Vacuum Homogenizer Mixer / Vacuum Emulsion Mixer

Application & Process

Prism Ultra Mixer is applicable for a wide variety of viscosity products, such as emulsions and semisolids. It integrates mixing, vacuuming, heating, cooling, and homogenizing functions into a single machine, resulting in a considerable reduction in cycle time. Our range stretches from a laboratory model of 10 liters up to a production model of 6,000 liters working capacity.

Applications:

• 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, Visco-plastics Substance, Lacquer, Putty, Paint

Theory of Operation:

The basis of the mixing system of Prism Ultra Mixer is a combination of an anchor agitator and high shear homogenizer. The anchor stirrer revolves in a clockwise direction in the central axis, generating a disturbance in the normally circular flow pattern and vortex formation. The paddles of the 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 the product during heating and cooling steps. The speed of the anchor agitator can be varied separately.

The homo disperser, located at the bottom of the vessel, accomplishes emulsification by physical action and centrifugal forces created by high-speed rotation of the rotor. These actions break up the oil phase/aqueous phase liquid stream into tiny and discrete droplets. Then, they will be intensively and continuously mixed by the 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. The homo disperser speed is adjustable by inverter control.

The cylindrical shell and torispherical bottom type mixing vessel is jacketed for heating/cooling and completely enclosed. All contact parts are made of stainless steel 316. The vessel is designed to operate under vacuum, allowing for mixing and emulsification without entrainment of air. The product container is mounted on four legs and fitted with a homogenizer and a product discharge gate. The top lid is motorized and has connections for the top anchor drive, charging gate with funnel and valve, liquid charging, sterilization pot, steam pressure gauge, pressure relief valve, CIP nozzle, air vent, temperature probe, sight glass window, and an eyeglass window.

A temperature measuring probe, which extends directly into the product, allows for the exact setting of the temperature for process management. For process reproducibility, the mixing time, product temperature, agitator speed, and homogenizer speed can be controlled to the desired conditions. Raw material can be manually fed into the Prism Ultra Mixer through the charging hole. Finished products can be discharged through a manual discharge valve or a 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.
• Bottom Mounted Homogenizer located at lowest point in the vessel for internal homogenization.
• Homogenizer having AC Frequency drives.
• Mixing bowl with heating / cooling, jacket insulated and vacuumized.
• Empty mixing bowl can be sterilizations.
• Top lid is mounted with Hydraulic 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.

Safety Features

• Overload relay protection and emergency stop.
• Top lid interlocking using limit switch.