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Emulsions dispersing Equipment

Dispersing systems are used to produce emulsions of two immiscible liquids or dispersions of solid particles in a liquid medium. The mixers generally operate on the rotor/stator principle and apply a high shear force on the suspended particles to break them down. The choice of a dispersion mixer depends on the physical state of the material being dispersed, the continuous or batch nature of the process, desired particle size, and the viscosity of the mixture. Dispersion mixers are widely used in the food industry for the dispersion of solid ingredients in oil or water and in the coatings industry for the dispersion of pigments.

Dispersing

You can make emulsions by combining two immiscible liquids (oil and water, for example) in a suspension through the use of force. The use of emulsifiers is necessary to keep this mixture stable and permanent.

Emulsions

For mixing and dispersing tasks that cannot be completed by conventional stirring means, equipment using the rotor/stator principal are often well suited.  Batchwise production of emulsions and suspensions of abrasive products is highly demanding and the use of well suited equipment is crucial.
<h2>Top entry rotor/stator dispersing equipment for highly abrasive products</h2>
The Ultra-Turrax UTS is IKA's dispersing machine for abrasive products when more conventional stirring equipment cannot be used.  Working on the rotor/stator principal, the units consist of a motor, a mounting flange, a stator with extension rods, a rotor, and a rotor drive shaft.  A variety of dispersion tools known as generators can be fixed to the rotor making the units adaptable to most mixing tasks.  The shaft seal is located at the motor flange and therefore is never in contact with the product.

These units are designed for diagonal from above or vertical off-center mounting orientations.  They can be used with open, or pressurized vessels.  For open vessel operations, the units are supported via wall mounts or floor stands. All variants of the UTS dispersing machines stand out for their unique ability to process highly abrasive ingredients.  Units are available for batch sizes from 500 to 1.700 liters.

Batch dispersing machine for abrasive products

When your process requires high performance mixing or dispersion but conventional stirring methods cannot be employed due to access or other restrictions, you need a machine designed for bottom entry into a vessel.
<h2>Bottom entry mixing in a simple and compact package</h2>
IKA's Ultra-Turrax UTE is a high performance dispersing machine designd for bottom entry into vessels.  It mixes, emulsifies, and disperses free-flowing or liquid media with a viscosity of up to 5.000 mPas in batch operation.  The units use the rotor-stator principal and a wide variety of generators is available to tailor the process to your needs.  No strong vortices or product aeration occurs as a result of the mixing action even when the vessel is filled to a very low level or is emptied during the stirring operation.

The units are compact and simple, primarily consisting of a motor, a a rotor drive shaft, a dispersion tool (generator) and a mounting flange conbined by a lantern housing.  The shaft seal is of an easily maintained mechanical type with several variants depending on the particular application.  Options for speed control, special materials, and special surface finishes also exist.  The units are available with batch capacities from 70 to 4.000 liters.

Batch dispersing machine for bottom entry into vessels

Innovators in process development need laboratory equipment that helps their ideas be reliably scaled up to production.  For dispersion equipment, this requires important process parameters like circumferential speed, tool, and mixing chamber geometry to be structurally identical to production level equipment.
<h2>A highly adaptable dispersion machine for the lab, designed for reliable scale-up</h2>
IKA's Labor-Pilot is a versatile, compact, and highly reliable inline laboratory dispersing machine.  It is designed for solid-liquid mixing, homogenizing, emulsifying, suspending, and wet milling.  It is designed specifically to match process characteristics of larger dispersion machines so developed processes can be reliably scaled up.  The units can work at elevated temperatures, pressure/vacuum conditions, and with abrasive substrates.  Changeout between the several different working modules is quick and easy with each module giving the machine the particular characteristics needed to perform particular tasks and work with a particular type of product.  Compared to stirrers, mixing time for a wide variety of dispersions from coarse to fine can be reduced by up to 50%.

Pilot dispersing machine for testing and scale-up

Innovators in a wide variety of industries need laboratory equipment on which processes and products can be developed and reliably scaled up to production.  For dispersion equipment, this requires important process parameters like circumferential speed, tool, and mixing chamber geometry to be structurally identical to production level equipment.
<h2>A highly adaptable dispersion machine for the lab, designed for reliable scale-up</h2>
IKA's Processs-Pilot is a versatile and highly reliable inline laboratory dispersing machine.  It is designed for solid-liquid mixing, homogenizing, emulsifying, suspending, and wet milling.  It is designed specifically to match process characteristics of larger dispersion machines so developed processes can be reliably scaled up.  The units can work at elevated temperatures, pressure/vacuum conditions, and with abrasive substrates.  Changeout between the several different working modules is quick and easy with each module giving the machine the particular characteristics needed to perform particular tasks and work with a particular type of product.  Compared to stirrers, mixing time for a wide variety of dispersions from coarse to fine can be reduced by up to 50%.

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In-line laboratory dispersing machine

Laboratory mixers have not always been easy to work with.  Getting all the product out of the mixing vessel, and mixing small batches were not as easy as they should be and mixing processes in general were often ineffective or too slow when powders and slightly more viscous fluids were involved.  Innovators need equipment designed for laboratory scale use that addresses these previously common issues.
<h2>Easy to use, effective mixing for the laboratory</h2>
The Magic PLANT series from IKA is a laboratory dispersing machine designed to address many of the issues and difficulties previously associated with mixers of this size.  Where historically it was sometimes difficult to remove all of a product from the mixing vessel, the Magic PLANT includes both a discharge valve at the bottom of the vessel and the ability to completely tilt the vessel to pour out its contents.

Where the processing of very small batches with traditional laboratory equipment was difficult or impossible, the Magic Plant's mixing vessel has a conical bottom allowing small batches to be mixed as effectively as large ones.  And where mixes involving powdered ingredients with a wide range of bulk densities were difficult or slow to form into homogeneous mixtures, Magic PLANT can be tilted while mixing to better engage all powders with the stirrer and a specialized spiral shaped stirrer is included.  Variants are available that are best suited for, batch, inline, or powder processing operations.  For all variants the intensity of the mixing and dispersing effect is adjustable and the overall design is modular allowing easy integration with other laboratory equipment.

Laboratory dispersing machine for low-viscous masses

Texture and consistency are critical to foods with delicate compositions like dressings and spread. But the base ingredients do not always mix into a homogenous recipe, especially in the case of emulsions such as mayonnaise.


<h3>Disperse your sauce ingredients uniformly into the mix</h3>
The Standard Production Plant (SPP) from IKA is a high-shear mixer for condiments and dressings such as mayonnaise, tomato sauce, and cheese spreads. The system incorporates a two-stage unit that blends the ingredients and, secondly, disperses them homogeneously across the medium.

A rotor-stator solution achieves dispersion with a narrow particle size distribution, ensuring stable emulsions and suspensions with the longest possible shelf-life. Meanwhile, the dispersing chamber produces a vacuum to maintain a constant flow rate regardless of viscosity level.

The SPP is available in batch volumes from 25 to 4,000 liters and is equipped with spray nozzles for quick and easy clean-in-place without additional pumps.

Industrial Sauce Homogenization and Emulsifying System

Processing high viscosity fluids or creating fine emulsions often requires achieving consistent homogenization. Challenges include ensuring uniform particle dispersion and maintaining product integrity during recirculation.
<h2>Homogenize and recirculate products efficiently</h2>
The in-line external homogenizer series AXOFAST by Axomatic (Marchesini Group) is designed for effective homogenization and recirculation of industrial fluids. With motor power options ranging from 10 to 40 kW and double fixed speeds of 1500/3000 RPM, it also offers speed adjustment via inverter from 300 to 3000 RPM. The flow rate varies between 10 to 80 m³/h, ensuring flexibility in various processing applications. Features include a ceramic mechanical seal for durability, easy cleaning with dismountable triclamp connections, and high efficiency in dispersing raw materials evenly. This homogenizer is suitable for industries requiring precise and efficient fluid processing capabilities.

In-line external homogenizer for industrial fluid processing

In continuous industrial processes, achieving uniform mixing is crucial, especially for liquid/solid mixtures like emulsions, dispersions, and suspensions. Challenges include maintaining homogeneity and preventing contamination in open tanks at atmospheric pressure.
<h2>Ensures uniform mixing for continuous processes</h2>
The LUMPP sealless top-entry mixer by HASLER Group is designed to be installed in open tanks operating at atmospheric pressure and temperatures below 100°C. This mixer is engineered for processes requiring high-performance mixing such as liquid/solid mixtures, emulsions, and dispersions. The mixer supports products with densities up to 1500 kg/m3 and viscosities up to 1500 cps, providing consistent homogeneity 24/7. With a wide variety of impeller profiles and materials including stainless steel and nickel alloy, it offers superior hydraulic performance while consuming less power. ATEX compliance ensures safe operation in hazardous environments. Key specifications include motor power range from 0.18 to 30 kW, operational speeds from 10 to 1,500 rpm, shaft lengths up to 10,000 mm, and impeller diameters exceeding 4,000 mm. These features make it suitable for industries including water treatment, specialty chemicals, and bioenergy.

Sealless top-entry industrial mixer

In various production processes, such as those in the chemical, food-processing, pharmaceutical, and cosmetic industries, high shear mixing is essential. Conventional mixing techniques often fall short when dealing with ingredient separation or space constraints within tanks, posing significant challenges.
<h2>Pump, disperse, homogenize, and emulsify products</h2>
The ME 4100 In-line Mixer by INOXPA offers a versatile solution for high shear mixing applications. This mixer is designed to pump, disperse, homogenize, and emulsify products in various industries. The mixing unit features a stator and rotor within a casing similar to that of a centrifugal pump. High shear is achieved through the precise tolerance between the rotor and stator, and the rotor's high operational speed (over 20 m/s). Additionally, if product viscosity exceeds 200cP or high discharge pressure is required, auxiliary pumps can be integrated. Built with sanitary single mechanical seals and CIPable design, the mixer is ideal for high-hygiene applications. Available materials include AISI 316L for product contact parts and AISI 304 for other components. Options for customization include various working heads, mechanical seals, and connection types. The design ensures efficient particle size reduction to less than 100 microns and is especially useful in existing plants needing efficient recirculation processes.

In-line high shear mixing solution

Making.com is a new online platform that helps makers find production technology quicker by grouping it around the products they make.

For all the bad rep that it gets, palm oil still makes up around 40% of the global vegetable oil supply, according to <a href="https://www.wwf.org.uk/updates/8-things-know-about-palm-oil" target="_blank" rel="noopener" data-attribute-index="0" data-entity-hovercard-id="urn:li:fs_miniCompany:805644" data-entity-type="MINI_COMPANY">WWF</a> estimates.

Alternative oils pose fewer risks to biodiversity and carbon release, but producing them is not as efficient. This puts the food manufacturing industry in a sticky situation.

But one company picked up this challenge. Its ultimate mission is clear from the name: <a href="https://www.nopalm-ingredients.com/" target="_blank" rel="noopener" data-attribute-index="2" data-entity-hovercard-id="urn:li:fs_miniCompany:73236339" data-entity-type="MINI_COMPANY">NoPalm Ingredients</a>.



Using a special yeast, the team developed a process to convert sugars and organic acids in virtually any kind of biomass into microbial oil.

<a href="https://www.linkedin.com/in/ACoAACUhMNEBMChbVERGkwwFhucNTiIbouuX9lg" data-attribute-index="6" data-entity-hovercard-id="urn:li:fs_miniProfile:ACoAACUhMNEBMChbVERGkwwFhucNTiIbouuX9lg" data-entity-type="MINI_PROFILE">Jochem de Vries</a> showed us a range of samples made from fermented grains.

The new, food-grade ingredient is ready to replace palm oil (or any other tropical oil).

NoPalm Ingredients typically works with sidestreams like potato peels or discarded vegetables, circulating the same waste material that producers generate.

Thanks to Jochem and the rest of the team, that 40% share of the vegetable oil supply will quickly evaporate. And tropical forests can flourish

#Changemaker: Stop facepalming at palm oil, start using fermented alternatives

Food

Edible oils are fats that you can extract from various plants and animal tissues. The most popular sources are olives and sunflowers. You can use them for different cooking techniques, such as frying, baking, and other methods. Manufacturers are now finding ways to extract oils with a higher natural fat content efficiently using edible oil extraction machines.

Edible Oil

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