Emulsifier machine: What is it?
The emulsifier machine or vacuum emulsifying mixer is an emulsifier mixer machine with many functions and can mix, disperse, homogenize, emulsify, and aspirate very viscous ingredients and materials. It features a system to avoid dead corners. on the inside surface of the machine. It is operated by electricity and may also use oil and water stored in nearby containers. It also functions as a vacuum and may heat or cool its surroundings. Creams, lotions, ointments, and liquid creams may all be mixed with the help of this emulsifier mixer machine.
Emulsifier machine: What is it used for?
This emulsifier mixer machine is a crucial piece of machinery for emulsifying and mixing a variety of goods. It combines liquid creams, cosmetics, medicinal ointments, and emulsions like oral syrups.
The emulsification plant may benefit from moving components between the water and oil tank. The vacuum cleaners included in this equipment’s design serve to remove dust. Helpful for getting machinery in working order again after a cleaning.
Emulsifier machine: How does it work?
The first step is to heat the two separate containers holding the water and oil. The water and oil are sucked into the emulsifying pot by the emulsifying pump. This vessel sits right below the two containers holding the raw materials: water and oil.
The scraper helps in getting things out of the mixer. After setting up the emulsifier mixer machine, the central mixer performs the material mixing. This will result in constantly producing new interfaces between the materials.
The rotating vane helps cut, crush, mix, and blend the components or ingredients throughout this process. High cutting wheel speeds and a stationary cutting cover are used until the materials reach a thickness of 200 nm to 2 um.
As the centrifugal force causes tearing and other wide-ranging effects, hundreds of thousands of hydraulic shears happen. This causes emulsification, and the final result is fine, stable, high-quality products with no bubbles.
Air produced during mixing immediately fills the vacuum in the emulsifying pot. Then the emulsified components settle and are released.
Emulsifier machine: What are the applications?
◎ Food
This emulsifier mixer machine emulsifies mayonnaise, salad dressings, jam, butter, sauce, margarine, etc., in the food sector. Thick materials, including dairy, oral solutions, baby food, chocolate, and sugar, are processed using this approach.
◎ Cosmetics
The cosmetics industry uses this in processing body creams, lotions, lipstick, detergents, face cleanser, nourishing honey, and shampoo are all mixed in it. Hair gel, ponds, lip balms, shaving gel, cold creams, sunscreen, and lip glows are all products that may be blended with this tool.
◎ Pharmaceuticals
This emulsifier mixer machine has also found use in the pharmaceutical industry. Ointments, oral syrups, latex, emulsions, and injections are some products that go through them.
◎ Paint Industry
This emulsifier mixer machine also applies in the paint industry to mix synthetic resin paints and other paints.
◎ Chemical
The chemical industry embraces this technique as well. It emulsifies polyesters and artificial fibers. Processing latex, saponification products, detergents, and coatings are additional common uses.
Emulsifier machine: What are the characteristics?
• This emulsifier mixer machine produces different creams and liquids. The final goods are unique in appearance, form, particle size, and viscosity, depending on the target product. The materials are very smooth and refined.
• The speed of mixing and homogenizing are flexible to accommodate various technical procedures.
• Because digital time and temperature include in the control cabinet, it is simple to determine the working time and temperature.
• The vacuum system makes it possible for the whole process to occur in a vacuum, which makes materials without bubbles.
• The operating hopper has two walls that provide heating and cooling.
• For convenience, the hopper lid may be raised electrically.
• The underframe is also portable, allowing users to relocate it anywhere they choose.
• The contact parts of this emulsifier mixer machine are 316L stainless steel.
In addition to its application in the petrochemical industry, it also finds use in the printing and dyeing auxiliary, paper, pesticide and fertilizer, plastics and rubber, and electronics sectors.
Other sectors of production have also recognized the value of this equipment. Products like paint, wax, shoe cream and liquid coatings are just some of the things that are emulsified and mixed with this emulsifier mixer machine.
Emulsifier machine: What are the benefits?
✔ This mixer emulsifier is one of a kind. It extensively uses vacuum features to boost mixing efficiency, resulting in improved mixing and optimal product handling.
✔ The mixing environment is controlled by a vacuum, which helps avoid aeration and might lead to mixing blade damage.
✔ The regulated mixing environment also contributes to the production of void-free final products.
✔ It is excellent for making powdery products in small, medium, and large batches, holding between 30L and 2000L of work.
✔ Creams and other fluid goods like cough syrups benefit significantly from this emulsifier mixer machine.
✔ Compared to the time-consuming manual process, this is a significant time saver. The automated equipment contributes considerable energy, accelerating the whole procedure.
✔ Controlled viscosity improves product homogeneity.
✔ The automatic model integrates a CIP to maintain the machine’s cleanliness and shield production from contamination.
✔ Reduces manual mixing waste. Thus, the processing sector benefits.
Emulsifier machine: What are its main parts?
An emulsifier mixer machine has many elements. Pre-treating boiler, vacuum pump, vacuum emulsifying and blending boiler, hydraulic pump, dumping system, electric control system, and work platform are among them.
What are the emulsifier machine’s main vacuum systems?
A water ring vacuum pump, vacuum gauge, and vacuum relief valve are components of the system. Vacuum systems remove air bubbles while mixing.
What kind of material is used to fabricate an emulsifier machine?
Stainless steel is the exterior shell that will not come into touch with anything. Parts that come into contact with the product are AISI or SS316L. The silicone that is safe for food is used for seals.
What is the purpose of product emulsifying?
This is so that materials may be perfectly emulsified, creating delicate, smooth final products. Additionally, it makes mixtures without bubbles.
What effect does use a vacuum emulsifier machine have on products?
The effect of the emulsifier mixer machine is to mix two materials into one that is smooth and refined. The original two distinct products, most likely immiscible, are uniformly emulsified into a single product.
How does an emulsifier machine differ from a homogenizer?
Each one delivers the same concept. Vacuum high-speed shear mixing may take place in one or more stages, mixing the components quickly and uniformly. The strong kinetic forces drive the materials into the narrow gap between the stator and rotor. It happens in seconds and includes hundreds of thousands of shears. Both large and small organizations use this emulsifier mixer machine to make viscous emulsions and dispersions.
What is low shear mixer?
The low shear mixing capability of this homogenizer is a result of its fin-type mixer and shear head combination. The rotor spins within the stator, and the fins extend outward from the shear head homogenizer. The stator with fins locks onto the rotor and rotates automatically. The rotor and stator of a high-shear mixer, on the other hand, spin in opposite directions. To get the parts to combine, you’ll need to switch the machine’s settings from low-shear mode to high-shear homogenizing mode. Changing a product’s attachments will prevent the procedure from completing successfully.
What is high shear mixer?
A homogenizer or high-shear mixer is a machine that moves and mixes incompatible materials. A rotor and stators are installed within the homogenizing tank or pipes to generate shear. In liquids, high shear rates cause the formation of emulsions, suspensions, and micro-aeration.
This machine applies in food, cosmetics, pharmaceutical, adhesives, and chemicals to emulsify, homogenize, disperse, and reduce particle size. It is driven by an electric motor that lets it rotates at high speed. This often leads to a series of rotations that end up causing shear.
Outside the diameter of the rotor, the fluid velocity is greater than that at the rotor’s center. The more significant the difference in speed, the greater the shear. The combination of a rotor and a stator is also referred to as the shear head or generator. Using these two components helps to generate a tight clearance space between the rotor and stator. This creates a very high shear zone when the materials exit the rotor.
The number of generators in the machine increases in proportion to the size of the shear head. The equipment can process batches as big as 400 US gallons and is easily maneuvered using moveable floor platforms. This type of equipment is ideal for gels, deodorant sticks, and things that get solid when they cool down.
What are the differences between a high-shear and low-shear emulsifier machine?
◎ In comparison to mild shear, emulsification occurs more quickly under high shear.
◎ Rotor solvers are for high-shear emulsification, whereas standard impellers are for low-shear emulsifying mixing.
◎ When using an emulsifying mixer, the results are optimal with high shear but subpar with low shear. Certain materials won’t dissolve in the liquid.
◎ Although, materials with a low viscosity should use the high shear machine. In contrast, low-shear ones are preferable for heat-sensitive, easily damaged, or freely flowing goods.
What are the different types of vacuum emulsifier machines?
The emulsifier mixer machine is available in the following configurations:
• Vacuum Homogenizer
This equipment can homogenize, stir, and deform and is controlled by an electric system. A vacuum emulsifier, an operating platform, and a vacuum system make up the machine.
Food processing machines like these turn basic resources or raw materials into finished products. Cosmetics companies make lotions, creams, and gels using them. Pharmaceutical ointments, oral syrups, and lotions are prepared this way.
The oil pot, water pot, and operating platform are all adjustable to your preferences. It is suitable for materials with low fluidity. Product contact components are SS316L, and production followed current good manufacturing practice guidelines.
• Vacuum Planetary Mixer
This mixes very viscous materials or ingredients. When operational, the planet carrier spins, setting the box’s stirring shaft in motion. It moves around the emulsifying tank at a very rapid pace. Emulsification, dispersion, and mixing of ingredients are made easier by the quick rotation, which puts the materials to a powerful shearing and kneading.
This device’s mixing tank has a scrapper resembling a knife—making materials sticking to the side of the mixing tank easier to remove, enhancing the machine’s performance.
It can handle water and other materials effectively and operate reliably under a vacuum. Oil and water may be used to heat or cool the mixing tank as well. The rack, lid, and agitator are hydraulically raised and lowered by a double column. This planetary vacuum mixer includes a reliable and practical charge and discharge mechanism.
• Stainless Steel Vacuum Mixing Pot
This is a more simple vacuum mixer type, excluding extraneous machine parts. This type of emulsifier mixer machine is perfect for industries that need to mix a few ingredients. Soups, fluids, and chemical building components are just some of the things that may be blended with this handy tool. It mixes daily washing chemicals, thus naming this a liquid washing pot.
Automatic vacuum emulsifier machine: What is it?
This emulsifier mixer machine contains a high-speed shear head, which allows it to run at a very high speed. It has a high-speed homogenizer for making emulsions and a blade mixer for mixing very thick substances.
Remove materials from the mixing tank’s surface using scrappers to avoid dead corners. The machine’s downward current mixes and pushes materials continuously. High-speed bottom-to-top pressure fluctuation within the homo-head breaks, mixes, and emulsifies. The contents pour out of the homo-top heads and are pulled back by the blade mixer’s downward force. When the upward pressure lessens, this occurs.
This machine is your best bet if you need to emulsify a substance with a low viscosity. The raw ingredients are automatically drawn into the mixer through a vacuum system. Vacuuming, heating and chilling may all take place in a single manufacturing phase. Because it is automated, emulsification, mixing, and homogeneous dispersion may be completed rapidly.
The automatic control system, which consists of a touch button, a timer, and a process recorder, makes it entirely hands-free. Any non-contact components are stainless steel. Its vacuum environment naturally keeps outside air out of the mixing chamber. This machine may also be equipped with CIP, which helps in regularly initiating mixer cleaning automatically.
Semi-automatic vacuum emulsifier machine: What is it?
This emulsifier mixer machine requires both manual and automated operation. The components are manually loaded into the designated vessels before starting the machines. It does the work of emulsification, and the finished product is poured out of the tank by hand. The equipment also requires manual cleaning and sterilizing as neither CIP nor SIP is included in the semi-automatic emulsifying mixer’s standard equipment.
This machine features a vacuum, hydraulic lifting, machine tilting, and water and oil pots. Heating, cooling, temperature control, and an electric control panel are also included. Like the automated one, it requires human input to emulsify.
What is a tabletop emulsifier machine?
This is a vacuum emulsifier in a tabletop configuration. It helps make viscous items like lotions, jellies, and ointments, using two mixing heads to work. Both the paddle mixer and the emulsifier operate either forward or backward. This one-of-a-kind technique results in more efficient goods.
The homogenizer’s revolving turbine is powered from above. Because it is colored, the machine features a visible control panel showing its operating capabilities.
A mechanical cover lifting feature and fully detachable vessels make cleaning the tabletop vacuum emulsifying mixer simple. Once the data is stored on an SD card, this system is simple to use. It contains glass and light for monitoring while it is in use.
What is the difference between a fluidized bed mixer and a vacuum emulsifier machine?
◎ Fluidized bed mixers combine powders and pellets, which are low and medium-density materials, respectively. Most of these substances are friable and may be optionally mixed with liquids. Vacuum emulsifying mixers, on the other hand, are used to mix thick substances like lotions, ointments, syrups, and creams.
◎ Fluidized Bed Mixer applications are fast. It gently handles items and washes them down occasionally. While the vacuum emulsifying mixer uses several cycles of hundreds of thousands of rotations to generate fine goods or mixtures.
◎ The Fluidized Bed Mixer may complete its work in as little as 10 seconds to as much as 20 minutes. It produces a coefficient fluctuation of around 5% when used in 30 seconds. Additionally, vacuum emulsifiers operate at a high rate of hundreds of thousands of cycles, producing perfect mixes.
◎ Flat, angular paddles with overlapping pathways make up the Fluidized Bed Mixer. It transports materials from a pair of parallel U-shaped troughs to the machine’s hub. The vacuum emulsifying mixer contains vessels with jackets for heating and cooling the ingredients within the vacuum. It features high-speed homogenizers, scraping agitators, vacuum pumps, and hydraulic pumps.
◎ A shorter mixing time and lower shear produced by a fluidized bed mixer result in less product deterioration. While high shear produced throughout the manufacturing process by the vacuum emulsifying mixer results in fine goods.
◎ An advantage of a fluidized bed mixer is that it features drop-bottom and full-length gates, allowing materials to be discharged faster. On the other hand, vacuum-emulsifying mixers release slowly because the components continue to settle at the bottom of the mixing vessel.
How are materials loaded into and collected from an emulsifier machine?
Materials are manually loaded into the machine above the pots. After adding the materials, then start the machine. Materials may also be loaded into the mixer using a content loader if the equipment is automatic. The high-speed shearing creates a forceful suction that pulls the materials out of their pots as the shear-rapid head rotates. The materials flow into the work head, where they are quickly combined. Discharging the mixture may be done manually or mechanically via a content discharge vessel after reaching the target consistency.
How to suck materials for emulsification using the vacuum function?
◎ If you wish to use the vacuum feature to suck ingredients for an emulsion, you may;
◎ Remember to seal off the metal shutoff valves leading to the water and oil storage tanks.
◎ To create a vacuum in the emulsification tank, open the valves on the vacuum ports.
◎ Select the vacuum option on the touchscreen. When the vacuum gauge reaches -0.09Mpa, you must push the vacuum button so that the valve may shut.
◎ You may now gradually open the valve to allow sucking materials. In this instance, they are the water and oil valves. After that, the components will go to the emulsifying tank to begin mixing.
What is the emulsifier machine’s operating temperature range?
This emulsifier mixer machine can operate in a temperature range between 50 and 60 degrees Celsius. When the valves are locked, power is activated to begin preheating the water and oil containers. Once the temperature reaches 50 degrees Celsius, you should agitate it to let it rise even more.
Stir the components at the desired temperature to match the cream or mayo mixing machine’s temperature. The water and oil pot heats the emulsifying pot to 60 degrees Celsius. First, shut the intake and exhaust valves and open the heating valve.
A vacuum emulsifying mixer may reach temperatures of 80 degrees Celsius or more during operation. However, success is possible if the emulsifying pump and bearing plate are cooled. A single-stage emulsion pump is optimal for this application.
In three-stage emulsion pumps, high-temperature O-rings may help. Effective operation is maintained up to 220 degrees Celsius. For continual emulsification, use a cooling system. This will reduce machine heat during manufacturing.
When using an emulsifier machine, will you have any problems? How to solve them?
There may be certain issues that arise, such as:
◎ Difficulty in dissolving the powder in water.
◎ The challenge of two-phase emulsification in producing a consistent final product.
◎ Particles at the emulsification pot’s bottom.
◎ Some substances clump and are highly challenging for agitators to dissolve.
Using modern industrial technology to mix substances seamlessly, issues like these may be solved. The device can also do two-phase emulsification. Smaller droplet sizes, extra low-density liquids, and micro-aeration may reduce the number of bottom sediments.
Flock deposits and bottom sediment emulsification—how to fix?
◎ To do this, we decrease the size of the material droplets.
◎ Maintaining a temperature of less than 100 degrees Celsius in the emulsion tube.
◎ Lower droplet density by adding lower-density liquid.
◎ Micro-aeration is another alternative, in which air is introduced into a mixture bit by little.
What use does CIP serve in a emulsifier machine?
Maintaining sanitary conditions in the processing area requires frequent machine cleaning. The CIP initiates the cleaning process mechanically, guaranteeing that the product is free of any impurities. The machine operator doesn’t have to take apart the components to clean them, which is a huge time saver. Even hard-to-reach areas of the equipment will be cleaned, reaching all sections.
Cost-effective CIP equipment help produces consistently finished goods. Chemicals may be harmful to humans; as a result, since the machine cleans, CIP eliminates human interaction with hazardous chemicals.
What are the Vacuum Emulsifying Mixer’s Safety Operation Regulations?
Keep several safety operating guidelines in mind when using this equipment:
◎ Emulsification Operation
Keep the emptying valve open during emulsifying to avoid damage. Keep all lids closed to keep out harmful elements, and don’t touch the tank cover or clips. If the operator will be standing on a platform, that platform has to be kept dry at all times. You risk harm from the tank’s negative pressure. Therefore, keep your hands away from the pressure release valve.
◎ Electric System
Using good, grounded cables when operating the vacuum emulsifier on a power supply is important. Regular inspections of the electric system are necessary for safety purposes. A highly moist environment shouldn’t be operating the emulsifier mixer machine as it might result in short circuits. The circuit control box needs excellent airflow to keep equipment safe.
◎ Pipes
Always double-check the tank pressure gauge and the open/closed status of the valves. Check that everything is functioning as it should for the designated task. It will aid in the prevention of burns.
What factors impact the emulsifier machine’s performance?
The effectiveness of the emulsifier machine is dependent on several factors. These are;
1. The effectiveness is often affected by materials’ density, dispersion, wettability, and viscosity.
2. Emulsifying materials’ unique characteristics are another aspect. Rough goods tend to clog pores, which leads to excellent emulsification.
3. Ingredients should be of equal size for a good blend. The effects of particle size variation are unfavorable.
4. Ingredient particle form also affects its efficiency. Material with a spherical form blends easily. In contrast, material particles with an irregular form are difficult to emulsify.
5. To prevent disrupting the emulsification process, particles with electrostatic charges that attract one another are often maintained separately from other components.
6. The choice of an emulsifier mixer machine is the last yet crucial component. Choose a reliable, economic, and effective machine to receive high profits.
Which quality standards should an emulsifier mixer machine meet?
✔ The emulsifier machine must adhere to CGMP specifications such as Clean-In-Place (CIP) and Sterilize-in-Place (SIP).
✔ Product contact components must be 316L stainless steel, and mirror-polished is essential. Stainless steel is also best for non-product-contact parts.
✔ Several safety features for operators, hydraulic pumps, and vacuum.
✔ Before operating, the machine needs a pre-programmed PLC panel. The PLC emergency stop button lets the operator stop the machine quickly.
✔ An excellent machine would be able to finish the whole procedure in a single cycle. Mix, disperse, emulsify, homogenize, vacuum, heat, and chill.
✔ Homogenizing and agitator equipment should have variable speeds.
How do you decide between single-stage and triple-stage inline homogenizers?
It is less expensive to use a single-stage homogenizer. Nevertheless, the triple-stage homogenizer is more effective. This is because a single-stage homogenizer’s emulsifier is a basic machine with a rotor and stator.
The triple-stage is more complex since it has three rotors and three stators instead of only two. As a result, it is more expensive than a simpler one.
Single-stage mixers are the way to go if you need to mix ingredients that are relatively easy to work with. Furthermore, stator designs may differ amongst single-stage homogenizers. You may choose whichever one you like to optimize your system for the tasks you intend to execute. Also, a single-stage homogenizer is a cost-effective solution for companies with limited resources.
How do inline vacuum emulsifying mixers differ from batch vacuum emulsifying mixers in continuous production?
When the operation is meant to be continuous, an inline emulsifier machine is the best option for large-batch production. This equipment likewise generates final products with no bubbles or aeration.
The self-pumping mechanism of an inline emulsifier is a bonus. A multi-stage inline machine may discharge vessels. Many versions of inline vacuum emulsifying mixers are available, including those for very dense materials. When compared to batch vacuum emulsifying mixers, inlets provide significant savings.
When working with very thick and sticky substances, a batch vacuum emulsifier is the tool of choice. As a result, the stator and rotor are of very high quality and are rather pricey. These shear heads provide a high centrifugal force, ensuring uniform dispersion of tiny, microscopic droplets and full dissolving of substances.
Batch vacuum emulsifying mixers have high repair and upkeep costs. This is because it has two distinct sections—an intake section and an output section. But, it is much superior to inline type in terms of efficiency. Batch-type vacuum emulsifying mixers also remove agglomerates and produce consistent mixtures. In conclusion, the inline vacuum emulsifier is affordable, easier to use, clean, and maintain.
What emulsifier mixer machine batch sizes are available?
These machines come in various batch sizes; some can handle medium-sized quantities, while others can manage big ones. The industry may operate a 20L, 30L, or 50L pilot plant for testing purposes. Businesses may use a machine with a 3000-liter capacity with a significant manufacturing capacity of products.
There are 20-liter, 30-liter, 50-liter, 100-liter, 200-liter, 500-liter, 1000-liter, 2000-liter, and 3,000-liter batches available. For this reason, the range of commercially available batch sizes is from twenty liters up to three thousand liters.
What type of emulsifier mixer machines do we provide?
MAKWELL manufacture vacuum emulsifying mixers that can homogenize and emulsify ingredients to create the best quality final products. They are suitable for mixing materials of mayonnaise, sauce, cosmetics, and ointments. These machines are perfect for processing materials with high viscosities and solid content.
A pre-treatment boiler, a vacuum emulsifying mixer boiler, and vacuum pumps make up our emulsifier mixer machine. Additionally, it contains an electronic control system, a tilting mechanism for the mixing pot, and a hydraulic system.
A key feature of these machines is their three blenders, lift cover, and high-velocity blender. They are effective, and the results are smooth and free of bubbles. The CIP/SIP is integrated into the mixers, so it is routinely and automatically cleaned and sterilized. The components that come into touch with the user are from corrosion-resistant SUS316L stainless steel. Stainless steel is used for the exterior shell, while 300EMSH is used for the mirror surface inside.
We are committed to ensuring that all our machines are of the highest quality. Our vacuum, buttons, transducers, and electric control parts are from the highest and best brands. The manufacturing process complies with CGMP requirements at all times. Furthermore, that we guarantee Our emulsifier mixer machines are among the most advanced and high-quality cream-making equipment available everywhere.