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Ointments 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 most significant decision when making ointments is likely to be the choice between automatic or semi-automatic processes for it. This impacts on individual phases of the ointment cream manufacturing process - the water phase and oil phase.

Ointment

Equipment operating under the rotor/stator principal is often employed when more traditional methods of stirring cannot achieve desired results. High performance continuous dispersing equipment is needed to achieve desirable results for almost any mixing process in circumstances where other machines fail.
<h2>Rotor/stator mixing in a robust and simple package that is easy to clean</h2>
The IKA ULTRA-TURRAX UTL 2000 is inline high-performance single-stage dispersing machine used for the production of emulsions and suspensions. The UTL 2000 uses the rotor/stator principle and is best suited for continuous applications that cannot be accomplished using conventional stirring methods.

During the full continuous process the components to be mixed are fed into the machine at an appropriate rate through various inlet connections. These components are then thoroughly mixed, dispersed or homogenized within the machine and discharged from the machine through the outlet. Thus, all particles or droplets are treated producing a narrow particle or droplet size distribution with minimal concentration/quality variations. Additionally, the UTL 2000 creates a pumping action which can be used for transfer purposes at low to moderate viscosities with a maximum of about 20 m (ca. 2 bar).

The machines are designed for easy and reliable scale-up and sizes are available with throughput from 50 to 125.000 liters per hour.

Dispersing machine for emulsions and suspensions

For products of medium viscosity and relatively consistent particle size such as honey, cremes, and some plastics, a simple, low cost mixing machine is useful to ensure even dispersion.  The most efficient production plants take advantage of such equipment in continuous production processes to minimize required floor space and serve double-duty as mixing and pumping/transfer equipment.
<h2>A basic effective mixing machine with transport pump capabilities and low cost</h2>
The lower-priced ULTRA-TURRAX UTL 1000 machines from IKA are particularly multifunctional and are used for the mixing, dispersing (emulsifying/suspending) and homogenizing of solid and liquid substances up to viscosities of several thousand mPa·s, such as honey, plastic masses and crèmes. The mixing components are fed into the machine at the inlet connection. The materials are mixed, homogenized and then discharged from the machine via the outlet connection. The economic dispersing machine does not have automatic suction, but does have a conveyor height of up to 20 meters.  Units are available with flow rates from 4.800 to 125.000 liters per hour.

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Economic dispersing machine for emulsions and suspensions

For continuous high performance mixing of solid and liquid raw materials rotor/stator equipment is often used because of the high shear forces it applies to the mixture which reduces particle size and aids dispersion.  Use of equipment that uses three stages of rotor/stator action to achieve extremely small and evenly distributed particles for production of very fine emulsions and suspensions will guarantee the success of your process.
<h2>Three stages of rotor/stator mixing power for extremely fine emulsions and suspensions</h2>
The IKA DISPAX-REACTOR® DR 2000 is a three-stage high shear inline dispersing machine used for the production of very fine emulsions and suspensions. Shear forces that occur in the working chamber produce a drastic increase of mass transfer and accelerate the dissolving rates of mono and macromolecular substances. Three rotor-stator combinations (generators) in a series ensure small- droplet or particle size and a very narrow distribution spectrum. This process promotes a long stability of mixtures in a single pass, especially when working with emulsions.

In order to configure the DISPAX-REACTOR® DR to meet a variety of application needs, IKA offers a wide selection of generators. The standard rotor-stator (generator) combination consists of a coarse, medium and fine rotor-stator. When installed in a series, this configuration ensures satisfactory particle size reduction while providing optimum dispersing results in a single pass. The units are designed for easy and reliable scalability and are available in sizes with flow rates from 80 to 125.000 liters per hour.

Dispersing machine for very fine emulsions and suspensions

Producing the finest micro-emulsions and suspensions requires a mixing machine that generates extremely high shear.  Multi-staged rotor/stator dispersing machines work well for this purpose because of the high shear forces applied to the mixture at each rotor/stator stage.  A rotor /stator dispersing machine that also incorporates extremely fast rotation and resultant tip speeds for even greater shearing action will lead to the creation of super-fine emulsions and ensure the success of your process.
<h2>Top-of-the-line rotor/stator dispersion with utlra high shear for nano-scale particle emulsions and suspensions</h2>
The DISPAX-REACTOR® DRS from IKA is an inline ultra high shear dispersing machine used to achieve the finest micro-emulsions and suspensions. Extremely high shear rates (up to 190.000 1/s) combined with a fine generator geometry enable crushing of droplets and solids particles down to the nanoscale. The resulting product has long-term stability which reduces the need for emulsifying agents and thickeners. Because of the extremely high energy density, other dispersing aids can be reduced or possibly eliminated.

The DRS is usually equipped with a two-stage rotor-stator system (generators). The high tip speed of 40 m/s (10.000 fpm) often negates the need for a third stage. The ultra-fine dispersing machine, designed with the same high quality features as the ULTRA-TURRAX® UTL and the DISPAX-REACTOR® DR, is especially well suited for challenging pharmaceutical applications.  The units are designed for easy and reliable scalability and sizes are available with flow rates from 70 to 40.000 liters per hour.

Ultra-fine dispersing machine for emulsions and suspensions

Several issues often arise when your process requires batch-wise mixing of powders into liquids.  The mixing process can be slow, dust and liquid solvent may be released to the surrounding work area, agglomerate powder masses may form and the ratio of ingredients may be inconsistent.  The right equipment is needed to address all of these issues and improve the efficiency and quality of your process.
<h2>Reliable batch mixing improves process quality and efficiency</h2>
The CMX 2000 inline batch mixer from IKA incorporates powders into liquids and mixes these materials reliably and consistently in a batch process. Its multi-level design and unique pumping stage enables processing of high viscosity products without any additional aggregates. The system is usually supplied with a solid material dosing feeder and mixing containers.

Depending on the application and the requirements of the customer, the solid material can be fed via a bulk bag unloader, a funnel, sack-emptying boxes or directly from the bag via a suction lance.  Units are available with typical batch sizes from 2 to over 5.000 liters.

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Inline batch mixer for solids and liquids

Certain mixing tasks present unique challenges and manufacturers need equipment that is specifically designed to handle them.  When a single pass process is needed, high solid concentrations are involved, the ingredients quickly react with one-another, the product is sensitive to air inclusions, or the solid is granular and needs to be mechanically crushed as well as mixed, the right equipment is needed to get the job done.
<h2>A single pass mixer, disperser, and homogenizer for difficult mixing tasks</h2>
IKA's MHD-2000 system is a continuous homogenizing system designed for the high quality dispersions of solids in liquids.  The system includes two horizontal liquid connections and one vertical connection for solids.  the liquids and solid components of the mixture are brought together in a controlled fashion in a pre-mixing chamber in which the liquid is evenly distributed by entering through several different apertures.  Immediately after mixing, the liquid and solid components are dispersed through a rotor/stator system with high shearing action creating a high quality, output product that is free of agglomerations.

Use of this system greatly reduces production times due to its continuous operation.  Its design allows it to process highly viscous liquid ingredients, mixtures with solid contents up to 80%, and even solids that are granular and must be mechanically crushed during the mixing process.  Units are available with throughput volumes from 60 and 40.000 liters per hour.
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Continuous homogenizing system

When extremely high accuracy is required in your recipe or formulation traditional mixing machines often give unsatisfactory results.  For precisely controlled, quantitative mixes of liquid and solid ingredients you need a machine with better control designed to create a ready-to-use product that meets your exact requirements every time.
<h2>Create precise, quantitative mixes and fine suspensions in a single pass</h2>
The Dispax-Reactor from IKA is a purpose-built high accuracy homogenizing system for the food, chemical, pharmaceutical, and other industries.  It achieves extremely accurate mixes and suspensions by dosing both the liquid and the solid phase into the mixing chamber unlike traditional mixers which typically only dose the solid.  In this way the exact quantities of the raw materials in the final product are known regardless of variations in the physical characteristics of inputs.  The units include three distinct dispersing stages which allow for the creation of extremely fine suspensions from a wide range of solid raw materials.  Different rotor/stator dispersing heads are available allowing the machine to be optimized to your particular process.  Capacities are available from 500 to 35.000 liters per hour.

High accuracy homogenizing system

For high viscosity products, better results and reduced process times can be achieved with kneading type rather than conventional extrusion type equipment.  Process engineers in a wide variety of industries need to reliably and efficiently mix highly viscous substrates.  Process engineers in these situations need efficient, thorough mixing with controllable parameters.
<h2>Better dispersion results with less processing time from a highly controllable process</h2>
IKA's high performance horizontal kneading machines known as HKD and HKS are twin-bowl kneaders with horizontally arranged kneading blades able to process mixtures with very high viscosities. These horizontal kneaders are unique in the selection of kneading elements that they can employ allowing them to process a wide variety of mixes with varying solid content.  This flexibility makes users' lives easy by facilitating product change over and allowing selection of  blades that are optimized o the particular products being mixed.

The kneading blades are inter meshing and driven at a 2:1 ratio crating an alternating motion of blade surfaces toward and away from one another.  This motion creates highly dynamic pressure gradients and shearing forces which achieve excellent dispersion results.  The blade speed is finitely controllable via a variable frequency drive.  The units are easy to clean and maintain with the entire side wall of the kneading bowl being removable.  This exposes the kneading blades and discharge screw for easy cleaning during product changeover.

Horizontal kneader

Production of highly viscous products with high solid content often benefits from kneading processes rather than conventional extrusion because more consistent dispersions can be achieved in a shorter time.  Competitive manufacturer's need controllable kneading processes with worry free seals and a degree of automated operation.
<h2>Better mixing in less time for highly viscous products</h2>
The Planetron HKV from IKA is a heavy-duty vertical kneading machine with two kneading blades.  The overhead mounting of the blades and drives allows all seals to never be in contact with the product.  These vertical kneaders achieve excellent kneading and dispersion results due to the action of inter-meshing kneading blades.  With one blade rotating in a planetary motion around the other and the two together having a mutual stripping action causing high pressure variations and shear forces in the substrate.  The geared motor that powers the machine is equipped with a variable frequency drive allowing the rotation speed of the blades to be infinitely adjustable giving the user precise control of the process and results.  All bowls in the HKV series are prepared for heating or cooling.  Units are available with working volumes from 0.5 to 1.600 liters.

Vertical kneader

Effective mixing of highly viscous products with extremely high solids content can be difficult and the results from traditional extrusion type equipment are often unsatisfactory.  Much more thorough and intense mixing can be achieved and higher solid contents attained with kneading technology.
<h2>Continuous highly controlled kneading from a flexible machine</h2>
IKA's Conterna machine is a multi-chambered continuous kneader which technology is patent protected all over the world. The standard continuous kneader consists of 6 chambers arranged together in a horizontal block.  Each chamber contains two kneading elements which are driven by a variable frequency AC motor.  There is one independently controlled motor for each chamber.  Liquid and solid ingredients are introduced into each chamber according to the process needs and the mix is advanced from chamber to chamber via the kneading action of the impellers.  By adjusting the motor speed and the discharge rate , users can control the resident time of the product in the machine to achieve the desired results.  The continuous kneading action ensures that evenly mixed products are produced and products with extremely high solids content can be processed. Units are available with approximate throughput rates of 80 to 4.000 kg/hour.

Continuous kneader

Equipment operating under the rotor/stator principal is often employed when more traditional methods of stirring cannot achieve desired results.  This technology can achieve desirable results for almost any mixing process in circumstances where other machines fail.
<h2>Rotor/stator mixing with flexible mounting and a robust simple package</h2>
The Ultra-Turrax UTC is IKA's batch dispersing machine for high quality mixing and dispersing of 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, 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.  These units are designed for diagonal from above, diagonal from the side, 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. Units are available for batch sizes from 150 to 6.000 liters.

Batch dispersing machine

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

Manufacturers need production mixing equipment that is capable, flexible, and easy to maintain. Accurate mixing form a reliable, user friendly machine will give plant managers the peace of mind and worry free operation they need to focus on improving other areas of their process. A high quality piece of equipment allows for low maintenance, easy cleaning, enables the direct feed of solids and liquids, mixing and dispersing of the vessel contents, heating or cooling of the product, and processing under vacuum or under pressure.
<h2>A universal mixing system with precise, reproducible results and safe operation</h2>
The Master Plant homogenizing and emulsifying system from IKA was designed specifically to meet the production mixing needs of the pharmaceuticals industry but has also proven useful in the production of food, beverages, cosmetics, and chemicals.  Several mixing heads are interchangeable depending on the process and desired results.  Each mixing head can be heated or cooled to control product temperature simultaneous to the mixing process. Flexible PTFE scrapers move with the mixing head and keep product from adhering to the vessel walls. Products of up to 100.000 mPas viscosity can be processed.  The GMP homogenizing systems  can be fully discharged without the need for additional pumping and are available in capacities from 10 to 4.000 liters.

GMP homogenizing system

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

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

Developing and validating new processes requires reliable and highly versatile equipment.  Innovators need mixing equipment that can be adapted to a wide variety of processes and has the function and controllability they need to fine-tune their results.
<h2>Multi-functional, small scale dispersion for the laboratory</h2>
The Magic LAB from IKA is a uniquely versatile small-scale dispersion machine.  It is designed for mixing, dispersing, wet milling, and incorporation of powders into liquids.  The laboratory dispersing machine is commonly used for developing new products and improving existing processes in the chemical, cosmetic, pharmaceutical, and food industries.  It is an ideal machine for continuous, circulating, and batch processing using different interchangeable modules.  It is designed to match functional parameters of larger scale production dispersion equipment making scale-up predictable and successful.  The units can be configured for single or multi-stage operation among others and important process parameters such as speed, torque, and temperature can be recalled.

Small-scale laboratory dispersing machine

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

When processes call for homogenized emulsions with extremely fine particle sizes the traditional toothed ring dispensers are not always sufficient.  For extremely high levels of disintegration required to produce true micro-emulsions, extreme pressure cycling is more successfully used.
<h2>Homogenization with pressure shock to achieve extremely small particle sizes</h2>
The HPH High Pressure Homogenizer from IKA uses one or more piston pumps to apply pressure up to 2000 bar to the liquid medium to be homogenized.  The fluid is then fed through a homogenizing valve which very quickly reduces the pressure to the atmosphere.  This abrupt change in pressure in the moving fluid causes cavitation, a high degree of turbulent flow, and internal shearing forces in the fluid all of which serve to break up and distribute larger particles forming a very fine emulsion.  The pressure applied on the uphill side of the homogenizing valve is infinitely adjustable as is the flow rate through the valve, so the process can be easily adapted to achieve a wide range of outcomes and to accommodate fluids with different flow characteristics.  All parts that contact the product flow are stainless steel and autoclavable and the entire unit is designed for robustness and long service life.

High-pressure homogenizer

<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

<span style="font-weight: 400;">Homogenization (or pharmaceutical micronization) is the process of reducing particle sizes, and is a vital step in making pharmaceutical creams and ointments more stable and clinically effective, and in producing high quality cosmetics. Homogenizing under vacuum produces the highest quality results, and a bespoke plant built to your exact requirements will increase your productivity and quality.</span>
<h2>Homogenization plants for the pharmaceutical and cosmetic sectors</h2>
<span style="font-weight: 400;">The homogenization plants from Ipros are a custom-built solution for the manufacture of high quality creams, ointments and other suspensions, whether under pharmaceutical or non-pharmaceutical production conditions.</span>

<span style="font-weight: 400;">Ipros modular design allows full configuration over mixing and homogenising equipment. Options range from vacuum processing to processing under the most stringent sterile and/or toxic conditions. The integrated engineering of the counter-rotating gearbox brings mixing, homogenising, cleaning, sterilisation, and drying systems together into one validated piece of equipment.</span>

<span style="font-weight: 400;">A range of solutions for Clean in Place and Sterilise in Place (CIP and SIP) can be selected to fit your exact production needs, and Ipros is pleased to offer the highest performing CIP/SIP performance currently available on the market, perfect for stringent pharmaceutical production.</span>

Homogenizer for creams

Preparation lines for formulating pharmaceuticals include fixed and mobile tanks for liquid solutions. These vessels must withstand high internal pressures while enabling fast production. Their design must meet aseptic standards for manufacture of pharmaceuticals, and comply with good manufacturing practice.
<h2>Preparation Tanks for Pharmaceutical Formulation</h2>
BRAM-COR manufactures a range of dissolutor tanks. All vessels are made of AISI 316L stainless steel, and comply strictly with PED standards and ASME "U" stamp certification.

Formulation tanks are an indispensable part of all pharmaceutical preparation processes. BRAM-COR DISS fixed or mobile tanks are suitable for low, medium, or high density liquid solutions. This includes parental solutions and also ointments and creams.

Every tank has at least one mixer / agitator, a spray ball for cleaning-in-place, and an optional load cell for maintaining safety, precision and performance. Various levels of automation are available for controlling raw material input. External heating jackets are provided where required.

Tanks capacities range from 50 to 25,000 litres. Staircases and safety platforms provide access to large installations for inspections.

Pharmaceutical formulation and mixing tanks

The production of creams or ointments can be either be a water in oil (w/o) or oil in water (o/w). When added to water, thickening, stabilizing and emulsifying ingredients can form agglomerates, in the same way that lumps can be formed in the oil phase. You thus need a solution capable of hydrating and dispersing the ingredients so well that the emulsion does not break during oil addition.
<h2>Modular designed mixing and dispersing solution</h2>
Designed by AZO LIQUIDS, the Batch vacuum processing plants type zoatec® BG can be used for mixing, dispersing, and emulsifying two different liquids, or liquids and dry powders.

Since it’s designed with standardized modules, the model can be adapted to different requirements with exceptional flexibility. This ensures shorter startup and installation times. AZO’s homogenizer has an innovative and unique configuration, making the homogenizer fully reachable from the outside. Thus, the entire working area can be removed without dismantling a lot of pipelines, making the cleaning and maintenance of the equipment very easy.

Moreover, the unit can be adapted to meet the current guidelines and standards for quality assurance, including Good Manufacturing Practice, SIP, and ATEX.

Apart from the pharmaceutical and cosmetics industry, for the production of ointments, gels and creams it can also be used for a wide range of liquid to paste-like applications in the food industry. These include sauces, ketchup, fish paste, marmalade and jam, chocolate fillings, concentrated soup, mayonnaise, dressings, cheese spread, and juices.

Batch vacuum mixer for emulsion-based products

From food to pharma, homogenization is an essential step in the production process that provides uniformity to the product by improving its physical properties. If not homogenized, the fluid product might degenerate over time, leading to the formation of sediments and phase separation. This will lead to the loss of desirable product properties like uniformity, viscosity, consistency and reduced shelf life. 
<h2>Reducing product particle size using cavitation provides fluid stability</h2>
High Pressure Industrial Homogenizer from HOMMAK facilitates permanent homogenization of heterogeneous fluid products like milk, fruit juices, creams, ointments and more. The homogenization effect is achieved by reducing the product particle size through cavitation, shear force, impact velocity and turbulence effect under pressure, thereby preventing phase separation in the product.

The homogenizer consists of two main elements – the compression block and the homogenization unit. As the name suggests, the compression block compresses the ingredients under high pressure. The homogenization unit micronizes the decomposed particles to the specified size per the product.

The equipment's design and manufacturing considerations like capacity, pressure, material selection and valve design are tailored to its specific industrial application.

Pilot plant homogeniser

Did you know that in the 30s, cosmetic creams that contained radioactive material were booming on the market because they promised to reduce wrinkles? Thank God that's no longer the case. To make a cosmetic cream today, you need to create a stable mixture of oil and water and add an emulsifier to join these otherwise immiscible substances.

Cosmetic creams

A cosmetic foundation comes in a powder, cream, or liquid form. And did you know that the liquid form came about because women in the 30s and 40s didn't want to wear stockings? So to cover up their legs, they turned to leg makeup, which played an essential role in our liquid foundation formula. The foundation making process involves balancing the oil and water phase interactions during the formulation stage, mixing ingredients, and packaging using a liquid foundation filling machine.

Cosmetic foundation

Every minute, your skin loses between 30,000 and 40,000 dead skin cells. This means losing millions of cells every day, which makes your skin look less glowing. Being a moisturizing agent, body lotion has the power to hydrate your skin and  give the glow back to it. Production involves water and oil phases, which you then mix with an emulsifier and blend until homogeneous. Preservatives are essential for any solution containing water for the prevention of microbial growth.

Body lotion

ProXES machines and process lines are used to produce and process liquid and semi-liquid foods, cosmetics, and pharmaceutical products. ProXES together with its clients co-creates first ideas, develops tailor-made processing concepts and accompanies them until go to market.

Have you wondered how to elevate the process of making cosmetic emulsions? We have a solution for you!



<a href="https://www.proxes.com/de/">ProXES</a> is hosting a webinar for <a href="https://go.proxes.com/en/cosmetic-emulsions-webinar">cosmetic emulsions</a> on the 27th of February, where they shed light on cold-pressing cosmetics. The webinar explains how the technology not only makes your products better but also makes the process more energy-efficient and environmentally friendly.

Webinar: cold-pressing cosmetics for sustainability

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

The topical route is a convenient route for the self-administration of drugs. But turning a pharmaceutical formulation into an easy-to-use cream involves specialized cream manufacturing equipment. Topical dosage forms are essentially an emulsion of oil and water.  But the ratios can be changed to process it into lotions, ointments, and gels.

Cream

AZO LIQUIDS is the partner you can rely on when it comes to innovative solutions for liquid and semi-solid processes in the pharmaceuticals, cosmetics, food and chemicals industries.

If you are <a href="https://making.com/products/creams">producing a therapeutic cream</a> that prevents, cures or alleviates a disease or injury, a license from a government is needed to sell the product.  The requirements for keeping such a license are quite stringent, looking at – for example- traceability, documentation and hygiene. The products must be safe, and you must be able to have proof of this. What does this mean for the manufacturing process, especially for smaller scale companies? What do you as a producer need to have in place?


<h2>Meeting the targets of the Pharmaceutical Quality System</h2>
In order to get and to be able to keep the pharmaceutical license, most authorized government bodies demand the producer to have a Pharmaceutical Quality System that follows Good Manufacturing Practice. Looking at for example the production, operations must follow clearly defined procedures. All materials and products must be stored under the appropriate conditions established by the manufacturer and in an orderly fashion to permit batch segregation and stock rotation. Operations on different products should not be carried out simultaneously or consecutively in the same room unless there is no risk of mix-up or cross contamination. At all times during processing, all materials, must be labelled or otherwise identified with an indication of the product or material being processed, its strength (where applicable) and batch number. This means almost everything needs to be documented or monitored to reach these standards.
<h2>Automated production when upscaling</h2>
Switching to an automated production line can reduce the risk of cross-contamination and make it easier to meet all these standards. If you want to adhere to these standards, it is rather difficult to do with manual production. Many companies decide to scale up and  a first step could be to install a second processing vessel that will only be used to manufacture the final product, where the other vessel is used for the intermediate product. A cleaning system (CIP) would also make it easier to follow stringent hygiene rules. As you grow, a next step could be the incorporation of machines that automate a part of the process or installation of fully automated plant design to eliminate all manual operations and automate a lot of documentation of the production. Apart from tracking all this information, the product would also be fully traced from the start of the manufacturing process all the way to the packaging, a topic that is at the heart of this pharmaceutical license. A good example of automated plants for creams production, is shown in the video below, of the modular vacuum processing plant of AZO LIQUIDS.

[embed]https://www.youtube.com/watch?v=YJQZ8u-r5Gc[/embed]

How to keep your government license for therapeutic cream production?

Pharmaceutical

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

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