Shear Pump Mixer -Wahal Engineers

 The emergence of numerous mixers restructured the mixing technology; thus, conveying healthy circular, cyclic flow patterns, and intense shear. Wahal Engineer High Shear Mixers attained numerous processes and objectives including homogenization, emulsification, powder wet-out, and deagglomeration. 

Additionally, the Wahal Engineer high shear pump mixers cater to the needs of diverse industries, including pharmaceutical, food, cosmetics, ink, adhesives, chemicals, and coating. For intense applications, Wahal Engineers provides advanced rotor/stator specifications such as Ultra-High Shear Mixers. They can provide advanced emulsions and scattering, which needs processing in an advanced colloid mill or high-pressure homogenizer. 

Consequently, Wahal Engineers In-Line Mixers provide extraordinary flow rates and the capacity to process high viscosity lines. The Shear Pump Mixer design consists of a single-stage four-blade rotor that turns at high speed even within a stationary stator. The rotating blades pass openings in the stator, the particles get mechanically sheared, and ultimately, they expel material at high speed into the mix, creating an intense hydraulic shear. 

The material is expelled and is accumulated at the end of the rotor generator, which ensures continuous flow and fast mixing. This is accomplished using a distinctive and innovative rotor design which increases the mixer power compared to standard In-Line mixers; thus, eliminating the need for extra pumps while processing products in the food, pharmaceutical, cosmetic, and chemical industries.

How does the shear pump mixer work: 

Wahal Engineer In-Line mixers have an advanced rotor that increases capacity to provide an efficient viscosity process. Let’s explore the steps one by one!

1. The high-speed, specially designed pumping rotor yields a precisely designed mixing system that forces liquid and solid materials into the rotor/stator assembly.

2. Milling action transpiring between the ends of the rotor blades and the inner wall of the stator is performed on the material after the centrifugal force drives the materials towards the periphery of the system. 

3. Lastly, the hydraulic shear forces material at high speed through perforations in the stator, and new materials get drawn into the system; thus, maintaining the mixing and pumping cycle.

Systems

A comprehensive range of systems and screens are available for all Wahal Engineers high shear mixers. These easy-to-operate systems offer a great range by letting any machine perform various mixing operations such as emulsification, homogenization, disintegration, dissolving, dispersion, blending, particle size reduction, and de-agglomeration. Also, the interchanging process between machines is easy and fast.

Technical specifications include:

1. Capacity 

2. Bypassing 

3. Interchangeable Systems 

4. Material 

5. Motor Specification 

6. Connections (Inlet/Outlet ) 

7. Cleaning

Processing treatments for baby food - Powder Liquid Mixer

 INTRODUCTION:

The newborns are exposed to a broad range of solid foods in the first two years of their life. During this period, their nutritional intake increases, and eating skills are also developed. Therefore, the manufacturers constantly need to add value to their infant and toddler food range through innovations related to safety, convenience, and nutrition. 

Processing treatments for baby food and infant formula

 

After meticulous research by our specialized food production and technology experts, Wahal Process Technologies Pvt. Ltd offer solutions that will meet the manufacturer’s needs and enable them to fulfill the growing demands of retailers and consumers. With our optimal solutions, they can produce a wide range of baby foods – from infant formula and ready-to-drink products to fruit purees.

The Wahal Engineer Powder Induction Mixer modifies the powder/liquid mixture. Unlike most powder / liquid mixers, which use the vacuum to extract powders, the Powder Induction Mixer literally forces the powder into a liquid stream. This not only allows it to spread and add more water to the powder but can be used at higher temperatures and viscosity mixes.

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Formulation of infant and toddler foods:

The success of infant and toddler foods is based on certain elements of product development such as safety, product purity (i.e., clean label), and developmental appropriateness.

Convenience and nutrition are major drivers that influence practically every aspect of the product and package development. Infant and toddler products are usually shelf-stable and represent a fairly broad cross-section of food types such as - instant cereals, purees, bakery, and snack items (teething biscuits, zwieback toast, and arrowroot cookies), rice instant cereals, and more.

Advantages of our mixers and homogenizers for the baby food manufacturing firms: 

1. By using our mixers, you can process the foods by hot-fill-hold or retort methods with a very low probability of spoilage or pathogen survival. 

2. They offer vacuum in processes.

3. Our mixers have conservative parameters for thermal processing and offer high standards for raw materials, packaging materials, and process control. 

4. They offer a significant improvement to particle size reduction for infant foods by grinding the fruits and vegetables before they are cooked, producing a coarse puree heated quickly to inactivate degrading enzymes. 

Let’s explore the variety of mixers available. 

1. Powder Liquid Mixing Machine as Powder Liquid Mixer

Powder liquid mixer works on the principle of Wahal's high-speed powder induction. It is capable of dust-free, loss-free, and contamination-free powder dispersing and mixing. It also includes working heads (i.e., rotor and stator) designed to produce vacuum in the flowing stream of powders induced through silos, stacks, hoppers, and barrels. It is suitable for continuous and batch (re-circulation) processes, ensures no lumps or agglomerates are formed, achieves up to 80% solids in the final product, and does not allow foreign air to get entrapped in the flowing stream.

Ready to eat product lines - Wahal Engineers

 The ready-to-eat product lines provide a variety of solid food options. A fully grown human loses iron and zinc, which begin to deplete, increasing the need for additional dietary intake. 

However, this demands the food safety standards be highly critical for ensuring the wellbeing and health of a baby. To establish these safety standards, the processed food manufacturers must use MicVac or the pasteurization method to maintain their product’s packaging integrity. And to help your ready-to-eat production line achieve the FILL, SEAL, COOK, and COOL sequence of the Micvac method, Wahal Process Technologies provides a  unique new range of industrial homogenizers designed for use plastic transportable intermediate bulk containers (IBC) tank mixers. Our machines are suitable for various applications, such as - mixing, blending, homogenizing light viscous liquid, and re-suspension of settled solids (through the dissolution of powders).

However, first, let’s understand the advantages of an IBC container: 

• It is designed for use on 1000/800-liter IBC Containers Mixers with 150 mm screw caps by Schutz, Sotralentz, and Van Leer

• Various stator designs are available to suit each application

• UP /Down movement is present either with hydraulic or through manual manner

• The motor can be supplied with VFD – to control the speed

• ATEX certifications are also there

All our homogenizers work on the principle of high centrifugal force produced due to the immense RPM of the rotor mounted on the main spindle. Thus, producing high shear due to the specially designed minimal tolerance between the rotor and stator. Additionally, they also homogenize the feed particles into a fine droplet size and are used for effective food pasteurization.

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:

1.  Inline homogenizer:

• Single Stage Inline Homogenizer

• Two-Stage Inline Homogenizer

• Four Stage Inline Homogenizer

2. In-tank homogenizer:

• Intank Batch Homogenizer (High Shear Batch Mixer)

• Enclosed Shaft Homogenizer

3. Bottom mounted homogenizers 

4. Dis-integrated dissolver:

These are best suited for disintegrating, dissolving, solubilizing, dispersing solid in the liquids, and accommodating more rigid solids into the liquids/solutions.

5. Planetary Mixer:

• Planetary Mixer/Double Planetary Mixers

• Power Mix Planetary Disperser (PDM) 

• Planetary Dual Disperser (PDDM)

6. Sigma Mixers (Z Blade Mixers)

7.  Bottom drive High Shear mixers ( Bottom mounted high shear mixer )

8.  Batch High Shear Mixer Homogenizers

• In-tank Batch high shear mixer

• Enclosed Shaft high shear mixer

9. Inline High Shear Mixer Homogenizers

• Single Stage Inline high shear mixer

• Two-Stage Inline high shear mixer

• Four Stage Inline high shear mixer

Pharma Injectables

 The Pharma Industry is an essential component of the healthcare system throughout the world. It is mainly based upon scientific research and the development of injectables that prevent and treat various diseases and disorders. From discovering the active ingredient to manufacturing the finished product, the production of a drug is time-consuming, complex, and expensive

However, the administration of drugs through injection to a human body was recorded first in the mid-1800s. Later in the 1900s, it became a viable process when the knowledge of microorganisms and sterilization techniques became more common. Nonetheless, sterilization techniques were extremely damaging to drug products till the time HEPA filters, sterilizing filters, and clean rooms became more common. 

• Planetary Mixer/Double Planetary Mixers: Wahal Engineers developed and extended the horizon of Planetary Mixer by incorporating High Viscosity Blades in design, raising the maximum viscosity range to around 6 million cP. Thus, offering better cleanability, a smaller footprint, and lower capital cost. Wahals’ PowerMix Planetary Disperser (PDM) reaches high enough viscosities where kneading can be effective and are designed for high shear intensity and faster solids dispersion. This being our latest addition to the planetary mixing line of industrial mixers known as the Planetary Dual Disperser (PDDM). PDDM delivers uninterrupted processing power for advanced batteries, adhesives, composites, pharmaceuticals, coatings, and chemicals.
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Cosmetics and Shampoos | Body washes Plants

 Shampoos and body washes are formulations used for cleaning  made up primarily of chemicals called surfactants that can surround oily materials on surfaces allowing them to be rinsed away by water. Shampoos are a solution form of cosmetic product, the simplest among cosmetic formulations. But if you’re just getting started in making cosmetics, in the case of shampoos and body washes you just have to mix the raw materials all together as they will blend very nicely because of their stable properties.

There are a limited number of shampoo types marketed, although they have lots of different names such as volumizing and moisturizing, shampoo for hair types (curly, coloured, baby hairs), natural shampoos, medicated shampoos, and speciality shampoos (powdered, spray, no-rinse, co-washing). However, while formulating a shampoo you need to figure out what characteristics you want like how thick it will be, the colour, and fragrance. 

Cosmetics and Shampoos | Body washes Plants

Shampoos and body wash are basically formulated with 80% of water; 10-15% of detergents (like ammonium lauryl sulfate, sodium lauryl sulfate (SLES) and Sodium Laureth sulfate, (SLS) decyl glucoside and lauryl glucoside); 5-10% foam boosters (like Lauramide DEA or Cocamidopropyl Betaine); thickeners; conditioning agents; preservatives; and other ingredients. 

Now let’s understand how the manufacturing process is conducted. 

1. Compounding: In this large scale cosmetic production, all the ingredients are mixed together in large, stainless steel tanks (3000 liters or more) by workers known as compounders. The raw materials are then poured into the batch tank and thoroughly mixed. The order and temperatures are determined and a computer interface is used to control the mixing speed. 

2. Quality Control check: Here the quality control department approves for things like proper pH, viscosity, colour, odour and other specified characteristics. Once approved, it is pumped out of the main batch tank into a holding tank where it is stored until the filling lines are ready. 

Filling:  This line is just a long conveyor belt. Here the empty bottles are put into a hopper and are physically manipulated by a machine until they are upright and correctly oriented. They move along the conveyor belt to the filling carousel holding the shampoo.

 

Inline homogenizer: High shear inline homogenizer ensures a high degree of mixing and replaces the simple agitator (which is ineffective in mixing). It is applied in situations of high speed and pressure for conducting complicated processes of mixing. It performs operations like emulsification, dissolution, high shear mixing, etc. Wahal Engineers offers different type of Inline Homogenizers as per application such as Single Stage Inline Homogenizer ( with a top speed of up to 95 m/s, 20 different rotor designs, self-pumping, lower power consumption per cycle, nil or low maintenance); Two-Stage Inline Homogenizer; and Four Stage Inline Homogenizer.

Primer - Red oxide paint mixer machine :- High Shear Homogenizers

  Topic: Paint Manufacturing Machine- Red Oxide Paint Mixer Machine 

There is more to paint than just a colour; it is a liquid material that dries to give a beautiful finish. The paint is generally carved using four materials: pigment, binder, solvent, and additive. Pigments provide colour, hide, and bulk; binders provide performance and support for dry paint film; solvent acts as a vehicle for the pigment and binder to get to the final surface; additives provide additional enhancements like biocides, deformers, co-solvents, and more. There are five crucial steps in the manufacturing of paint: ingredient preparation, pigment dispersion, let down, laboratory testing, and canning. To conduct this process with fluidity, various paint manufacturing machines are used since 1718. 

To ameliorate the paint manufacturing process, companies these days use the Primer / red oxide paint mixer machine. The Primer/ Red oxide paint mixer machine combines cement and oxide first in the dry form and then slowly adds water to get a consistent slurry-like mix. This mix is a natural or synthetic inorganic red pigment that provides a lightfast colour at a low cost. The machine makes sure that purity, suitable size, and brightness remain the same for each lot. So paint manufacturing companies can use this stellar and agile mixer machine and help their customers provide an adequate base coat to the desired metal surface. 

                               

Wahal Engineers provides an efficient solution with a variety of machines such as High Shear Homogenizers, which is designed to incorporate customers’ need for application, relying on the principle of the high Centrifugal force. This force is produced due to the high RPM of the rotor mounted on the main spindle, in turn creating a very high shear resulting from the sleek design of minimal tolerance between the rotor and stator, culminating in a precise technique. Besides, we also provide a wide variety while talking about homogenizer, as we have increased our horizons to cover Bottom drive Homogenizers, Bottom mounted homogenizers, Batch Homogenizer, Intak Batch Homogenizer, Enclosed Shaft Homogenizer, Inline Homogenizer, Single Stage Inline Homogenizer, Two-Stage Inline Homogenizer, and Four Stage Inline Homogenizer each serving a purpose to make its application service efficient. 

Primer- Red Oxide Paint Mixer Machine: High speed disperser for paints

In addition to this, another solution provided by Wahal Process Technologies Pvt. Ltd is Bead Mills with its peer variants such as Dyna Mill, Dyno Mill, and Sand Mill that are manufactured using high-grade raw material to increase optimization. Premium  ZR splash series provides energy transfer from main motors to the grinding beads and is provided with a well-built agitator disc. It ensures to break solid matters into grounded form with low power consumption, highest efficiency, and fine milling effect. Therefore, Wahal engineers welcome leading paint manufacturers, high speed disperser for paints to paint making machine take advantage of these stellar and vivacious mixer machines that will provide flawless solutions for them. Be rest assured as these machines are manufactured in compliance with the set industry standards using graded stainless steel, mild steel, Hastelloy, and nickel. So, choose these machines to create a robust foundation for top-notch quality paint.

Automotive coatings, Paints

High Shear Mixers for Paint, Automotive Coating Industries  

Wahal Engineer’s High Shear Mixer has the all round solution to this problem. The affectivity of the disperser fails to produce a uniform dispersed emulsion.

The emulsion may apparently appear to be uniform and well dispersed but with time it becomes unstable and one phase soon separates. Wahal Engineer’s manufactured high shear mixer has formulated an efficient way out to resolve the challenge.

The turbulence produced as a result of the high shear obtained from the rotor and stator indulges in the breaking up of the larger solid particles into minute size and to form a stable uniform emulsion.  In some cases the disperser is able to achieve a sufficiently small droplet size, but that success comes only at the cost of excessive heat build-up, and an unnecessarily long and costly mix cycle.

 

Wahal Process Technologies Pvt. Ltd  manufactured high shear mixer is the ultimate solution when time and cost is a concern, as the time required by the high shear mixer is drastically reduced because of its high efficiency. This in turns affect the product quality thereby increasing productivity.  In emulsion applications involving materials as epoxies, silicone polymers, acrylics and urethanes, the failure in disperser can be averted with a Wahal Engineering manufactured batch-type high shear mixer (HSM) with a rotor/stator design. As the rotating blades pass each opening in the stator, materials are expelled at high velocity into the surrounding mix. Combining mechanical and hydraulic shear, the rotor/stator can quickly reduce droplet size to the submicron range. For non-shear sensitive formulations, a fine screen stator will accelerate this process producing superior dispersions in a fraction of the time.