Vacuum Emulsifying Blender

Equipment Introduction

This unit is a three-axis multifunctional blending equipment, driven by dual motors, combining high-speed emulsification with low-speed blending, capable of adapting to the dispersion, emulsification, homogenization, refinement, dissolution, and mixing processes for medium to high viscosity materials. The working section is composed of a frame-type blender, a multi-layer paddle-type blender, and an emulsifying homogenizer. The frame-type blender and paddle-type blender rotate in opposite directions at the same low speed, while the emulsifying homogenizer's rotor rotates at high speed, with the stator rotating in the same direction and at the same speed as the paddle-type blender. The three work in harmony, complementing each other, resulting in a multiplied effect. Both the emulsifying homogenizer and the frame-type blender, as well as the paddle-type blender, can be used simultaneously or separately as needed for production.

There are various types of rotors and installation methods available to match different operating conditions.

Heated and cooled jacketed containers with insulation jacket and temperature control system, capable of electric heating, steam heating, or heat transfer medium circulation heating and cooling.

Equipment comes with a vacuum system, capable of vacuum feeding or vacuum degassing.

Operating Principle:

During operation, the PTFE scraper blades around the trough mixer adhere to the drum wall, effectively removing material adhered to it, continuously generating new surfaces; the material is sheared, compressed, and folded by the trough mixer and counter-rotating paddle mixer, then drawn into the bottom emulsifying homogenizer. The high-speed rotating rotor generates high shear line velocity and frequent mechanical effects, causing the material to experience intense mechanical and hydraulic shearing, centrifugal pressing, fluid layer friction, impact tearing, and turbulent actions within the narrow gap between the rotor and stator. This quickly breaks the material into small particles, allowing immiscible solid, liquid, and gas phases to be instantaneously and finely dispersed and emulsified under the combined action of the appropriate process and additives. Through cyclic repetition, a stable and high-quality product is ultimately achieved.

The emulsifying machine operates under a vacuum, which efficiently removes gases present in the material and bubbles generated during the mixing process. This results in a product with a glossy finish, fine texture, and excellent extensibility, suitable for long-term storage without oxidation.

Common Processes:

Narrow the particle size of liquid-liquid, solid-liquid material particles through the action of mechanical force, uniformly distribute one phase into another or multiple phases, forming a stable emulsion state. Suitable for processes such as mixing, dispersing, emulsifying, homogenizing, deaggregating, suspending, refining, and dissolving.

Emulsification: The process of preparing a stable emulsion from incompatible liquid substances.

Homogenization: The process of further disassembling, refining, and evening out the dispersed phase in a disperse system material.

Dispersed: Paste prepared for solid-liquid dispersion systems, consisting of insoluble solid powder or dispersed in a liquid.

Solubility: Solutions prepared by dissolving solid or liquid substances in another liquid

Blended: Uniformly blended to prepare a new material from various dispersed systems

Application Products:

Cosmetics, food, creams, lotions, toothpaste, face creams, hand creams, eyeliner, shampoos, body washes, facial cleansers, detergents, hair dyes, ointments, preparations, cell lysates, drug synthesis, vaccines, fat emulsions, suspensions, salad dressings, mayonnaise, jams, ketchup, fondue bases, ice cream, cheese, milk drinks, yogurt, reconstituted milk, juices, jellies.

Component Parts:

Drive motors, reducers, bearings and seals, emulsifying and mixing sections, lifting systems, vacuum systems, heating and temperature control systems, electrical control systems, optional CIP cleaning systems, containers, and other auxiliary components

Complete unit functions available:

Working Volume: 5L-1500L (Custom Large Volume Available)

Emulsifying Power: 0.55kW - 18.5kW (High Power Customization Available)

Blending Power: 0.18kw-7.5kw (High-power customization available)

Power Source: 220/380/400/415/440/480V; 50/60Hz; 3P

Motor Types: Standard, Explosion-proof, Variable Frequency

Energy Efficiency Rating: GB2 (IE3), GB3 (IE2)

Protection Level: IP54, IP55, IP65

Work Environment: Vacuum

Installation Methods: Top Insertion, Bottom Insertion

Lifting Method: Electric Lifting, Hydraulic Lifting, Fixed Type

Speed Regulation: Variable Frequency Speed Regulation, recommend using imported brand variable frequency inverters.

Sealing Method: Skeleton Oil Seal, Mechanical Seal

Material Input: Manual Feeding, Vacuum Input

Discharge: Bottom valve for pot unloading, discharge directly (can be pressurized or pumped), tilting the pot for pouring out

Container Cap: Vacuum Sealed Lid

Insulating Sleeves: Heating/Cooling Sleeves, Insulation Sleeves

Heating Methods: Electric Heating, Steam Heating, Conductive Medium Circulation Heating

Gauge Valves: Voltage Gauge, Current Gauge, Speedometer, Vacuum Pressure Gauge, Steam Pressure Gauge, Temperature Sensor, Drain Valves, Safety Valves

Washing: Manual cleaning, CIP cleaning system (manual, semi-automatic, fully automatic)

Material: 304, 316L, Sanitary Grade (Meets GMP compliance standards)

Operation Panel: Standard Button Cabinet, Intrinsically Safe Explosion-Proof Button Cabinet, Flameproof Explosion-Proof Button Cabinet, Standard Touchscreen, Explosion-Proof Touchscreen

Electrical Control: Relay Control, PLC Control, Vector Control, Temperature and Pressure Detection

Typical Parameters:

Note:

The above typical parameters are based on a solid content of <30%, density of <1.3g/cm³, and a full load material viscosity range of 100~10000cp.

Please specify your required processing volume, equipment type, size requirements, or the characteristics of the material you need processed, along with the process details.密斯科思's sales engineers will provide a satisfactory solution.

Key Features:

1. Attractive appearance, fine craftsmanship, imposing and generous, with strong visual appeal.

2. Compact and rational structure; easy installation, operation, and maintenance; stable performance, safe and reliable.

3. This machine boasts powerful functionality and high automation, integrating dispersion, emulsification, stirring, vacuum, lifting, heating, insulation, automatic control, and CIP cleaning system. It is capable of adapting to various preparation processes for different materials.

4. High efficiency and superior product quality: The equipment line speed is high, enabling rapid and even distribution of one phase into another or multiple phases, achieving refined homogenization, dispersion, and emulsification effects, resulting in high-quality and stable products.

5. High precision processing and long lifespan; the rotating stator is made of forged material and processed by a CNC machining center, featuring minimal stator gap and excellent shearing fineness, with high emulsification and dispersion efficiency, thereby extending the product's service life.

6. The stator is easy to disassemble and clean.

7. Variable frequency speed control, low energy consumption, recommend imported brand heavy-duty configuration.

8. Minimal air entrapment during operation; medium to high-speed operation allows for rapid dissolution of material, resulting in smaller secondary particles.

9. Utilizes a sealed design to minimize solvent evaporation, reduce material loss, and save on environmental protection; vacuum suction to effectively prevent dust飞扬; achieves vacuum degassing of materials, meeting hygienic and sterile requirements.

10. Equipped with safety protection features, ensuring safe and stable production operations.

Highly customizable to meet various material characteristics, processing capacity, high-temperature and high-pressure, flammable and explosive, intelligent, and digital requirements. Materials can be customized according to specifications, including SS304, SS316L, and sanitation-grade materials compliant with GMP standards.

12. Strong production continuity, capable of running for long periods of 24 hours.