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Serums homogenization Equipment

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

Cosmetic serums are a very light formulation with a high density of active ingredients dispersed in oil, water, or gel. This makes serums well suited to the delivery of vitamins, antioxidants, and anti-aging ingredients, but provide less moisturization and protection. Serum production is mainly divided into stages related to optimal mixing and preventing degradation of the active ingredients.

Serums

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

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

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

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

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;">Biotech and pharmaceutical development programs often require a mixing method that achieves both particle size reduction and complete cell lysis. When piloting production systems, it’s vital that you have complete control over the pressure to accommodate all cell types, and that the results of testing are completely scalable to full production.</span>
<h2>High-pressure homogenizer offering all configurations</h2>
<span style="font-weight: 400;">The DeBEE 2000 from BEE International is a complete pilot solution for high pressure homogenization in a highly compact format. Offering user-adjustable pressure control from 5,000 to 45,000 psi, the unit is suitable for a wide range of pharmaceutical and biotechnology applications and its modular design means lower costs of maintenance and repair.</span>

<span style="font-weight: 400;">This pilot unit also offers a wide range of options to suit all process and budget requirements, including Dual Feed, Dual Jet, control of cavitation, shear and impact and secondary additive feed for particle synthesis.</span>

<span style="font-weight: 400;">PLC control and HMI touch screen provide simple monitoring, and the unit is designed to be easily cleaned (Clean in Place) and portable.</span>

High pressure pilot homogenizer

<span style="font-weight: 400;">For any industrial pharmaceutical process that relies on high pressure homogenization it’s vital that the equipment used is robust enough to cope with the demands of continuous operation. More than this, modern production demands high levels of process control and automation, as well as seamless integration with plant controls and providing results that satisfy the highest regulatory demands.</span>
<h2>Homogenizer offering the highest level of automation, compliance and capacity</h2>
<span style="font-weight: 400;">The DeBEE 4000 series from BEE International is the company’s top-of-line homogenizing solution for high performance situations. Designed from the ground up to achieve the best results as efficiently as possible, the DeBEE 4000 uses DeBEE’s proprietary homogenization technology for unequalled results, coupled with a hydraulically driven vertical intensifier pumps with a slow stroke rate to provide higher pressure and higher process intensity, all with lower maintenance costs.</span>

<span style="font-weight: 400;">Featuring a PLC with bespoke HMI software and full-colour touch screen, the DeBEE 4000 offers easy access to several features including security modes and authorisations, integrations with plant controls using network data gathering, and dynamic visual schematics for at-a-glance system status and component parameters.</span>

<span style="font-weight: 400;">The DeBEE 4000 features a fully sanitary design making it ideal for pharmaceutical and biotech production, as well as use in the chemical industries.</span>

High pressure industrial homogenizer

<span style="font-weight: 400;">It’s vital that small units for experimentation can scale up with 100% accuracy. Ease of use, reliability and simple maintenance means increased work efficiency, and rapid cleaning and suitability for sanitary uses increase flexibility and improve return on investment.</span>
<h2>Cost-effective benchtop homogenizer with reliable and consistent process for R&amp;D</h2>
<span style="font-weight: 400;">The Nano DeBEE from BEE International is a market-leader in laboratory-scale homogenizers. Designed for maximum flexibility, the Nano DeBEE can be used for a range of procedures including cell disruption, particle size reduction, nano/micro emulsions and nano/micro dispersions. Despite the minimum sample size of only 5ml, the results obtained from the DeBEE are guaranteed 100% scalable to production processes.</span>

<span style="font-weight: 400;">Offering excellent value for money, the Nano DeBEE can operate at up to 45,000 PSI of pressure and yet it is simple to clean and maintain and it’s suitable for sanitary applications where required. A further major benefit is that DeBEE will provide new staff training for the lifetime of the product.</span>

High pressure electric laboratory homogenizer

<span style="font-weight: 400;">Offering lab-scale to small pharmaceutical production scale output for in one unit means maximum cost-benefit when acquiring a homogenizer. Capable of achieving a range of processes including cell disruption, particle size reduction, creating stable nano/micro emulsions and working with polymers and liposomes, this benchtop scale unit can operate at up to 15 litres per hour capacity, yet still offer lab quality results.</span>
<h2>Air-operated, compact, bench-top homogenizer suitable for a broad range of applications</h2>
<span style="font-weight: 400;">The Micro DeBEE from BEE International is a compact, laboratory-scale homogenizer that can also be used for small-scale production. This is an air-powered unit that can process as little as a single 5ml sample, up to as much as 15L per hour, offering exceptional flexibility.</span>

<span style="font-weight: 400;">Features that make it an excellent R&amp;D machine include maximum pressure of 45,000 PSI/3100 bar (at 150 PSI, 55 CFM). In addition, the back pressure can reach 5,000 PSI/350 bar, but this is adjustable to your specific process.</span>

Micro DeBEE is simple in operating, and exceptionally easy to maintain and clean (with no disassembly required), adding further to the value proposition.

High pressure air powered laboratory homogenizer

When working with pharmaceutical or biotech samples, achieving consistent particle size reduction and mixture uniformity is essential. Precision and reliability are key factors in ensuring effective homogenization of small batches, especially when dealing with abrasive or viscous products.
<h2>Ensures precision and reliability in small batch homogenization</h2>
The Quark from Bertoli, a brand under Interpump Group, is a laboratory homogenizer designed for high-pressure applications. Its single plunger design ensures reliable scaling from test to production, making it ideal for R&D settings. With a power capacity of 0.75 kW and capable of delivering up to 3 l/h at 2,000 bar, the Quark addresses the needs of small-volume and high-pressure homogenization. The unit is equipped to handle minimum sample volumes as low as 10 ml, and its construction makes it suitable for abrasive and viscous products. Featuring welding flanges DIN 11851 for product inlet and outlet, it ensures seamless integration into existing processes. Weighing 50 kg, it is also available in ATEX configuration for use in explosive atmospheres. Additionally, the Quark can be fed with syringes, increasing its versatility in the laboratory.

Laboratory homogenizer for pharmaceutical and biotech applications

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