What is emulsifying equipment?

What is emulsifying equipment


What is emulsifying equipment?: A vacuum emulsification mixer, also known as an emulsifying machine, is a tiltable vacuum emulsifier used in the cosmetic, pharmaceutical, food, and chemical industries to create viscous emulsions and suspensions. It is the most common kind of vacuum emulsification equipment and may process anything from a few ounces to many gallons of cream or emulsion at a time.

By decreasing droplet size to below 1 micron, the emulsifying machine produces exceptionally stable and fine emulsions. Although they begin at relatively modest flow rates, the pressure and mechanical shear in such emulsification processes may be easily go up.

The emulsifier machine reduces the droplet size of the secondary oily phase to ensure that non-soluble liquids remain intact in a uniform liquid mixture. High shear and spinning propeller mixers are two common mechanical methods for doing this.

What’s Emulsification?

The term “emulsification” refers to the dissolution of oil droplets in an initial phase of liquid. In reality, emulsions are only suspensions of two streams of liquid that, if mixed together, would swiftly split. Emulsions are widely common in many regular products, such as lotions, ointments, mayonnaise, sauces, and many other.

Emulsifying is a method that mixes two incompatible liquids. The goal of emulsifying is to break up the discontinuous phase into smaller and smaller droplets. For emulsifying purposes, rotor-stator machines excel. Because of the mixing head’s intense shearing and expanding pressures, they produces very small droplets. Rotor-stator devices may aid in the quick movement of emulsifier molecules to the fresh surfaces by creating conditions of high turbulences.

Achieving the finest droplet size is essential for producing a stable emulsion. When shear energy adds to the mixture, the droplets in suspension shrink, resulting in a finer, stabler emulsion.

When making an emulsion, emulsifiers like tensides are frequently goes into one of the two components in order to stabilize the emulsion. Emulsifiers have properties that make them both water- and fat-loving. The emulsifier molecule forms bonds with both the water and the oil, but only on one side. By doing so, emulsifiers prevent the emulsion’s droplets from coalescing into larger globules. 

Here are some modern emulsifying mixing methods that are applicable to make a wide variety of emulsions:

  • Using dispersion machines for emulsification in batch processes.
  • The use of rotor-stator dispersion devices allows for continuous emulsifying.
  • The use of rotor-stator dispersion devices allows for continuous emulsifying.
  • Emulsification during the recycling process.

🔵 Emulsification Applications

Chemical manufacturing, liquid pharmaceuticals, and food and beverage industries extensively use emulsification. Emulsions may be made using a variety of different types of mixers, including stirring vessels or agitators, static mixers, and homogenizers. However, rotor-stator mixers work very effectively for this purpose (in particular for macro-emulsion droplet sizes).

Emulsions are common in a wide variety of industries, including food such as milk, mayonnaise, and sauces, ointments in pharmaceuticals, face cream in cosmetics, and so on. As an analogy, consider the emulsifying process in terms of the combination of water and oil or fat. Do oil and water even mix? The oil returns to the water’s top even after prolonged, vigorous agitation. Not only does the amount of energy matter, but so does the applicable technique (emulsifying).

🔵 High Shear Emulsion with Easy Emulsion Stability

Emulsions with droplet sizes of 2 to 5 microns are readily achievable using the high-shear rotor-stator mixer, which is well-suitable for this application. In specific preparations, emulsions as small as 0.5 microns in size are possible.

Some mixers have the extraordinary capacity to produce very minute droplets without the need for ancillary tools like high-pressure homogenizers. By optimizing the shear forces in the mixer, producers may streamline the homogenization procedure, cut down on expenses, and boost productivity.

How does emulsifying equipment work?

The agitator in the outer frame steadily spins in a clockwise direction while mixing ingredients. Materials that might otherwise adhere to the wall of the emulsifying tank and catch fire are scraped from the tank’s inside using Teflon blades and moved upwards.

Meanwhile, the cream is pushed downhill into the high-speed homogenizing and emulsifying area by the inner straight impeller, which spins slowly in a counterclockwise direction.

The cream in a vacuum emulsification blender rolls over the device from top to bottom and back to top due to the opposing forces of the central agitator and the wall scraper. It doesn’t take long for the cream’s internal wall to absorb the jacket’s heat after mixing well.

Emulsifying equipment relies on a batch mixer or emulsifier that composes of a high-velocity rotor and a stator with holes. Motors turn the rotor at 3000 rpm, creating a powerful suction force. Shearing, cutting, emulsifying, and homogenizing take place in the shear gap between the stator and rotor as materials enter the rotor from both the top and bottom. They are then propelled through the stator’s openings at high speeds.

These three categories of slow and high pressures keep cycling over and over again. Also, the cream may be uniformly combined, distributed, emulsified, and homogenized by circulating it within the emulsification machine.

 When you need to get rid of air bubbles that form during processes like mixing, dispersing, emulsifying, and homogenizing, a water ring-type vacuum pump -0.09Mpa will do the job. It moves materials between the oil and water phase tanks and the emulsification facility. The suction sucks tiny granules as well to keep the air clean.

To access the mixing chamber of the primary emulsification mixer, we use the hydraulic oil pump. The mixing section cannot start when there is no lid present. Hence, adding extra safety features for emulsifying process.

MAKWELL Emulsifying Mixers for Preparing Emulsions

For the purpose of emulsion preparation, we provide a comprehensive selection of tanks and mixers. We offer a wide range of high-quality mixers for a variety of emulsion preparation applications, from small-scale lab mixers for R&D to massive production machines for mass production.

Our mixers’ innovative features allow manufacturers to whip up stable emulsions with uniformly large droplets reliably. This not only increases efficiency in making emulsions but also guarantees high-quality final products and happier consumers.

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