Bottom Drive high shear mixer

 Bottom Drive high shear mixer

Wahal Engineers manufactured Bottom drive high shear mixer are designed in a manner to fit into the bottom or side of a mixing vessel. They are used to disperse immiscible liquids, and for the preparation of homogeneous slurries by mixing chips, powder and breaking of larger size polymer particles. These high shear mixers are typically used in conjunction with a slow speed stirrer or scraper unit for high viscosity products. All the larger particles are crushed to reduce their size into an optimal ratio to obtain the desired slurry. Its major application is for emulsification, blending, dissolution of solids into the liquids as desired by the application. They are also designed for the efficient and homogenous wet granulation of powders to form a medium to high density granule. The working head, i.e., the rotor/stator breaks down hard solids into fine particles. This type of mixer is ideal for high viscosity cosmetic, pharmaceutical and food products. Wahal Engineer’s bottom drive mixers is comprehensively used for a wide range of services, which includes product and process development, process scale up, calibration, maintenance program and pro active project management.

Working Principle:

1. The major working principle is the shear force produced between the high speed rotations of the rotor blades which exert a powerful suction. This suction draws the solid and liquid material into the centre of the stator head.

2. The centrifugal force produced then pumps the material out from the rotor head centrifugally towards the stator walls. Here they are milled between the clearance of the rotor and the stator.

3. Due to the minimum tolerance between the rotor and stator material is crushed subjected to the intense shear force produced and homogeneous product comes out forcefully from the stator. The crushed materials are projected radially outward towards the sides of the mixing vessel. Fresh material is further simultaneously drawn into the workhead to maintain the mixing cycle.

4. Since it’s a batch process the turbulence created in the mixing vessel disperses a homogenous mixture as an end product.

The system works on the basic Features:

•  Mixing, homogenization & emulsification.

•  Dissolving powder ingredient in liquid feed.

• Particle size reduction with uniform dispersion.

• Disintegration of enlarge particle cluster.

• Crushing of large size particle and size reduction.

• Disintegration of agglomerates

• Batch mixing homogenization & emulsification

• Create stable emulsion & suspension

Technical Specification:

Capacity 500 ml – 1000ml

Material of Construction Stainless Steel -304/S. S-316L, Hastelloy, SS 321 all wetted parts

Sealing Single or double mechanical Seal with self pumping Thermosyphon system, Gland Sealing

Compatibility Higher pressure up to 10 Bars and vacuum operation.

Rotor Head Four blade type rotor

Stator head wide range of stator

Heads Emulsion/Slotted/High Shear/Disintegrating/Square

 

Its Application includes:

• Pharmaceutical Industry :

• Ointment & creams

• Cough syrups

• Tablet Coatings

• Vaccines

• Cosmetic Industry :

• Carbopol Gels

• Lipsticks

• Toothpaste   

• Food Industry :

• Preparation of Mustards

• Manufacture of Mayonnaise

• Manufacture of Tomato sauces and ketchups.

• Preparation of Ginger Garlic paste.

 

Wahal Engineer’s bottom drive high shear mixer is the ideal solution for your wet granulation and to satisfy your mixing needs.

High-Speed Dispersion of Titanium Dioxide

 High-Speed Dispersion of Titanium Dioxide

Titanium dioxide (TiO2) is chemically neutral and has a special whiteness and whiteness. These structures have led to their widespread use in many industries.

The process

Titanium dioxide is usually given as a powder mark but can also be dispersed in advance in oil or water systems. The variety of applications leads to many different processing methods, however, the process requirements are the same:

• TiO2 is usually given in powder/pre micronized form and reducing particle size (digestion) does not work in most cases.

• In order to maximize transparency and shine, TiO2 must be fully dispersed and evenly distributed throughout the product.

• Dust / soluble emissions should be reduced.

Machine are uses as : 
Wahal Engineers Mixer 

In-line Batch homogenizer mixer

Process Vessel

In-tank Batch Homogenizer
High Shear Mixes
Wahal Industrial Agitators 
High Speed Mixers

Inline Homogenizers 
Titanium dioxide process 
High Speed Dispersion

 

The problem

The following problems can be encountered when using conventional mixers with agitators:

• In addition to water, solvent, varnish or other media particles often reassemble.

• Ordinary combinations cannot break these down effectively.

• Long mixing cycles are required to achieve uniform dispersion.

• Extended processing time contributes to the production of solvents.

• The powder should be added under controlled conditions that can be time-consuming and lead to an increase in dust emissions.

Solution

• The high speed, high shear mixers performance of the Wahal Engineer mixer provides a solution to these problems.

• The subject of rotor/stator activity rapidly disperses Ti02 particles into the surrounding liquid, resulting in the same product and shorter processing times.

• This can be achieved by using a In-tank Batch Homogenizer immersed in the process vessel, or by adding a Wahal Engineer In-Line mixer to the existing system in the rotation system as shown:

In tank Batch Homogenizer - High Shear Mixer

 

In-tank Batch Homogenizer

 

In Tank Homogenizer, our In Tank Homogenizer, which helps in the homogenization and is more efficient than a conventional Mixer as the material passes through set of rotor and stator.

 

 High Shear Mixer Manufacturer Supplier in India  

High Shear Mixers: At Wahal Engineers we specialise in custom-designed state-of-art high shear batch mixers. And they come in two models: In-tank Batch high shear mixers and Enclosed shaft high shear mixers (Rotor/Stator dispersion system); Batch Type High Shear Mixers and; Inline High Shear Mixers.

 

 

In-tank homogenizer:

In-tank Batch Homogenizer (High Shear Batch Mixer)

Enclosed Shaft Homogenizer

 

 

 Batch High Shear Mixer Homogenizers

In-tank Batch high shear mixer

Enclosed Shaft high shear mixer

 

Apart from this, another Wahal Engineers’s product that provides the most efficient ready to make product line is homogenizers and mixers; we have categorized all machines with different units as follow:

 

 Inline homogenizer:

Single Stage Inline Homogenizer

Two-Stage Inline Homogenizer

Four Stage Inline Homogenizer

 

In-tank homogenizer:

In-tank Batch Homogenizer (High Shear Batch Mixer)

Enclosed Shaft Homogenizer

 

Production of Medicinal Cream and Ointments

 Production of Medicinal Cream and Ointments 

Pharmacy preparations to treat conditions such as rashes, skin irritation, itching, fungal infections, etc. they are usually supplied in the form of cream or ointment as this provides effective ways to bring the active ingredient directly to the required area. Products can be water in oil (w / o) or liquid oil (o / w) emulsion, which includes waxes, emollients, and lubricants dispersed in the oil phase, and a water phase containing emulsifying, stabilizing, and thickening agents, preservatives. and in some cases, color. The active ingredients are dispersed in any phase or added when the emulsion is formed and allowed to cool.

The process

The ingredients, composition, and viscosity of the product vary greatly, however, the standard production process is divided into four functions each:

• Oil phase adjustment. Flake/powder ingredients, sometimes dried prematurely, are dissolved in mineral oil or silicone oil. Heating may be necessary to dissolve other ingredients.

• Hydration of aqueous phase ingredients. Emulsifiers, thickeners, and stabilizers are dispersed in water on a separate vessel. Heat may be needed to speed up the flow of water.

• Forming Emulsion. These two phases are combined under intense stirring to form an emulsion.

• Dispersion of Active Ingredient. The active ingredient usually makes up a small portion of the composition; this should be well dispersed to increase productivity and productivity.

The problem

Using common agitators can be met:

• When added to water, solidification, solidification, and emulsifying ingredients can form agglomerates that agitators can break down.

• Similarly, the ingredients of the oil phase can form lumps that need to be cut to disperse.

• Ingredients must be fully hydrated to obtain the required viscosity and improve yield.

• Slightly submerged materials can form on the wall of the vessel, tank baffles, and parts of the agitator.

• Agitators cannot adequately reduce the droplet size to form a stable emulsion.

• Active ingredients can be sensitive to heat. Cooling the product before adding the active ingredient increases the processing time.

• Improper distribution of active ingredients interferes with product efficiency.

• Longer mixing times and additional equipment may be required to obtain a balanced and stable finished product.

Solution

Wahal Engineer mixer can quickly dissolve solids into liquids, hydrate thickening and stabilizing agents, break down agglomerates, and effectively reduce particle and globule size to form stable emulsions and solvents. Mixing times are greatly reduced, while product consistency and consistency are greatly improved. This is achieved as follows:

Stage 1

Rotating the large rotary speed inside the work head creates a strong absorption that pulls the solid and solid ingredients up from the bottom of the vessel to the tip of the work. 

Stage 2

Centrifugal force takes the lead to the surrounding area of ​​the work head where the agglomerates are separated by a mechanical gap between the tips of the rotor blades and the inner wall of the stator. The product is then forced out of the stator and distributed to the body of the mixture. At the same time, new items are being pulled from the job title. 

Stage 3

The insertion and expulsion of the ingredients by the work headsets the rotation pattern for mixing on the vessel. All ingredients exceed the job title several times in a short mixing cycle, which gradually reduces the particle size, and ensures that the final product is aggressive, stable, and balanced.

We have Pharmaceutical manufacturing Plant Machinery are :

Industrial agitators sanitizer machine | High Shear Mixer | Sanitizer Machine | Powder Induction Machine | High Speed Powder Induction | Liquid Powder Mixers

Why inline blending beats batch mixing ?

 Can Inline integration systems be used to eliminate other bulk mixing limits?

Drum pumps may be used to transfer liquid to the tank based on weight. Small pairs of material will be rolled up to the top of the tank and discarded by hand. A centrifugal or PD transfer pump can be transported by wheels and connected to a tote as many of the materials used are also transmitted by weight gain.

Inline Homogenizer

Large production sites with a large budget process can be complicated in their own way by making these transfers automatically and will generate mass storage compared to tote, drums, etc, where possible. These ingredient supplements are still discarded one at a time by weight. Load cells or floor scales should take into account the weight of the tank, so their adjustment is usually poor when it comes to small dumping of the ingredient, thus providing poor balance control between the ingredients.

High Shear Mixers 

The most advanced industries can use expensive bulk flow meters to fly in liquid vessels at the same time, but without a guarantee that the right amount was discarded, as flow meters will not take into account the residual in plumbing, drainage rates, etc. Usually, manufacturers' recipes include large amounts of water or a specific ingredient. Transferring water to a bulk tank is a wasteful practice, but we will get to that later.

What exactly is linear integration?

Mixing is done in one tank where all the ingredients are usually added one at a time. This method has many problems:

• A large, expensive tank is needed. 

• The tank (s) use an important floor area. 

• The ingredients are usually added one at a time.

• A bulk material or water that is transferred to this tank consumes an important area. High movement HP is required in the tank. 

• The rate control is inaccurate due to low adjustment flow rates or load cells. 

• Many tanks are added, and more ground space is used as the demand for additional capacity increases.

Liquid powder mixer - LPM

 Liquid powder mixer. 

The Powder Induction Mixer is a very efficient device to mix powders with liquids. 

The special design of the rotor creates powerful suction inside the router status assembly and suction powders in a very fast efficient and clean manner. This can be applied to a variety of applications, including food cosmetics and chemicals. The design is highly sophisticated in nature and it can be changed as per the customer requirement.

The liquid powder mixer comes with a variety of options to feed powders, including the following :

1. Jumbo bag unloading system. 

2. Flexible hose to suck powders from silos directly 

3. Custom-designed Hopper

4. Bag tipping station 

The LPM ( Liquid powder mixer) is connected to a vessel ( with a recirculation loop ) Which can be of any quantity. And the PLM (Powder Liquid Mixer) is designed according to the viscosity and the volume, and the kind of powder. The suction rate of the powders depends on the Specific gravity of the powders and also their nature. 

We also have a variety of starter designs. To ensure the kind of mixing output, we get from the mixer. 

Wahal also does customized mixing vessels. Paired with liquid powder mixer, and the power dosing system. We also use a variety of automation. 

The powders and the liquids are dosed in a very precise manner using automation. 

The design of the system depends on the pressure , temperature, viscosities, and the process cycle time is taken into consideration. The range of viscosity, which we can handle is from 100 CPS to 100,000 CPS.