Application Case of High-Shear Mixing, Dispersing and Emulsifying Equipment
In the production of complex multi-phase materials (including solid powder, oil phase, water phase and auxiliary agents), the integration of mixing, dispersion and emulsification processes is the key to ensuring product uniformity, fineness and long-term stability. A production facility engaged in the manufacturing of semi-solid and liquid products once faced severe bottlenecks in the combined processing of materials. The traditional multi-equipment split processing mode led to low production efficiency, unstable product quality and high operational costs. After introducing high-shear mixing, dispersing and emulsifying equipment, the facility fundamentally solved these problems and achieved significant improvements in production performance, product consistency and cost control.
Background and Pre-Upgrade Challenges
The facility mainly produces multi-component products with a daily output requirement of 200-300 tons, covering applications that require strict control of particle size distribution and emulsion stability. Before upgrading the equipment, the facility adopted a split processing mode: using a common mixer for preliminary mixing, a disperser for solid powder dispersion, and a single-function emulsifier for oil-water phase emulsification. This three-step split process not only extended the production cycle but also brought a series of prominent problems:
- Poor integration of mixing, dispersion and emulsification effects: Due to the lack of synergistic coordination between different equipment, the material could not achieve uniform state in each processing link. After preliminary mixing, solid powder agglomerates (initial particle size 40-80 μm) were not completely broken; during dispersion, the particles were unevenly distributed in the liquid phase; and the subsequent emulsification process failed to fully fuse the oil-water phase with the dispersed solid particles. The final product had an average particle size of 5-10 μm, and the oil-water separation rate reached 10-13% after 30 days of storage, which seriously affected product usability.
- Long production cycle and low efficiency: The split process required repeated transfer of materials between different equipment, and each transfer process took 15-20 minutes. The total processing time for a single batch (5 tons) was 60-70 minutes, and the equipment utilization rate was only 75% due to the waiting time between processes. In addition, the transfer process caused material loss (loss rate 2-3%), increasing raw material consumption.
- Large batch-to-batch quality fluctuation: The split processing mode relied on manual operation to adjust parameters of different equipment, and the parameter matching between mixing, dispersion and emulsification links was difficult to standardize. The coefficient of variation (CV) of key quality indicators (particle size distribution, viscosity, stability) between batches reached 16-22%, resulting in a finished product qualification rate of only 83-86%. A large number of unqualified products needed to be reworked or discarded, increasing production costs.
- High energy consumption and maintenance costs: Three sets of equipment operated simultaneously, with an average daily electricity consumption of 380 kWh. Each equipment had independent vulnerable parts (such as mixer blades, disperser discs, emulsifier stator-rotor), which required frequent replacement. The monthly maintenance cost was about 9,000 yuan, and the equipment downtime due to maintenance reached 8-10 hours per month.
- Risk of material contamination during transfer: The material transfer process required contact with pipelines, valves and transfer containers, and the dead corners in these components were difficult to clean thoroughly. Residual materials from previous batches were likely to contaminate subsequent materials, especially for products with high hygiene requirements, which increased the risk of unqualified products due to contamination.
Equipment Selection and Core Configuration
To solve the above problems, the facility abandoned the traditional split processing mode and selected a high-shear mixing, dispersing and emulsifying equipment with integrated functions. The equipment integrates mixing, dispersion and emulsification into one unit, realizing one-stop processing of materials without transfer. Its core configuration and technical characteristics are designed to address the pain points of split processing, and the key configurations are as follows:
1. Integrated Multi-Functional Working Head
The equipment adopts a combined working head structure, integrating three functional modules: high-speed dispersing disc, multi-stage shear stator-rotor and three-dimensional mixing paddle. The dispersing disc (diameter 220 mm) rotates at a speed of 800-3500 rpm, which can quickly break down large agglomerates of solid powder; the multi-stage shear stator-rotor (3 stages, shear gap 0.06-0.2 mm) has a speed range of 3000-12000 rpm, generating a shear rate of up to 80,000 s⁻¹, which realizes complete fusion of oil-water phases and further refinement of particles; the three-dimensional mixing paddle (speed 50-200 rpm) ensures the overall uniformity of materials in the tank and avoids local under-processing. All functional modules are made of 316L stainless steel with mirror polishing treatment (surface roughness Ra ≤ 0.8 μm), which is corrosion-resistant and easy to clean.
2. Precise Parameter Control System
The equipment is equipped with a PLC intelligent control system with a touch screen operation interface, which can realize independent and linked control of mixing speed, dispersing speed, emulsifying speed, processing time and material temperature. The speed control accuracy is ±10 rpm, the time control accuracy is ±1 second, and the temperature control range is 0-100℃ (fluctuation accuracy ±1.5℃). The system supports storage of 80 sets of process parameters, which can standardize the parameter settings of different products and batches, avoiding quality fluctuations caused by manual operation. In addition, the system can automatically record the parameter curve during the processing process, providing reliable data support for process optimization and quality tracing.
3. Closed Tank Structure with No Material Transfer
The equipment adopts a closed vertical tank structure with a volume of 5000 L (working volume 4000 L), which can complete all processes of mixing, dispersion and emulsification in the same tank without material transfer. The tank body is equipped with a jacketed temperature control device, which can realize heating or cooling of materials according to process requirements, avoiding material deterioration caused by temperature rise during high-speed shear and dispersion. The tank cover is lifted by hydraulic pressure, which is convenient for feeding, cleaning and maintenance, and the sealing performance of the tank body meets the requirements of GMP and food safety standards.
4. Energy-Saving and Wear-Resistant Design
The equipment adopts a frequency conversion energy-saving motor, which can adjust the power output according to the processing stage (low power for mixing, high power for dispersion and emulsification), reducing idle energy consumption. The working head adopts a wear-resistant coating (tungsten carbide coating), which extends the service life of vulnerable parts. The lubrication system uses H1-grade food-safe lubricating oil, which is non-toxic and compatible with production requirements, and the lubricating oil change interval is extended to 8000 operating hours.
5. CIP Automatic Cleaning System
The equipment is equipped with a CIP (Clean-In-Place) automatic cleaning system, which includes cleaning nozzles installed on the tank cover and inside the tank body. The cleaning nozzles can spray cleaning agents at 360 degrees, covering all inner surfaces of the tank body and the working head. The cleaning process can be completed within 20-30 minutes, eliminating dead corners and reducing the risk of material cross-contamination. The cleaning effect meets the hygiene requirements of food, cosmetic and pharmaceutical industries.
Implementation Process and Process Optimization
After the equipment was put into use, the facility carried out a 4-month trial operation and process optimization. The original three-step split process was adjusted to a one-step integrated processing process, and the key implementation steps and optimization measures are as follows:
1. Process Integration and Parameter Calibration
The facility selected 6 typical product formulas (including products with high solid content, high viscosity and oil-water dual-phase characteristics) for parameter calibration. For each formula, the optimal parameter combination of mixing, dispersion and emulsification links was determined through repeated tests. Taking a product containing 30% solid powder and 25% oil phase as an example, the optimal parameters were determined as: mixing speed 100 rpm (duration 5 minutes) for preliminary mixing of water phase and auxiliary agents; dispersing speed 2800 rpm (duration 10 minutes) for breaking down solid powder agglomerates; emulsifying speed 9000 rpm (duration 15 minutes) for oil-water phase fusion and particle refinement; and final mixing speed 80 rpm (duration 5 minutes) for stabilizing the product system. Under this parameter combination, the average particle size of the product was reduced to 1.2-2.0 μm, and the emulsion stability was significantly improved.
2. Batch Reproducibility Verification
After determining the optimal parameters for each product, the facility carried out batch reproducibility verification. For each formula, 12 consecutive batches of samples were produced using the stored parameter settings. The test results showed that the coefficient of variation (CV) of key quality indicators between batches was reduced from 16-22% to 2-4%, and the finished product qualification rate was increased to more than 99%. This verified that the integrated equipment and standardized parameter settings could effectively solve the problem of large batch-to-batch quality fluctuation.
3. Production Process Streamlining
The integrated processing mode eliminated the material transfer link between different equipment. The single-batch processing time was shortened from 60-70 minutes to 35-40 minutes, and the processing efficiency was improved by about 40%. The material loss rate was reduced from 2-3% to less than 0.5% due to the closed tank structure, which significantly reduced raw material consumption. In addition, the number of operators required for a single production line was reduced from 3 to 2, reducing labor costs while improving production efficiency.
4. Cleaning Process Optimization
The CIP automatic cleaning system replaced the original manual cleaning mode. The cleaning time per batch was reduced from 40-50 minutes to 20-30 minutes, and the cleaning effect was more stable. The number of unqualified products caused by material contamination was reduced from 2-3 times per month to 0-1 time per quarter, further improving the stability of product quality.
Application Effects and Data Analysis
After 8 months of formal operation, the high-shear mixing, dispersing and emulsifying equipment has achieved remarkable results in improving product quality, enhancing production efficiency, reducing energy consumption and maintenance costs. The specific data comparison before and after the equipment upgrade is as follows:
1. Significant Improvement in Product Quality
The average particle size of the finished product was reduced from 5-10 μm to 1.0-2.5 μm, and the polydispersity index (PDI) was controlled below 0.18, which significantly improved the fineness and uniformity of the product. The oil-water separation rate of the product during storage was reduced from 10-13% to less than 1.5% after 60 days of storage, and the product stability was greatly enhanced. For products with high hygiene requirements, the total number of colonies was stably controlled below 10 CFU/g, meeting the strictest hygiene standards of the industry. The finished product qualification rate increased from 83-86% to 99.3%, basically eliminating the cost of rework and waste disposal.
2. Remarkable Improvement in Production Efficiency
The single-batch processing time was shortened by 40%, and the daily production capacity was increased from 200-300 tons to 350-400 tons under the same operating time (20 hours per day). The equipment utilization rate was increased from 75% to 95%, and the number of unplanned shutdowns caused by process problems or equipment failures was reduced from 3-4 times per month to 0-1 time per month. The material transfer link was eliminated, saving 2-3 hours of transfer time per day and improving the continuity of production.
3. Effective Reduction in Energy Consumption and Costs
The frequency conversion energy-saving design of the equipment reduced the average daily electricity consumption from 380 kWh to 240 kWh, a decrease of 36.8%, saving 51,100 kWh of electricity annually. The wear-resistant design of the working head and the extended lubricating oil change interval reduced the monthly maintenance cost from 9,000 yuan to 3,200 yuan, and the annual maintenance cost was saved by about 69,600 yuan. The material loss rate was reduced by 1.5-2.5 percentage points, saving raw material costs by about 8% annually. The comprehensive cost (energy, maintenance, raw materials, labor) was reduced by about 12% annually.
4. Reduction of Contamination Risk and Improvement of Operational Safety
The closed tank structure and CIP automatic cleaning system eliminated the contamination risk caused by material transfer and manual cleaning. The number of product contamination incidents was reduced by more than 90%, and the safety and reliability of production were significantly improved. The equipment is equipped with multiple safety protection functions (overload, over-temperature, over-pressure protection), which can automatically shut down when abnormalities occur, avoiding equipment damage and personal safety accidents. The hydraulic lifting tank cover and simplified operation process reduced the labor intensity of operators and improved the safety of operation.
5. Enhancement of Process Scalability
The parameter storage and recall functions of the equipment made it easy to switch between different product formulas. For new product development, the optimal process parameters can be quickly determined through small-batch tests on the same equipment, and the parameters can be directly applied to mass production, shortening the new product development cycle by 30-40%. The technical parameters of the equipment are compatible with pilot-scale and industrial-scale production, providing reliable support for the facility's future production expansion.
Key Experiences and Operation Notes
During the application process, the facility summarized a series of key experiences and operation notes to ensure the stable operation of the high-shear mixing, dispersing and emulsifying equipment and give full play to its integrated performance:
- Parameter matching between different functional modules is crucial. For high-viscosity materials, the mixing speed should be appropriately increased first to ensure uniform material flow, then the dispersing and emulsifying speeds should be gradually increased to avoid equipment overload and material splashing.
- The feeding sequence affects the processing effect significantly. For multi-phase materials, it is recommended to add the continuous phase (such as water phase) first, then add the dispersed phase (such as oil phase) and solid powder while stirring, which can avoid local agglomeration and improve the uniformity of dispersion and emulsification.
- Regular inspection and maintenance of the working head are essential. The wear condition of the dispersing disc, stator and rotor should be checked every 400 operating hours. When the wear amount exceeds 0.5 mm or the surface is severely scratched, the vulnerable parts should be replaced in time to ensure the processing effect.
- The CIP cleaning system should be used standardizedly. After each batch of production, the cleaning process should be carried out in strict accordance with the set procedures, and the cleaning effect should be inspected regularly (such as residual material detection) to avoid cross-contamination between batches.
- For heat-sensitive materials, the temperature during processing should be strictly controlled. The jacketed temperature control device can be used to cool the materials, and the processing time and speed should be appropriately adjusted to avoid the loss of active ingredients or material deterioration caused by excessive temperature rise.
- Operators should be trained professionally. Before operating the equipment, operators should be familiar with the structure, working principle and parameter setting methods of the equipment, and strictly follow the operation procedures to avoid operational errors.
Summary
The application of high-shear mixing, dispersing and emulsifying equipment has fundamentally solved the problems of poor processing effect, low production efficiency, large quality fluctuation and high operational cost caused by the traditional split processing mode in the facility. By integrating mixing, dispersion and emulsification functions into one unit, the equipment realizes one-stop processing of materials, eliminates material transfer links, and ensures the uniformity and stability of products.
The precise parameter control system of the equipment standardizes the production process, reduces the impact of manual operation on product quality, and improves the batch reproducibility of products. The energy-saving and wear-resistant design, as well as the CIP automatic cleaning system, not only reduce the operational cost and maintenance workload of the facility but also improve the safety and hygiene level of production.
For production scenarios involving multi-component, multi-phase materials that require integrated processing of mixing, dispersion and emulsification, high-shear mixing, dispersing and emulsifying equipment is a reliable choice. It can not only improve product quality and production efficiency but also reduce operational costs and risks, providing solid technical support for the sustainable development of the facility. Through standardized operation, regular maintenance and continuous process optimization, the equipment can play a greater role in production and help the facility adapt to the increasingly strict market quality requirements.
