Preparation of ice cream mixes

Preparation of ice cream mixes

Ice cream mixes are formulated from whole milk, skim milk, cream, and in some cases water, along with other added ingredients.

The Process

A typical mix would be prepared with the following approach: 

• Liquid ingredients are weighed and metered into the process vessel. Heating follows to aid the melting of the fat,
• dissolving, and hydration of the subsequent ingredients.
• Powdered ingredients such as skim milk powder, sugars, whey powder, and more are added to the liquid and mixed
• until appropriately dispersed.
• Then the stabilizing and emulsifying agents are added. These may be dry premixed with the other ingredients, including
• sugar, to decrease particle agglomeration and further “weight” the powder to incorporate the liquid.
• Then the fat is added. But before that, butter or other solid fats are melted in a separate vessel. 
• Then the mix is pasteurized at 185ºF (85ºC).
• The mix is then homogenized, usually by passing through a high-pressure homogenizer. 
• The product is then “aged” into a holding or ripening tank allowing the stabilizing agents to hydrate and the fat to crystallize.
• Flavour and coloring can be added at this particular stage. 
• The finished mix is then frozen in special freezers, which whip a controlled amount of air into the mix.

In many countries, the legislation covers the composition and labeling of products. These regulations restrict the user to particular ingredients and specify the minimum content of the fat and total solids to be used.

Refining of Edible oil

 Edible oils are found in coconut, corn, cotton, olive, palm, nuts, soybeans, and sunflower. Furthermore, they contain gums and other impurities that are removed by reducing, weakening, and inserting candles. Let’s understand the process to refine them. 

Edible oil processing plant

1. Degumming: The first stage of the vegetable oil refining process

Motivation is the first stage of refining vegetable oil that begins with the heating of crude oil. The feed is placed in a degumming container where the oil temperature rises slightly. Besides, the oil weight is reduced by removing Phospholipids / Gums from the raw vegetable oils. There are usually two different types of phospholipids present in crude oil depending on hydration levels:

• Hydratable or Water Degumming

• Allergic or Acid Degumming

2. Neutralizing: Phase Two of the Vegetable Oil Refining Process

Neutrality or simply Neutralizing is the second step to refine the vegetable oil after finishing. In this process, the feedstock is transferred to Neutralizers where the ambient temperature is maintained at 55 C to 70 C depending on the quality of the crude oil. Further, the oil is constantly disturbed to maintain consistency.

The main purpose of energy reduction is to remove the Free Fatty Acids present in crude vegetable oils. In chemical refining, alkali is used to reduce FFA and to remove oil acidity.

The main purpose of the Neutrality Process is to replenish FFA with an alkaline solution and reduce the soaps in the water phase. In the edible oil industry, caustic soda is used in the treatment of FFA's. Sometimes potassium hydroxide can also be used by other processors. 

FFA is a stearic acid that breaks down into a triglyceride molecule leaving diglyceride in fats.

The free fatty acid is derived from the H + carboxyl group. This H + of the active stearic acid group reacts with the OH- caustic soda (NaOH) group to produce soap and water.

Wahal Engineers offers a wide range of suitable additives for acid and sodium hydroxide, as well as Flash mix for clay distribution:

1. High Shear In-Line Mixers

• Aeration is free

• Easily restored to an existing plant

• Ready for ongoing processes

• Availability of ultra sanitary models

• Availability of multistage units, thus offering a high degree of cutting, resulting in refined particle size and faster processing times

2. Wahal Engineer Flash Mix

• Designed for rapid dispersion of powders into liquids

• Reduced cleaning requirements

• Small operator input is required

Read more ... https://wahalengineers.com/inline-homogenizer/

Shoe Polish production process

Various polishes for floors, furniture, and shoes can be provided in a solid way. It is prepared with a water emulsion containing particles such as paraffin wax, bex wax, and carnauba wax, and also includes other additives such as dyes, stabilizers, and surfactants.

Wahal Engineer High Shear mixer can eliminate the intermediate production stages. Further, product quality and consistency can be improved and processes reduced significantly. Additionally, the beauty of the Wahal Engineer mixer in addition to the standard agitators, comes from the mixing/shearing action that works in a 3 phase mixing cycle.

Shoe Polish production process : - Cream, Waxing, Polish

The manufacturing/production process

While the composition of polishes varies depending on the end-user, the typical production process can be as follows:

• The wax is weighed in a boat and heated until melted, between 120 - 185 ° F (50 - 85ºC) depending on the type.

• Then the water is charged to a separate vessel and heated to help distribute the additives.

• Surfactants, stabilizers, and dyes are placed in a liquid phase and mixed until completely dissolved.

• A hot water phase is added to the melted well and then mixed to form an emulsion.

• The product is then cooled to just above the setpoint and then poured or thrown into mold or cans as needed.

• Lastly, the polish solidifies by continuing to cool. ...... Read more

Basket Mill Machine

 Wahal Engineer's produced Basket Mills has a reclassified bunch scattering framework. This structure protects materials to go through the high thickness scattering zone inside the processing chamber at a high recurrence. This framework offers a serious extent of scattering which can be commonly more effective than conventional media processing frameworks. Through all-bearing solid force created by unpredictable crash between the crushing globules, the molecule size of the materials decreases.

lt is appropriate for coatings, inks, shades, colorants, pesticides, beautifiers and different enterprises with high prerequisites of fineness.

The manner in which this processing machine works is straightforward. The bin chamber is loaded up with media that is fomented by a pole with pegs on the end that turns inside the bin. On a different shaft there is an impeller that pivots at an alternate rate or they will at the same time turn at a similar rate contingent upon the material. This assists with furnishing even course of the fluid with in the tank.

The vortex and divergent power that is made takes the material and gets it in through the cuts of the screen while the media separates particles and scatters them all through the fluid. Premixing, scattering and shearing are completely done in one procedure sparing time, while expanding creation. The effortlessness of Wahal Engineer's fabricated Basket Mill Machine framework takes into consideration exceptionally high material yields from bunch to group, as high as 99%. This implies less tidy up and a decrease in squander solvents. Premixing, scattering, exacerbating and weakening are completely cultivated in a solitary unit that requires less space, less time and less vitality to accomplish greater outcomes.

High Pressure Homogenizer

 High-Pressure Homogenizer

High-Pressure Mixer Homogenizers are fast and effective. They are capable of providing a precise droplet or particle size ranging between 2-5 microns. This variety of products use a precise degree of homogenization, such as creams and ointments, lotions, sauces, and flavor emulsions. Wahal Engineer builds a diverse range of mixer homogenizers for advanced applications. Also, their system produces incomparable high shear rates in a three-stage process that quickly homogenizes the product to the described uniformity. 

 

An application that uses a very small particle can use a high-pressure homogenizer. Wahal Engineers High-Pressure Homogenizer improves throughput, process efficiency and reduces operating costs. A high-pressure homogenizer works best with a mixture of uniform and fine particle size, allowing the product to cross the homogenizer at an extremely faster rate in and around. They fulfill a diverse customer requirement with a wide range of  High-Pressure Homogenizer Pumps used in laboratories, industries, and various other applications. 

high pressure pump homogenizer manufacturer in India

 Wahals’ High-Pressure Homogenizer Pumps are tested and reliable with accurate dimensions. This Inline Homogenizer is used for homogenizing, emulsifying, and many other purposes.

 

The high-pressure homogenizer HPH is an inline dispersing machine for energy-efficient, continuous production of superfine emulsions. Compared to other Wahal Engineer inline machines, the dispersing action of the high-pressure homogenizer HPH is not based on the rotor/stator principle. Rather a better homogenizing effect is achieved through spontaneous decompression of the liquid from max—2000 bar to ambient pressure. 

 

With the same energy input, the Wahal Engineer HPH produces considerably finer emulsions than conventional toothed ring dispersers. The use of high-pressure homogenizers is recommended when a disintegration down to the nano range. Also, these machines do achieve a smaller flow capacity than conventional dispersers.

 

Structure of High-Pressure Homogenizer:

 

1. High-pressure piston pump
2. Homogenizing valve

 

The high-pressure homogenizer structures with a high-pressure piston pump along with a downstream homogenizing valve. The pressure build-up within the HPH occurs because of one or more piston pump(s), which, with the help of ceramic pistons, ensure a volume flow that is independent of pressure and is virtually pulsation-free. The desired homogenizing pressure can be adjusted infinitely. The pressure can be reduced in a selected adjustable gap of the homogenizing valve but the quick pressure decreases in a moving medium leading to extremely high turbulence and cavitations, which cause the grinding of raw product. Also, the machine’s design can be adapted to fit customer-specific tasks. 

The high-pressure homogenizer is available in two sizes with either one or more pistons of varying diameters. These parameters determine the maximum homogenizing pressure possible for a specific machine type, the minimal permitted feeding volume, homogenizing results, and flow capacities.

 

Advantages of the Wahal Engineer high-pressure homogenizer HPH:

• Highest possible energy input 
• Proven construction 
• Long service life
• Low noise 
• Low Sample volume
• Available in multiple sizes and versions for flow capacities from 2 to 100 l/h
• The robust drive can be used for industrial production
• Optional availability: a controller for adjusting the rotational speed of the driving shaft leads to corresponding adaptation of the throughput to flow characteristics of a medium
• Parts that have contact with the product are produced of stainless steel and ceramic material
• No elastomers are present in the product area
• The parts that have contact with the product are autoclavable and available along with the FDA approval

 

Applications:

These are used for many applications and products in the food, pharmaceutical industries, and biotechnology. However, the particle sizes in the nano range have to be achieved in the following cases. 

• Cell disruption in biotechnology
• Homogenizing milk products
• Production of infusion solutions
• Production of micro-fibrillated celluloses
• Production of all types of microemulsions

 

Features:

• Resistance against rust
• Reliable operation
• Compact design
• Rugged design
• Abrasion resistance
• Longer service life

Preparation of Drilling Fluids

 Preparation of Drilling Fluids

Dispersion and hydration of Barite ( a mordant material) require an advanced system other than rotor/stator mixers. Diffusion of the bentonite and rheology transforms into water or brine for preparation of the water/oil emulsions. The following processes fulfill this transaction: 

• Efficient incorporation and dispersion of powders into the water

• Surrounding liquid with finest constituent parts of particles to expose the maximum surface area for gelling effect

• Functional Shear Degree

• The rapid in-tank movement 

• Sufficient droplet size for a stable emulsion

Problems with basic equipment:

• The particles collected using conventional mixers are not effectively broken.

• During the gelling effect, conventional products are inefficient and are unable to reduce particle size.

• Extra mix tanks are required to pre-hydrate bentonite in a minimum of 4 hours.

Drilling fluids include:

• Bore cuttings of the surface

• Cooling and Lubrication of the drill

• Control of subsurface pressure

A Wahal Engineer high shear mixer/homogenizer can overcome each problem resulting in a stable water/oil emulsion. Also, it takes little time compared to conventional methods. The operation is as follows:

1. The high-speed rotation of the rotor produces an efficient suction that collects the water and bentonite in the system which is subjected to high shear. 

2. Milling action occurs between the rotor and stator, which breaks and ensures contact between the liquid and solid particles. 

3. Fresh material is pushed into the system after the complete product is pushed out of the stator.

4. A lump-free dispersion after the combination of deagglomeration and vigorous mixing produces further; thus, accelerating the hydration process.

Advantage of our product:

• Fitting in the existing plant

• Breaking of hard agglomerates

• Powder dispersion

Pharmaceutical Vessels

 Wahal engineers is among well-reputed and experienced manufacturers, suppliers and exporters of an extensive range of Pharmaceutical Vessels that comprises Pressure Vessel, SC Plant, Filling Vessel and CIP Vessel. The processing of liquids in the pharmaceutical industry has specific purity requirements that can only be met with great technical knowledge and skills, and the use of high-quality materials. Our products are fabricated to meet the defined industry standards and are resistant to the hazards such as poisonings, suffocation, fires, and explosion hazards. These high-quality process vessels are safe and reliable and offer a competitive advantage to their clients. 

We manufacture complete turnkey solutions for manufacture of herbicides, fungicides , insecticides etc. Products like SC ,  suspension concentrate, emulsion concentrate, Lambda, CS Lambda, fipronil and WDG manufacturing, nano emulsions, and other liquid fertilizers .

The processing of sterile and non-sterile liquids, such as blood plasma have certain purity criteria that can only be completed with great technical skill and experience. Pharmaceutical vessels from Wahal Process Technologies Pvt. Ltd set standards and ensure that our customers 'central process components' have competitive advantages. These Vessels are developed using only high-alloy stainless steel. These materials require the most exacting welding and grinding techniques to ensure the integrity, long life and reliability of the vessels. We check each weld using modern techniques to provide continuous monitoring of results. 

Application of preparation vessel for production of highly sterile products can be listed as:

• Preparation vessel for production of highly sterile products

• Buffer preparation vessel for blood plasma fractionation

• Media preparation for pharmaceutical fermentation processes