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The colloid mill is a kind of machine for fine milling of fluid and semi-fluid materials. It has excellent superfine pulverization, dispersion, emulsification, homogenization and mixing. With this device, particle size of raw material can reach 2-60 microns after processing, and the homogeneity can reach more than 95%. Therefore, it is an ideal equipment for ultra-micro processing.
Compared with pressure homogenizers, firstly colloid mill is a centrifugal equipment. Secondly, it has the advantage of simple structure and easy maintenance. In addition, it is suitable for high viscosity materials and materials with large particles. The machine combines the various properties of ball mills, three-roll mills, mixers and other machinery. Meanwhile its efficiency is several times that of the above-mentioned machinery.
SeFluid has years of experience in the production of colloid mills and are capable of manufacturing various specifications and types of colloid mills to meet different customer needs. Over the years, our products have been exported to all over the world, and with excellent quality and good service, they have received high praise from our customers.
On SeFluid's colloid mill series, a motor drives a rotating tooth (or rotor) through a belt drive. And, the rotor rotates at high speed against a matching stationary stator. The processed material is pressurized by its own weight or by external pressure (which can be generated by a pump). As a result, a downward spiral impact force occurs. The material flows through the gap between the fixed and rotating teeth (adjustable gap).
Meanwhile the material is subjected to strong shear forces, friction, high frequency vibrations and high speed vortices. As a result, it is effectively emulsified, dispersed, homogenized and crushed. Ultimately, the effect of ultra-fine crushing and emulsification of materials is achieved.
Except for the motor, all parts in contact with the processed material are made of high strength stainless steel. Most importantly, the key grinding components, both rotator and stator are reinforced. Therefore the parts have good corrosion and abrasion resistance. So, processed material is pollution-free and hygienically pure.
Features of SeFluid's Colloid Mill Series
High-precision milling assembly and tight hard gear structureAdjustable particle size, easy for regulationGood sealing, stable performance and convenient operationAdopt quick-fit joints, easy to install, easy to disassemble and cleanSquare or tubular discharge port for various user optionsDouble reinforced base, excellent stability, stable operation
Applications of Colloid Mill
The colloid mill is a versatile machine that is used in a wide range of industries to process materials such as emulsions, suspensions, and other similar products. Here are some of the common applications of the colloid mill:
Food Industry
It is widely used in the food industry to produce emulsions, such as mayonnaise, salad dressings, and sauces. It is also used to produce peanut butter, almond butter, and other nut butters. In addition, the colloid mill is used in the production of dairy products such as cheese, yogurt and cream.
Pharmaceutical Industry
The machines are used in the pharmaceutical industry to produce suspensions, gels, and creams. They are also used to produce ointments, lotions, and other topical products. The colloid mill is ideal for producing pharmaceutical products because it can produce small particle sizes and a uniform particle size distribution.
Chemical Industry
Colloid mills are used in the chemical industry to produce pigments, paints, and other similar products. It is also used to produce adhesives, lubricants, and other industrial products.
Cosmetic industry
This type of mills is ideal for the cosmetic industry to produce creams, lotions, and other similar products. It is also used to produce makeup products such as lipstick, mascara, and foundation. They are ideal for producing cosmetic products because it can produce small particle sizes and a uniform particle size distribution.
Biotech industry
The colloid mill is used in the biotech industry to produce cell suspensions, protein solutions, and other similar products. It is also used to produce vaccines and other biopharmaceutical products. The colloid mill is ideal for producing biotech products because it can produce small particle sizes and a uniform particle size distribution.
Petroleum Industry
It is used in the petroleum industry to produce drilling muds and other similar products. It is also used to produce lubricants and other industrial products. The machines are ideal for producing petroleum products because they can handle a wide range of materials and produce small particle sizes.
In addition, colloid mill is used in many other industries such as paper and pulp, textile, and mining. It can also be used in research and development laboratories to produce small batches of products for analysis.
The inline high shear pump is a kind of high efficiency mixing equipment. It can improve the mixing efficiency by more than 90% than an agitator. Meanwhile, it has a better mixing effect. This mixer is a precision combination of rotor and stator. The rotor/stator assembly generates strong shearing force in high-speed rotation.
So, inline high shear pump can achieve the purpose of mixing, crushing and emulsifying. This efficient in-pipeline dispersing equipment can continuously process materials and eliminate the quality difference between batches. The basic structure consists of a pump cavity and a pair of fixed rotors. SeFluid's inline high shear pump series can mix mediums with different substance phases efficiently and evenly. And the substance phases become mutually insoluble.
The basic working principle of an inline high shear pump involves the following steps:
Fluid Intake
The pump is connected to a fluid source, typically through an inlet pipe. The fluid enters the pump through the inlet and is directed towards the rotor/stator assembly.
Rotor-Stator Assembly
The key component of an inline high shear pump is the rotor-stator assembly. The rotor consists of a rotating shaft with multiple blades or teeth, while the stator is a stationary part with corresponding grooves or channels. The rotor and stator are precisely engineered to create a narrow gap between them.
Centrifugal Force
As the fluid passes through the narrow gap between the rotor and stator, the rapidly rotating rotor blades create a strong centrifugal force. This force pushes the fluid outward towards the stator, creating a high-velocity flow.
Mechanical Shearing
As the fluid moves through the gap, it experiences intense mechanical shearing forces. The shearing action is a result of the interaction between the rotor and stator blades, which continuously cut and disperse the fluid into small particles or droplets.
High Shear Zone
Within the narrow gap, a region of high shear is formed. This high shear zone subjects the fluid to intense turbulence, which effectively breaks down larger particles or aggregates, promotes mixing, and ensures thorough dispersion.
Homogenization and Emulsification
The combination of centrifugal force and mechanical shearing action leads to the formation of fine emulsions and homogeneous mixtures. The high shear pump effectively reduces particle size, eliminates agglomerates, and creates a uniform distribution of components within the fluid.
Fluid Discharge
Once the fluid has passed through the rotor-stator assembly, it is discharged through an outlet pipe. The resulting homogenized or emulsified fluid can be used in various industrial processes, such as food processing, pharmaceutical manufacturing, chemical production, and more.
Features of Inline High Shear Pump
1
Large processing capacity, high efficiency.
2
Ideal for inline continuous production.
3
With self pumping ability.
4
Applicable for automatic system.
5
Eliminate differences quality between batches.
6
Narrow particle size, high particle uniformity.
Shear Part of Inline High Shear Pump
According to different material properties, we can choose different shearing parts for the machine. In most cases, toothed stators and rotors can meet the needs of most applications. However, for some special materials, the rotor may need to be a shear impeller style, while the stator may need to be a round hole, a grid hole or a belt hole shape to meet different mixing applications. The spacing between the stator and rotor is very close, usually less than 0.5mm.
Accessories of Inline High Shear Pump
Cooling System
During the homogenization of some materials, a large amount of heat is generated. If this heat is not removed in time, it may affect the quality of the final product. On our mixer heads, an optional cooling jacket is available to avoid this.
Sampling Valve
During the mixing process, it may be necessary to sample the material being homogenized. In addition, after the homogenization process is completed, the residual liquid in the working chamber needs to be removed for the next operation. For this reason, spare valves are preset at the bottom of our machine heads for easy sampling inspection and removal of residual liquids.
Protective Cover
Some materials, especially corrosive materials, may splash and contaminate the machine during the operation of the machine. To this end, we equip each inline high shear pump with a splash guard cover to keep the machine running safely.
Applications of Inline High Shear Pump
With advances in mixing technology, inline high shear pump has become one of essential mixer categories in many industries today.
Mixed Dissolution
Soluble solid or liquid and liquid are dissolved together in a molecular or colloidal state. Crystalline powder, salt, sugar, ether sulfate etc.
Dispersed Suspension
Incompatible solids and liquids form smaller particle size mixtures or suspensions. Catalysts, matting agents, pigments and paints.
Homogenization
Make emulsification and suspension particle size smaller and more evenly distributed. Cream, condiments, juice, jam, cheese.
Emulsification
The non-phase solution of the liquid cream. Ice cream, animal oil, vegetable oil, protein, silicone oil or light oil, mineral oil.
High speed disperser is a type of mixer that can quickly and efficiently disperse solid particles or soluble solids in a liquid medium. It works by transferring energy from a rotating disc blade to the mixture, creating shear forces that break down the agglomerates and aggregates of the solids.
SeFluid's high speed disperser series is very suitable for high-speed mixing and processing of dispersion. The products are widely used in various industries, such as paints, coatings, inks, cosmetics, pharmaceuticals, and agrochemicals.
The principle of a high speed disperser is based on the generation of high shear forces in a liquid medium. The disperser consists of a motor, a shaft, and a blade that rotates at high speeds to create a shearing and turbulence effect in the liquid medium.
When the blade rotates, it creates a vortex in the liquid medium, drawing in the materials to be dispersed. As the materials are drawn into the vortex, they are subjected to high shear forces generated by the blade. The high shear forces cause the materials to break apart and disperse in the liquid medium.
The disperser blade is designed to generate high shear forces by accelerating the materials to high velocities and then decelerating them rapidly. This creates a shearing effect that breaks down agglomerates and ensures uniform distribution of materials in the liquid medium.
The speed of the disperser blade can be adjusted to control the intensity of the shear forces. Higher speeds result in more intense shear forces, while lower speeds result in less intense shear forces.
High speed dispersers are often used in combination with other mixing equipment, such as tanks or vessels, to ensure efficient mixing and dispersion of materials. The liquid medium may also be heated or cooled to optimize the mixing process.
Feature of High Speed Disperser
Safe and Convenient Operation
Hydraulic cylinder for controlling working head's up/stop/down; Easy to clean, disassembly and replace the dispersing blade; Various blades for different mediums. Different clamping types (Belt Clamping, Manual Rotation Clamping, Pneumatic Clamping) for fixing tanks.
Higher Efficiency
SeFluid hydraulic high speed disperser series have a speed up to 2930rpm, and the linear velocity is over 20m/s. Our machines can rapidly disperse the powder in the liquid evenly. Due to its high shear forces, the material will be uniformly dispersed and formed a good suspension effect.
Various Installation Way
Multiple installation modes are available: Floor type, platform type and in tank type installation for options.
Wide Range of Specification Option
Explosion-proof type, vacuum type, multi-tanks type, co-axial type and dual-shaft type; Material can be SS304SS321 SS316SS316L.
Applications of High Speed Disperser
In the production process of many industries, high speed disperser is one of the essential equipment. Especially in paint, coating and chemical industries, It is widely used. Here are some application examples:
Paint and Coatings Industry
High-speed dispersers are extensively used in the production of paints, coatings, and pigments. They are used to disperse and blend the raw materials, such as pigments, fillers, binders, and solvents, to achieve a homogeneous and consistent mixture.
Adhesives and Sealants
High-speed dispersers are employed in the manufacturing of adhesives and sealants. They help disperse and mix various components, such as resins, solvents, fillers, and additives, to create a uniform adhesive or sealant formulation.
Cosmetics and Personal Care Products
High speed dispersers play a crucial role in the production of cosmetics and personal care products, including creams, lotions, gels, and emulsions. They are used to blend and disperse ingredients like oils, emulsifiers, thickeners, pigments, and fragrances, ensuring a smooth and consistent product texture.
Pharmaceuticals
In the pharmaceutical industry, high-speed dispersers are used for the preparation of suspensions, ointments, and creams. They help disperse active pharmaceutical ingredients (APIs), excipients, and other additives to achieve uniform distribution and enhance product stability.
Food and Beverage Industry
High-speed dispersers find applications in the food and beverage industry for mixing and blending various ingredients. They are used in the production of sauces, dressings, mayonnaise, dairy products, beverages, and more. These dispersers aid in achieving uniform texture, emulsification, and distribution of ingredients.
Chemical Industry
High-speed dispersers are widely used in the chemical industry for mixing and dispersing chemicals, resins, polymers, and additives. They facilitate the production of adhesives, resins, inks, dyes, and specialty chemicals, ensuring consistent and efficient blending.
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Inline high shear mixer is a special equipment for large volume rapid mixing. It can quickly mix a variety of different substance phases (gases, liquids and solids) together. This mixer type uses a strong mechanical shear force for mixing, rather than relying on the material's own flow to achieve mixing. Therefore, an inline high shear mixer has higher efficiency than an usual agitator. Moreover, it can complete a series of work such as dispersing, emulsifying and crushing at same time when mixing. SeFluid is a leading manufacturer of high shear mixers for 20 years.
Inside an inline high shear mixer, there is one or more rotors fixed on the shaft. Each rotor corresponds to a stator. The gap between the stator and rotor is less than 0.5 mm. On the stator and rotor, there are interlocking teeth and there is a gap between the teeth. When the stator rotates at high speed, it generates a strong centrifugal force and leads to a negative pressure to draw the fluid into the work head.
When the fluid enters the gap between the stator and the rotor's teeth, it is strongly sheared, homogenized and emulsified together with the surrounding medium, finally achieving a good mixing effect and being discharged from the discharge outlet.
https://youtu.be/l9vyJcObIGY
Features of Inline High Shear Mixer
100% Mixing and No Dead Spots
Usual agitator may form sludge and settle at the container bottom. Moreover, it is hard to mix materials with different physical gravity such as water and oil. By using a SeFluid's inline high shear mixer, the external cycling, strong shear and mechanical kinetic energy can mix the fluids well. So, it is easy to avoid the agitator's shortage. All raw material inside the container will be forcely mixed and homogenized into a steady state.
Better for High Speed Dissolving
Our inline high shear mixer series can make solubilizing to have higher efficiency for industries such as food, resin, rubber, polymers and petrochemical. When the high speed rotation of the rotor sucks liquid and solid materials into the working chamber. The fluid will experience intense targeted shear in rotor/stator assembly. With each pass, the particle size will become smaller. Then the surface area of particles increases to the surrounding liquid and speed up the solubilization process.
With Self-pumping Ability
In conventional mixing, there is a centrifugal pump for feeding raw materials. Feeding pumps may often cause excessive energy consumption, leak, or a mismatch between pumping and mixing capacity. Consequently, poor mixing performance or even jamming will happen. In our inline high shear mixers, the shearing parts generates strong centrifugal force to draw the fluid into working chamber and can pump the fluid up to 20 meters. Therefore, there is no need of the feed pump any more.
Ability of Mixing Raw Material with Significant Different Viscosity
If blend miscible liquids with similar viscosities, an agitator will be suitable. But sometimes there is a big difference in viscosity between blended liquids. The liquids may move around, yet there is no actual blending between them. Moreover, it will take a long time to get a good blending.
SeFluid's inline high shear mixer series mixes the fluids rapidly and blend fluids almost instantaneously in a single pass. It is very suitable choice for continuous dilutions.
Our Inline High Shear Mixer Series Are Better for Emulsion Making
The most important thing to get stable emulsion is to make the droplet size as small as possible. More shear energy will get smaller suspended droplets and a better stable emulsion. SeFluid's high shear inline mixers are very ideal for this application. It can easily obtain an emulsion with a droplet size of 2 to 5 microns. Moreover, smaller size down to 0.5 microns also can be get based on different formulations. We produce full range of high shear inline mixers widely used for making of emulsions.
Deagglomerating and Removing Lumps for Powder Liquid Mixing
When putting powders and liquids together, it is very liable to form agglomerates. An usual agitator cannot remove the agglomerates completely. The high shear action of SeFluid's high shear inline mixers can rapidly break agglomerates or lumps using the strong shear force. So, our machines can expose increasing areas of the solid to the surrounding liquid. Therefore, it is easy to get an agglomerate-free solution within minutes.
Stage of Inline High Shear Mixer
For an inline high shear mixer, one stage means a pair of stator and rotor. A single stage means that the machine has only one pair of stator and rotor in the working head. Similarly, three stages mean three pairs of stators and rotors in the working head. For each stage, the medium is sheared and mixed at least once.
Usually, the more stages mean the more times the fluid is sheared, the finer and better the final mixing effect. At the same time, the flow rate is also lower, because the kinetic energy of the fluid is lost with each mixing. Therefore, the selection of stage quantity should be based on the characteristics of processed fluid.
Shear Parts of Inline High Shear Mixer
Apart from the number of stages, the main difference between inline high shear mixers is the shear assembly shape, especially the stator. In most cases, a toothed stator is enough for all shearing and mixing requirements.
However, for some special materials, such as homogenization of lime slurries, the stator may also need to have a shape of round hole, a grid hole, or a waist shape hole to meet different mixing applications. For the rotor, it is usually toothed or impeller-shaped and closely spaced with the stator (clearance less than 0.5 mm).
Accessories of Inline High Shear Mixer
In addition to the shear components, an inline high shear mixer has a some other important auxiliary components that are critical to the mixing process.
High Efficiency Heating / Cooling Jacket
First, in the mixing process of some special materials, such as in the production of modified bitumen, high temperatures are required to keep the bitumen liquid, while in the mixing process of biological agents, lower temperatures is necessary. Therefore, in some special applications, there is a jacket layer round the working head for heating or cooling, with high temperature liquid or cooling liquid circulating to meet different mixing application needs.
Valve for Sampling and Draining
Secondly, after each batch of mixing work is completed, there will be a certain amount of residue left in the working chamber, which may deteriorate over time and thus affect the next batch of production. In addition, during the closed production process, the user may need to take micro-samples at any time to observe the mixing effect. Therefore, there are additional small drainage ports with valves on the working head for draining residual night or for micro-sampling.
SS304 Splash Protection Cover
Moreover, in certain industries with high hygienic requirements, such as food, beverage, pharmaceutical, cosmetics, etc., a stainless steel splash production shield is necessary to the cover the motor to prevent contamination or corrosion of the machine by spilled liquids and to facilitate the cleaning of the inline high shear mixer. Meanwhile, At the same time, this shield can effectively protect the operators of the production line and prevent accidents.
The Reason to Take SeFluid's Inline High Shear Mixer Series
Experienced Fluid Handling Engineering Team
SeFluid has over 20 years of experience designing and manufacturing fluid handling equipment. Over the years, our engineering team has accumulated a wealth of experience in fluid handling cases based on our tens of thousands of real-world applications. Upon receiving an inquiry from a customer, our strong engineering and technical teams are able to quickly select the best mixing solution and equipment configuration for the customer based on their actual application needs.
Precision Manufacturing
We use precision multi-axis machining centers on producing inline high shear mixer parts to avoid the use of welding processes as much as possible. Especially for the shear assembly, we insist on using a single piece to machine out the assembly; Meanwhile, many our competitors weld the shear teeth to the stator or rotor. As a result, our mixers have higher mechanical strength and longer life. Moreover, because our manufacturing machinery is more precise, SeFluid's mixers are less noisy and has better mixing effect.
Strict Quality Control
SeFluid regards the quality of our products as important as life, therefore, we always put strict quality requirements throughout the production of our products. During the production process, we implement ISO quality management system into every production process. Our technicians measure and check the strength and dimensional accuracy of every mechanical part, find defective products and select them in time, thus ensuring that only qualified and well-performing machines and equipment are delivered to our customers.
Full-time Service & Support
Excellent service is one of key factors for users to purchase a machine or not. Therefore, providing good pre-sales and after-sales services is one of SeFluid's cornerstones of surviving and development. At any time, we will provide full-time service and support by e-mail, telephone, video or sending engineers to the site. It is our consistent orientation to timely solve emergencies and failures for our customers in a fast manner and to minimize the impact of user's downtime on production.
Applications of Inline High Shear Mixer
Inline high shear mixers are versatile equipment used in various industries for mixing, emulsifying, dispersing, and homogenizing fluids and suspensions. They offer several benefits, including efficient and uniform mixing, reduced process time, and improved product quality. Here are some common applications of inline high shear mixers:
Water Treatment Industry
Inline high shear mixers play a crucial role in the water treatment industry for processes like flocculation, coagulation, and chemical dosing. They are used to disperse and activate chemicals, such as coagulants and flocculants, to improve the efficiency of water treatment processes. These mixers assist in achieving rapid and uniform mixing, enhancing the removal of impurities, and optimizing the overall treatment performance.
Food and Beverage Industry
Inline high shear mixers are widely used in the food and beverage industry for emulsifying, blending, and dispersing ingredients. They are employed in the production of sauces, dressings, mayonnaise, dairy products, beverages, and various food additives. These mixers ensure the uniform distribution of flavors, stabilizers, emulsifiers, and other ingredients, resulting in consistent product quality.
Paint and Coatings Industry
In the paint and coatings industry, inline high shear mixers are utilized for pigment dispersion, particle size reduction, and achieving consistent color and texture. They help in achieving better color development, reducing agglomerates, and ensuring the smooth and uniform application of paints and coatings.
Chemical Industry
Inline high shear mixers find extensive application in the chemical industry for homogenizing, emulsifying, and dispersing liquids and powders. They are used in the production of paints, coatings, adhesives, lubricants, polymers, and various chemical additives. These mixers enable efficient blending of different components and enhance product consistency and quality.
Pharmaceutical and Cosmetics Industry
In the pharmaceutical and cosmetics industry, inline high shear mixers are utilized for emulsifying, dispersing, and creating stable suspensions. They are used in the formulation and production of creams, lotions, ointments, gels, and various personal care products. The high shear generated by these mixers helps in achieving fine particle size reduction, improving product stability, and enhancing the absorption and effectiveness of active ingredients.
Petrochemical Industry
In the petrochemical industry, inline high shear mixers are employed for various processes such as emulsification, dispersion, and homogenization of oil-water mixtures, as well as blending of different petroleum-based products. They are used in the production of fuels, lubricants, emulsions, and other petrochemical derivatives. These mixers ensure proper mixing of different components, minimize phase separation, and improve product stability.
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https://www.sefluid.com/products/adjustable-superfine-colloid-mill/?feed_id=244&_unique_id=6563c7b8d6943
Apart from the number of stages, the main difference between inline high shear mixers is the shear assembly shape, especially the stator. In most cases, a toothed stator is enough for all shearing and mixing requirements.
However, for some special materials, such as homogenization of lime slurries, the stator may also need to have a shape of round hole, a grid hole, or a waist shape hole to meet different mixing applications. For the rotor, it is usually toothed or impeller-shaped and closely spaced with the stator (clearance less than 0.5 mm).