Lab Ultra Mixer

Application & Process

Prism Vacuum Emulsify Mixer is applicable for a wide variety of viscosity product, i.e. emulsions and semisolid. It integrates mixing, vacuuming, heating, cooling and homogenizing functions into single machine, resulting in a considerably reduction in cycle time. Our range stretches from laboratory model of 10 liters up to production model of 6,000 liters working capacity.

APPLICATION

• Pharmaceutical: Ointment, Cream, Gel, Lotion, Paste
• Cosmetics: Cream. Gel, Lotion, Mascara, Wax, Lipstick, Sunscreen, Face masks
• Body Care Products: Toothpaste, Shampoo, Conditioner, Liquid soap
• Food: Mayonnaise, Ketchup, Sauce, Mustard, Dressing, Jam, Margarine
• Chemical: Adhesives, Grease, Shoe Polishing, Car Polishing, Lubricants, Household cleaner, Viscoplastics Substance, Lacquer, Putty, Paint.

Theory of Operation:

The basis of mixing system of Prism Ultra Mixer is a combination of anchor agitator and high shear homogenizer. Anchor stirrer revolves in clockwise direction in central axis, generating a disturbance in the normally circular flow pattern and vortex formation. The paddles of anchor blade are pitched to promote top – to bottom flow. In addition, adjustable scrapers are utilized to prevent the build-up of a stagnant film between the agitator and the vessel, and assure efficient heat transfer to product during heating and cooling steps. The speed of the anchor agitator can be varied separately.

Homo disperser, locates at the bottom of the vessel, accomplishes emulsification by physical action and centrifugal forces created by high speed rotation of the rotor. These actions would break up oil phase/ aqueous phase liquid stream into tiny and discrete droplets. Then they will be intensively and continuously mixed by rotating anchor agitator mechanism, and become final products. For versatility of use, interchangeable high viscosity and low viscosity homo disperser heads are provided with the system. Homo disperser speed is adjustable by inverter control.

Cylindrical shell & Torispherical bottom type mixing vessel is jacketed for heating / cooling and completely enclosed. All contact parts are stainless steel 316. The vessel is designed to operate under vacuum; mixing and emulsification can then be performed without entrainment of air. The product container is mounted on 4 nos. legs and fitted homogenizer and product discharge gate. Top lid is motorized lifts and down. Top lid haves connection for top anchor drive, charging gate with funnel & valve, Liquid charging,   sterilization pot, steam pressure gauge, pressure relief valve, CIP nozzle,  Air vent, temperature probe, sight light glass window  and eye glass window.

A temperature measuring probe, extending directly into the product, allows exact setting of the temperature with a view to process management. For process reproducibility, mixing time, product temperature, agitator speed, and homogenizer speed can be controlled to the desired condition.

Raw material feeding to Prism Ultra Mixer can be manual through the charging hole. Finished product is discharge by manual operated valve or can be through special design transfer pump.

Salient Features

• Design complies with cGMP (Current Good Manufacturing Practices).
• All product contact parts are made of AISI 316/316L stainless steel, while non-contact parts are made of AISI 304 stainless steel.
• Machine compact in designed single base structure to for simplicity in mounting.
• Top drive Anchor Agitator with extremely efficient shearing force.
• The anchor agitator having nos. of paddle with 45° orientation.
• Anchor Agitator is fitted with self pressure adjustment Teflon scrapper.
• Anchor agitator drive through hollow shaft reduction gearbox with motor.
• Agitator having individuals drive and rotate by AC Frequency drives.
• Top Mounted Homogenizer for internal homogenization.
• Homogenizer having AC Frequency drives.
• Mixing bowl with heating / cooling, jacket insulated and vacuumized.
• Empty mixing bowl can be sterilizations.
• Bowl is mounted with Pneumatic lifting device.
• Top lid having connection for sterilization, charging, CIP, Vacuum, 0.3 micron Air Vent and visualize window.
• Discharge with manual operated valves.
• Vacuum pump and vacuum equipment with Vacuum Gauge. Non Return Valve.