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Showing posts with label high_shear_mixer. Show all posts
Showing posts with label high_shear_mixer. Show all posts
Laboratory high shear mixer is a kind of equipment for laboratory research and development to emulsify liquid mixtures into stable emulsions.
Introduction of Laboratory High Shear Mixer
The laboratory high shear mixer is a kind of equipment designed for laboratory research and development, aimed at emulsifying liquid mixtures into stable emulsions using high shear forces. It consists of a rotating rotor and a fixed stator, designed with blades on both components that match each other. When the rotor spins at high speed, the intense turbulence and shear forces created between the blades result in strong mechanical action on the liquid mixture, leading to the mixing and emulsification processes.
The primary function of the laboratory high shear mixer is to combine and emulsify two or more immiscible liquids to form small and stable emulsions. These liquids can be combinations of oil-water emulsions, liquid-liquid emulsions, or liquid-solid emulsions. By utilizing high-speed rotation and cutting action, the laboratory high shear mixer efficiently disperses and evenly distributes droplets, resulting in uniform emulsions.
specification
Power
1.1-4 KW
Speed
0-3000 rpm
Bead
0.8-2.0 mm
Material
SS304, SS316
Principle of Laboratory High Shear Mixer
The laboratory high shear mixer combines liquids together by utilizing high-speed rotation and shear forces. Its working principle involves the following key steps:
Rotor and stator configuration
The laboratory high shear mixer typically consists of a rotating rotor and a fixed stator. The rotor is equipped with blades, while corresponding blades are present on the stator.
Shear and turbulence action
When the rotor spins at high speed, it creates intense turbulence and shear forces between the blades. These forces subject the liquid mixture to vigorous mechanical action between the rotor and the stator.
Liquid mixing
The shear and turbulence action results in strong interactions among the components of the liquid mixture. This leads to the dispersion of immiscible liquids and the formation of small liquid droplets. Meanwhile, the soluble components in the liquid also mix more effectively.
Micro-mixing
Under the influence of high shear forces, the liquid droplets continue to be cut and dispersed, ultimately forming uniformly dispersed micro-droplets. This ensures a more even distribution of the mixture's components throughout the system.
The working principle of the laboratory high shear mixer relies on the shear forces and turbulence generated by high-speed rotation. These actions allow for effective mixing and dispersion of the liquid mixture, achieving a homogeneous mixing effect.
Features of SeFluid's Laboratory High Shear Mixer Series
Power supplement technology to fit different viscosityOne-button stepless speed regulation for smooth runningLCD digital displayer for more simple and intuitive operationThree work heads for option to suit different liquid media
Applications of Laboratory High Shear Mixer
A laboratory high shear mixer is a versatile piece of equipment used in various industries for mixing, emulsifying, dispersing, and homogenizing processes. It utilizes a high-speed rotor or impeller that generates intense shear forces and turbulence to achieve efficient and uniform mixing. Here are some common applications of laboratory high shear mixers:
Pharmaceuticals
In the pharmaceutical industry, laboratory high shear mixers are used for blending active pharmaceutical ingredients with excipients, dispersing powders into liquids, and emulsifying oil-based or water-based formulations. They are also employed in the preparation of ointments, creams, gels, and other topical formulations.
Cosmetics and Personal Care Products
Laboratory high shear mixers find extensive use in the cosmetics industry for trial manufacturing of creams, lotions, emulsions, and suspensions. They enable efficient dispersion of pigments, incorporation of additives, and production of stable emulsions.
Food and Beverage
Laboratory high shear mixers are employed in the food and beverage industry for a range of applications. They are used to mix ingredients for sauces, dressings, mayonnaise, and other emulsions. They can also be used for dispersing flavors and colors, and producing stable suspensions.
Chemicals and Coatings
Laboratory high shear mixers are utilized in the chemical industry for mixing and dispersing various chemicals, dyes, and pigments. They are also employed in the small batch production of coatings, paints, inks, and adhesives, where they ensure thorough dispersion of solids and uniform distribution of additives.
Research and Development
Laboratory high shear mixers are extensively used in research and development laboratories across different industries. They are employed to test and optimize formulations, study the effects of different mixing parameters, and develop new products and processes.
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High shear mixers are essential equipment in various industries, including pharmaceuticals, food processing, cosmetics, and chemical manufacturing. These mixers are designed to efficiently blend, emulsify, disperse, and homogenize different types of materials. When selecting a high shear mixer for a specific application, several factors need to be considered to ensure optimal performance and productivity. Here are the key considerations in the selection of high shear mixers.
Selection of High Shear Mixer Type
There are different types of high shear mixers available, each with its own advantages and limitations. The most common types include rotor-stator mixers, inline mixers, and batch mixers. Rotor-stator mixers are versatile and suitable for a wide range of applications. Inline mixers provide continuous processing, making them ideal for large-scale production. Batch mixers, on the other hand, are suitable for smaller batches and offer flexibility in terms of operation.
Process Requirements
Understanding the specific process requirements is crucial in selecting the right high shear mixer. Consider the desired mixing intensity, shear rate, viscosity range, and the materials being processed. For example, some applications may require gentle blending, while others may need intense shearing. It's important to match the mixer's capabilities with the process requirements to achieve the desired results.
Capacity and Scale
The capacity of the mixer should align with the production requirements. Consider the volume of material to be processed per batch or per hour. High shear mixers are available in a wide range of sizes, from laboratory-scale to large industrial-scale units. Choosing the appropriate size ensures efficient and cost-effective processing.
Material Compatibility
Different high shear mixers are designed to handle specific materials. Consider the characteristics of the materials to be processed, such as viscosity, temperature sensitivity, and chemical compatibility. Some mixers are better suited for low-viscosity liquids, while others can handle high-viscosity pastes or solids. Ensure that the mixer's construction materials are compatible with the materials being processed to avoid contamination or equipment damage.
Ease of Cleaning and Maintenance
Efficient cleaning and maintenance are essential for maintaining hygienic and reliable operations. Look for high shear mixers that are designed for easy disassembly, cleaning, and reassembly. Consider features such as quick-change tooling, accessibility to internal parts, and the availability of cleaning-in-place (CIP) systems. Easy maintenance procedures and access to spare parts can minimize downtime and enhance productivity.
Safety Features
Safety should always be a top priority when selecting any equipment. High shear mixers can involve high speeds and powerful forces, which present potential hazards. Look for mixers with safety features such as interlocks, emergency stop buttons, and guarding to protect operators and prevent accidents. Additionally, ensure that the mixer complies with relevant safety standards and regulations.
Cost and Return on Investment (ROI)
Consider the initial investment cost of the high shear mixer, as well as the long-term operating costs. Evaluate the durability, reliability, and performance of the mixer to determine its overall value. A higher-quality mixer may have a higher upfront cost but can deliver better performance, increased productivity, and lower maintenance and operating expenses in the long run.
Conclusion
Selecting the right high shear mixer is crucial for achieving efficient and effective mixing processes. By considering factors such as mixer type, process requirements, capacity, material compatibility, ease of cleaning and maintenance, safety features, and cost, one can make an informed decision. Consulting with equipment manufacturers or experts in the field can provide valuable insights and assistance in selecting the most suitable high shear mixer for a specific application.
SeFluid is a leading China manufacturer of fluid processing equipment. Over the past decade, our products have been widely used in numerous fluid applications worldwide. Please click on below relevant products to learn more details or send us an inquiry, and our sales engineers will contact you as soon as possible.
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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NEWS
The laboratory high shear mixer combines liquids together by utilizing high-speed rotation and shear forces. Its working principle involves the following key steps:
Inline High Shear Mixer
SeFluid's Inline High Shear Mixer is an equipment for large volume rapid mixing. It can quickly mix a variety of different substance phases.
High shear mixers are essential equipment in various industries, including pharmaceuticals, food processing, cosmetics, and chemical manufacturing. These mixers are designed to efficiently blend, emulsify, disperse, and homogenize different types of materials. When selecting a high shear mixer for a specific application, several factors need to be considered to ensure optimal performance and productivity. Here are the key considerations in the selection of high shear mixers.
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).
