High shear viscous liquid disperser

Types of high shear viscous liquid dispersers

High shear viscous liquid dispersers are specialized mixing equipment designed to process and mix liquids with high viscosity. Numerous high-shear mixers are available in the market to cater to different industries and viscosity levels. Here are some popular types.

• Product characteristics

  -Hammer - an Industrial mixer with a hight-speed motor creates a powerful impact that can break up solids and get them dispersed into the liquid matrix. High shear hammers are ideal for processing highly viscous liquids that contain large solids or a high percentage of dry matter. They are usually used in foods (mayonnaise, dressings, juices, ketchup, sauces, and others), chemical (adhesives, waterproofing, rust removers, foam agents, multi-surface cleaners, and others), and pharmaceutical (liquid medicines, syrups, solutions, and others) industries.

• Product characteristics

  -Inline - An In-line/inline industrial high shear mixer usually comes with a separate motor and gearbox to ensure the right speed and torque for the application. Inline mixers are ideal for large volumes of product or continuous process applications. Generally, they are plumbed into existing product lines and run with the product continuously.

• Product characteristics

  -Batch - A batch high shear mixer processes discrete quantities of viscous liquid and may also be known as a batch mixer or kettle mixer. It immixes of the specific volumes at a time. The advantages are that it usually occupies less floor space compared to inline models. They also tend to process more viscous liquids than inline models.

• Product characteristics

  -Pumping - A pumping high shear mixer has a unique design that allows it to create high shear forces while moving material through a pumping action.

Specifications and maintenance of the high shear viscous liquid disperser

The following are some common specifications, along with their maintenance tips and requirements:

• Speed control: Usually, the disperser has a maintenance-free motor and gearbox. But, check the coupling and tension of the belts regularly to ensure they are properly aligned and tensioned. If the motor has a variable frequency drive (VFD) or soft starter, inspect the VFD parameters and soft starter settings. Also, monitor the motor's operating temperature to ensure it's within the manufacturer's specified limits.
• Dispersing blades: Inspect the blade for any signs of wear or damage. Look for nicks, chips, or bends in the blade's edges. If there is any, replace the blade. Ensure that the blade has the correct clearance from the vessel bottom and sides as specified by the manufacturer. Also, check the blade's alignment and level to ensure that it is properly aligned horizontally and vertically. More importantly, clean the blades after use to remove any residue or product buildup.
• Motor power: It is usually measured in kilowatts (kW) or horsepower (HP). Select the appropriate motor power for the application. A higher power motor may be oversized, while a lower power may not be sufficient. Monitor the motor load and power consumption to ensure it operates within the expected range.
• Speed (RPM): Check the disperser's final product viscosity and ensure the proper RPM is set for the processing. Take note that higher RPM may cause excessive shearing and heating, while lower RPM may be insufficient to achieve the desired results.
• Motor bearings: Inspect the motor bearings regularly to ensure they are in good condition and free from play, overheating, or noise. Also, monitor the bearing temperature and noise levels to detect any potential issues.
• Seal and gaskets: Check the condition of the seals and gaskets in the high-shear mixer. Look for signs of leakage or damage. Replace them with the seals and gaskets are worn out or damaged.

Scenarios

High shear disperser emulsifiers are crucial for numerous industries where the need to break down, mix, and develop stable products is essential. Here are some industries where these machines are commonly used:

• Food Industry: The Food industry employs high shear dispersers to make mayonnaise, sauces, coffee, fruit juices, ice cream, milk, salad dressing, and other emulsions. It is also used to refine starch and make homogeneous and stable food substances. These machines help create stable emulsions, dispersions, and homogenized products with even consistency and texture.
• Chemical Industry: Chemicals, such as paints and coatings, inks, adhesives, cosmetics, detergent, and pesticides, are processed by high shear dispersers for better mixing and the production of stable and uniform products. The dispersers ensure consistent distribution of pigments and fillers, improving product quality.
• Pharmaceuticals Industry: In the Pharmaceuticals industry, high shear mixing is used to manufacture different syrups, creams, ointments, lotions, emulsions, and dispersions. The machines allow for the production of homogenous and stable formulations that meet the required quality standards.
• Plastics and Polymers: The Plastics and Polymers manufacturing industries employ high shear mixing technology in the process of compounding and modifying polymers. They help improve the material's melt viscosity and its physical properties and uniformity.
• Textiles Industry: The high shear disperser mixer can be used in dying and textile industries to process fiber. This may include spinning and coating. It offers a solution to the preparation of dye dispersions and textile treatments.
• Ceramics and Glass Industry: A high shear disperser mixer works with powders in the ceramics and glass industry. It is used to knead and homogenize ceramic slurries, glass melts, and other viscous ceramic materials. Its use ensures uniform distribution of additives and pigments.

How to Choose a High Shear Viscous Liquid Disperser

The following tips may help when searching for an ideal high shear mixer for an industrial application:

• Understand Product Characteristics and Processing Needs

  Know the specific physical and chemical attributes of the product to be mixed, such as its density, viscosity, temperature, volume, etc. Also, determine the desired processing result, like particle size reduction, emulsification, homogenization, etc. And consider the required processing capacity and time.

• Review Machine Performance

  Choose the high shear mixer that can handle the materials' viscosity and the machine's maximum permissible viscosity. Check the shear forces generated by the equipment, as a higher shear generally results in a finer and more uniform product. Consider the capacity of the machine and its processing speed. Calculate how many units would be necessary for the intended application. Examine the energy efficiency of the mixer, as this can significantly impact operational costs.

• Consider Construction Quality

  Ensure the device is built with high-quality materials to ensure durability. Check if the construction is solid enough to resist frequent, prolonged use. Choose an apparatus with a simple design for adequate, rapid cleaning and maintenance. Select an appropriate machine for the intended installation type, such as a stand-alone, wall-mounted, or integrated unit.

• Check Safety Features

  Verify that the chosen mixer has the necessary safety features, such as overload protection, emergency stop buttons, etc., and ensure that it complies with safety standards and regulations. Consider the need for any additional safety measures, such as equipment guarding or safety interlocks.

High shear viscous liquid disperser Q & A

Q1 What is the difference between a low shear and a high shear mixer?

A1 Low-shear mixers can usually handle large batches. They are used for gentle mixing and mainly to create homogeneous products without gas escaping. Low-shear mixers are also belt-driven rather than motor-driven. On the other hand, high shear mixers break down particles using high energy and speed. They disperse the product well and create emulsions.

Q2 Can a high shear mixer emulsify?

A2 Yes, a high shear mixer can emulsify products. An emulsion is a mix of two or more liquids that normally do not combine, like oil and water. High shear mixers create stable emulsions thanks on the intensity of the mixing process.

Q3 Can a high shear mixer make foam?

_A3_ Yes, high shear mixers can make foams. The process of mixing at high speed introduces air into the product. Surfactants, fox example, can create stable foams.

Q4 What are the benefits of a high shear mixer?

A4 The high shear mixer is versatile and can do many things, like homogenizing, emulsifying, dispersing, and breaking down solid particles. It is an efficient and time-saving piece of equipment. The mixer can handle different viscosities from low to high. It is simple to operate and clean.