What is the standard operating process for a homogenizing vacuum emulsifier?

Step 1: Pre-Operation Preparation

• Inspection: Check the machine for visible damage (e.g., cracks in the tank, loose hoses) and verify that all components (homogenizer, vacuum pump, temperature controls) are functioning. Ensure the vacuum seal is intact—leaks will compromise performance.
• Ingredient Prep: Preheat or cool oil-phase and water-phase ingredients separately (if needed) to the target temperature (e.g., 70–80°C for melting waxes). This reduces mixing time and improves dispersion.
• Tank Cleaning: Clean the mixing tank and homogenizer with a neutral detergent and rinse thoroughly to prevent cross-contamination from previous batches.

Step 2: Loading Ingredients

• Add the continuous phase (e.g., water for oil-in-water emulsions) to the mixing tank first. Start the low-speed stirrer to create gentle circulation.
• Gradually add the dispersed phase (e.g., oil) while stirring. Avoid pouring too quickly, as this can cause uneven mixing.
• Add emulsifiers, stabilizers, or other additives (e.g., preservatives) at the recommended temperature (check ingredient guidelines—some emulsifiers work best at specific temperatures).

Step 3: Homogenization and Vacuum Application

• Activate the vacuum pump to reduce pressure in the tank (typically to -0.08 to -0.095 MPa). Wait until the vacuum reaches the target level before starting homogenization.
• Turn on the homogenizer and adjust the speed or pressure (depending on the type) to the desired setting (e.g., 8,000–15,000 rpm for rotor-stator systems). Run the homogenizer for 5–15 minutes, depending on the formulation—longer times may be needed for high-viscosity materials.
• Monitor the temperature and vacuum level throughout the process. Adjust the jacketed heating/cooling system if temperatures deviate from the target.

Step 4: Post-Homogenization and Unloading

• Once homogenization is complete, reduce the homogenizer speed to low and maintain gentle stirring while cooling the emulsion to room temperature (if needed). Add heat-sensitive ingredients (e.g., fragrances, active peptides) at this stage to avoid degradation.
• Release the vacuum slowly (sudden pressure changes can cause the emulsion to foam).
• Drain the finished emulsion through the tank’s outlet valve, ensuring the line is clean to prevent contamination.

Step 5: Post-Operation Cleaning

• Disassemble detachable parts (e.g., homogenizer probe, stirrer blades) and clean them with warm water and detergent. For food or pharmaceutical applications, sanitize parts with a food-grade disinfectant or autoclave (if compatible).
• Wipe the tank interior and exterior with a clean cloth. Ensure all components are dry before storing to prevent rust or mold.