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Gels mixing Equipment

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

The easiest and most commonly used method of making gels is mixing gelling agents with water to form a weakly cohesive internal structure. The gel production process is pretty linear and straightforward, from mixing hydrocolloids and water to labeling and sealing containers.

Gels

Producers in a wide variety of industries benefit from equipment that can continuously create highly accurate homogeneous mixtures of liquid and solid ingredients.  The use of a continuous process requires less floor space for storage and greatly reduces production times.  Closed systems eliminate the creation of dust thereby enhancing safety and efficiency.  Equipment that offers all these characteristics will give its users an edge over the competition.
<h2>Continuous dispersion of solids into liquids without the generation of dust</h2>
IKA's mixing Plant MHD includes a mixing machine, metering units, an electrical control system, and peripheral equipment which is customized to meet the customer's facility and process needs.  The Plant MHD is a homogenizing system that allows the dust-free mixing of liquids and solid granules or powders in a continuous process.  The ingredients are continuously fed into the plant's working chamber in the precisely controlled ratios required by the final product, where they are mixed and then dispersed.  In this way, a ready-to-use final product is produced in just one pass.

The units can handle mixtures of up to 80% solid content and viscosities of up to 50.000 mPas.  Since the only agitation of the solid occurs within the machines working chamber after the liquid components have been introduced, no dust is generated.  A wide variety of solid feeding systems is available and IKA can help select the process that is best suited to your needs.  The Plant MHD unit is available with capacities from 200 to 40.000 liters per hour.

Dust-free continuous homogenizing system

Onsite dilution of liquid process ingredients has historically been associated with several issues that limit its economic benefits.  Manufacturers need equipment that can easily dilute liquids with a wide variety of characteristics while avoiding many of the common issues.  They need a quick process, a small required equipment foot print, and a resultant mix that is homogeneous and free of air.
<h2>Rapid, accurate closed system dilution</h2>
IKA's DPV Dilution Plant is a completely closed dilution system for combining two or more liquids in a controlled proportion.  The closed system eliminates the need for large storage and mixing vessels common to traditional dilution methods and also eliminates the introduction of air and resultant generation of foam.  Inputs with a wide range of viscosities and concentrations are easily processed.

The core of the unit is a single stage in-line dispersing unit and metered pumps specially designed for high accuracy delivery.  A full array of sensors and feedback is also available and optionally utilized for automation of the system.  The components to be mixed are only in contact with each-other immediately before dispersion which avoids any unwanted reactions or lump-formation.  Capacities are available from 3.000 to 15.000 liters per hour.

Dilution system for two or more liquids in one pass

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

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

Mixing fluids of medium viscosity for many production processes requires an agitator with a simple and proven reliable design while at the same time being flexible and adaptable enough to give optimum results for your particular application.  For acceleration of dissolving, temperature transfer, or simply mixing powders into liquids.
<h2>Proven agitator design optimized for your process</h2>
The Turbotron line from IKA are agitators that satisfy a huge array of needs from a wide variety of processes.  The machines include output shafts coupled directly to the motor, or through a gearbox.  They can be used with pressurized or open containers and can mount directly to the vessel for pressurized applications and supported on a wall mount or floor stand in open vessel applications.  Sizes are available suitable for batch sizes from 100 to 20.000 liters with motor powers from 0,37 to 9,2 kW and rotation speeds from 250 to 1500 rpm.  A wide variety of lengths is also available.  Interchangeable tools on the agitator shaft and options VFD drives for rotation speed control make the units extremely adaptable to a wide variety of fluid viscosities and output characteristics.

Agitator for medium viscosity media

Reliably agitating fluids in open or pressure-less vessels in a laboratory or small scale production environment is often an important step in developing new products and processes for a wide variety of industries.  Innovators need simple, reliable mixing equipment that is simple to operate and optimized for their particular output requirements.
<h2>A simple, safe, and powerful rotary agitator with a variety of interchangeable heads</h2>
The Turbotron RKG line from IKA is a simple and robust rotary agitator for lower viscosity fluids designed to act from above on an open or pressure-less vessel in a variety of industries.  The units are powerful, with motor powers from .25 to .75 kW and have infinitely adjustable agitating shaft speeds from 20 to 1200 rpm.  Interchangeable agitating tools can be fixed to the shaft to optimize the action on the fluid to achieve your desired results.  Tools available include, propellers, turbines, and dissolvers, as well as centrifugal, paddle, or anchor stirrers.  All parts that contact the product are stainless steel and optional safety guards to protect personnel from the rotating shaft are also available.

Agitator for low viscosity media

<span style="font-weight: 400;">The production of high quality pharmaceuticals often requires mixing of suspensions and similar solutions. A key challenge to overcome is the unwanted incorporation of air to the mix. Air incorporation causes major problems in processing and end-product quality. Air in the product may </span><span style="font-weight: 400;">cause excessive foaming, increased fouling in heat exchangers, and cavitation in homogenizers. A modern vacuum mixing solution can overcome these problems, as well as ensuring efficient operations with longer production hours, lower maintenance costs, and a safe, high-quality end product.</span>
<h2>Mobile and fixed vacuum mixing units for pharmaceutical production</h2>
<span style="font-weight: 400;">The vacuum mixer range from Ipros has been designed specifically for the pharmaceutical industry, and units are tailor made to suit your exact solution production requirements.</span>

<span style="font-weight: 400;">Based on an all-stainless GMP frame design, the vacuum mixer range is available with vessel sizes from as small as 30 litres up to 500 litres in a portable format, and from 500 litres up to 1000 litres in fixed format with forklift supports. This makes the range suitable for all scales of production.</span>

<span style="font-weight: 400;">The Ipros vacuum mixer units can run with a vacuum down to -1 bar, and can be specified with heating or cooling elements, and as insulated or non-insulated vessels as your requirements dictate. All vessels can be designed to connect to a wide variety of automated, semi-automated and manual process systems for simple integration.</span>

<span style="font-weight: 400;">Perfect for use in the most stringent pharmaceutical production environments, the vacuum mixers have integrated cleanable and sterilisable energy connections, GMP motor and utility housings, and are supplied with an operator panel and software allowing for full process control. These mixers can be used for any ATEX compliant executions.</span>

Vacuum mixer for suspensions

In industrial settings, achieving homogeneous mixing of various materials can be challenging. Dry powders, wet suspensions, and viscous substances each require specific handling to ensure uniform results without residue or clumping.
<h2>Achieve homogeneous mixing with versatile conical blender</h2>
The AM Conical Mixer from Amixon is designed to deliver high-quality mixing results for dry, moist, and viscous materials. The spiral mixing blade initiates a three-dimensional flow, creating a helical upward movement on the periphery and a downward flow in the center. This ensures thorough mixing and complete discharge. The mixer can handle a range of materials, including powders, wet suspensions, and pastes. It meets FDA and 3-A Sanitary Standards, making it suitable for sterile applications and compliant with EHEDG requirements. The mixer can also be equipped with high-speed cutting rotors for deagglomeration and is driven from the top using a single top bearing, ensuring low maintenance. Jacketed and vacuum-rated versions are available for use as a vacuum dryer or reactor.

Conical mixer for dry, moist, and viscous materials

In the pharmaceutical, daily chemical, and food industries, processing high viscosity products such as ointments, lipsticks, and gels often presents challenges. Traditional mixing equipment struggles to handle the flow and circulation of these dense materials, leading to inefficiencies and inconsistent results.
<h2>Optimize mixing for high viscosity fluids</h2>
The Co-Axial mixer, developed by AUSTAR, is designed for complex mixing processes such as dissolution, dispersion, reaction, emulsification, and condensation. Supporting high viscosity products with an effective volume range from 50L to 5000L, its unique internal paddle and external frame combination improves flow and circulation, enhancing both the mixing and thermal efficiency. Equipped with adjustable speed settings through a frequency converter, it caters to various product requirements. This mixer is suitable for a wide array of industries, including pharmaceutical, daily chemical, and food production. Multiple options are available to tailor the mixer to specific needs.

High viscosity product mixer

When developing new food recipes or testing product processes on a small scale, it's critical to achieve a homogeneous mixture quickly to evaluate the formulation accurately.
<h2>Achieve lump-free, air-free homogeneous mixes</h2>
The LabMaster by Daniatech is a compact, high-shear mixer designed for small-scale recipe development and pilot productions. It uses vacuum to draw powder into the mixer below the liquid level, instantly wetting the powder. The high-shear mixer and scraper agitator generate a controlled vortex, separating air from the liquid and achieving a homogeneous, air-free dispersion within seconds. The mixer comes with an insulated jacket for fast heating and cooling with steam or ice water, and it can be equipped with a direct steam valve for extra quick heating. Suitable for mixing sauces, dressings, gels, creams, and emulsions, it achieves homogenization down to 1µ and viscosities up to 50,000 cP. Standard features include a vacuum system, direct steam system, scraper agitator, integrated PLC control system, and EHEDG-compliant construction.

Lab-scale high-shear mixer for recipe development

When producing personal care products like ointments, lotions, or shampoos, maintaining a constant product quality despite varying viscosities is a key challenge. Traditional methods often struggle with this, especially when dealing with diverse mixture consistencies and integrating multiple processes like heating and cooling.
<h2>Ensures consistent quality over varying viscosities</h2>
The inline systems from Dutch Process Technology specialize in producing personal care products with consistent quality across a wide range of viscosities. These systems can be customized and come with various mixing technologies, vacuum control, and heating and cooling options to suit specific needs. The user-friendly operator interface offers recipe storage and data logging, providing easy operation and process control. Ideal for manufacturers of ointments, lotions, creams, gels, and shampoos, these systems ensure that each batch meets high-quality standards. Additionally, Dutch Process Technology supports its clients from idea conception to process commissioning, allowing for tailor-made solutions tested in their pilot plant.

Inline system for personal care product production

In the cosmetic and pharmaceutical industries, developing new formulas and small batch productions requires precise control of mixing parameters. Traditional methods often fall short in maintaining consistent conditions for scale-up, leading to unreliable results.
<h2>Enable precise, small batch production</h2>
The UNIMIX laboratory and pilot plant mixers from EKATO are designed to address the challenges of scaling up from product development to production. The UNIMIX LM, available in 3 or 6 liter versions, allows for adjustable speed, temperature, and pressure, ensuring reliable data collection and scalability. The integrated homogenizing system is advantageous for both internal and external homogenization while also serving as a cleaning and emptying pump. For medium-sized batches, the UNIMIX SRT series, available in sizes from 15 to 70 liters, offers similar control and design features, making it ideal for producing creams, gels, and other cosmetic and pharmaceutical products. Both systems are available for testing and rental, providing flexibility for various development needs.

Vacuum processing units for lab scale applications

Producing high-quality lotions, creams, and gels requires specialized equipment due to the complexity of mixing and homogenizing high-viscosity products. This ensures uniform texture and optimal product quality, which traditional methods often fail to achieve efficiently.
<h2>Homogenize and mix with precision and speed</h2>
The EKATO UNIMIX vacuum processing units offer a versatile solution for producing various high-viscosity products such as lotions, creams, gels, and toothpastes. Combining the patented EKATO PARAVISC impeller and the EKATO S-JET homogenizer, these units ensure rapid, effective mixing and homogenization. The PARAVISC impeller provides excellent axial mixing, while its open design allows for the use of a central baffle and wall scrapers, optimizing heat transfer. The S-JET homogenizer is designed for internal and external homogenization, enabling swift and precise product dispersion. The system supports capacities ranging from 100 liters to 20,000 liters and includes features like heating and cooling functions, automated feeding, and Cleaning in Place (CIP) systems. It meets ASME, PED, and SELO standards, ensuring reliable performance across industries such as cosmetics and pharmaceuticals.

Vacuum processing units for high-viscosity products

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

Manufacturing hydroalcoholic gels, which contain a significant amount of alcohol, requires efficient dispersion of hydrocolloid products. Traditional agitators can fail to provide a homogeneous mix, leading to issues with product consistency.
<h2>Efficiently mix hydrocolloid products</h2>
The CMC-ATEX mixing unit by INOXPA is designed for the fast dispersion of hydrocolloid products like carboxymethylcellulose (CMC), flours, carbopol, pectin, and guar or xanthan gum, crucial in the production of hydroalcoholic gels. The system includes a rotor-stator mixer at the bottom of the tank, enhancing the water-additive contact area to prevent lump formation. An agitator with a cowles-type propeller ensures efficient powder circulation, reducing dispersion time. The system can also handle highly viscous products, adapting to viscosities up to 5000 cP. For safety, the ATEX version is designed for use with potentially explosive products, ensuring compliance with strict standards. Key features include a vertical agitator, high-shear mixer, CIP spray balls, manual butterfly valves for discharge, and a control panel for non-classified zones. The unit is constructed from AISI 316L stainless steel with polished welds for durability and hygiene.

Hydroalcoholic gel mixing system

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