Vacuum MIXER HOMOGENISER
GENERAL
Vacuum mixer homogenizer is a vacuum mixer for the manufacturing of viscous emulsions and suspensions in the cosmetics, pharmaceuticals, food and chemicals industries. It is especially suitable for making big batches of cream and emulsions with big quantity powders.
COMPONENTS
It is usually made of main mixer homogenizer, oil phase mixer, water phase mixer, vacuum system, hydraulic lifting system, materials circulation system, heating and cooling system, temperature control system, electrical control panel etc.
The main mixer homogenizer is composed of a high speed high shear homogeniser mounted from the bottom of the vessel, wall scraper and two fixed propellers with holes.
The bottom homogenizer consists of one three-layer toothed rotor and one two-layer toothed stator. An external circulation pipe comes along the tangent of rotor and connects to the top edge of the tank body.
The oil and water phase mixers have exactly the same construction. There is a high speed dispenser mounted from the top of the cover which helps dissolve the ingredients. Some customers will omit the oil and water phase mixers and keep the main mixer homogenizer only.
WORKING PRINCIPLE
During the mixing operation, the outer anchor agitator rotates clockwise slowly. With the attached Teflon blades, the materials are scraped off the vessel wall and move upwards so they will not always stick to the wall and burn.
At the same time the two fixed impellers keep still and give the materials a counterforce and drive the cream downward into the high speed homogenizing and emulsifying zone. The cream goes through the holes on the paddles and increases mixing effect.
Because of the two opposite forces by fixed impellers and wall scraper, the cream rolls over the vessel from top to bottom and back to top repeatedly. When the cream is completely mixed, the heat from the jacket is quickly transferred to every part through the inside wall.
The heart of vacuum mixer homogeniser is bottom homogenizer (emulsifier) which consists of one three-layer toothed rotor and one two-layer toothed stator. The design is different from the homogenizer in vacuum emulsifying mixer and is much better.
The rotor is connected with homogenizing motor by a synchronous belt with the shaft ratio of 1:1.2. The ABB or Siemens motor rotates at the speed of 3000rpm and drives the rotor to rotate up to 3600rpm producing strong suction force.
The materials go into the rotor from top opening of the homogenizer and are cut, sheared, emulsified and homogenized through the shear gap between the rotor and stator. Then they are accelerated to jet out through the pipeline along the tangent of the rotor. The cream runs inside the external circulation pipe and goes back to mixing tank for the slow mixing or another emulsification and homogenization.
The above two types of slow and high forces repeat and repeat. And the cream can be circulated through the pipeline and are completely mixed, dispersed, emulsified and homogenized.
Water ring type vacuum pump (-0.097Mpa) is powerful to pull out the bubbles generated during mixing, dispersing and homogenizing. It also helps transfer the ingredients from the oil and water phase mixers to the main vacuum mixer homogenizer. The small quantity perfumes are also sucked by vacuum to avoid dust.
Oil hydraulic pump is used to lift the cover of main vacuum mixer homogeniser. Safety device is equipped to guarantee that the mixing part will not start when the cover is lifted.
FEATURES
- Complete process of mixing, dispersing, emulsifying, homogenizing, vacuum, heating and cooling in one unit
- Working capacity from 50L to 10000L
- Suitable for cream and emulsions of 50000~80000cps viscosity
- Perfect particle size of 2 micrometers and evenly distributed
- External emulsifying and homogenizing by bottom homogenizer with pipes
- Cooling system for mechanic seal inside the homogenizer for longer homogenizing time
- Split type homogenizer with synchronous belt to better protect motor
- The homogenizer also works as a transfer pump for discharging finished product
- Contra mixing system of fixed impellers with holes and wall scraper
- Outer anchor agitator has pipe design for enhanced mixing and good appearance
- Variable speed for homogenizer and agitators
- Oil hydraulic lifting system for easy cleaning and maintenance
- Double jackets for heating and cooling
- Different jacket designs available for steam and electric heating
- Double temperature probes and controllers for electrical heating in main vacuum mixer homogeniser
- Vacuum system to take out the air bubbles during mixing and to transfer the ingredients
- Compressed air to help discharge the finished cream
- Multiple safety protection devices for vacuum, hydraulic pump and workers
- All contact parts are made of SS316L and mirror polished
- Spray ball is equipped to connect to customer CIP system
- The specifications of the vacuum mixer homogenizer comply with cGMP regulations
- Push buttons control panel for easy operation
- Power supply of 415V, 50Hz, 3 Phase
Options
- Fixed cover with bolts or welding to save budget
- Different slow mixing part designs available
- Extra openings on the bottom homogenizer for adding hot and cold ingredients and powders
- Panasonic or Siemens PLC for automation of mixing, dispersing, emulsifying, homogenizing, vacuum, transferring, heating and cooling etc
- Mettler-Toledo load cells
- Pressure vessel design for different steam pressure
- SIP is available upon request
APPLICATIONS
Cosmetics & Toiletries: cream, lotion, toothpaste, wax, mascara, and gel
Pharmaceuticals: ointment, dental composite, syrup, injection
Food: mayonnaise, dressing, jam, butter, margarine, wasabi
Chemicals: polyester, synthetic fiber, shoe cream