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Emulsions emulsifying Equipment

An emulsifier is used to mix two immiscible liquids. Heating or cooling requirements during emulsification, overpressure or vacuum requirements, the need for wall scrapers, design of the mixing head, the viscosity of the liquids, and the desired droplet size are all important considerations when selecting an emulsifying system. Emulsifiers are typically used in the food industry for the production of batters, creams, and sauces, in the pharmaceutical and cosmetics industry for the production of creams and lotions, and in the chemical industry for the production of paint and other emulsions.

Emulsifying

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

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

Manufacturers of cosmetic products need mixing equipment that is capable, flexible, easy to maintain, and low-cost to stay competitive.  Accurate mixing from a reliable, user-friendly machine will give plant managers peace of mind and worry-free operation to focus on improving other areas of their process.
<h2>Consistent mix quality from an easy-to-use, low-cost system</h2>
IKA's SPP Standard Production Plant is a simple yet very capable system for all standard mixing processes, such as homogenizing, emulsifying, stirring, and dispersing ingredients.  The emulsifying system includes a robust anchor agitator with a fixed flow breaker which moves the entire batch volume even for mixes of high viscosities.  A highly advanced scraper design keeps the vessel walls free from scaling, and unique vessel geometry allows the processing of small batches down to 30% of the rated working volume.

The system includes interchangeable dispersing tools and adjustable speed control, dispersing quality and options for a heated or cooled double-walled vessel, and vacuum degassing of the working chamber, among others.  The unit is easy to clean using a CIP system, and maintenance and inspection is simplified by concentrating major components in easily accessible areas.  This design also helps keep the required floor space of the units as low as possible. The SPP is available in working capacities from 25 to 4.000 liters.

Cost-effective homogenizing and emulsifying system

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

Processes including homogenization, dispersing, suspension, emulsification and dissolving benefit with the addition of a dispersing rotor/stator system to the functionality of traditional overhead stirring equipment.  With traditional equipment, achieving desired results in high viscosity media is often difficult and slow and issues such as sediment formation and air inclusions are common.  Adding a high speed rotor and jet pipe in close proximity to the mixing vane greatly enhances the process and helps avoid many of these issues.
<h2>Fast and efficient agitation of highly viscous fluids</h2>
IKA's Rototron RTS is a line of agitators that uses jet-flow technology to speed mixing processes while avoiding many of the issues seen when more traditional equipment is used.  The jet flow agitators use a high speed rotor and jet pipe in close proximity to the mixing vanes to disperse and circulate products within a vessel while avoiding inefficiency caused by back flow, air inclusions caused by a static whirlpool effect, and the need for flow breakers caused by continuously rotating mixtures.  The circulation mechanism also avoids the common issue of sediment formation when being used to produce emulsions.  The units can be used with open and pressurized vessels and mounting options exist to accommodate a wide variety of vessels and configurations.  With this equipment, no seal material makes contact with the product and food or pharmaceutical grade versions are readily available.  Motor sizes are available from 2,2 to 15 kW with max batch sizes from 1.000 to 20.000 liters.

Jet flow agitator for high-viscosity media

Lab-scale mixers are vital in the design or small-batch production of a range of pharmaceutical products. Traditional high shear mixers on this scale are single-purpose units. A modern, multi-function machine allows the processing of a much wider range of substances, offering better value than single-purpose alternatives.
<h2>Flexible lab-scale mixer for mixing or emulsifying powders or liquids</h2>
The DS 3 Mixer from Multigel is a compact, yet powerful, lab-scale high-shear mixer designed specifically for use in design and manufacture of pharmaceuticals.

Supplied with 4 different heads, the DS 3 can be used with powders or liquids such as emulsions used as cosmetic or pharmaceutical carriers, and dispersing powders such as carbomers or alginates.

The powerful yet economical 600W motor enables the DS 3 to reach very high speeds, adjustable up to 12,500 rpm. This power allows it to process up to 10 litres of product at a time, increasing efficiency.

All product-contacting parts have been designed and constructed for fully hygienic operation, and are made from stainless steel and FDA-approved materials.

Weighing only 18kg, and with a form factor of only 280mm x 430mm, the DS 3 can be installed anywhere and is easy to move, requiring only a single-phase electricity supply.

High shear lab mixer for creams

In manufacturing processes of cosmetics, pharmaceuticals, or food and beverages, achieving uniform homogenization and stable emulsions for high-viscosity products is critical. Efficient control of process parameters like temperature, pressure, and stirring speeds is essential to ensure consistent quality.
<h2>Control processing parameters for uniform mixtures</h2>
The Bachmix Compact, available from Bachiller, is an industrial vacuum mixer and reactor designed for liquids and semi-solids. This system enables operations such as homogenization, emulsification, and sterilization under controlled vacuum and pressure conditions. It integrates a slow anchor stirrer with a rotor-stator emulsifier to create fine and stable emulsions, even for products with high viscosity and complex rheology. Users can precisely adjust and monitor process parameters through a PLC control system with a color touchscreen interface. The equipment’s sanitary design is compliant with cGMP and FDA standards. With capacities ranging from 150 to 10,000 liters and an operational temperature up to 200°C, it caters to sectors such as cosmetics, pharmaceuticals, and food processing.

Industrial vacuum mixer and reactor for liquids

In the manufacture of products like cosmetics, pharmaceuticals, and fine chemicals, achieving both thorough homogenization and fine emulsions is essential. Ensuring consistent mixing while managing vacuum and pressure conditions can be challenging, particularly for medium-viscosity products.
<h2>Control process parameters for precise mixing and emulsifying</h2>
The Bachmix L, provided by Bachiller, is a vacuum mixer and reactor designed for handling liquids and semi-solids. It supports a range of operations, including homogenization and emulsification, under vacuum or pressure. The design features a slow anchor stirrer and a rotor-stator emulsifier that produce fine, stable emulsions. With capacities ranging from 150 to 1,000 liters, it operates at temperatures up to 200º C and pressures up to 3 bar(g). The unit includes a heating/cooling jacket, PLC control system with a touch screen interface, and a mirror-polished interior for easy cleaning. Designed to meet cGMP and FDA standards, it is versatile for use in industries like cosmetics, pharmaceuticals, food, and chemicals.

Vacuum mixer for liquids and semi-solids

In industries such as cosmetics, pharmaceuticals, and food processing, precise mixing and reaction conditions are paramount. Manufacturers face challenges including handling high-viscosity materials, achieving stable emulsions, and maintaining stringent hygiene standards.
<h2>Achieves fine and stable emulsions with precision</h2>
The Bachmix Multifunction by Bachiller is an industrial vacuum mixer and reactor designed for processing liquids and semi-solids. It facilitates various operations such as homogenizations, emulsions, vacuum, and pressure operations, as well as washing and sterilization. This mixer controls process parameters including stirring speeds, temperature, and pressure, making it suitable for high-viscosity and complex rheology products. It features a slow anchor stirrer in combination with a rotor-stator emulsifier for extremely fine and stable emulsions. Suitable for cosmetics, pharmaceuticals, fine chemicals, and food and beverage industries, the Bachmix Multifunction operates under conditions that avoid final de-aeration of the product. The unit has capacities ranging from 150 to 5,000 liters and includes a lifting lid with an automatic SUPERCLAMP closing system. Additional features include independently controlled coaxial mixing tools and an integrated PLC control system with a color touch screen interface. The design adheres to ASME VIII div.1, AD-2000, and EN-13445 standards, ensuring compliance with cGMP and FDA validation.

Vacuum mixer reactor for liquids and semi-solids

In the development of cosmetic, pharmaceutical, and food products, achieving consistent homogenization, emulsification, and deaeration is essential. Researchers and product developers often face the challenge of processing high-viscosity and complex rheology materials under controlled conditions.
<h2>Achieve consistent mixing and emulsification</h2>
The Bachlab is a laboratory vacuum mixer reactor designed for liquids and semisolid materials, providing versatile functionality for various processes. Utilizing coaxial mixing tools and a high-shear rotor-stator system, it ensures stable emulsification and dispersion. The equipment integrates vacuum, pressure, heating, and cooling operations, all controlled via an intuitive PLC system with a color touchscreen. Available in capacities from 5 to 150 liters, with options for standard and recirculation versions, the Bachlab allows precise process control and data registration via Ethernet. Ergonomically designed for easy access, it adheres to GMP and EHEDG standards, making it ideal for cosmetic, pharmaceutical, chemical, and food industries. Bachiller offers this mixer as part of a broader range of products, ensuring seamless scale-up to industrial production.

Laboratory vacuum mixer reactor for liquids and semi-solids

In various industrial processes, achieving consistent product quality requires precise mixing techniques. Challenges such as droplet size reduction, emulsion formation, and viscosity control often demand specialized equipment.
<h2>Ensures homogeneous mixing for varied applications</h2>
The MixMaster from Daniatech is a versatile, compact solution for inline high-shear mixing. Operating on the rotor-stator principle, it uses a closed mixing wheel to pass the product through patented slots. This makes it suitable for low to medium viscosity products, performing its out-pumping action autonomously. For higher viscosity applications (>250cP), positive feeding is needed. The MixMaster provides efficient mixing through both batch and inline operations and includes light homogenization in certain setups. Applications range from emulsions and slurries to yogurt smoothening and pigment solutions. The unit features options like double mechanical shaft seals, bypass loops, and both batch and inline configurations. Standard equipment includes a mixer unit with a flushed shaft seal, tri-clamp inlet/outlet, motor cover, and a stable frame.

Inline high shear mixing unit for low to medium viscosity products

In food processing and chemical industries, achieving a uniform emulsification of liquid and pasty products is crucial for consistency and quality. Traditional methods often struggle with efficiency and cleanliness, particularly when dealing with large batch sizes and varying viscosities.
<h2>Ensures uniform emulsification with integrated temperature control</h2>
The AGM Emulsifying Plant from GLASS Maschinen is designed for precise and efficient emulsification of both liquid and pasty products. The plant features capacities of 80, 150, and 300 liters, catering to various production requirements. The automatic lid operation and motor-driven swivel drum simplify handling and ensure ease of use. Equipped with a cutter head and hygienic seals that can be replaced without disassembling the motor or gear unit, it minimizes maintenance downtime. Additionally, the integrated vacuum pump and direct steam injection system allow for optimal temperature control, enhancing product quality. Cooling equipment and precise dosing devices further contribute to the equipment's efficiency. The EasyClean drain valve flush with the drum wall ensures thorough cleaning, maintaining hygiene standards.

Emulsifying plant for pasty and liquid products

In the production of emulsions, cream, and UHT milk, maintaining stability and consistent texture can be challenging. This often requires high-pressure homogenization to efficiently break down fat globules and create uniform mixtures.
<h2>Achieve stable, uniform emulsions under high pressure</h2>
The HST homogenizers from HST Maschinenbau are designed for high-pressure applications to produce stable and uniform emulsions. Utilizing turbulent and laminar forces in a narrow ring-shaped gap, they efficiently break up agglomerates, enhancing product stability, color intensity, flavor, and consistency. Available in various series such as HL, HLI, and HLE, these homogenizers offer capacities ranging from 300 liters per hour up to 80,000 liters per hour. Each model can be optionally configured for aseptic or Atex design, ensuring compliance with stringent hygiene and safety standards. Notable features include noise insulation cladding and reduced water consumption in certain models. Key applications span across the food, pharmaceutical, cosmetics, and chemical industries, processing products like fresh milk, baby food, intravenous emulsions, and lubricants.

Homogenizers for high-pressure applications

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

In the cosmetic and pharmaceutical industries, achieving a homogenous mixture and consistent emulsion despite varying product viscosities is essential. Reliable temperature control and the ability to operate under vacuum are crucial to ensure product quality and stability during the mixing process.
<h2>Achieve homogeneous mixing and emulsification</h2>
The MCR Counter-Rotating Blender by INOXPA is designed for mixing and homogenizing dispersed products at a controlled temperature, regardless of viscosity. Featuring an anchor-type agitator and counter-rotating blades, it ensures thorough mixing and emulsifying. The units can operate under vacuum, from -1 to 0.5 bar, with an operating temperature range of -7 to 120 ºC. Equipped with a CIP system for easy cleaning, it supports monitoring of temperature, pressure, pH, weight, and viscosity. This makes it suitable for a range of applications from pharmaceutical creams and gels to food industry sauces and emulsions. Built to FDA standards, it includes AISI 316 stainless steel parts in contact with the product and optional weighing and lid lifting systems.

Counter-rotating blender for cosmetic and pharmaceutical mixing

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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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