The Bottom-Entry High Shear Emulsifying Tank is a high-performance mixing and homogenizing system designed for fine emulsification, dispersion, and dissolution of liquid–liquid and liquid–solid mixtures.
It is ideal for applications in the food, dairy, beverage, pharmaceutical, cosmetic, and chemical industries that require stable emulsions, fine particle distribution, and efficient homogenization.
Unlike conventional top-mounted emulsifiers, this tank integrates a high-speed rotor–stator emulsifying head installed at the bottom of the vessel. This configuration ensures that all materials are continuously drawn downward into the high-shear zone for rapid circulation and thorough homogenization.
Combined with a top or side mechanical agitator, the system provides complete macroscopic and microscopic mixing, delivering superior product uniformity and smooth texture.
Working Principle
The bottom-mounted high shear emulsifier consists of a rotor–stator structure driven by a high-speed motor (typically 1,450–3,000 rpm).
During operation, materials are drawn into the emulsifying chamber by centrifugal force, where they experience intense shearing, tearing, and hydraulic turbulence.
This process breaks down particles or droplets into micron-sized emulsions (1–5 μm), achieving fine, stable, and uniform mixtures.
The bottom-mounted design enhances material circulation within the tank, particularly beneficial for high-viscosity and high-solid-content products.
Main Features
● Efficient Bottom Shear Design
The emulsifying head located at the tank bottom ensures powerful shear action and continuous material circulation. It prevents "dead zones" inside the vessel and guarantees complete emulsification.
● Dual Mixing System
The tank can be equipped with a top-mounted or side agitator for large-scale mixing, while the bottom emulsifier provides fine homogenization. Together they deliver both macro and micro-level mixing.
● Temperature Control Capability
The jacketed double-layer structure allows for heating, cooling, or temperature maintenance using thermal media such as steam, hot water, or glycol water.
● Hygienic & Food-Grade Construction
All contact parts are made of SUS304 or SUS316L, with inner surface polished to Ra ≤ 0.4 μm, complying with GMP, FDA, and 3A hygiene standards.
Equipped with CIP spray balls and optional SIP connections for automated cleaning and sterilization.
● Powerful Homogenizing Performance
High-speed rotor–stator shearing action creates fine droplets and uniform emulsions, improving product smoothness, stability, and shelf life.
● Automation Ready
Optional PLC + HMI control system enables automatic operation and real-time monitoring of temperature, mixing speed, emulsifying speed, and batch timing.
Detailed Structural Description
1. Inner Tank:
Constructed from SUS304 / SUS316L with mirror-polished interior and rounded corners to eliminate residue accumulation.
2. Jacket Layer:
For circulation of cooling or heating media; available in dimple jacket, half-pipe, or full-jacket configurations.
3. Insulation Layer:
Filled with polyurethane foam or rock wool for energy-efficient temperature control.
4. Bottom High Shear Emulsifier:
Rotor–stator type, bottom-mounted for efficient shear. Creates strong hydraulic turbulence for fast emulsification and dispersion.
5. Agitator System:
Optional top or side-mounted agitator (anchor, frame, or propeller type) driven by a motor with VFD control for adjustable speed.
6. Control System:
Includes temperature sensors, motor control, and optional touch-screen HMI for easy process management.
Technical Parameters (Customizable)
| Item | Specification |
| Capacity | 50 L – 10,000 L |
| Material | SUS304 / SUS316L |
| Structure | Double-layer with jacket and optional insulation |
| Heating / Cooling Medium | Steam / Hot water / Chilled water / Glycol |
| Temperature Range | -10°C – 120°C |
| Emulsifier Type | Bottom-entry rotor–stator high shear |
| Emulsifier Speed | 1,450 – 3,000 rpm |
| Agitator Type | Anchor / Frame / Propeller / Turbine (VFD adjustable) |
| Surface Finish | Internal Ra ≤ 0.4 μm, External Matte or Mirror Polish |
| Control System | Manual / Semi-automatic / PLC + HMI |
| CIP / SIP | Available |
| Design Standards | GB / ASME / DIN / 3A optional |
Tank & Agitator Design
● Single or double-layer stainless steel structure (SUS304 / SUS316L)
● Flat, conical, or sloped bottom to facilitate full discharge
● Bottom-entry high-shear rotor-stator mixer
● Optional top-mounted secondary agitator (paddle, anchor, propeller)
● Open or closed top lid
● Support legs with adjustable feet
Agitator & Mixing Parameters
● Bottom-entry rotor-stator type for high-shear mixing
● Variable speed: fixed or VFD (500–3,000 rpm, customizable)
● Adjustable rotor-stator gap to control particle size and emulsion quality
● Suitable for low- to high-viscosity liquids
Operating Conditions
● Temperature range: 0–150°C (with optional jacket)
● Working pressure: atmospheric or low-pressure jacket
● Handles viscous, sticky, or particulate-laden materials efficiently
Connections & Accessories
● Inlet/outlet tri-clamp fittings
● Sampling valve optional
● CIP spray ball optional
● Jacketed heating/cooling ports (optional)
● Vacuum or pressure relief valves optional
Control & Monitoring
● Manual or PLC-controlled operation with touch screen
● Adjustable rotor speed and emulsification parameters
● Alarm system for over-speed, over-temperature, or abnormal liquid level
● Optional data recording for process verification
Material & Hygiene Standards
● Product-contact material: SUS304 or SUS316L
● Structural material: SUS304
● Seals & gaskets: Food-grade silicone, EPDM, or PTFE
● Rotor-stator assembly: SUS316L (or corrosion-resistant variant for aggressive media)
● Welding: TIG argon welding, smooth interior surface
● Piping: Seamless sanitary stainless steel
● Compliance: FDA, 3A, GMP
● Design standards: ASME, DIN, GB
The tank is designed for hygienic production, CIP compatibility, and easy cleaning, ensuring no dead corners or contamination risks.
Advantages
● Efficient emulsification with strong bottom shear and rapid circulation
● Suitable for high-viscosity or high-solid-content materials
● Uniform emulsification without dead corners
● Heating, cooling, and mixing integrated into one vessel
● Sanitary, durable, and easy to clean
● Customizable structure and control system for different processes
Optional Configurations
● VFD speed control for rotor and secondary agitator
● High-shear emulsifier or homogenizer upgrade
● Jacketed heating/cooling with precise temperature control
● CIP spray ball & pipeline integration
● Load cells for precise weighing
● Level gauge (magnetic or electronic)
● Sight glass with LED illumination
● Vacuum or pressure relief valves
● Skid-mounted mixing platform for easy relocation
Installation, Operation & Maintenance
Installation
● Place on level ground or platform
● Connect inlet/outlet piping and optional jacket lines
● Electrical wiring for agitator and control panel
● Optional safety railing and ladder
Operation
● Add raw materials into the tank
● Start bottom-entry high-shear agitator (set speed if VFD installed)
● Mix until desired consistency and particle size is achieved
● Discharge through outlet valve
● Perform CIP/manual cleaning after production
Maintenance
● Regular inspection of tank, rotor-stator, and seals
● Lubricate agitator motor if required
● Check tri-clamp fittings and valves
● Maintain PLC system and sensors if automated
Applications
● Dairy & Beverage: Flavored milk, protein drinks, cream, fruit jam
● Food Industry: Mayonnaise, condiments, sauces, emulsified oils, syrups
● Cosmetic Industry: Creams, lotions, gels, shampoo, conditioner bases
● Pharmaceutical: Ointments, suspensions, liquid emulsions, nutrient solutions
● Chemical Industry: Emulsions, dispersions, detergents, lubricants
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