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

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.