Many people might be confused when they hear the term "emulsifier" or "emulsification equipment." What's an emulsifier for? Let's take a look at what an emulsifier is used for.
Emulsifiers are specialized equipment used for high-speed shearing, dispersion, and mixing of materials. They are primarily used for stirring, homogenizing, emulsifying, mixing, and dispersing fluid materials. During the high-speed relative rotation of the spindle and rotor, a powerful shearing force is generated, ensuring thorough mixing and breaking down of the materials. Vacuum is used to remove air bubbles during the mixing process.
Working principle of emulsifier equipment :
The material is first preheated and stirred in a water or oil pot, then directly drawn into the homogenizing pot under vacuum through a conveying pipe. Inside the homogenizing pot, the material is continuously exposed to new interfaces by the PTFE scrapers on the agitator (which always conform to the shape of the pot, sweeping away any adhering material). It is then subjected to shearing, compression, and folding by the frame agitator and its counter-stirring blades, causing it to mix and flow downwards to the homogenizer below the pot. There, the high-speed rotating rotor and stator generate strong shearing, impact, and turbulence, cutting the material into particles ranging from 200nm to 2μm. Material micronization, emulsification, mixing, homogenization, and dispersion can be completed in a short time. Because the homogenizing pot is under vacuum, air bubbles generated during stirring are promptly removed. After homogenization, the pot lid is raised, and pressing the tilt button allows the material to be discharged into an external container (or the bottom valve and pressure valve can be opened for direct discharge). The heating temperature of the homogenizing pot is displayed on the temperature controller on the control panel; the homogenizing agitator and paddle agitator can be used separately or simultaneously; the homogenizing time is determined by the user according to the properties of the material and can be adjusted via the control panel. After use, the pot body can be cleaned by opening the cleaning ball valve.
Emulsifier equipment structure:
An emulsifier consists of a main pot, an oil pot, a water pot, an electrical control system, a hydraulic system, a vacuum system, and a frame.
The main pot consists of a homogenizing mixing tank, a homogenizing mechanism, and a two-way mixing mechanism.
Emulsifier Equipment Functions:
1. The main pot has a top liquid inlet and a trace element addition function; the water pot and oil pot are semi-open for easy ingredient addition.
2. Vacuum feeding function for the main pot.
3. The frame mixer and the blade mixer operate in opposite directions, with variable frequency speed control. The frame mixer is equipped with a scraper, eliminating dead corners.
4. Use a high-shear homogenizer with foreign technology for upper homogenization.
5. The bottom of the main pot uses a bottom valve with positive pressure discharge function, eliminating dead corners.
6. Both the emulsifying pot and the premixing pot are made of three layers with an inner jacket. Water can be introduced to achieve heating or cooling.
7. Main pot lid hydraulic lifting function. Pot body tilting function for easy cleaning inside the pot.
8. The control panel has on/off and emergency stop switches, temperature upper and lower limit settings display, stirring speed (frequency conversion speed regulation), homogenization speed, homogenization time control settings, vacuum, lighting, all functions including the premixing pot, and lifting control of the hydraulic system.
9. The main pot lid is equipped with a light and a cleaning mirror for easy observation of the pot's contents.
10. Also equipped with an emergency stop function.
Precautions for installation and commissioning of emulsifier equipment :
1. Connect the power supply, ensure the power is compatible, and guarantee that the ground wire is reliably grounded. Turn on the main power switch.
The power indicator light is on. (After wiring the motor or when restarting it after a long period of disuse, it should be jogged briefly for a test run. The direction of rotation of the stirring frame is reversed when viewed from above. During debugging, jog the stirring mechanism first to confirm that everything is working correctly before running the homogenizer!)
2. Correctly connect all pipes of the homogenizer (including overflow outlets, drain outlets, and sludge outlets).
3. Before vacuuming, always check that the pot is flush with the lid, and that the pot opening and material inlet covers are tightly sealed. Close all valve ports on the lid, then open the vacuum valve on the lid, and start the vacuum pump to create a vacuum. Once the required vacuum is achieved, turn off the vacuum pump and simultaneously close the vacuum valve. (See the operation process flow chart for details.)
4. Homogenization and Scraper Agitation: After adding materials (water can be used during commissioning), turn on the corresponding control switches to control the operation of the homogenizer and the scraper agitation. Before starting the agitation, briefly run the agitator to check for any abnormalities in the agitator and scraper wall; if any are found, eliminate them immediately.
5. The vacuum pump can only be started when the homogenizing pan is sealed. If it is necessary to start the pump with the atmosphere open, it should not be run for more than 3 minutes.
6. The vacuum pump must not be operated without working fluid. The exhaust port must not be blocked while the pump is running.
7. Regularly check the lubricating oil and grease in all components and bearings, and replace them with clean lubricating oil and grease in a timely manner.
8. Keep the homogenizer clean. Clean the parts of the homogenizer that come into contact with the working fluid each time you stop using it or change materials, especially the cutting wheel and cutting sleeve at the head, and the sliding bearing and sleeve inside the homogenizing bushing. After cleaning and reassembly, there should be no jamming when manually turning the impeller. After the two flanges of the pot body and pot cover are fixed in place, jog the homogenizer motor to ensure the rotation direction is correct and there are no other abnormalities before starting operation.
9. All pots and pans shall be cleaned by the user in accordance with the standard procedures.
