What Is a Vacuum Mixer?
Vacuum mixers are a common tool used for mixing, emulsifying, homogenizing and dispersing liquids and solids. They serve the pharmaceutical, food and cosmetic industries.
They are available in batch sizes ranging from 20 to 3000 liters. They are also suitable for pilot productions.
1. High shear
High shear mixers provide a powerful method for achieving hard-to-mix tasks such as homogenization, dispersion, emulsification, and particle size reduction. Unlike ordinary mixers, which rely on friction to mix, a high shear mixer utilizes shearing forces to direct the material into a stationary stator at a very fast speed. Variable rotor speeds allow you to tailor the amount of sheer energy in each mixing operation and therefore deliver a specific type of dispersion or emulsion.
There are a few different types of high shear vacuum mixers, including batch, in-line, powder injection and granulators. All of these types are a variation of the same concept, but each has some unique features.
A batch model mixes all ingredients in a single vessel. This is often used in the pharmaceutical industry where different mixtures need to be mixed together in order to create a finished product. In this system, a mixing head can be permanently mounted or suspended from a portable lift that serves several vessels.
In-line high shear vacuum mixers are less bulky and can produce results in a fraction of the time required by batch systems. They also provide a more controlled mixing environment and are less prone to contamination.
To make the most of these high shear vacuum mixers, you’ll need to know how they operate. Typically, the shearing zone of an in-line high shear mixer is perpendicular to the input and output ports. The mixing materials are fed into the shearing area and discharged via an axial outlet.
Once the materials have been sheared, they are either recirculated back into the mixing chamber or transferred to downstream equipment for further processing. The mixture is usually re-circulated until the desired particle size and continuous phase are achieved.
These high shear vacuum mixers are able to handle a wide variety of raw materials. The most common are liquids, but they can also be used to mix powders.
Some of the most challenging powders to process include gums, thickeners and paint thins. These powders are difficult to work with and can cause a number of problems when trying to achieve an emulsion or dispersion. Ross’s new SLIM (Solid/Liquid Injection Manifold) technology solves these problems by drawing the powdered components into a vacuum-generated rotor-stator assembly to mix them with the liquid stream.
2. Low shear
Shear strain is a fluid dynamics phenomenon that occurs when two liquids or solids move across each other at differing speeds, causing an area of deformation along the contact surface. It is a common technique used to completely mix difficult-to-mix materials that would not otherwise mix using conventional methods.
Low shear vacuum mixers are designed to operate at very high speeds to generate a fine particle size distribution and homogenize dispersed liquids and solids into a continuous phase. These high speed mixers produce vortices that are fixed above and below the mixing head to draw the mixture into the rotor, radially releasing it through the stator slots. The vortex also draws agglomerates that float on the surface of the product into the mix.
These mixers can be used to complete the hydration, emulsification, and homogenization processes in a single pass. They provide a more compact, less bulky mixing environment that yields a superior final product in a shorter amount of time.
High shear vacuum mixers can be used to produce a variety of products including cosmetics, ointments, lotions, shampoos, skin care creams, soaps, detergents, paints, coatings and more. They can be adapted to accommodate different types of ingredients and processes.
They are available in various models vacuum mixer to suit your needs, including batch and mobile configurations. The batch model can be permanently mounted to a vessel or suspended over a vessel with a portable lift, which allows you to vary the position of the rotor/stator generator to process a wide range of materials.
The mobile model is a great choice for processes that involve frequent changeovers between vessels. It is equipped with a simple valve that can divert the finished product to another vessel or switch from one process to another.
When using a low shear vacuum mixer, it is important to clean the equipment regularly. This is to ensure that the product does not become contaminated or harmful to people. CGMP requirements require that these mixers be cleaned and sterilized under controlled conditions, known as Clean-In-Place or CIP.
3. Vacuum
A vacuum mixer is a type of industrial mixer that allows the operator to mix products in a vacuum environment. This vacuum prevents excess air from being trapped and helps limit bubble formation. These mixers are used for a variety of applications, including scientific research and food service.
Vacuum emulsifying mixers are commonly used in the pharmaceutical industry to make mixing products such as gels and preparations. They also help produce ointments and liquid creams.
They are also widely used in the chemical industry to produce coatings, inks, ano materials and printing and dyeing auxiliaries. They can help you produce more consistent results and ensure a higher level of quality.
In addition, the vacuum emulsifying mixer can be used to help you produce creams and ointments. It can mix and disperse oil and water with ease and is also easy to clean.
These types of mixers can be purchased from many companies for a wide range of uses. These companies also sell vacuum mixer replacement parts for the machine and can help you get the most out of it.
When purchasing a vacuum emulsifying mixer, it is important to consider the size of the product being mixed and how much pressure the mixing will need. You need to choose a model that is large enough to handle the amount of product you are mixing.
Another important factor to consider is the size of the vacuum. This will determine how fast the machine will work and the overall efficiency of the mixing process.
A larger mixer is more likely to have the best performance. This is because it has the capacity to mix more material at once. This is also the most efficient way to mix a mixture, as it reduces processing times.
One thing to keep in mind when using a vacuum emulsifying mixer is that it can be difficult to dissolve powdery materials and conduct two-phase emulsification. This is because powdery materials can be difficult to break down and agitators can become frustrated trying to move the particles.
Vacuum emulsifying mixers have a lower discharge speed than fluidized bed mixers. This is because the vacuum emulsifying pots settle at the bottom of the mixer.
4. Flexibility
Flexibility is a key factor to consider when choosing a vacuum mixer. It can affect the performance of your machine as well as its safety.
If a mixer is not flexible, it may cause mechanical problems that could result in a breakdown or even a fire. These issues can also be a problem if the mixer is used for hazardous materials or applications.
It is important to design a mixer with flexibility so that it can accommodate process changes. If a mixer is not flexible, it will likely be unable to meet changing requirements and will probably fail before the end of its service life.
When designing a vacuum mixer, it is important to account for how the mixer will move and to design the supporting structure accordingly. This is especially true if the mixer has a nozzle or pad that must be supported across the head of the tank.
This is because a nozzle or pad mounting that does not provide adequate stiffness and support may not only move with the load, but it may actually bend the shaft or wear shaft bearings. This will cause a variety of mechanical problems that will not only reduce the mixer’s efficiency but will also have a negative impact on the safety of the mixer and the product.
The nozzle or pad mounting of a mixer will typically use gussets to increase the stiffness and support of the head. It is also common to add a reinforcing or stiffening plate called a “skull cap” to the head of the tank so that it can withstand considerable flexure.
In addition, the nozzle or pad should have the proper width and depth so that it will not be distorted by deflections in the tank. This is particularly important if the nozzle or pad is to be supported over the top of a tall, open tank.
The ability to adjust the nozzle or pad’s height is another important aspect to consider when designing a mixer. This allows the nozzle or pad to be adjusted so that it can be positioned correctly in the tank and not interfere with the material that is being mixed.