What is a Vacuum Emulsifier?

What is a Vacuum Emulsifier?

Vacuum emulsifier is a type of machine used to make viscous emulsion. It can be used in cosmetics and chemical industries. The machine conforms to CGMP standards like clean-in-place (CIP)/sterilize-in-place.

It comprises homogenizer & center blade stirrer/scraper residues stirrer to provide the best mixing route. The vacuum control the blending climate that helps in averting air circulation that might trigger blending blade degeneration and assists in getting void-free final results.

1. High-speed shearing

Vacuum emulsifiers make use of high-speed shearing to produce products such as cream, preparations and gels. These are used in the cosmetic, food, pharmaceutical industry and chemistry for applications such as ointments, syrups and eye drops.

The heart of the machine is a batch mixer consisting of a holed stator and high speed rotor. The rotor rotates at 3000rpm and produces strong suction force to draw materials in from the top and bottom. The high linear velocity and strong kinetic energy produced in the shear gap between the rotor and stator causes the materials to be crushed, chopped, dispersed, emulsified and homogenized by the rotor’s rotating blades.

The mixture is then pumped to the work head and combined by shearing and impact forces. The resulting emulsion can then be easily discharged. This process saves time and effort compared to the manual mixing method used in previous production.

The vacuum emulsifier has a fully enclosed design that reduces the product’s contact with air, ensuring hygiene and sterility. It is also easy to clean and maintain. It is ideal for lab small-scale emulsifying, homogenizing and dispersing experiments and production. It meets GMP specifications and can be fitted with CIP/SIP systems. All parts contacting the material are made of stainless steel (316L for medical application) to ensure safety and cleanliness.

2. High-pressure evaporation

As the gas molecules in a liquid rise toward the surface, they hit the walls of the container and produce pressure. When they reach a certain point, they stop rising and the number of gaseous molecules that are escaping is balanced by the number returning to the liquid. This equilibrium is called saturated vapor pressure, and it can be measured using a simple piece of apparatus.

The boiling point of the liquid is the temperature at which the vapor pressure is equal to atmospheric pressure, or 760 mm of mercury (mmHg). This means that when the temperature of the liquid Vacuum emulsifier increases, its vapor pressure will increase as well. This is because the molecular kinetic energy of the vapor molecules will be greater at higher temperatures, so more will escape from the surface of the liquid.

A vacuum emulsifier can be used to dewater oily materials, such as mazut or kerosene. The process is similar to that of high-speed shearing, but the resulting oil-water droplets are much smaller. This allows for a higher emulsification efficiency.

For the emulsification to be effective, the emulsion must be prepared with both phases at a temperature above their boiling points. Also, the shape of the particles of the ingredients is important. Rough particles tend to inter-pore, while spherical particles mix very well.

3. High-pressure cavitation

Vacuum emulsifiers are used to produce pharmaceutical products, such as ointments, preparations and gels. These machines have a fully enclosed vacuum system, which allows the materials to be emulsified, homogenized, heated and dispersed without contacting the air. This can reduce the risk of contamination and ensure that the final product meets strict hygiene standards.

The emulsion is pumped into the vacuum chamber using an electric pump. The vacuum pumps create a high-shear environment, which breaks down the agglomerates that form at the bottom of the emulsification pot. It then creates a high-speed flow that mixes and disperses the material evenly. This process can be completed in a fraction of the time that it would take using a conventional mixer.

Another advantage of a vacuum emulsifier is that it can be used to heat and dissolve chemicals, which are often too volatile for conventional mixing methods. This can help to speed up the production process, save energy and improve the quality of the final product.

In addition, a vacuum emulsifier can be used to perform degassing of liquids. This is accomplished by generating cavitation bubbles that serve as autonomous chemical mini-reactors, which can rapidly change complex hydrocarbon mixtures. The energy released during the implosion of these bubbles can also be used to break down solid agglomerates. This can be especially useful for emulsifying high-viscosity products like oils and grease.

4. High-pressure mixing

The heart of the vacuum emulsifier is a high speed mixer or homogenizer. Its rotor rotates at a high speed producing strong Automation equipment supplier suction force and the materials enter through the shear gap between the rotor and stator. They’re sheared, dispersed, emulsified and homogenized by the action of depolymerization, crushing, centrifugal extrusion, liquid layer friction and shearing. The emulsion then flows to the homo-head through holes and the pressure variation created in the homo-head results in mixing, breaking, and influencing. The emulsion then gets sucked back by the blade mixer and the downward current produced by it.

The machine also helps in improving the uniformity of a product and reduces the rate of wastage that occurs during manual blending. It’s a good choice for creating creams and other fluid products like hack syrups.

In the chemical industry, it’s a widely used equipment to process polyesters and synthetic fibers, latex, saponification products, sauce, detergents and paints. The petrochemical, printing and dyeing auxiliaries, paper, pesticide and fertilizers, plastic and rubber industries also make use of this technology. The cosmetic cream industry also finds it worthy to mix and emulsify its products using this machine. However, it is important to note that the machine should be operated in a dry environment to avoid damage or harm from negative pressure in the tank. It’s also advisable to keep hands away from the tank pressure valve to prevent burns.

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