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Industrial emulsifiers

emulsifying-process

Emulsifying-process

Spreads

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

Liquid

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

Batch

Industrial

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

Emulsifying plant for pasty and liquid products

Blending

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Emulsifying

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

liquid

Continuous

When producing emulsified sauces or dressings, maintaining consistency and quality is paramount. This is vital in ensuring that each batch meets the same high standards, whether for full fat or starch-based low-fat mayonnaise.
<h2>Single pass emulsifying with automatic flow calibration</h2>
The turnkey skid mounted in-line mayonnaise emulsifying system from Dutch Process Technology is designed to produce various types of emulsified sauces, including full fat and low-fat mayonnaise, with a single pass inline process. This system features automatic flow calibration, recipe storage, and touch screen controls for ease of use. Additionally, it supports Clean-In-Place (CIP) cleaning, ensuring minimal downtime for maintenance. Optional features include a premix system for mixing key ingredients like egg powder and sugar, and an inline mixer for adding starch paste and particulates. The solution is versatile, suitable for batch production of up to 3000 litres, making it ideal for large-scale operations.

In-line mayonnaise emulsifying system

From laboratory scale to large volume food or cosmetic production, it pays to have all-around equipment that can effectively cut, mix, emulsify, and even heat your products. Whether producing chocolates, processed cheese or beauty creams, a robust system that is flexible enough to handle products from different industries simplifies production steps while increasing overall productivity without compromising quality.


<h2>All-in-one processing system with direct or indirect heating of products</h2>
The Stephan Universal Machine from ProXES is an all-in-one processing system that includes cutting, mixing, emulsifying, and heating functions for food and cosmetics applications. The system is available as a tabletop or floor-mounted unit with frequency-controlled knives and with or without direct steam injection. Direct steam injection allows quick heating of products, like processed cheese, up to 95⁰C or 125⁰C, depending on the model. Various models are available for laboratories, R&amp;D, and industrial scale production with maximum batch sizes of 2.5 liters up to 170 liters. Finished products are discharged through a discharge valve or by tilting the bowl up to 90 degrees for highly viscous products. Various specially shaped tools and high-speed knives ensure quick mixing and cutting of products, making them ideal for most product applications. The system is equipped with either a soft touch keyboard or a touch panel for easy operation with an option of data recording via a USB stick.

Complete cutting, mixing, emulsifying and heating system

Cutting

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

solid

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

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

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

Vacuum

In industries such as food processing, cosmetics, pharmaceuticals, and fine chemicals, it is often necessary to thoroughly mix and homogenize products under atmospheric pressure. Challenges include achieving uniform dispersion, emulsification, and minimizing product aeration.
<h2>Achieve uniform mixing and homogenization</h2>
The ME 1100 series from INOXPA is a range of high shear vertical mixers specifically designed for tasks such as dispersion, emulsifying, homogenization, and disintegration of solids. Featuring high-speed rotor-stator interactions, the mixer generates high suction potential, ensuring rapid and thorough mixing. Products are suctioned from the bottom of the tank, mechanically sheared by the rotor at speeds of 20 m/s, and then hydraulically sheared while leaving the stator. This process ensures that the ingredients pass through the working head multiple times, promoting uniform homogenization. The mixer’s design minimizes product aeration and can handle a variety of viscosities, making it ideal for a wide array of applications in the food-processing, cosmetics, pharmaceutical, and fine chemistry industries.

High shear vertical mixer for dispersion and emulsification

When working with high viscosity liquids in industrial processes, achieving thorough dispersion, emulsifying, and homogenization is crucial. Common challenges include maintaining uniformity and preventing particle settlement throughout the process.
<h2>Promotes efficient mixing and uniform particle distribution</h2>
The ME 6100 series by INOXPA is a high shear tank bottom mixer designed for demanding industrial applications like food processing, cosmetics, pharmaceuticals, and fine chemicals. It ensures efficient dispersion, emulsifying, homogenization, and disintegration of solids. The mixer can be used in both open and closed tanks at atmospheric or varying pressures. Its high-speed rotor and precise rotor-stator tolerances create a powerful suction that draws the product to the center of the head, where it is radially thrust and mechanically sheared. This results in particle size reduction to less than 100 microns. The mixer is constructed from high-quality materials, including AISI 316L stainless steel for parts in contact with the product, ensuring durability and ease of cleaning (CIP/SIP). Its design allows for easy maintenance, including stator replacement without disassembling the mixer, and features a sanitary single mechanical seal.

Tank bottom mixer for high viscosity applications

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

Dispersing

When producing processed cheese or similar applications, achieving a uniform, lump-free product consistently is critical. Traditional methods often face challenges like inconsistent mixing, long batch times, and energy inefficiency, hampering productivity and product quality.
<h2>Achieve consistent, lump-free emulsification</h2>
The ShearTherm from the Natec Network, part of Hochland Natec, is an advanced emulsifier and steam batch cooker designed to deliver high-quality, lump-free food products. Utilizing patented M4E emulsifying technology, it ensures thorough mixing and emulsification in each batch. The integrated vacuum system and variable speed homogenization units provide high repeatability and consistency, while the direct steam injection offers precise temperature control up to 98°C (208°F). Capable of processing up to 2,400L per hour with minimal raw material waste and energy consumption, the ShearTherm is ideal for applications such as processed cheese, cream cheese, sauces, and plant-based products. The system's design supports fast Clean-In-Place (CIP) processes, further enhancing productivity by minimizing downtime.

Lump-free emulsifier and steam batch cooker for processed cheese

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

Entry level

In food processing and manufacturing, achieving consistent texture and quality across various products can be challenging. Homogeneous grinding, emulsifying, and fine grinding are vital for processes involving meat, pet food, dairy, and vegan products.
<h2>Homogenize and ultra-fine grind diverse product types</h2>
The I-iT grinder from Handtmann Inotec offers advanced grinding technology suitable for small-scale to industrial production. The grinder features a modular 1- to 5-stage cutting system with automatic adjustment, ensuring precise positioning and minimal wear. This flexibility allows for consistent and homogeneous grinding of different products, including meat, dairy, vegan substitutes, confectionery, and pet food. It can handle various consistencies—chunky, liquid, pasty, and powdery—as well as fibrous and hard components. The entry-level I140 model is ideal for small-scale producers, while the I175-iT and I225-iT models can handle up to 15,000 liters, making them apt for industrial use. Features such as the electromechanically controlled cutting system and original Inotec cutting sets of varying materials ensure long service life and optimum results. The grinder is user-friendly, has a language-independent interface, and continually monitors and regulates product temperature and cutting tool status, ensuring process reliability and economic efficiency.

Industrial grinder for ultra-fine grinding and homogenizing

Grinders use a spinning blade or rotating abrasive elements to reduce the size of various materials. The specifications, RPM and grit of the engineered grinder, will result in various particle sizes. As a result, what you want to make will determine the type of grinder you need. Grinding is used for improving the texture and flow properties of various products and to enhance the flavor of food products such as coffee, spices, sugar, nuts, sesame, poppy seeds, lentils, wheat, and rice. Choosing the right rotational speed, grinding elements, and processing power allow the grinding and shredding of a wide range of materials into coarse or fine powders. Popular types of heavy duty grinders in food processing include angle grinders, bench grinders and meat grinders.

Grinding

Powder

In the food, pharmaceutical, and cosmetics industries, achieving consistent product quality often relies on effective mixing, blending, and homogenizing processes. Ensuring that products remain homogeneous and properly emulsified can be challenging without the right equipment.
<h2>Optimize mixing, blending, and emulsifying</h2>
The stainless steel agitators from GPI De Gouwe are designed in-house to meet specific industry standards and customer needs. These agitators are suitable for mixing, blending, homogenizing and other processes in diverse industries including food, pharmaceutical, and cosmetics. Designed for compatibility with stainless steel tanks, the agitators come in various types such as gate, anchor, and propeller configurations. They are developed to ensure minimal product damage while achieving the desired consistency and texture. With construction featuring a surface roughness of Ra 0.8 as standard, they meet high hygiene levels required in sensitive applications. Customization is available to suit specific process requirements, and options such as scrapers and stators can be integrated for enhanced performance. GPI De Gouwe guarantees that its agitators deliver efficient heat transfer, uniform mixing, and precise emulsification, making them an ideal choice for demanding industrial processes.

Stainless steel agitators for pharmaceutical and food applications

In food processing, achieving consistent texture and temperature control is crucial when emulsifying or reducing meat and other food products. These processes require precision and versatility to ensure high-quality results.
<h2>Ensure consistent, high-quality emulsions</h2>
The PrimeCut CPF-7 Compact / Posi-Feed Emulsion / Reduction System from Cozzini (Middleby) is designed for both continuous and batch production. This system includes a variable speed feed pump that allows complete control over product texture and temperature, ensuring consistent output. The self-adjusting outlet temperature control, combined with the Cozzini MultiCut 7″ diameter single or double plate/knife cutting system, provides superior quality cuts and emulsions. Operator-friendly Allen-Bradley touch screen controls make the system easy to use. Its compact and portable design allows it to fit directly under the discharge of a mixer/blender or bowl chopper, making it adaptable to various plant layouts. USDA accepted and CE approved, this system meets stringent sanitary equipment design principles.

Compact food emulsion and reduction system

In the food processing industry, achieving consistent particle reduction and emulsion quality is crucial, particularly for products such as sausages, meatblends, and pet foods. Traditional methods often require multiple pieces of equipment and are prone to contamination issues.
<h2>Achieve consistent particle size reduction</h2>
The Cozzini AR901 Gravity-Fed Emulsion System is an advanced solution for reducing and emulsifying meatblends, pet food, and rendering products. It features a 9-inch diameter single plate/knife cutting system, ideal for high-capacity processing. The system's hopper holds up to 200 liters, and its unique separation design prevents lubrication contamination. The AR901 can accommodate various holeplate sizes, ranging from 1.0 mm to 9.9 mm. Casters on the base allow for easy portability. The system's specially designed impeller can transport product up to 10 feet vertically, making it versatile for integration with other processing equipment. Certified by USDA and CE, it meets stringent sanitary standards and is built in conformity with AMI sanitary equipment design principles.

Gravity-fed emulsion system for meat and pet food processing

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

In the pharmaceutical, cosmetics, chemical, and food industries, achieving homogeneous, high-quality liquid and cream products can be challenging. Issues like inconsistent blending, air entrapment, and improper temperature control frequently arise during mixing and processing stages.
<h2>Homogenize, emulsify, and de-aerate with precision</h2>
The Bachmix R by Bachiller is an industrial vacuum mixer designed to handle liquid and viscous products up to 20,000 liters. It excels in homogenizing, emulsifying, and de-aerating processes, making it ideal for applications that require high-viscosity homogenization. The mixer operates under vacuum or pressure and supports washing and sterilization. Its internal and external homogenization capabilities ensure thorough mixing, while its design adheres to GMP and EHEDG standards, ensuring compliance with industry regulations. Suitable for a wide range of industries including pharmaceutical, cosmetics, chemical, and food, the Bachmix R offers a versatile and robust solution for complex mixing needs.

Vacuum mixer for liquid and cream processing

Deaeration

Industrial sterilization processes are employed in different industries to completely eliminate all living microorganisms from the final product. For instance, in food processing, sterilization equipment is used to produce a stable product with a long shelf-life by eradicating harmful bio-contaminants. Instead, in the medical field, sterilization technologies aim to prevent the transmission of microbes to patients by sterilizing all the tools and medical devices that come in contact with the patient. Most sterilization equipment, such as autoclaves, employs high-temperature pressurized steam to destroy bacteria and disinfect surfaces from spores. Other methods include radiation sterilization or using chemicals such as hydrogen peroxide for disinfection.

Sterilization

Industrial washing systems are used to clean and disinfect a variety of items in research and manufacturing facilities. Industrial washers use solvents and cleaning agents with mechanical action to remove deposits and residues from stainless steel machinery components, empty containers, and other soiled surfaces. The selection of an industrial or commercial washer depends on the type of items and surfaces to be cleaned, the type of deposits/residue that is typically present, whether drying is required after rinsing and the level of sterilization necessary. Manufacturers will have cleaning specifications and as a result, require washers to be engineered to meet these specs.

Washing

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

Vacuum mixer for liquids and semi-solids

In beverage production, achieving uniform mixture and proper hydration of stabilizers like pectins, guar gum, and xanthan gum is essential. These stabilizers are used to enhance shelf life and texture, but need to be fully dispersed to be effective.
<h2>Ensure proper dispersal and hydration of stabilizers</h2>
The EASY.Mix by A Due is a customizable system designed for dissolving stabilizers such as pectin, guar gum, and xanthan gum in beverages. Offering different options based on the desired solution viscosity and stabilizer properties, the system includes turbo emulsifiers, tri-blenders, hydrodynamic hoppers, and dispersers. The triblender assembly, ideal for low concentration solutions, ensures homogeneous mixtures with a mesh filter and hopper for efficient powder transfer. For medium concentration solutions, the high shear mixer with a 1000-litre vessel and emulsifying system is used. For high concentration solutions, the vacuum disperser in conjunction with a 1000-litre vessel enables lump-free, smooth textures even with minimal water. Each option ensures optimal dispersion and hydration of stabilizers, crucial for product consistency and quality.

Stabilizer dissolving system for beverage production

In beverage production, achieving consistent quality and stability can be challenging when using additives like pectins and gums. Proper dispersion and hydration are crucial to prevent issues like clumping and poor texture.
<h2>Ensures uniform stabilizer dispersion and hydration</h2>
A Due offers advanced stabilizer dissolving solutions designed to efficiently handle various stabilizers, including pectin, guar gum, xanthan gum, and carboxymethylcellulose (CMC). These systems include triblenders, high shear mixers, and vacuum dispersers, each tailored to specific dissolving needs based on stabilizer type and desired concentration. For example, the triblender system utilizes a loading hopper and fast propeller stirrer to create low concentration solutions such as 0.5% pectin at 50°C or 0.2% CMC at 20°C. The high shear mixer, with its emulsifying system and self-priming pump, is ideal for medium concentration solutions like 1.5% pectin at 50°C or 0.5% xanthan gum at 20°C. For high concentration solutions, the vacuum disperser efficiently disperses powders to create smooth, lump-free mixtures, handling up to 6% pectin at 50°C or 3% guar gum at 20°C. These systems are crucial for maintaining product quality and extending shelf life in various beverage applications.

Stabilizer dissolver for beverage production

Dispersion

Delicacies such as meringue, ganache, and marzipan undergo various processes like mixing, whipping, emulsifying, heating, and cooling. Traditionally, each process requires different equipment and a lot of manual interventions that can lead to inconsistent product quality.


<h2>Preparing bakery creams and egg whites in a single system with easy tools changeover</h2>
The Stephan UM from ProXES is a versatile all-in-one processing system for the bakery market and includes different functions for cutting, mixing, whipping, emulsifying, heating, and cooling your bakery creams and pastries. The system can be coupled to application-specific processing tools and has vacuum support to produce even the finest professional-quality ganache. The integrated cooling function ensures cream stability and enhances shelf life.

The whipping process for creams and egg whites has shorter production times – up to 50% - with maximum throughput for different batch sizes. In addition, for mid and larger-scale bakeries, production costs of marzipan have proven to be 50% less than purchasing ready marzipan.

The mixing system is equipped with a tilting bowl for easy product and ingredient handling. The set of processing tools is specially designed for all bakery applications and allows easy, quick changeover. The UM family has a wide capacity range of 0.5 to 170 liters per batch. Its design allows easy water cleaning, which results in low energy costs. The different programming options for temperature regulations and recipe controls help reduce process time and ensure product quality.

Flexible mixing system for whipped cream and pastries

When processing alternative proteins or making products such as smoothies and sauces that require multiple production steps such as cutting and dispersing, having a single system that can combine the different processes in one, makes production more practical and efficient, saving costs and time.


<h2>Fine cutting and emulsifying of food products in one solution</h2>
The Stephan Microcut from ProXES is a multifunctional food processing system for fine cutting and homogeneous emulsifying. It can provide stable emulsions and disperse solids in liquids. The unit has a pre-cutter that can reduce product sizes of 100mm down to 1-2mm. It can be installed with a single or double cutting system consisting of cutting head(s) as the rotor, cutting ring(s) as the stator, and a feeding disc. The cutting rings are equipped with knives of specific gap sizes from 0.05 to 3mm, and the feeding discs are available in different designs. Product applications include meat emulsions, marinades, sauces, vegetable, and fruit grinding, and nut grinding. The system has a unique layout for cutting vegetables, fruits, frozen products, and rework of bakery products.

Multifunctional cutting and dispersing machine

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

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

High shear lab mixer for creams

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%.

&nbsp;

In-line 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

Formulation technologies are an integral process in many industries such as pharma and food. Chemical mixtures require strict handling to combine the separate ingredients into the homogenized recipe that makes your final product. Formulation technology stores, mixes and subjects the elements to a range processing parameters according to your specifications to develop the base material. The resulting formulas are then weighed, formed, packaged, or sent for further formulation.

Formulation

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

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

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

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

In-line high shear mixing solution

Pumping

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

Homogenizers for high-pressure applications

Pilot

In laboratory and pilot environments, achieving fast and reliable milling results is often challenging due to the need for equipment that can handle various materials and allow quick change-overs.
<h2>Facilitate diverse material processing with immersion milling</h2>
The Hockmeyer Micro Mill is a compact immersion mill designed for laboratory and pilot environments. This mill offers multiple head attachments, enabling a wide range of processing capabilities, from fine dispersion to emulsification. Its optimized Control Center features user-friendly software with digital automatic controls, providing easy batch readings and precise speed control. The Micro Mill is constructed with a stainless steel column and foot for durability and includes a low noise level design for an ergonomic working environment. Various features like an adjustable timer with automatic stop, immersion mill, sweep blade, rotor stator, and ‘F’ blade add to its versatility. It even comes with vessels and a vacuum assembly for specialized operations.

Lab and pilot scale immersion mill

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

In food processing, achieving smooth, lump-free emulsions and dispersions can be challenging, especially when working with ingredients like cheese, sauces, and mayonnaise. Traditional methods often fall short in delivering the desired texture and stability, resulting in increased thickener use and production costs.
<h2>Create stable emulsions and dispersions</h2>
The Magnet for Emulsion Technology (M4E) from Hochland Natec produces the smoothest, lump-free emulsions and dispersions by combining turbulent flow conditions with the LORENTZ force of a permanent magnetic field. This combination causes particles to spin and collide, resulting in their deformation and break-up. Once the product has passed through the magnet, it is perfectly dispersed or emulsified in a single pass. This technology eliminates the need for mechanical high shear, leading to significantly lower thickener requirements and reduced raw material consumption. The M4E technology is ideal for applications in soups, sauces, dressings, meat products, baby food, and specialty food industries. It is cost-effective, has a small footprint, and ensures high yield with lower energy and maintenance costs.

Magnet for emulsion technology for lump-free blends

For industries involved in food processing, achieving precise emulsification and comminution is a critical challenge, especially when working with a variety of textures and viscosities. Ensuring consistency and quality in products requires advanced technology that can handle diverse ingredients with high precision.
<h2>Perform fine and precise comminution</h2>
The BestCut by GLASS Maschinen is designed for continuous fine comminution and emulsification, utilizing a proven rotor-stator principle. It features cutting rings available with and without bar, allowing for exact cuts through precise bearing with no bruising of the product. The BestCut's polygon shaft ensures maximum power transmission and hygiene, contributing to reliable production. This equipment offers flexibility with variable speeds and a cutting gap adjustable from 0.1mm to 3mm. High durability is achieved through its encapsulated motor and easy assembly and disassembly of the cutting system, backed by temperature monitoring for production reliability. Ideal applications include convenience food, delicatessen & cheese, vegetarian & vegan products, meat production, confectionery, and spices.

Precision emulsification equipment for food industry

Comminution

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

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

In industries such as pharmaceuticals, biotechnology, and chemical manufacturing, achieving uniform particle size distributions and reducing particle size are critical for product quality and performance. Traditional methods may not meet the necessary precision and consistency required, posing significant challenges.
<h2>Reduce particle size, achieve uniformity</h2>
The ShearJet HL60 V2 by Dyhydromatics is an electric hydraulic driven processor specifically designed for research and development (R&D) applications. It operates with volumes ranging from 3 mL to 500 mL and beyond, with pressures from 5,000 to 30,000 psi. Each stroke generates a flow rate of 68 mL/min. The system includes a superior cooling product heat exchanger, ensuring consistent operation at maximum pressure. The HL60 V2's small footprint and quiet operation make it ideal for lab environments. Additionally, the integrated Human-Machine Interface (HMI) displays critical process parameters like pressure, duration, temperature, and data acquisition, allowing for precise control. Its robust design ensures continuous and repetitive processing, making it an indispensable asset for creating innovative products with uniform nanoparticles.

High-shear processors for uniform nanoparticles

Manual

In beverage production, achieving a consistent and high-quality blend when dissolving stabilizers like pectin, CMC, or xanthan gum poses a significant challenge. Traditional methods often result in uneven mixes, affecting both the texture and stability of the final product.
<h2>Ensures uniform blending of stabilizers and liquids</h2>
The stabilizer dissolution system by Della Toffola is a specialized unit designed to dissolve, emulsify, and homogenize stabilizers such as pectin, CMC, and xanthan gum. The system combines a high-efficiency in-line blender with a mixer controlled by an inverter, ensuring a consistent and homogeneous blend. The powder injection unit allows stabilizers to be added manually, with the option to automate the power boost function on request. This system is particularly ideal for the beverages industry, ensuring a high-quality blend critical for product consistency. Della Toffola's extensive experience in the food and beverage industry underscores the reliability of this system.

Stabilizer dissolution system for beverage industry

Dissolution

In production environments where precise emulsification, droplet reduction, or slurry shearing are critical, conventional mixers might fall short. These applications need advanced equipment to handle high viscosity levels and achieve ultra-fine homogenization down to 1µ, ensuring a consistent and high-quality output.
<h2>Achieve fine homogenization with high shear rates</h2>
The Ultra MixMaster from Daniatech is an ultra-high shear mixer designed to deliver high speeds, higher outlet pressure, and increased capacity. Utilizing a rotor-stator principle, the unit operates with a shear rate up to 120,000 s-1. This mixer achieves homogenization equivalent to 50-80 Bar and can handle up to 1µ lump-free products. Ideal for both batch and inline operations, it can self-pump low to medium viscosity materials or be fed positively for high-viscosity applications (over 500 cP). Catering to numerous industries such as dairy, plant-based beverages, sauces, and personal care, the mixer offers flexibility with multiple setup options and auxiliary features like double mechanical shaft seals and manual regulating seat valves for flow adjustment. The Ultra MixMaster is available in models with motor power ranging from 18.5 kW to 22 kW, handling flow rates from 10-50 cubic meters per hour and outlet pressures between 2.5 to 7 Bar. Options for different fittings and motors, including NEMA standards, make it adaptable for diverse requirements.

Ultra-high shear mixer for emulsification and homogenization

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

Inline high shear mixing unit for low to medium viscosity products

In high-volume production of dairy products or beverage concentrates, a critical challenge is integrating a high-shear mixing process that can manage large quantities of ingredients efficiently and ensure uniform consistency. This becomes essential for achieving stable emulsifications while minimizing air entrapment and clumping.
<h2>High shearing and mixing with minimal air entrapment</h2>
The InlineMaster by Daniatech is a sophisticated inline mixer designed to handle high capacities and significant powder intake. Leveraging a vacuum system, ingredients are efficiently drawn and mixed below liquid level, facilitating rapid and thorough wetting. The integrated high-shear mixer creates a controlled vortex that expels air and ensures a homogeneous, stable product. This mixer can manage up to 40,000 liters per hour with a powder intake of up to 14,000 kg per hour, making it suitable for various applications, including dairy products, soft drinks, and syrup solutions. Its hygienic design conforms to EHEDG standards, ensuring minimal maintenance requirements and energy-efficient operation.

High-capacity inline mixer for dairy and beverages production

In the meat processing industry, achieving consistent particle size and texture is crucial for product quality. Conventional methods often struggle with repeatability and efficiency, resulting in uneven output and increased operational costs.
<h2>Ensures consistent emulsion and reduction for meat</h2>
The Cozzini PrimeCut AR922 Emulsion/Reduction System is designed for high-quality meat processing. The system features a 230 mm diameter cutting chamber available in single or dual knife configurations. Holeplate sizes range from 1.0 mm to 9.9 mm, making it versatile for different texture requirements. Its unique separation design between the bearing housing and cutting chamber prevents lubrication contamination. Sensors monitor product inlet pressure and temperatures, ensuring precise control. The system is USDA accepted and CE approved, meeting strict sanitary standards. It can operate with a variety of knife holders and plate combinations, optimizing the emulsion and reduction processes. The AR922 can replace bowl choppers and other emulsifiers, saving space and reducing labor and energy costs while increasing production efficiency.

Emulsion and reduction system for meat processing

In the confectionery industry, ensuring precise metering and mixing of raw ingredients is crucial for maintaining product quality and consistency. Challenges often arise with complex mixtures involving different temperatures and ingredient states.
<h2>Accurate metering and mixing of ingredients</h2>
The AUTOGRAV® by CHOCOTECH GmbH is a batch weighing system designed for precise metering and mixing of raw ingredients. Available in multiple versions, this system accommodates various processes such as cold mixing, warm slurry mixing, and dissolving sugar crystals for subsequent cooking. Its steam-jacketed design not only ensures full dissolution of sugar but also includes optional scrapers on the anchor stirrer to prevent build-up or burn-on residues. For specialized applications like making caramel or other fat-containing masses, a high shear mixer can be added to achieve optimal emulsification and rehydration. This flexibility makes the AUTOGRAV® suitable for a wide range of confectionery products.

Batch weighing system for precise raw ingredient mixing

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Metering

In the confectionery industry, achieving a consistent and high-quality caramel is essential. Traditional batch methods can be time-consuming and may not always produce uniform results, leading to inefficiencies and variability in the final product.
<h2>Cook and caramelize caramel continuously</h2>
The YPP® is a continuous cooker designed by CHOCOTECH to mimic traditional batch caramel-making processes while incorporating modern efficiencies. The unique design allows both cooking and caramelization to occur simultaneously, ensuring a homogenous and well-emulsified caramel mass. The solution is pumped through the bottom of a specially designed tank equipped with multiple steam jackets and is agitated by two counter stirrers that enhance emulsification. The residence time for caramelization is controlled through a special weir design at the top of the tank where the mass is discharged. This cooker supports various capacities ranging from 200 to 1200 kg/h, depending on the recipe requirements, making it suitable for different production scales.

Continuous caramel cooker for candy production

Producing shortenings and margarine involves transporting and processing emulsions at high pressures to achieve the desired consistency and quality. The challenges include maintaining consistent flow rates and pressure levels, and ensuring a hygienic environment to prevent contamination.
<h2>Efficiently transport and process emulsions</h2>
The high pressure product pumps from CHEMTECH are designed specifically for managing shortening and margarine emulsions. These pumps handle flow rates ranging from 100 to 20,000 kg/hour at pressures up to 200 bar. They are skid-mounted and come equipped with pulsation dampers, pressure transmitters, and integral pressure relief valves. The sanitary design includes stainless steel and ceramic contact parts to maintain product purity. These features ensure consistent operation and compliance with hygiene standards, making them ideal for the food industry.

High pressure pumps for margarine production

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

In industrial settings, managing volatile organic compounds (VOCs) and unpleasant odors is a common challenge. Traditional methods may not achieve the required reduction levels, leading to health risks and environmental concerns.
<h2>Reduce Voc and odor emissions efficiently</h2>
The Centriair DEO™ is a regenerative catalyst system designed for eliminating VOC and odor emissions from various industrial processes and waste applications. Featuring a patented mesh catalyst technology, this system offers optimized and compact reactor geometry with a large catalyst area and excellent heat capacity. The DEO™ unit requires low maintenance, eliminating the need for media changes, and provides significant cost savings and stable performance throughout its lifecycle. The system achieves a conversion rate of more than 98% of most VOCs, including those that are difficult to eliminate with conventional technologies like ionization, ozonolysis, UV radiation, scrubbers, and active carbon filters. The DEO™ system by Centriair is ideal for applications in biogas production, substrate and sludge holding tanks, hygienization, sewage pipelines, pumping stations, and sewage treatment plants.

Catalytic system for industrial odour and Voc elimination

Handling

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

In the food processing industry, maintaining optimal temperatures for various operations like chilling seafood or dairy products is crucial. Traditional cooling methods may fall short in achieving the desired efficiency and temperature consistency, leading to potential product loss and quality issues.
<h2>Achieve uniform and fast cooling</h2>
The Cabinplant Baudelot Chiller is a water chiller designed to enhance cooling efficiency. It operates on the principle of falling film cooling, where water flows uniformly from an overhead trough over the surface of vertical stainless steel plates, forming a thin film. This film maximizes the heat transfer surface area, resulting in rapid cooling to near refrigerant temperatures. Inside the plates, refrigerant boils along a computer-designed path, ensuring a high internal film coefficient and low-pressure drop. The system includes a stainless steel collection tank with built-in float valve for make-up water, maintaining consistent water levels. Recirculation pumps in the tank pump chilled water to the required locations, ensuring a steady supply of cold water. Designed with easy maintenance in mind, the unit remains fully enclosed during operation and features an optional rotating filter for added filtration. The Baudelot chiller is ideal for processes and industries requiring precise temperature control, such as dairy food, seafood, fruits and vegetables, and convenience food.

Industrial water chiller for efficient cooling

In industries like dairy, foodstuff, cosmetics, and pharmaceuticals, achieving consistent mixtures and emulsions is crucial. The challenge lies in dissolving various components, whether soluble or non-soluble, into liquids efficiently and maintaining high homogeneity throughout the process.
<h2>Mix and dissolve liquids and solid ingredients efficiently</h2>
The Turbo Mixer TM by Boema S.p.A. is a versatile solution designed for dissolving and preparing solutions of pectins, thickeners, and other secondary components. This equipment is capable of dissolving non-soluble products into liquids, obtaining homogeneous suspensions, and quickly dissolving soluble products. It effectively creates emulsions of greases and oils into hot water or other liquids. Its primary applications include processing liquid products in the dairy, foodstuff, cosmetic, and pharmaceutical industries. Its design leverages mechanical shear strength through specifically engineered stirrers, ensuring high efficacy and uniformity in the final product.

Turbo mixer for homogeneous solutions in food and pharmaceutical industries

In industries like cosmetics, pharmaceuticals, and food production, achieving uniform emulsions and blending high viscosity products can be challenging. Precise control over mixing parameters, including agitation speeds, temperature, and pressure, is essential for consistent product quality.
<h2>Achieve fine emulsions with vacuum-based mixing</h2>
The Bachmix R by Bachiller is a vacuum-based blender-homogenizer designed for laboratory, pilot, or industrial production. This unit can handle high viscosity homogenizations and fine emulsions through vacuum and pressure operations, clean-in-place washing, and sterilization capabilities. The Bachmix R offers precise control over agitation speeds, temperature, and vacuum/pressure settings. It features independently controlled coaxial or helicoid mixing tools and a rotor-stator homogenizer with adjustable GAP for stable high fineness emulsions. The integrated system includes a vacuum group, weighing system, heating control module, and automated supervision via a touch interface. It meets ASME VIII div.1 – AD-2000 – EN-13445 standards and is CGMP sanitary designed, validating FDA requirements.

Industrial mixer for liquid and viscous products

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

Laboratory vacuum mixer reactor for liquids and semi-solids

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

Vacuum mixer reactor for liquids and semi-solids

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

Industrial vacuum mixer and reactor for liquids

In industries such as pharmaceuticals, cosmetics, and food processing, achieving consistent and high-quality emulsions and dispersions in high viscosity products presents a challenge. Reliable control over particle size and distribution is crucial for product stability and performance.
<h2>Ensure consistent emulsion and dispersion quality</h2>
The HRB Homogenizer from Bachiller allows for both internal and external recirculation during the homogenization process. It incorporates an adjustable gap system ranging from 0.1 mm to 1.5 mm, which can handle shear rates up to 250,000 s-1. This ensures the production of fine emulsions and dispersions with particle sizes from 10 μm to 1 μm. The HRB is designed to introduce raw materials directly into the high turbulence zone, bypassing the limitations of conventional suction methods. It can process high viscosity products, making it suitable for applications in the cosmetics, pharmaceutical, and food industries. The built-in CIP system simplifies cleaning and maintenance.

Homogenizer for high viscosity emulsion and dispersion

In industries where precise mixing and homogenization of ingredients is essential, traditional methods often fall short in maintaining product consistency and quality. Especially in sectors like pharmaceuticals and cosmetics, achieving a high degree of uniformity is crucial to meet regulatory standards and customer expectations.
<h2>Ensure uniform mixing and efficient homogenization</h2>
The Axomix 25-50 by Axomatic, part of the Marchesini Group, is an under vacuum homogenizer designed for consistent and efficient mixing of complex formulations. Contra-rotating slow mixing with Teflon scrapers and a high-speed homogenizing turbine (up to 3,000 rpm) ensure thorough processing. This equipment features a mechanical lifting cover and tilting vessel for easy discharge of finished products. The system's ability to suck raw materials under vacuum and discharge the finished product through central bottom valves adds to its efficiency. Optional features include check weighters, a cleaning system by spray balls, production data printing, and steam heating. The control panel T&S color kind displays all key operating data to enhance user oversight. The equipment includes a vacuum pump with a power of 0.75 kW and heating elements rated at 6 kW. Key industries that benefit from this technology include pharmaceuticals, cosmetics, and food processing.

Industrial under vacuum homogenizer

In industries where consistent and precise mixing of viscous products is essential, conventional mixing methods often fall short. Techniques such as slow mechanical stirring can be inefficient, time-consuming, and may fail to achieve the desired emulsification quality, especially under vacuum conditions.
<h2>Optimize mixing with vacuum and high-speed homogenization</h2>
The Axomatic Axomix 100 - 300 is a vacuum homogenizer designed for the thorough mixing and emulsification of viscous products. This equipment features contra-rotating slow mixing with teflon scrapers for consistent blend quality, even under high viscosity conditions. The high-speed homogenizing turbine operates at speeds up to 3,000 rpm, ensuring efficient particle size reduction and emulsification. The unit includes a hydraulic lifting cover and vessel tilting, which facilitate easy cleaning and product discharge. For monitoring mixing phases, it has an inspection window with light. Additional options include check weighters, cleaning systems with spray balls, and steam heating. Axomatic, part of the Marchesini Group, manufactures this homogenizer, making it an excellent choice for industries like cosmetics, pharmaceuticals, and food processing that require precise mix quality and operational efficiency.

Vacuum homogenizer for high-quality mixing and emulsification

Industrial inspection equipment is used for checking compliance with health, safety, and quality control standards. For that reason, inspection systems are most commonly utilized in the food and pharmaceutical industry but, they are also used in other industries too. Inspection solutions are often integrated into a production process or production line. Visual inspection systems perform checks to detect variation in size, shape, and color and ensure the presence of labels and closures. Check-weigh systems help ensure that product packages are not under or over-filled. Metal detection systems can help guard against the presence of foreign objects in product containers and X-ray inspection equipment is used to detect physical defects and to ensure high quality package seal integrity.

Inspection

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

In industrial food processing, achieving a consistent texture and uniform blend is crucial when dealing with high-viscosity products like hummus, sauces, and vegetable creams. Traditional methods often fall short in efficiently handling and homogenizing such products.
<h2>Efficient grinding and mixing</h2>
The shear pump from Aurum Process Technology is a versatile tool that functions as both a centrifugal pump and a high-performance grinder. Featuring a high-speed rotor within a stator, it allows the product to flow efficiently while ensuring a homogeneous mix. The pump is easily disassemblable for maintenance, making it practical for regular cleaning and upkeep. It is particularly effective for viscous products in the food industry, providing a hygienic design compatible with Clean-In-Place (CIP) procedures. The pump can handle high temperatures and pressures, enabling continuous operation without incorporating air or lumps into the mixture. Ideal for processes that require homogenization, emulsification, disintegration, de-agglomeration, and dissolution, it stands out for its efficiency and practicality. Additional peripherals can be installed depending on the process requirements, and it is known for its competitive pricing and low maintenance costs.

Industrial shear pump for high-viscosity food applications

In industries such as food, cosmetics, chemicals, and pharmaceuticals, achieving a uniform emulsion with fine droplet structures is crucial. Traditional methods often face challenges with shear-sensitive goods and viscosity, requiring a versatile and efficient process.
<h2>Produce and homogenize fine emulsions efficiently</h2>
The Hydro Grind® Processing system from AK Systems offers a self-developed homogenizing unit that facilitates the seamless introduction of solids into liquids, achieving a fine droplet structure akin to high-pressure homogenization. The system merges multiple process steps into one unit, ensuring shear-sensitive goods are gently mixed into highly viscous emulsions. A key feature is the direct dosing of solids into the dispersing turbine area, preventing lump formation and ensuring a homogeneous mix. This patented technology is adaptable across various industries, producing storage-stable emulsions. The dynamically controlled shear forces provide flexibility, enhancing product quality without the need for multiple system changes.

Emulsion processing system for homogenizing solids into liquids

In the food, beverage, and pharmaceutical industries, producing stable emulsions often requires high shear mixing to prevent issues such as fisheyes and agglomerates. Creating lump-free emulsifications while managing high viscosities can be challenging without the right technology.
<h2>Optimize shear rates for consistent results</h2>
The Rotostat™ High Shear Emulsifier from Admix features Optishear technology, a patented design that combines a revolving stator with a high-efficiency rotor and lower propeller. This design optimizes shear rates and pumping rates while carefully controlling particle size reduction, preventing overshearing. Capable of handling viscosities up to 50,000 CPS, it ensures superb emulsion stability and extended shelf life. The all-stainless-steel construction makes it suitable for hygienic applications and various industries, such as food, beverage, and pharmaceuticals. Available in lab models and production sizes up to 100 HP, it supports scales from pilot to full industrial production.

High shear emulsifier for hygienic applications

Size reduction

Reducing costs and maintaining consistency in mayonnaise and salad dressing production can be challenging with the rising popularity of low-fat and egg-free recipes. Achieving stable emulsions with traditional colloid mills often results in high maintenance costs and production inefficiencies.
<h2>Enhances emulsion stability and reduces maintenance</h2>
The Admix MayoMill is an inline wet mill designed for the efficient production of mayonnaise and other emulsified dressings. Unlike conventional colloid mills, the MayoMill can operate continuously 24/7, eliminating common issues such as problematic cleaning and shear rate adjustments. The MayoMill features superior mechanical seals rated at 725 PSI, preventing downtime caused by seal failures. It allows precise shear rate adjustments electronically via speed control without gap adjustments, ensuring consistent emulsion quality. The fixed gaps optimize shearing, enhancing emulsification for both conventional and cost-reduced formulas. This innovative design reduces the viscosity issues and over-pressurization problems typical with traditional mills. Moreover, the MayoMill is clean-in-place (CIP) compliant, drastically reducing manual cleaning time and associated costs.

Inline wet mill for mayonnaise emulsions

In the food and beverage industry, achieving consistent and uniform product mixtures is crucial for maintaining quality. For applications involving dairy products, salad dressings, or emulsified beverages, challenges such as maintaining stable emulsions and reducing particle size effectively arise.
<h2>Ensures precise mixing and emulsification</h2>
The Dynashear Inline Continuous Mixer from Admix is a high-speed, high-shear mixer designed to meet the demands of continuous processing applications. Constructed entirely of 316 stainless steel, it features unique dual stage axial and radial heads that optimize throughput and flow. These heads generate shear rates that reduce droplet and particle sizes down to 3-5 microns, with excellent distribution. Available in three models (DS-215, DS-425, DS-575) and constructed to withstand uneven flow patterns and pressure fluctuations, the Dynashear is suitable for various applications including dairy, beverage, salad dressings, pet food, and pharmaceutical/API processing. With its easy installation and low maintenance requirements, it is a cost-effective solution designed for rapid cleaning and inspection. Select models are available through Admix's Quick Ship program.

Inline continuous mixer for dairy and beverage processing

When working with highly viscous materials like epoxies and slurries, traditional mixing methods often introduce air bubbles and require significant cleanup. Ensuring uniform particle distribution and achieving a bubble-free mixture can pose considerable challenges.
<h2>Achieve precise and bubble-free mixing</h2>
The FlackTek DAC 330-100 SE SpeedMixer from Across International is designed for a wide range of mixing applications, including epoxies, slurries, formulations, and emulsifications. This dual asymmetric centrifugal mixer ensures perfect, bubble-free mixing without the need for cleanup. It features a 4.3-inch touchscreen for manual variable speed control, allowing you to store up to 3 custom programs. With a top speed of 3500 RPM, the mixer is highly effective at degassing and evaporation. The compact and powerful design is ideal for R&D, formulation, lab screening, and specialty production. The bladeless mixing technology minimizes material waste, making it perfect for precise dosing and small batch processing.

Dual asymmetric centrifugal processing system for epoxies and slurries

Degassing

Emulsions enhance foods with a creamy mouthfeel and richer flavors. But the immiscible nature of oil-and-water mixtures makes it challenging to maintain consistency in textures and taste across batches.


<h2>Versatile, powerful, and reliable</h2>
The ProxxD® high-shear emulsifier from ProXES guarantees reproducibility batch after batch. The built-in proprietary automation system hands full control over the shear energy input and other critical parameters.

Droplet distribution impacts emulsion stability and the sensory profile of the final product. FrymaKoruma specializes in droplet size control and is the world market leader in emulsion-based food processing systems.  Its technology solution disperses fine droplets with precision to create superior-quality foods and extend their shelf-life.

The ProxxD® is a highly versatile system that is easily adaptable to match your exact processing needs. Besides emulsification, the ProxxD® performs a range of food processing functions, including dosing &amp; weighing, mixing, and vacuum deaerating.

The integrated unit has been redesigned with a small footprint but large capacities, reaching up to 5,000 kg/hour depending on the product recipe.