Dries and Mixes Industrial Solids Efficiently

The Vacuum Dryer – SOLIDMIX VST/VPT from EKATO is designed to meet the rigorous demands of industrial solid processing. This innovative equipment excels in efficiently drying and mixing solids, utilizing patented EKATO impeller technology for enhanced heat transfer and uniform product quality. A versatile solution, it serves diverse applications including fine chemicals, pharmaceuticals, and biopolymers, delivering controlled moisture removal crucial for end-products like active pharmaceutical ingredients and biodegradable polymers.

Operating on a batch process, the SOLIDMIX dryer offers volumes ranging from 50 to 32,000 liters, adaptable for both laboratory and production scales. Its design facilitates easy integration into existing production lines, boasting automation via a comprehensive PLC system that supports remote monitoring. Engineered for efficiency, it minimizes energy consumption with low-power input for maximum vertical mixing—an essential feature for reducing operational costs.

Constructed from corrosion-resistant materials and compliant with GMP standards, the SOLIDMIX VST/VPT ensures both durability and safety in processing. The inclusion of cleaning-in-place (CIP) systems facilitates efficient maintenance and contamination-free operations. Customizable elements such as adjustable impeller types, heating and cooling options, and adaptable system configurations ensure the equipment meets specific process requirements, backed by EKATO’s engineering support.

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Mixes, Homogenizes, and Circulates High-Viscosity Products

The UNIMIX Vacuum Processing Units by EKATO SYSTEMS redefine precision mixing and homogenization across industries like cosmetics, pharmaceuticals, and chemicals. Featuring the patented EKATO PARAVISC impeller and S-JET homogenizer, these units excel in processing products with varying viscosities, from lotions and creams to gels and serums. Designed for both batch and continuous operations, they incorporate advanced automation with a PLC-controlled interface and remote monitoring capabilities. Available capacities range from 100 to 20,000 liters, accommodating both laboratory and large-scale production environments. The units boast energy-efficient heating and cooling functions, optimizing resource use. Built to withstand demanding conditions, they are available in corrosion-resistant materials, ensuring longevity and reliability in diverse applications. These systems comply with GMP standards and include an integrated CIP system for effective and contamination-free cleaning, while offering extensive customization options to meet specific production needs.

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Blends and Homogenizes Bulk Solids Efficiently

The SOLIDMIX Vertical Pharma Vacuum Blender from EKATO is engineered for high-performance blending of powders and granules, catering to chemical, pharmaceutical, and food industries. Its innovative vertical mixer design optimizes the mixing process, using a conical bottom and EKATO SOLIDS-PARAVISC impeller for efficient, homogeneous blending with minimal product residue. Available in various capacities up to 32,000 liters, it supports diverse batch sizes from pilot to full production scales. The SOLIDMIX system integrates seamlessly with existing production lines, featuring CIP systems for efficient, contamination-free cleaning, and ATEX-certified versions for use in hazardous environments. Engineered for energy efficiency, it ensures low operational costs, while customization options allow tailored solutions to specific process needs.

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Facilitates Hydrogenation for Diverse Chemical Processes

The EKATO Modular Hydrogenation Plant is designed to tackle complex hydrogenation challenges across pharmaceutical and chemical industries. What sets this system apart is its modular approach, allowing for versatile production configurations. Central to its design is the EKATO hydrogenation reactor, equipped with the combined gassing system for efficient gas-liquid reactions. Utilizing a two-zone dispersion for optimal mass transfer, this plant efficiently processes active pharmaceutical ingredients, sugar alcohols, and hydrogenated vegetable oils, among others.

With reactor volumes ranging from 50 to 6000 liters and design pressures up to 150 bar, the plant supports both batch and continuous operations. The plant features PLC automation for seamless production line integration and energy-saving technologies like self-aspirating gas turbines, which reduce operational costs. Fabricated with corrosion-resistant materials, these plants ensure long-term reliability and meet stringent regulatory standards, including GMP compliance. Cleanup and maintenance are streamlined through integrated CIP systems, providing quick cleaning turnaround and minimizing downtime.

Moreover, EKATO offers extensive customization options and engineering support, tailoring solutions to meet specific client requirements and ensuring optimal performance in diverse operational environments.

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Facilitates Gas-Liquid Reaction Development

The Laboratory Plant ELA 5 from EKATO is a versatile and portable reactor unit designed for efficient gas-liquid reaction development, adaptable for use in both EX-proof areas and standard laboratory settings. It features a specialized agitation system, including the EKATO Combined Gassing System with PHASEJET and GASJET impellers, ensuring minimized mixing times and maximized mass transfer. Ideal for applications such as hydrogenation, carboxylation, and oxidation, it’s perfect for producing hydrogen peroxide, ibuprofen, and biodiesel.

Operating between 25 and 250°C and up to 81 bar, with a working volume of 3 liters and a gas feed capacity of up to 1.6 m³/h, the ELA 5 is well-suited for batch and semi-batch processes in R&D environments. The reactor’s modular design allows for integration into existing systems with adaptable baffle configurations and removable inner cooling coils. Its energy-efficient operation benefits from precision-controlled parameters, while compatibility with low-viscosity fluids ensures broad applicability.

This system is built for seamless scale-up and data analysis with EKATO’s process guarantees and monitoring capabilities, including gas feed rate, pressure, and temperature tracking. Engineers have the option for material customization to ensure chemical resistance and compliance with industry standards, supported by EKATO’s engineering and start-up services. The ELA 5 is an indispensable tool for chemical producers and biotechnology firms seeking reliable, efficient process development.

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Processes Highly Viscous Materials in Pilot Batches

The Pilot Plant ELA 50 from EKATO is designed specifically for processing highly viscous materials under controlled conditions. Featuring a coaxial agitator system with both central and close-to-the-wall impellers, it withstands viscosities up to 1,000 Pa·s. This plant is EX-proof (T3, IIB), making it suitable for flammable liquids and a range of applications, including pharmaceuticals, biopharmaceuticals, and specialty chemicals. It excels in processes like mixing, degassing, and solvent evaporation, offering batch and semi-batch operations up to 60 liters. Integrated with a vacuum station for efficient solvent recovery, it ensures optimal energy use, enhanced mass and heat transfer, and reduced mixing times. The ELA 50 supports GMP compliance with modifications available, such as steam injection, to meet diverse operational needs. Maintenance is streamlined with support from EKATO’s mixing specialists, providing trials, scale-up expertise, and analytical monitoring.

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Mixes and Homogenizes Cosmetic and Pharmaceutical Products

The UNIMIX LM and SRT series from EKATO provide tailored solutions for R&D in the cosmetic and pharmaceutical sectors, designed specifically for lab and pilot plant settings. These vacuum processing mixers stand out for their dual functionality in mixing and homogenization, utilizing an integrated homogenizer that doubles as a cleaning pump. This efficient system facilitates the development of products such as creams, lotions, and gels by allowing easy scale-up from small batches. Available in various capacities ranging from 3 to 70 liters, the equipment is designed for flexibility, enabling precise control over speed, temperature, and pressure. Constructed with high-grade stainless steel, the units ensure robust corrosion resistance and longevity. They’re compliant with GMP standards, ensuring safety and quality in pharmaceutical applications. Designed for easy integration within existing process lines, the mixers feature PLC control for seamless operation. Additionally, the equipment is available for rental and testing at EKATO’s facility in Schopfheim, Germany, offering a reliable scale-up pathway for developing new formulations.

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Harnesses UV Light for Chemical Synthesis

The EKATO Photochemical Reactor integrates specialized stirred technology, ideal for complex multiphase reactions. Designed for efficiency, it utilizes UV light from ATEX-certified sources, eliminating the need for catalysts in processes such as chlorination and sulfoxidation. With reactor sizes up to 50 m³ and a robust agitator system, it ensures high circulation rates for optimal mass transfer, crucial in producing intermediates and polymers like PVC and specialty adhesives. The reactor offers material versatility with options in enameled steel and titanium, supporting diverse chemical environments. Automation is seamless with the EKATO Combined Gassing System, enhancing dispersion efficiency for gaseous reactants. The system comes equipped with double-acting seals for safe operation with hazardous substances, and supports continuous and scalable production, making it a crucial asset for industries like pharmaceuticals, biotechnology, and consumer goods manufacturing. Comprehensive engineering support and customization are available to meet specific processing needs, ensuring reliable integration into your production line.

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