High-shear, high-speed mixing equipment supplies the mechanical energy necessary to reduce the size of solid particles and liquid droplets in emulsions and dispersions. As a family-owned and family-run business, Hielscher prioritizes highest quality standards for its ultrasonic processors. Choose Zip at checkoutQuick and easy. The mixing head that can be lifted and suspended to serve many vessels can also be set for batch high shear mixers. All sonotrodes and reactors, which are the only parts that get in contact with the medium, are CIP/SIP (cleaning and sterilization in place). Vibrating at 20 kHz means that the horizontal surface of the probe is expanding and contracting 20, 000 times per second.
Petrochemicals: heavy oil emulsification, diesel emulsification, lubricating oil, etc. Ross inline high shear mixers from 1 through 250 HP accelerate mixing, emulsification and homogenization in both recirculation and continuous modes. Installation Examples. As the material leaves the rotor, the stator generates an exceptionally high-shear zone by forming a small clearance gap between the rotor and itself. Time- & energy-efficient.
Rotor/Stator Mixers are generally applied on products that are up to approx. A Mayonnaise batch should take not more than 10 – 25 Min, and a single -pass is preferred through the high shear mixer is preferred. Advantages include simple operation, high throughput rates, consistent product quality, easy cleaning procedure and low maintenance. Assay of Pharmaceutical Products.
High Shear Mixers Overview. Contact us for more info. Portable high-shear mixing solution thanks to light weight and benchtop form factor. Its counter rotating blades reach every corner of the tank, ensuring that all product passes evenly through the Dynamic HS mixing head, resulting in a homogenous end product regardless of viscosity. When all the oil has been added to the mixer, the vinegar is added. Cosmetics and Toiletries.
Literature / References. Adherence to the CGMP regulations assures the identity, strength, and quality of manufacturing operations. A feed tube adjacent to the back of the rotor provides a path to inject solids directly into the stream. Daily-use chemicals: laundry powder, concentrated laundry powder, liquid detergent, all kinds of cosmetics, skin care products, etc. The main design considerations are the rotor's diameter and rotating speed, the separation between it and the stator, the amount of time spent inside the mixer, and the number of generators used. All product-contacting parts have been designed and constructed for fully hygienic operation, and are made from stainless steel and FDA-approved materials. High shear mixers, also known as high shear reactors (HSRs), rotor-stator mixers, and high shear homogenizers, are used to emulsify, homogenize, disperse, grind and/or dissolve immiscible mixtures with components of the same or different phases... Homogenizer. The ROSS X-Series Inline Ultra-High Shear Mixer produces quality dispersions, suspensions, and emulsions in a variety of industries.
PerMix has been manufacturing mixing and blending equipment since 1954 for the pharmaceutical, nutraceutical, cosmeceutical, food, and chemical industry. Consider upgrading your emulsification and homogenization processes to an ultra-high shear mixer to obtain finer droplet sizes and handle higher viscosity emulsions. No nozzles / no clogging. A batch that has been agitated and deaerated under vacuum winds up denser than it was initially. Can it perform faster production with less to no downtimes, promote uptimes, and maintain the best product quality? As a result, vortices are produced at the bottom of the mixing head. If practical, visit the laboratory of a reputable mixer manufacturer and test-run a Multi-Shaft Mixer using your own raw materials, replicating your process environment as closely as possible. Until now mills and homogenisers have been used for production of high quality emulsions. 4 Reviews (75% Positive). Thomas Leong, Muthupandian Ashokkumar, Sandra Kentish(2011): The Fundamentals of Power Ultrasound. To form the oil-in-water (O/W) emulsion, the oil needs to be broken up into small droplets. As a result, the next batch of products may contaminate the initial batch's leftovers. A range of materials of construction.
In contrast, less-powerful rotor-stator batch mixers usually take longer to process ingredients. Since the Inline High Shear Mixer runs in a continuous manner and is a more compact configuration than the Batch High Shear Mixer, it is more suitable and recommended for manufacturing plants with limited space. In addition, the rotor is precisely shaped to produce a high pumping capacity and shear intensity. New technologies for continuous mixing and homogenization of nano-filled materials. With vacuum we can quickly take the batch material through a series of changes in physical state – from slurry to a paste, and from a paste to a granulation or dry powder. Types: Continuous Type Inline Shear Mixer & Batch Type In-Tank Shear Mixer. The product in your process is dispersed, sheared, refined, crushed, emulsified, mixed, and homogenized by the layers of rotor and stator, making a smaller particle size than a regular single-stage or two-stage mixer. The traditional design features a four-blade rotor running at tip speeds in the range of 3, 000–4, 000 ft/min within a close-tolerance fixed stator. This design promotes good flow and minimizes the possibility of dead spots where unmixed materials can collect. The material enters through an inlet connection and by centrifugal force is accelerated outwards. The mixing head, or generator, is the collective term for the rotor and stator.
High shear rotor/stator mixers are commonly used in the production of emulsions. Unique mixer design. Ross High-Shear Mixers are specifically designed to achieve these kinds of liquid and solid blends, whether it is by emulsification, wetting out, shearing or disintegrating powdfrom variousious advanced rotor/stator combinations. Our Standard design includes features such as: - Explosion proof inverter duty motors. High shear mixing subjects the liquids to intense high-energy which reduces the droplet size sufficiently and allows the two phases to combine, resulting in a stable emulsion which will not separate once the shear energy has been removed. For example, this vessel could be a batch mixer or a straightforward mixing chamber. Lab-scale mixers are vital in the design or small-batch production of a range of pharmaceutical products. Intensive maintenance. This equipment is used in beverage, food processing, dairy, pharmaceutical, cosmetic, and fine-chemicals industries. A useful tool to lower the temperature of your batch material by evaporation. Emulsions, suspensions, and granular products can all be made using a high-shear mixer.
Biological pharmaceutical industry: tissue, cell body grinding, injection; antibiotics; drug ointment; microcapsules emulsion; Cosmetics Industry: Emulsion various facial cream, lipstick, liquid detergent, Ximian Nai, skin care products, shampoo; Chemical industry: resin emulsion, surfactant, carbon black dispersion; dye coating. 10 to 100L/min||UIP16000|. High-Shear Mixers / SLIM. Which method and tools are right for your mixing needs? Rotor tip speeds between 3, 000 to 4, 000 ft/min are typical. In addition, the number of rows, angle, and width of the spaces between the teeth are all variables. Disintegrator Dissolver is ideal for dis-integrating, dissolving, solubilizing, dispersing and homogenizing the coarse solid granules directly into the material.
But when dealing with challenging emulsions that conventional rotor/stator mixers cannot successfully produce, manufacturers are compelled to switch to more aggressive, higher energy devices such as colloid mills and high pressure homogenizers. The material goes through several cycles, thus completing the process of dispersion, emulsification and homogenization. During each transit through the rotor-stator, the material is subjected to a succession of increasingly intense shearing events -until it finally exits downstream, or is recirculated for another pass through the mixer. Others recirculate product back through a batch reactor for a 3-5 minute total blend time. As a result, the homogenization of scattered particles and liquids into a continuous phase happens more quickly. Fast inherent reaction rates. Intensively Designed, Engineered and Manufactured in a Packaged Deal Fit for Many Industrial Factories.
The emulsifier has a wide range of applications, such as adhesives, paints and coatings, cosmetics, food, pharmaceuticals, plastic resins, printing and dyeing, ink, asphalt and other industries. It also allows you to refine your mixing technique an important step in optimizing the performance of any mixer. The pros and cons of homogenizing. Ultrasonic cavitation has a strong impact on solid particles: The cavitational liquid streams erode the surface of solids and transports the eroded fragments into the liquid producing thereby a homogeneous suspension. With less to no air entering the system, cavitation or formation of bubbles in a liquid, which causes blade damage, is prevented. This is usually common in manufacturing cements or epoxy-based composites when they are subjected to stress. Viscous mixes are where this issue is most obvious. The top of the vessel is often where the components are charged. Lab Scale Dynashear. For more information about our products and how they can best serve you and your business needs. With the UIP16000, Hielscher offers the most powerful ultrasonic high-shear mixer worldwide. In some applications, quality control is generally concerned with average particle size, while others follow strict standards pertaining to the largest diameter particles permitted in a suspension. The overall mixing system forms a close loop, meaning it prevents unwanted air from entering into the system. Shritara Engineers & Project Consultants.
Ultrasonic high-shear mixers easily produce nano-sized particles and droplets with a very narrow particle / droplet size distribution. 3A-approved sanitary models are available with tri-clamp inlet/outlet connections and a one-piece stator/chamber cover for even quicker disassembly and clean-up. MIDC, Ambad, Nashik-10, Nashik. This is a common processing method for cosmetics, creams, shampoos, sunscreen and ointments. Air/oil hydraulic lift.
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