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high-shear-mixer-for-creams

high shear mixer for creams

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

Mixing

The 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

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

A high-shear mixer produces flow and shear in a fluid to help disperse separate phases. Choosing a shear mixer requires multiple considerations including the degree of dispersion and homogeneity required, the targeted time cycle, heating or cooling requirements, and the desired batch volume or flow rate. High shear mixers are used in the pharmaceutical industry for the production of syrups, creams, and ointments, in the chemical industry for the dispersion of pigments or other powders in a liquid medium, and in the food industry for the preparation of sauces and dressings.

Industrial

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

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

Emulsifying

liquid

Batch

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

Manual

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

Hydroalcoholic gel mixing system

Blending

Handling

Continuous

In industries such as food processing, cosmetics, pharmaceuticals, or chemicals, achieving effective mixing and dissolution of low-viscosity products requires dependable high-speed agitation, even in smaller vessels.
<h2>Ensures powerful and high-speed agitation</h2>
The PBC Portable Agitator by INOXPA is designed for vertical direct motor-driven use with a clamp. Specifically tailored for processes requiring strong and rapid agitation, this agitator is ideal for mixing, dissolution, and dispersion in industries like food processing, cosmetics, pharmaceuticals, and chemicals. It can be attached to small tanks of up to 1,500 liters, accommodating a range of applications with low-viscosity products. Operating principles involve using a retainer for secure attachment and a combination of bearing support and propeller rotation to maintain optimal fluid dynamics. Featuring an IEC B14 motor running at 1500 rpm, the agitator offers a maximum power output of 0.75 kW. Robust AISI 316L stainless steel components and an IP 55 rating ensure durability and hygiene standards. Optional features include motors with varying protections and speeds, a welded propeller with a finer surface finish, and pneumatic drive capabilities.

Portable agitator for high-speed mixing

Dissolution

Managing the agitation and mixing of high viscosity products poses significant challenges in maintaining consistency, temperature, and homogeneity. Processes involving complex fluid behaviors require specialized agitators to ensure effective mixing and heat transfer, preventing product degradation.
<h2>Optimize mixing and heat transfer for viscous products</h2>
The MCR Counter-rotating Agitator by INOXPA is designed to handle the mixing and homogenization of medium to high viscosity products. It features two coaxial shafts with independent geared motors rotating in opposite directions. The central shaft operates at higher speeds with propellers for dispersing low-viscosity phases, while the outer shaft, equipped with an anchor and scrapers, removes product from tank walls and acts as a deflector for the central propellers. This configuration ensures efficient heat transfer and prevents overheating. It is particularly suitable for processes with variable viscosity, featuring a variable frequency drive for adjustable rotation speeds. Compliant with EHEDG guidelines, it supports CIP and SIP processes, and is configurable with various options including surface finishes and ATEX certification.

Counter-rotating agitator for high viscosity products

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

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 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

solid

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 beverage industry, achieving a consistent and homogeneous solution when mixing raw powdered ingredients with liquids can be challenging. Ensuring optimal dissolution and safety for operators is essential to maintain the high-quality standards of the product.
<h2>Achieve homogeneous solutions rapidly and safely</h2>
The Powder Mixer by Innotec (Omnia Technologies) is an automatic dissolving system designed to solubilize raw powdered ingredients efficiently. The system ensures quality and homogeneity while prioritizing operator safety by separating the induction points of the liquid and powder to prevent premature reactions. High-speed friction between the liquid and powders at the center of the impeller ensures prompt dissolving. The design minimizes contact with air, thus reducing oxygen presence in the solution. Unlike traditional marine propeller agitators, the Powder Mixer combines the powder with the liquid more effectively, offering dissolution capacities ranging from 3,000 to 9,000 kg/h.

Powder mixing system for beverage industry

Powder

In pharmaceutical production, achieving precise mixing and granulation of powder ingredients is crucial to ensure product quality and consistency. Traditional methods often struggle to prevent powder sticking and contamination, leading to inefficiencies and potential product losses.
<h2>Optimal shear for consistent granulation</h2>
The ROTO MIX by IMA is a latest-generation high shear mixer granulator specifically designed for the dry mixing of powders and wet granulation in the pharmaceutical industry. Inspired by the proven Roto technology, it ensures the optimum shear for granulation at all speeds. The mixer uses a unique impeller and chopper combination along with a liquid binder distributor to achieve efficient mixing and agglomeration. Its design minimizes powder sticking, thereby maximizing product yield. The through-the-wall installation optimizes room layout and integrates seamlessly with other granulation equipment. Additionally, the in-line dry milling enables wet granule sizing and direct transfer to a fluid bed dryer. Equipped with strategically positioned washing nozzles, the system also offers Wash In Place (WIP) capabilities, ensuring thorough cleaning even in hard-to-reach areas.

High shear mixer granulator for pharmaceutical applications

Granulation

In pharmaceutical R&D labs, precise granulation and coating of small batches are critical for formulation and scale-up studies. Challenges include accurate processing, efficient use of materials, and maintaining consistent quality throughout various stages of production.
<h2>Achieves uniform granulation and coating efficiently</h2>
The MYLAB by IMA is a compact and modular fluid bed and coating system designed for small batch processing. It features a Main Technical Unit (MTU) with an integrated air-handling unit, spray system, and control panel for seamless operation. The fluid bed module allows both top and bottom spray processes, accommodating batch sizes from 3 to 6 liters. Additionally, a high shear mixer is available for dry mixing and wet granulation tasks. The coating pan module offers interchangeable drums, including fully perforated, solid wall, and Wedge wire screen options, suitable for batches from 0.5 to 10 liters. The MYLAB ensures precise control and scalability, making it ideal for pharmaceutical development and formulation studies. Compliant with stringent GMP standards, it simplifies product changes and enhances productivity.

Fluid bed and coating system for small batch processing

To coat your consumer products with color or taste-enhancing substances, specialized technologies are available that ensure all the contents are individually and evenly covered. The process starts with loading your goods onto rotating drums, exposing the products to spray nozzles that treat them with your prescribed coating formula.

Coating

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

In scenarios where precision powder mixing, particle surface modification, and consistent shape enhancement are crucial, traditional mixers often fall short. These challenges necessitate equipment that combines multiple processing capabilities to handle nano to micron-sized particles without using binders.
<h2>Achieve precise composite material production</h2>
The Nobilta super high shear mixer from Hosokawa Micron is a multifunctional processing device designed for high-speed, precision mixing, particle surface modification, and shape enhancement. It effectively combines particles into composite materials through mechanical force in a dry process. The mixer’s horizontal cylindrical vessel and specially designed rotor operate at high speeds of up to 30 m/s, exerting equal impact, compression, and shear forces on each particle. This makes the Nobilta particularly suited for nanoparticle processing, where overcoming strong agglomeration forces is essential. The unit is equipped with a jacketed vessel to manage heat, preventing the degradation of heat-sensitive materials. Applications include batteries, catalysts, cosmetics, dry powder inhalants (DPI), functional resins, pigments, and toner. The mixer is available in five models, with batch volumes ranging from 0.5 to 300 liters, power options from 5.5 kW to 200 kW, and motor speeds from 780 to 6000 rpm.

Super high shear mixer for nano to micron powders

When dealing with sensitive powders and bulk solids, achieving a homogeneous mix without damaging the materials can be challenging. Traditional mixers often require extra steps to break up lumps, adding complexity and time to the process.
<h2>Achieve homogeneous mixing with reduced cycle times</h2>
The Vitomix ribbon screw mixer by Hosokawa Micron is a mid-shear batch unit designed for efficient and gentle mixing of powders, pastes, and slurries. Featuring a double ribbon screw mounted on an orbital arm, it ensures efficient material transport and homogeneous mixing. The Vitomix can handle up to eight times more transport volume than standard mixers, making it highly efficient. It operates at speeds ranging from 0.4 m/s to 6.0 m/s and is capable of incorporating liquids without the need for lump breakers. Available in sizes ranging from 500 to 10,000 liters, it is suitable for various applications such as coating, granulating, and flavoring. The system includes unique features like a liquid spraying system, ensuring flexibility in nozzle placement. Enhanced by the reliable Nauta® mixer technology, the Vitomix offers up to 8 times faster mixing with energy-efficient operations and full discharge capabilities through a bottom discharge valve.

Mid-shear mixer for powders and bulk solids

In industries dealing with powders and bulk solids, uniform mixing is critical to maintaining product consistency and quality. Traditional manual mixing methods are often labor-intensive and can lead to variability in the final product, necessitating more precise and automated solutions.
<h2>Ensure uniform mixing of powders and bulk solids</h2>
The powder mixing systems from Hosokawa Micron are designed to deliver optimal performance and precision. These systems integrate various components like conveying, handling, dosing, and weighing to create a complete and tailored solution. Offering a wide range of mixer types, including low, medium, and high-shear mixers, they cater to both batch and continuous operation needs. Key elements include accurate dosing systems, efficient weight control, and custom-built designs focusing on safety, reliability, efficiency, and hygiene. These systems are suitable for numerous industries such as food and beverage, pharmaceuticals, and chemicals, ensuring consistent product quality. With modern control systems including HMI-PLC panels for operator identification and lot traceability, seamless automation is achieved. Hosokawa Micron leverages its century-long expertise to provide bespoke mixing solutions tailored to specific application requirements.

Powder mixing systems

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

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

Weighing

When blending solids and liquids into highly viscous pastes or plastic masses, achieving uniform consistency can be challenging due to the high material density. Traditional mixing methods may fall short in delivering homogeneous mixtures, especially in continuous production environments.
<h2>Kneads, mixes, and extrudes continuously</h2>
The Extrudomix from Hosokawa Micron is a mixer/extruder that combines high shear mixing and low to medium pressure extrusion in one continuous process. A horizontally aligned shaft with blade segments arranged in a spiral pattern moves material through the chamber. As the material advances, it undergoes continuous kneading and mixing due to stationary anvils positioned between the rotating blades. This results in homogeneous pastes and plastic masses efficiently and cost-effectively. The Extrudomix features heating and cooling jackets and a variety of die shapes and sizes, making it versatile for numerous applications, such as homogenizing filter cakes or mixing base powders with liquids. Available in several models with capacities ranging from 340 kg/h to 4550 kg/h, it caters to both small and large-scale production needs.

Mixer/extruder for viscous pastes and plastic masses

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

<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

Kneading

In industrial applications like food, pharmaceuticals, and chemicals, achieving homogenous mixing of cohesive powders with liquids or melt binders and processing slurries are common challenges. Special attention is needed for rapid and precise mixing to ensure high product quality and efficiency.
<h2>Ensures rapid and homogeneous mixing</h2>
The Cyclomix high shear impact mixer by Hosokawa Micron is a high-speed, intensive paddle mixer and agglomerator designed for cohesive powders, slurries, and liquids. It features a conical mixing vessel with a central paddle rotor that can reach speeds of up to 30 m/s, creating centrifugal forces that disperse materials against the vessel walls. The upward movement and impact blade facilitate excellent liquid dispersion and agglomerate size homogeneity within ultra-short processing times. This highly intensive mixing also ensures effective heat transfer for temperature control. Suitable for industries like food, chemicals, and pharmaceuticals, it allows processing of varying product properties efficiently.

High shear impact mixer for agglomeration and dispersion

Agglomeration

In industries requiring highly homogeneous mixtures of powders and liquids, achieving optimal product consistency can be a challenge. High mixing accuracy is critical in applications like modification of starch or production of detergent powders.
<h2>Achieve accurate and homogeneous mixing</h2>
The Flexomix high impact mixer by Hosokawa Micron is a continuous vertical mixer and agglomerator designed for precise and homogeneous mixing of powders and liquids. With a vertical cylindrical chamber and a high-speed rotating shaft, this mixer creates a turbulent air flow for effective mixing. Adjustable knives on the shaft ensure optimal agitation and collision rates. The system allows for simultaneous addition of different liquids using atomizing nozzles, making it suitable for various viscosities and sticky media. Compact design and capacities from 50 kg/hr to 40 t/hr ensure versatility. Short residence time (<1 second) and a self-cleaning chamber contribute to low maintenance and high efficiency. Applications include agglomeration of veterinary antibiotics, hydration of phosphates, and instantizing of drinking chocolate.

High impact mixer for powders and liquids

Industries processing materials like carbon black or paracetamol require machinery capable of continuous operation even in harsh conditions. Traditional grinding systems often struggle with maintaining consistent performance and require frequent maintenance.
<h2>Continuous grinding of soft to medium-hard products</h2>
The Pulverizer MP from Hosokawa Alpine is a high-speed hammer mill designed for continuous operation in demanding environments. Capable of reaching peripheral speeds of up to 100m/s, it is suitable for grinding, mixing, and homogenizing soft to medium-hard products. Its robust construction ensures reliable operation, while the easy-to-clean design simplifies maintenance. The Pulverizer MP is versatile, capable of handling a range of materials including carbon black, paracetamol, cocoa, sugar, dyes, and melamine resin. Special designs, like the Pulverizer SCB, are optimized for specific materials, such as carbon black, featuring a suction inlet or injector to improve performance.

High-speed pulverizer for carbon black production

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

In industries such as ceramics, handling materials with high viscosity can present several challenges. Achieving uniform wetting and thorough mixing without dead spots often requires specialized technology to prevent material buildup and ensure efficient operation.
<h2>Achieve uniform and rapid mixing</h2>
The Horizontal Paste Mixer by Hockmeyer Equipment Corporation is designed for efficiently mixing high-viscosity materials, eliminating dead spots with triple mixing blades and a specially designed impeller. The overlapping arms of the mixer prevent material buildup, while the double-rolling action provides exceptional shear and wetting. This model conserves power by eliminating wasted motion and comes in various sizes from 20 to 1600 gallons. It is available with options for a vacuum and jacket design, inverter-driven variable speed, and different blade types including high viscosity blades, paddle blades, and ribbon blades. The construction materials include stainless steel or carbon steel with finishes ranging to highly polished surfaces. The Horizontal Paste Mixer is suitable for environments requiring either standard or hazardous electrical components.

Horizontal paste mixer for high-viscosity materials

When producing high-viscosity products such as sealants, adhesives, or creams, achieving a homogeneous mixture is essential. Traditional single high-speed dispersers often struggle with such tasks, leading to inefficiencies in mixing.
<h2>Ensures homogeneous mixing and product uniformity</h2>
The HHL-III Triple Shaft Mixer/Disperser by Hockmeyer Equipment features a center-mounted low-speed helical or anchor blade and one or more high-speed dispersion shafts. It is designed to mix medium to very high viscosity products effectively. The high-speed shaft ensures proper shear to disperse or dissolve ingredients, while the low-speed blade blends and folds the mass in the vessel, ensuring uniform product consistency. Patented scrapers improve heat transfer and aid in incorporating powders. This mixer can handle a range of material volumes, from laboratory scale to 3500 gallons, and offers configurations for both hoist and tank mounting. It is adaptable to vacuum, pressure, or atmospheric operations and can be built with either stainless steel or carbon steel materials. The HHL-III is ideal for applications such as printing inks, sealants, caulks, hot melt adhesives, magnetic media slurry, and more.

Triple shaft mixer for high viscosity products

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

In many industrial applications, achieving uniform mixing in large tanks can be challenging due to issues like dead zones and inefficient fluid circulation. Examples include wastewater treatment, chemical processing, and the pharmaceutical industry where precise mixing is essential.
<h2>Ensures efficient fluid mixing with high-speed rotor</h2>
The LUMPP side-entry horizontal mixer by HASLER Group offers a high-performance solution for continuous industrial agitation and mixing. Designed to be mounted on the sides of tanks, it generates turbulence with a high-speed rotor for efficient homogenization of large fluid volumes. Capable of being installed on DIN or ASME flanges, either vertically or inclined, this mixer is customizable with various propellers for axial or radial flow to suit different applications like mixing, dispersion, or solid suspension. With motor power ranging from 0.55 to 55 kW and speeds between 1.5 to 350 rpm, the LUMPP mixer can adjust its performance based on the viscosity and density of the fluids. Adapted for use in sectors such as wastewater treatment, chemical production, and pharmaceuticals, it offers a cost-effective, space-saving, and easy-to-maintain mixing solution. Optional features like baffles and flow control devices help to optimize mixing efficiency further. ATEX certification ensures safety in explosive environments.

Side entry mixer for industrial fluid mixing

Agitation

In industries like petrochemicals, fine chemicals, and coatings, dealing with high viscosity liquids or complex rheological products demands a robust mixing solution. Challenges such as heat dispersion and preventing clogging are common and need specialized performance equipment.
<h2>Handles high viscosity and complex rheology</h2>
The LUMPP Coaxial Mixer-Agitator by HASLER Group offers an advanced mixing solution specifically designed to tackle high viscosity and complex rheology liquids. This system features a central impeller rotating in one direction and an outer impeller rotating in the opposite direction. The impellers are designed to mix even the most viscous fluids swiftly and prevent film formation on tank walls. The mixer can come with a variety of impellers, such as helical screws and dispersion turbines, to enhance mixing efficiency and heat exchange. Suitable for various industries, including petrochemicals, fine chemicals, and oil and gas, this mixer is versatile. The system can operate at speeds ranging from 200 to 1,500 rpm and handle motor power between 0.55 to 45 kW. It is built with high-quality materials like stainless steel and nickel-based alloys.

Coaxial mixer for high viscosity liquids

When developing new OTC products or testing formulations in a lab, consistent production in small quantities is crucial. A precise, scalable system can ensure that raw materials are mixed uniformly and dosed accurately.
<h2>Produce small quantities with scalable quality</h2>
The Lab+ unit by Hänsel Processing is designed to produce from 8 to 16 kg/h continuously, making it ideal for small batch production and research and development. It has an integrated raw material preparation station with a high-shear mixer, allowing homogeneous mixing of various materials including crystals, powders, and liquids. The system includes an option for integrated weighing, a frequency-controlled dosing pump for precise delivery, and subsequent vacuuming to lower temperature and water content. The Lab+ unit does not require a compressed air connection or steam installations, simplifying setup. Direct access to process parameters is also provided, which is critical for product development. The system is designed for quick installation and fast start-up, minimizing product loss and ensuring an excellent price/performance ratio.

Laboratory unit for small quantity production and r&d

Vacuum

In the chocolate production industry, maintaining the quality and consistency of chocolate during storage and processing is a significant challenge. Proper temperature control, homogeneous mixing, and specific hygienic standards are required to ensure the end product meets the desired quality.
<h2>Ensures homogeneous storage and precise temperature control</h2>
The stainless steel chocolate tank by GPI De Gouwe is designed for the homogeneous storage and processing of chocolate. Available in sizes ranging from 50 liters to 50 cubic meters, these tanks are equipped with double jackets for precise temperature control, essential for maintaining the quality of chocolate. Each tank can be customized with various types of agitators, such as anchor, gate, or scraping agitators, to ensure uniform mixing. Further options include integrated heating systems like dimple, half-pipe, electric tracing, or au-bain-marie. These tanks meet the highest hygiene standards with an internal roughness of Ra 0.8 and can be tailored to specific requirements, ensuring they meet the demands of different chocolate processing stages.

Stainless steel chocolate tank for storage and processing

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

In the industrial production of potato flakes, ensuring consistent product quality and characteristics such as taste, color, and shelf life is challenging. This requires precise mixing and dosing of various additives into mashed potatoes before they are processed further.
<h2>Mix and dose additives accurately to potato flakes</h2>
The Additiveline by GPI De Gouwe is a specialized system designed for mixing and dosing various additives into potato flakes in large-scale production. This system addresses the growing need for automation in potato processing lines. Additives such as emulsifiers, phosphates, and dextrose are precisely dosed into mashed potatoes, which are then processed into thin layers, dried, and broken into flakes. The system can handle both dry and liquid additives and features various setups, including single and multi-tank configurations. These setups offer flexibility and enhanced product quality by allowing separate dosing of specific additives. Options include a vacuum transport system to keep dry additives separate from the wet part of the line, various mixing principles like high-speed mixers and inline mixers, and automated control systems for consistent results.

Additive mixing and dosing system for potato flakes

Pilot

Industrial production of high-quality powder materials often requires precise control over particle size and composition. Challenges include maintaining consistent quality in mass production and achieving specific material characteristics tailored to end-use applications.
<h2>Optimizes powder synthesis and particle coating</h2>
The Glatt ProAPP® series reactors are advanced synthesis reactors designed to meet the diverse requirements of producing, modifying, or coating powder particles in the nanometer and micrometer range. Utilizing pulsating gas flow in a continuous vertical reaction tube, these reactors allow for tailored adjustments to raw material feed rates and process temperatures. Reactor options range in diameter from 80 mm for small-scale production to 500 mm for larger quantities. The reactors can achieve process temperatures up to 1300°C with electric or gas heating options, and allow for precise product separation via filters and samplers. Suitable for various materials such as battery powders, ceramic powders, catalytic powders, and pigments, the ProAPP® reactors are customizable to fit specific industrial applications. Glatt’s facilities offer lab-scale options for research and pilot-scale reactors for scaling-up production, ensuring flexibility for both small and large campaigns.

Powder synthesis reactors for nanometer and micrometer particles

Classifying

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

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

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

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 production of powders and granular materials, achieving precise mixing and granulating is essential to meet industry standards. Traditional methods often fail to provide uniform mixing, leading to inconsistencies in product quality and increasing operational costs.
<h2>Achieve consistent and precise powder mixing</h2>
The VAS Pulver by GLASS Maschinen is a high-speed mixer designed specifically for mixing and granulating powders to perfection. Available in various capacities ranging from 80 to 2200 litres, it offers flexibility for diverse production needs. This mixer features an automatic lid operation and a motor-driven swivelling drum, ensuring ease of use and efficient operation. The drum's discharge height can be customized according to user requirements, and the EasyClean drain valve allows for quick and efficient cleaning. With the option of chopper configurations including double-U shape or knife head, the VAS Pulver is designed for precise granulating and mixing. Integrated temperature control, direct steam injection, and an integrated vacuum pump enhance the functionality, making it suitable for high-standard hygienic applications. The equipment also complies with EHEDG guidelines, ensuring adherence to the latest hygienic engineering standards.

High-speed mixer for granulating and mixing powders

Entry level

In research and development (R&D) settings and for pilot plant operations, achieving consistent and high-quality mixing of small batches is essential. Traditional industrial mixers often do not scale down effectively, leading to inefficiency and inconsistent results in small volume operations.
<h2>Fast and efficient small batch mixing</h2>
The GMS Compact Batch Mixer by Gericke is specifically designed for laboratory and small-scale production. This twin-rotor mixer offers excellent mixing quality with a volume range of 1 to 20 liters. Its low-speed operation, characteristic of the GMS family, creates a fluidized zone using two horizontally arranged, superimposed mixing tools. This design ensures even mixing while preserving high-quality ingredients. The mixer is built for easy cleaning and sterilization, with interchangeable mixing chambers and dismantleable parts. Operating at an optimal Froude number of 1.1, it reduces R&D costs due to its low minimal filling volume. This compact mixer is also mobile, standalone, and requires only a standard electric supply (220 V AC/50 Hz), making it ideal for agile product development and recipe formulation.

Laboratory mixer for r&d and small batch production

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

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

In pharmaceutical and industrial applications, forming medium to high-density granules from powders is often challenging. Precise control and uniform mixing are essential to ensure high product quality and efficiency.
<h2>Facilitates homogeneous wet granulation</h2>
The GMX GRANUMEIST® is a high shear granulator and mixer designed by Freund for the efficient and homogeneous wet granulation of powders. Its top-drive design enhances user safety and enables faster processing times. The removable bowl and mixing blade with a fixed bowl lid allow for superior cleaning and maintenance. The vertical shaft chopper improves granulation, while the user-defined mixer and chopper speeds offer processing flexibility for both aqueous and solvent materials. Optional features include vacuum drying for one-pot processing and a jacketed bowl for product temperature control. The system is equipped with a color touch screen control for validatable process control, configuring both automatic and manual modes. It also supports 21 CFR Part 11 compliant data and recipe handling. The GMX GRANUMEIST® series comes in various models, offering bowl capacities from 150 to 1200 liters.

High shear wet granulation line

In pharmaceutical manufacturing and other powder processing industries, achieving uniform granule density and size is crucial. Traditional mixing methods often struggle with consistency and efficiency, leading to variations in the final product quality.
<h2>Rapid and uniform granulation</h2>
The GMX-LAB Mini GRANUMEIST® from Freund is a high shear wet granulation system designed to provide consistent and efficient granulation of powders. Its top-drive design facilitates easy cleaning and maintenance, ensuring faster processing times and enhanced safety. This granulator features interchangeable 4L and 8L bowls, user-defined mixer and chopper blade speeds, and an integrated peristaltic pump for precise solution addition. The system can handle both aqueous and solvent processing with optional jacketed bowls for temperature control. Its quick-change design requires no tools and is mounted on casters for easy maneuverability, making it an ideal solution for flexible and scalable production needs.

Mini High shear granulator for wet granulation

Achieving consistent and homogenous granulation of powders is crucial in pharmaceutical and chemical manufacturing. Traditional methods often struggle with inefficiencies, extended processing times, and intricate maintenance, making innovation in wet granulation technology necessary.
<h2>Ensures consistent and homogenous wet granulation</h2>
The GMX-LAB Micro GRANUMEIST®, from Freund, is a state-of-the-art high shear granulation system designed to streamline the wet granulation process for powders. Its top-drive design facilitates easy cleaning and maintenance, while ensuring faster processing times and enhanced user safety. With interchangeable 1L and 4L bowls, it offers processing flexibility and accommodates varying batch sizes. User-defined settings for mixer and chopper blade speeds, along with an integrated peristaltic pump, provide precision in solution addition. An optional jacketed bowl allows for precise product temperature control. The Smart-Safe™ containment option adds an extra layer of security, and the color touchscreen control system supports validatable process control with various end-point detection parameters. This system is well-suited for industries requiring medium to high density granules, including pharmaceuticals and chemicals.

High shear lab granulation system for powder processing

When producing pharmaceuticals or food products, achieving a homogeneous wet granulation of powders is crucial for consistent product quality and process efficiency. Processing powders into medium to high-density granules requires a granulation system that ensures rapid mixing and uniform consistency.
<h2>Enhanced wet granulation with flexible bowl capacities.</h2>
The GMXB-Pilot GRANUMEIST® by Freund is a high shear granulator designed for efficient and homogeneous wet granulation of powders. It features a bottom-drive system that enhances user safety and simplifies maintenance. The modular design allows for interchangeable product bowls in capacities of 10L, 25L, and 65L, catering to various batch sizes. An integrated peristaltic pump and user-defined settings for mixer and chopper blade speeds provide operational flexibility. Optional features include a jacketed bowl for temperature control and vacuum drying for one-pot processing. The system is equipped with a color touchscreen control system with both automatic (recipe driven) and manual modes, ensuring process control. Data can be collected via a USB port, and the system supports 21 CFR Part 11 compliance for data and recipe handling. The GMXB-Pilot GRANUMEIST® is suitable for pharmaceutical, nutraceutical, and food industries, offering scalable granulation solutions from lab to production scale.

Pilot High shear granulator for wet granulation

In the pharmaceutical and chemical industries, achieving a consistent particle size and density during wet granulation is crucial. Traditional granulation methods can present challenges such as long processing times and difficult maintenance, affecting production efficiency and output quality.
<h2>Enhance wet granulation efficiency and uniformity</h2>
The GMXB-LAB Mini GRANUMEIST® by Freund is a bottom-drive high shear granulator and mixer designed for efficient and homogenous wet granulation of powders. This system features interchangeable product bowls with capacities of 4L, 6L, and 10L, allowing for flexibility in processing different batch sizes. Its bottom-drive design simplifies cleaning and maintenance, resulting in faster processing times and improved user safety. The system includes user-defined settings for mixer and chopper blade speeds, an integrated peristaltic pump, and optional features such as a jacketed bowl for product temperature control and vacuum drying for one-pot processing. The GMXB-LAB Mini GRANUMEIST® allows for both aqueous and solvent processing, supporting a wide range of granulation requirements. Furthermore, the system features a color touchscreen control system with validatable process control and multiple endpoint detection parameters, ensuring consistent and reliable results.

High shear granulator for wet granulation of powders

In pharmaceutical production, achieving uniform granules with controlled density is crucial for consistent tablet formulation. Traditional granulation methods can often result in uneven particle sizes and inefficient processing times.
<h2>Facilitates efficient wet granulation with user-defined settings</h2>
The GMXB-LAB Micro GRANUMEIST® by Freund is a bottom-drive high shear wet granulation mixing system designed for homogenous granule formation. Its design allows for faster processing times and easy cleaning and maintenance, ensuring superior user safety. The interchangeable product bowls range from 1L to 6L, enabling process flexibility with both aqueous and solvent processing. User-defined settings for mixer and chopper blade speeds, as well as an integrated peristaltic pump, provide tailored granulation control. The Smart-Safe™ containment option and proportional mixer blade tip speeds add to the equipment's efficient and safe operation. The system also features a jacketed bowl for optional product temperature control and a color touchscreen control system with validatable process control and USB data collection port.

High shear GMP wet granulator

In pharmaceutical or chemical manufacturing, obtaining uniform granules with specific density and size is critical. Traditional granulation methods can lead to uneven granules, prolonging production times and complicating downstream processes.
<h2>Create uniform granules with precise control</h2>
The GMXB GRANUMEIST® from Freund is a high shear granulator and mixer designed for efficient and homogenous wet granulation of powders. It features a bottom drive mechanism and is built using GMP-compliant 316 stainless steel, ensuring robust, clean processing suitable for pharmaceutical and chemical applications. The granulator supports flexible processing with user-defined settings for mixer and chopper blade speeds, allowing for aqueous and solvent processing. An optional jacketed bowl enables precise product temperature control, and the system can also be equipped for vacuum drying for all-in-one processing. Built with ease of access in mind, it allows for straightforward maintenance, calibration, and inspection. Engineered scalability allows for processing volumes ranging from 30 liters to 1800 liters, accommodating various production needs. The Smart-Safe™ containment and EcoClean™ technology enhance safety and simplify cleaning, making it a versatile solution for granulation suites.

High shear granulation mixing system

Lyophilization

In pharmaceutical and chemical industries, achieving uniform and dense granules from powder mixtures is crucial for product consistency. Traditional mixing methods may result in uneven granulation and poor end-product quality, necessitating an advanced approach in wet granulation processes.
<h2>Ensures uniform and efficient wet granulation</h2>
The GMX-25 GRANUMEIST® by Freund is a high shear granulator designed for efficient and homogeneous wet granulation of powders. Its top-drive design facilitates easy cleaning and maintenance, rapid processing times, and enhanced user safety. Equipped with user-defined settings for mixer and chopper blade speeds, and an integrated peristaltic pump for precise solution addition, it offers processing flexibility for aqueous and solvent processing. An optional jacketed bowl allows for precise product temperature control. The removable bowl and vertical shaft chopper improve granulation and ease of maintenance. The system is portable, with electrical and compressed air connections mounted on casters for maneuverability. The color touchscreen control system supports both automatic and manual modes, offering validatable process control and USB data collection.

High shear wet granulation system

In pharmaceutical manufacturing, achieving uniform particle size and consistent mixture quality is essential. Traditional mixing processes often struggle with issues like uneven granule size and excessive heat generation, which can compromise the product’s quality.
<h2>Ensures uniform mixing and granulation</h2>
The High Shear Mixer Granulator by Fabtech is designed to address these challenges with its ergonomic and compact design. It facilitates both dry mixing and wet granulation processes, ensuring homogeneous mixing and even binder distribution. The four-blade impeller design provides efficient dry mixing, while the rapidly moving chopper blades break down oversized agglomerates and distribute the binder uniformly. Constructed in SS 316, the mixer includes features such as a wet co-mill at discharge for uniform drying, a binder addition port with sprinkle nozzle, and a pneumatically operated top lid and discharge port. The system is GMP and 21 CFR Part 11 compliant, making it suitable for various scales of pharmaceutical production, from lab to commercial models.

High shear mixer granulator for efficient wet granulation

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

Vacuum processing units for high-viscosity products

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

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 pharmaceutical production, ensuring uniform granulation and mixing on a large scale is crucial. Traditional methods often face challenges like inconsistent granule size and labor-intensive cleaning processes, which can hinder efficiency and compliance with regulatory standards.
<h2>Ensures uniform granulation and efficient mixing</h2>
The P 250-1250 by Diosna is a high-performance pharmaceutical mixer granulator designed for large-scale production. It features an automated cleaning system that simplifies maintenance and ensures hygiene. The equipment's advanced mixing tool and bowl design deliver consistent and high-quality granules. It integrates seamlessly with fluid bed processors, optimizing workflows. The stable operating platform offers easy access to the mixer bowl, enhancing operational convenience. Additionally, the integrated industrial PC enables precise batch data logging and meets 21 CFR part 11 requirements, ensuring regulatory compliance. With options like the DIOSNA-Toollift for shaft seal inspection, it minimizes downtime and maximizes efficiency in pharmaceutical manufacturing.

Pharmaceutical high-shear mixer granulator

For pharmaceutical production start-ups, achieving consistent product quality and process reproducibility is crucial. Challenges include maintaining homogeneous mixtures and achieving optimal granulation with smaller batch sizes.
<h2>Efficiently mix and granulate small batches</h2>
The P 100 is a high-shear mixer granulator designed by DIOSNA to support production start-ups in the pharmaceutical industry. This granulator provides excellent blending and granulation, ensuring reproducible processes for batch sizes ranging from 30% to 90% of the total volume. It features a compact design that is pressure shock resistant and complies with ATEX requirements for inerting applications. The P 100's swing-open spout housing allows for easy cleaning, and its effective mixing tools and optimized vessel geometry guarantee the best product flow. Flexible installation options enable placement in the technical zone or the production hall, adapting to your spatial constraints.

High-shear mixer granulator for pharmaceutical production start-up

When developing new product formulations in industries such as food, pharmaceuticals, or chemicals, experimenting with small batches allows for precise adjustments and rapid iteration. This approach helps fine-tune product quality and performance before scaling up to full production.
<h2>Consistently mix and experiment with small batches</h2>
The Pegasus® R&D Mixer by Dinnissen is designed for small-scale experimentation and product development. Capable of handling batches ranging from 10 to 200 liters, the mixer allows you to test and refine various product compositions and mixing techniques efficiently. Featuring proven Pegasus® mixing technology, it ensures precise control over mixing times, rotation speeds, and temperature management. The compact and mobile design enables easy integration into existing lab setups. The mixer’s stainless steel construction facilitates straightforward cleaning and minimizes residue. Such reliability and flexibility make it ideal for sectors like food, pharmaceuticals, pet food, feeding, and aquafeed, and chemicals.

R&d mixer for small batch experimentation

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

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

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 various industries, blending powders uniformly can be challenging. Achieving an efficient and thorough mix without the inclusion of dead spaces is crucial to ensure product consistency and quality.
<h2>Optimizes mixing and ensures complete discharge</h2>
The Guedu® mixing agitator by De Dietrich Process Systems is designed for optimal powder blending. The system employs a vortex motion, creating three distinct mixing effects: division, separation by thin layer, and dispersion. It features a cylindrical vessel with a flat base, minimal clearance between the vessel and agitator, and a discharge door flush with the vessel wall to prevent carry-over between batches and ensure efficient discharge. High-speed lump breakers, either side or top-mounted, are used for achieving desired mixing efficiency. The construction eliminates dead spaces and the unit can be charged from the top, with discharge options including manual or automatic side discharge doors or valves.

Powder blender for efficient mixing and discharge

When producing high-viscosity products like ice cream or syrups, ensuring air-free and lump-free mixtures can be challenging. Traditional mixing methods often fall short in delivering the homogeneity required for high-quality end products.
<h2>Ensure homogeneity with high shear and vacuum</h2>
The VacuumMaster is a high shear mixer developed by Daniatech for handling medium to high viscosity products. It features a directly driven high shear mixer at the bottom and a top-mounted agitator. The vacuum function allows for automatic powder dosing directly from big bags or silos, efficiently drawing powder into the liquid and creating instant wetting. A controlled vortex, along with the vacuum, effectively separates air from the liquid, producing a stable, air-free, homogeneous dispersion within seconds. This mixer can operate as a batch or in-line mixer, requiring a circulation loop for the latter. The compact design ensures energy-efficient operations and minimal maintenance. It is suitable for various applications, such as spray drying products, soft drinks, ice cream, and soups.

Vacuum high shear mixer for medium to high viscosity products

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 the production of sauces, dressings, and emulsions, achieving a homogeneous product is crucial. Traditional mixing methods often fall short, resulting in a mixture with air bubbles and lumps. This complicates consistency and quality control.
<h2>Achieve lump-free high viscosity mixes quickly</h2>
The ProcessMaster by Daniatech is specifically developed for mixing products with medium to high viscosities. Utilizing a vacuum system, it draws powder below the liquid level to instantly wet the powder, eliminating air incorporation and ensuring a homogeneous dispersion in seconds. The mixer features a high-shear mechanism combined with a scraper agitator that generates a controlled vortex in the tank. The unit comes equipped with an insulated jacket, allowing for rapid heating and cooling using steam or ice water. For faster heating, direct steam valves can be added. This results in a stable, lump-free product with an optimized energy-efficient mixing process, reducing maintenance costs. The ProcessMaster is ideal for producing sauces, mayonnaise, dressings, gels, creams, and emulsions. It ensures homogenization down to 3µ and handles viscosities up to 50,000 cP.

High-shear mixer for high viscosity products

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

When mixing various liquid and powder ingredients in food production, achieving consistent texture and integration with minimal clumps is often challenging. Specific cases include creating recombined dairy products, emulsifiers and stabilizers, or sugar solutions, where an effective and precise mixing method is essential.
<h2>Ensures consistent mixing and homogenization</h2>
The LiquidMaster by Daniatech operates on the rotor-stator principle, distributing products through patented slots with a special closed mixing wheel. Designed for versatility, it recirculates approximately 75% of the liquid back into the vessel. The system integrates a butterfly valve for manual control of liquid levels and automatic pumping action for low to medium viscosity liquids. For higher viscosity applications over 250 cP, positive feeding setups are required. Featuring an ergonomic table design, the LiquidMaster ensures an optimal working position. Standard features include a shaft-sealed mixer unit, Tri-clamp inlet/outlet, and a CIP spray ball. Available options offer further customization, such as double mechanical shaft seals, various control cabinets, and ATEX compatibility.

Mixer for low to medium viscosity products

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

Lab-scale high-shear mixer for recipe development

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 numerous industrial processes, mixing powders with liquids efficiently presents a challenge. Traditional methods often result in incomplete mixing, powder clumping, and high energy consumption. Achieving homogeneous mixtures while maintaining low energy costs can be particularly tough for low to medium viscosity products.
<h2>Efficient inline high-shear mixing</h2>
The InjectMaster by Daniatech is an inline high-shear mixer designed with an innovative injector that generates strong powder suction. The mixer operates on the rotor-stator principle, where a specifically designed mixing wheel passes the product through patented slots. The system accelerates the liquid, creating pressure in the injector pipe, which draws powder from the powder funnel. The powder quantity is managed via a manual butterfly valve. The InjectMaster excels in mixing low to medium viscosity liquids autonomously and is compatible with high-viscosity applications using positive feeding. Ergonomically designed, it can be integrated into a table for optimal working height. Key industries for this solution include dairy, food, and beverage sectors, where ensuring lump-free homogeneity down to 2μ is crucial. The InjectMaster boasts low energy consumption and maintenance costs, ensuring high efficiency.

Inline high-shear mixer for powders and liquids

For industries requiring efficient incorporation of powders into liquids for products like soft drinks, soups, and ice cream mixes, achieving a homogeneous dispersion without lumps and minimal air content can be challenging with traditional mixing solutions.
<h2>Create stable, lump-free mixtures quickly</h2>
The BasicMaster from Daniatech is a manually operated mixer designed for high-capacity applications. Powder is added manually through a manway and instantly incorporated into the liquid, generating a controlled vortex that separates air and ensures a perfect homogeneous dispersion within seconds. The mixer is compact, energy-efficient, and virtually maintenance-free. It can be used both as a batch mixer or in an in-line setting if equipped with a circulation loop. The BasicMaster is suitable for various industries, including dairy, food, beverages, and personal care. It handles viscosities up to 2000 cP and is optimized for products that need to be pumpable with a standard centrifugal pump.

High-capacity manual mixer for industrial applications

When refining oils, particularly in chemical refining processes, one major challenge is effectively reducing residual soap content in the neutralized oil to ensure high-quality final products. The process often requires adjusting temperature and retention times based on oil quality.
<h2>Optimize oil quality with adaptable neutralizing processes</h2>
The Crown MultiPure Neutralizing system, provided by Crown Iron Works, is designed for flexibility and efficiency in the chemical neutralizing of oils. It offers multiple neutralizing processes—including two-stage and three-stage procedures—allowing for customization according to the oil's characteristics. The system can either water-wash the oil or employ special sorbents to lower residual soap levels, with the added benefit of minimal wastewater production when sorbents are used. Innovative features, such as an atmospheric reactor with variable retention times and a high-shear variable-speed mixer, ensure optimal mixing and reaction conditions. Additionally, temperature control at each step of the process allows for precise adjustments, enhancing overall process efficiency.

Oil neutralizing technology for chemical refining

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 laboratory environments, preparing small batches of powder and granules often requires precise and consistent mixing. Facing limitations in space and needing compliance with strict regulations, finding a versatile and compact solution is crucial to maintain efficiency in experimentation and development.
<h2>Ensures consistent mixing with digital controls</h2>
The Mini Laboratory Mixer from Cos.Mec is designed for tabletops, making it ideal for installation in compact spaces. Featuring a tabletop design with interchangeable bins of various sizes, it offers flexibility in handling different batch volumes. The mixer supports dual inclination, both 15° on the horizontal and vertical axes, ensuring thorough mixing. Equipped with a digital display, potentiometer, and timer for setting precise mixing durations, it allows for controlled and repeatable operations. The unit's construction in fine satin polished AISI 304 stainless steel meets EC and cGMP regulations, ensuring compliance with industry standards. Additionally, the lexan protection panels with a safety microswitch enhance operational safety. The speed of mixing can be easily adjusted thanks to the integrated inverter, providing users with full control over the mixing process.

Mini laboratory mixer for tabletops

In pharmaceutical R&D and quality control, achieving uniform wet mixing and granulation for small batch sizes is crucial. Traditional methods may fall short in terms of precision and control, leading to inconsistent particle sizes and suboptimal end products.
<h2>Mix, granulate, and dry small batches efficiently</h2>
The laboratory high shear mixer by Cos.Mec is designed for the precise wet mixing, granulation, and drying of small quantities of pharmaceutical products. Equipped with an array of advanced features, this unit offers both manual and automatic management of processing cycles via a PLC touchscreen. A key highlight is its granulating chamber, available in various volumes, complete with a transparent lid and an exhaust filter for safe operation. The mixer includes a funnel and manual valve for precise addition of granulation liquids, and a pad valve with pneumatic control. Constructed with high-quality materials, all parts in contact with the product are made from mirror-polished AISI 316 L, achieving a roughness average (RA) of ≤ 0.4 μm, while other parts are made from AISI 304 with an RA of ≤ 0.8 μm. Optional features include a product temperature probe and a heating jacket with a vacuum system for enhanced drying capabilities. Connectivity is ensured through USB and RJ45 terminals, allowing for efficient recipe management and data collection.

Laboratory high shear mixer for wet mixing and granulation

In industries where high-speed and gentle homogenization of bulk materials is critical, achieving efficient processing without compromising particle integrity or causing heating is a common challenge. This necessity often arises in sectors like plastics manufacturing, where uniform mixing is essential.
<h2>Ensures high-speed and gentle homogenization</h2>
The MIX-A-LOT, provided by Coperion, is an advanced bulk material mixer designed to blend materials rapidly while preserving particle integrity. The mixer features an optimized rotor that facilitates efficient mixing through low circumferential velocities, minimizing particle destruction and preventing product heating. Available in three sizes, the MIX-A-LOT can process up to 5 tons per hour and includes an ATEX-certified version for hazardous environments. The mixer is built for easy cleaning with large inspection doors offering comprehensive access to the mixing chamber and discharge section. The electro-polished surface of the mixing chamber ensures a clean process, making this mixer an ideal solution for industries requiring precise and gentle handling of bulk materials.

Bulk material mixer for high-speed homogenization

In industries where high volume production of materials with low bulk density is crucial, traditional extrusion methods often face challenges. These include difficulties in feeding materials with poor flow properties and achieving high throughput rates without compromising product quality.
<h2>Enhance throughput and efficiency with advanced twin screw technology</h2>
The ZSK Mv PLUS by Coperion is a twin screw extruder optimized for processing materials with low bulk density and high filler content. Its design features a large free screw volume and high screw speeds, allowing for maximum throughput with specific energy requirements below 0.13 kWh/kg. This extruder offers gentle product handling, reducing thermal and shear stress, which is essential for maintaining product quality. The series is capable of speeds up to 1,800 rpm and provides a specific torque of 11.3 Nm/cm3, which boosts productivity by up to 40% compared to previous models. With application-specific solutions such as quick-release features and side devolatilization (ZS-EG), the ZSK Mv PLUS is ideal for industries requiring flexible and efficient processing capabilities. Key applications include polymerization, powder coating, catalyst carriers, adhesives, and food processing.

High throughput twin screw extruder for low bulk density products

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

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

Metering

In laboratory settings, producing various types of jellies requires precise control over ingredient mixing and temperature. A common challenge involves achieving homogeneous hydrocolloid mixtures without manual intervention, often necessary in ensuring consistent product quality while scaling down from industrial-sized production processes.
<h2>Utilizes high shear mixing and vacuum technology</h2>
The PRINCESS® JELLYMASTER by CHOCOTECH is an advanced lab equipment system designed to streamline the production of jellies. The system features a mix tank with a high shear mixer specifically for hydrocolloids, ensuring uniform mixing and consistency. A slurry metering pump feeds the integrated Sucrotwist® pressure dissolver, and the complete vacuum chamber along with the vacuum system allows for the production of all types of jellies. Additionally, the system includes a 'Direct Steam Injection' (DSI) jet cooker, ideal for pressure dissolving high amylose starch. The entire system is PLC-controlled, providing precise and automated operation, enhancing accuracy and replicating production-sized unit capabilities within a lab-scale environment.

High shear mixer system for hydrocolloids

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

When producing various confectionery products like caramel, binders, and jelly, maintaining precision in the cooking process is crucial. Achieving homogeneous and lump-free masses, while ensuring efficient and consistent ingredient integration, poses a significant challenge.
<h2>Smoothly cook and integrate confectionery masses</h2>
The CARASTAR® by CHOCOTECH is a flexible batch cooker designed to handle various confectionery masses, including caramel, jelly, and sugar solutions. The unit is available in different sizes, with batch capacities ranging from 60 kg to 250 kg and throughput rates of up to 750 kg/h. It stands out due to its versatility in cooking methods, enabling atmospheric, under pressure, under vacuum, post-vacuuming, and cooling processes. For greater automation, it features load cells for automatic ingredient feeding when a batch weigher is unavailable, and a high shear mixer for homogenization. Additional options include a vacuum installation, CIP booster pump, and dairy valving for inline washing using 360° spray balls. The system often incorporates a reservoir tank for continuous downstream processing, making it ideal for large-scale confectionery production.

High-shear mixers

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