What are common problems with homogenizing vacuum emulsifiers, and how to solve them?

Problem 1: Emulsion has air bubbles or froth

• Cause: Vacuum leak (damaged seal, loose hose), vacuum level too low, or adding ingredients too quickly (trapping air).
• Solution:
  1. Check for leaks by applying soapy water to hoses and seals—bubbles indicate a leak. Tighten hoses or replace damaged seals.
  2. Increase the vacuum level to the recommended range (-0.08 to -0.095 MPa).
  3. Add ingredients more slowly, especially the dispersed phase (e.g., oil), while stirring gently.

Problem 2: Emulsion separates after production

• Cause: Insufficient homogenization time/speed, incorrect emulsifier dosage, or temperature fluctuations during mixing.
• Solution:
  1. Increase homogenization time by 3–5 minutes or raise the speed/pressure (avoid exceeding the manufacturer’s limits).
  2. Verify the emulsifier dosage—too little will fail to stabilize the emulsion. Consult the formulation’s ingredient guidelines.
  3. Ensure the jacketed tank maintains a consistent temperature (avoid sudden drops or spikes) during homogenization.

Problem 3: Vacuum pump fails to reach target pressure

• Cause: Clogged air filter, low pump oil level, or worn pump components.
• Solution:
  1. Clean or replace the air filter.
  2. Check and top up the pump oil (use the recommended type).
  3. If the problem persists, inspect the pump for worn vanes or diaphragms—replace these parts or contact a technician.

Problem 4: Homogenizer makes unusual noise (e.g., grinding, squealing)

• Cause: Worn rotor-stator blades, loose components, or foreign debris in the homogenizer.
• Solution:
  1. Stop the machine immediately to avoid further damage.
  2. Disassemble the homogenizer and check for debris (e.g., ingredient particles). Clean thoroughly.
  3. Inspect blades for wear—replace if they are dull or chipped. Tighten any loose bolts or fasteners.

Problem 5: Temperature control fails (e.g., tank overheats or won’t heat)

• Cause: Faulty temperature sensor, broken heating element, or blocked jacketed tank (e.g., scale buildup).
• Solution:
  1. Calibrate the temperature sensor—if it’s inaccurate, replace it.
  2. Check the heating element for continuity (use a multimeter). Replace if defective.
  3. For jacketed tanks, descale the interior (use a mild acid cleaner) to remove mineral buildup that blocks heat transfer.