolving consistency.
Our Services
Technical services covering process design, system selection, equipment manufacturing, commissioning, and after-sales support.
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Process Design
We design dissolving processes and system solutions based on material properties, dissolving requirements, throughput, and operating conditions.
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System Selection
We configure agitation, heating, conveying, and automatic control equipment according to material properties and production requirements.
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Equipment Manufacturing
We handle equipment fabrication, assembly, and factory testing in-house to control manufacturing quality and ensure reliable system performance and delivery.
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On-Site Commissioning
We provide installation guidance, on-site commissioning, and operation support to ensure stable system performance and meet actual production requirements.
VI Dissolving System FAQs
Common questions about High-Speed Dissolving Systems, top-entry agitation, equipment configuration, and system selection.
What Is a Dissolving System?
A VI Dissolving System is an automated system that processes polymer blocks, gels, high-viscosity polymers, and other solid additives into uniform liquid additives through heating, agitation, or high-speed shearing. It is widely used in lubricant, grease, and chemical production.
What Is the Difference Between High-Speed Dissolving and Top-Entry Agitation?
A High-Speed Dissolving System uses bottom high-speed shearing to break up, shear, and disperse materials during dissolving, allowing polymer blocks to be processed more efficiently. Top-entry agitation mainly relies on mixing and recirculation, with limited breakup and shearing capability, so polymer blocks are typically cut into smaller pieces before heating and agitation.
Does a High-Speed Dissolving System Require a Polymer Cutter?
Not necessarily. The High-Speed Dissolving System has a bottom high-speed shear unit that can break down polymer blocks during dissolving, so a polymer cutter is optional. Adding a cutter can further reduce block size, shorten dissolving time, and improve processing efficiency.
Why Does a Top-Entry Agitated Dissolving System Require a Polymer Cutter?
Top-entry agitation is mainly used for material mixing and circulation, with limited breakup and shearing capability. Processing full-size polymer blocks directly can result in longer dissolving times. Therefore, top-entry agitated systems typically use a cutter or crusher to reduce block size before heating and agitation.
What Materials Can a Dissolving System Process?
Depending on the process configuration, a Dissolving System can process polymer blocks, gels, waxy additives, high-viscosity polymers, powders, and granular additives. The choice between top-entry agitation and bottom high-speed shearing depends on material viscosity, physical form, and dissolving characteristics.
How Do You Choose Between Top-Entry Agitation and Bottom High-Speed Shearing?
Selection depends on material type, block size, viscosity, production cycle, capacity requirements, energy consumption, and project budget. Top-entry agitation can be used for conventional materials and production processes, while bottom high-speed shearing can be considered for high-viscosity polymer blocks or applications requiring faster dissolving.
What Are the Advantages of an Automated Dissolving System?
An automated Dissolving System can control material conveying, cutting, heating, agitation, shearing, and feeding processes, reducing manual handling and operating errors while improving production safety, product consistency, and efficiency. The system can also be integrated with PLC, MES, DCS, and SCADA control systems.
Get in Touch
Contact us to discuss your project requirements and find suitable manifold, pigging, and fluid handling solutions.