Designed by Prometals Ligas de Aço for demanding special fibers. Benefit from precise cutting edges, optimized grooves for chip evacuation, and metallurgy tuned for abrasion and impact.
- Controlled particle size distribution and fiber opening
- Stable operation with reduced torque spikes
- Extended disc life and predictable maintenance windows
GAIA patterns balance cutting intensity and flow to handle heterogeneous, elastic, or mineral-loaded fibers.
- Edge architecture: reinforced primary edges with micro-bevels to mitigate torque spikes and edge chipping.
- Groove topology: deep, tapered grooves for chip evacuation; anti-pack ribs to prevent matting.
- Open area ratio: tuned for shear stability at variable consistencies (2–10%).
- Hardfacing & heat treatment: alloyed wear zones with impact-tough cores.
- Back relief and cooling notches: reduce heat build-up on rubber-rich feeds.
- Throughput: up to 15–40% higher vs. generic discs on differential feeds (depending on fiber mix and consistency).
- Particle size distribution: D50 typically 0.8–2.5 mm for leather/fibrocement targets; narrow tailing.
- Specific energy: 10–25% reduction at matched PSD vs. legacy patterns.
- Stability: measured torque variance reduction up to 30%.
- Wear life: extended service intervals with predictable overhaul cycles.
Results are indicative; final values depend on machine model, plate clearance, stock consistency, and thermal conditions.
Supported equipment families include single-disc, double-disc, and conical refiners/defibrators from major OEMs. GAIA discs are produced to OEM interfaces or per drawing.
- Outer diameters: 300–1340 mm
- Hub/bolt interfaces: per OEM spec or custom retrofit
- Segmented and monoblock options
- Handedness: left/right with matched flow orientation
- Custom geometries for pilot lines and R&D
- Base alloy: high-Cr white iron with proprietary modifiers for abrasion and impact balance.
- Surface treatment: selective hardfacing on leading edges; shot-peened stress relief.
- Thickness: typical 25–65 mm; reinforced hubs for large diameters.
- Operating window: 2–10% consistency; temperature guidance below.
- Quality: 100% inspected geometry; dynamic balancing per ISO.
- Feeding: ensure even feed and controlled tramp removal; pre-size elastomer pieces to avoid wrap.
- Consistency: start at 4–6% for mixed streams; adjust for target PSD and energy.
- Clearance control: ramp-in with thermal stabilization; monitor torque and vibration bands.
- Temperature: maintain below 70–80°C for rubber-rich blends; use cooling loops as needed.
- Condition monitoring: log PSD, energy/kWh/t, and torque variance to dial-in settings.
Composite panel producer processing leather offcuts and mineral loads.
- Objective: tighten PSD and reduce energy.
- Outcome: D50 from 3.2 mm to 1.9 mm; specific energy −18%; torque variance −24%.
- Notes: implemented micro-bevel pattern with anti-pack ribs; service interval +22%.
Explore guidance on refining non-wood and specialty fibers in our Technical Catalogs and related articles.
- Technical Catalog: GAIA Discs for Differential Fibers
- Featured article: Refining Differential Fibers—Leather, Rubber, and Fibrocement
For deeper process optimization, see our Services overview.