A vacuum emulsifying mixer is a machine that makes dispersion, viscous emulsion, and product suspension. The primary mechanism of the mixer is to get rid of dead or hard corners and purify emulsified products. Ointments, lotions, creams, and other liquids are products this system purifies and delivers.
For processing plants to get the best results, they need rotating mixers dealing with different materials and mixtures. When mixing impellers rotate in a batch, they put shear, or stress, on the materials to mix them. The force needed to mix the materials depends on the viscosity and other properties of liquids, as well as whether or not solids are present. The amount of shear depends on how the blade is made and how fast it spins. Depending on your needs, mixers can use either high shear mixing or low shear mixing to combine the different materials into one.
High Shear Emulsifying Mixer
Stator blenders are another name for high shear emulsifying mixers. They are usually used to make emulsions with a low to medium viscosity, up to about 10,000 cps. The typical rotor/stator blender gets its high shear properties from the interaction between a rotor whose tip is moving at speeds of up to 4,000 feet per minute and a stator.
In a parallel field, one force pushes one part of a mixture while another force pushes another part of the mixture in the opposite direction. This creates a shear force. The more shear force there is, the better the materials can mix together, even if they are solids and liquids with different viscosities.
These machines have a fast-moving rotor that pushes the mixture against a slow-moving stator to create shear. The batch is stirred and moved around by these mixers. One type of high shear mixing is called dispersion, which uses much horsepower to make even more shear. High shear forces mix the ingredients together and ensure that the materials are spread out evenly in the batch.
High shear mixers are used all over the industry to make emulsions for so many different uses. These equipment come in different styles and sizes, depending on how much mixing power the dairy care industry needs to make its products.
Low Shear Emulsifying Mixer
Most companies with low-class mixers use emulsifying mixers with low shear. But some don’t know much about how their emulsifying mixers work or how good they are. Low-shear mixers are most often used to make a different kind of coffee. It has been said that almost half of the people in the United States drink espresso and drink about 3.1 cups a day. This is equal to about 159 million people.
Low shear blending, also known as low energy blending, is the process of thoroughly combining two or more ingredients without affecting the blending cycle. Low-cost consumers or those who want to manufacture products with the least amount of energy use should choose low-shear mixers.
Low shear mixing is a method that doesn’t use as much force. This works best for materials that can mix together without a lot of energy or force. It can also handle fragile materials, like glues, polymers, food products with a specific shape, and materials with large particles that shouldn’t be broken up during mixing. When the shear rate is too high, the materials can start to break down because of the shear. In low shear mixing, the rotor blades can be made in many different ways, and the flow and turbulence in the tank helps to mix the materials.
| High Shear Emulsifying Mixer | Low Shear Emulsifying Mixer |
| High shear emulsifying mixers work by shearing between the rotor and the stator. | Low-shear mixers are used to manufacture goods that need less energy and repair. |
| High shear mixers, which provide large amounts of energy to form various products, have a high pressing and mixing factor. | Because the rotor has low energy, the mixer is often used to handle low-energy materials. |
| High shear mixers have a high speed when mixing. | Using the low mixer, there is a good chance that the amount of mixing will decrease. |
High and Low Shear Mixing Applications
Both high shear and low shear mixing are useful in different situations. Some uses of high shear mixing equipment are:
- Homogenizing and emulsifying liquid-liquid mixtures.
- Getting powders to mix with liquids.
- Combining liquid-liquid mixtures with different levels of viscosity.
- Adding solids to liquids and dispersing them.
- Lowering combination particle sizes.
Low shear mixing is used for materials that need to be handled more gently or need less force to get the right result. Examples of popular uses:
- mixing fluids and miscible liquids
- Liquid chemical mixture. Flavoring
- Have better results from heating mixtures
- Keeping particle suspension
How to Choose?
Excellent emulsification professionally, homogenous equipment solves problems in the cosmetics, pharmaceutical, chemical, food, and other industries. The engine of this great mixer uses a vacuum made by a high-speed thread running between the rotor and the stator. The mechanism will speed up the blending process while keeping the consistency high.
Get High Shear and Low Shear Mixing Solutions Now
Both high shear and low shear mixing are essential parts of manufacturing products. Some mixtures might need to be homogenized, while others might need solids that stay in suspension. For high shear or very forceful mixing, high-speed impellers are used. Mixing, flow, turbulence, and rotational force are used for low shear or less forceful.
At Makwell, we specialize in designing and manufacturing emulsifying machines. Our equipment is carefully modeled to ensure it has the best shear mixing force for each customer. Getting the right mixing tools for your facility can be as easy as requesting a quote!