Top-Entry High Shear Emulsifying Tank

Working Principle

The top-mounted high shear emulsifying head consists of a rotor and stator assembly. When the rotor spins at high speed (typically 1,450–3,000 rpm), it generates strong centrifugal force and hydraulic shear. The materials are continuously drawn into the emulsifying head, subjected to intense shearing, turbulence, and impact, and then expelled through the stator holes at high velocity.
This process breaks down solid or immiscible liquid particles into fine droplets (1–5 μm), forming a stable and uniform emulsion or suspension.

Main Features

● Integrated Mixing & Emulsifying System
The tank is equipped with both mechanical agitator (anchor, frame, or paddle type) for macro-mixing and a top-entry high shear emulsifier for micro-level dispersion. The dual-action system ensures homogeneity across the entire batch.

● Precise Temperature Control
The jacketed double-layer design allows circulation of cooling or heating media (steam, hot water, or glycol water) to maintain ideal process temperature during emulsification.

● High Shear Efficiency
The rotor–stator assembly generates a powerful shear zone capable of dispersing powders, oils, and viscous materials into liquids quickly and evenly.

● Sanitary and Hygienic Design
Manufactured from SUS304 or SUS316L, with all contact surfaces polished to Ra ≤ 0.4 μm, the tank meets GMP and food hygiene standards.
Equipped with CIP spray balls and optional SIP connection for automated cleaning and sterilization.

● Automation and Control
Optional PLC + HMI system for automated control of temperature, mixing speed, emulsifying speed, time, and cleaning functions, ensuring repeatable and stable production.

Detailed Structural Description

1. Inner Tank:
Food-grade stainless steel construction with sanitary polishing and rounded corners.

2. Jacket Layer:
Enables circulation of heating or cooling media; available in dimple or full-jacket type for precise thermal control.

3. Insulation Layer (Optional):
Filled with polyurethane foam or rock wool for temperature retention and energy efficiency.

4. Top High Shear Emulsifier:
Rotor–stator type, directly driven by a motor or gearbox. High-speed shear creates strong turbulence for fine emulsification.

5. Agitator System:
Optional slow-speed anchor or frame agitator for overall mixing. Adjustable speed via frequency inverter (VFD).

6. Control System:
Temperature, speed, and process parameters can be displayed and controlled via touch screen or control panel.

Technical Parameters (Customizable)

Tank & Agitator Design

● Single or double-layer stainless steel structure (SUS304 / SUS316L)

● Flat, conical, or sloped bottom

● Top-entry high-shear rotor-stator mixer

● Open or closed top lid

● Support legs with adjustable feet

Agitator & Mixing Parameters

● High-shear rotor-stator type, top-mounted

● Optional secondary agitator: paddle, anchor, propeller

● Mixing speed: fixed or VFD variable speed (500–3,000 rpm for high-shear rotor, customizable)

● Homogenization efficiency adjustable by rotor-stator gap and speed

Operating Conditions

● Temperature range: 0–150°C (with optional jacket)

● Working pressure: atmospheric or low-pressure jacket

● Suitable for low- to high-viscosity liquids

Connections & Accessories

● Inlet/outlet tri-clamp fittings

● Sampling valve optional

● CIP spray ball optional

● Jacketed heating/cooling ports for temperature control (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

● Data recording optional 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 customized for high corrosion resistance)

● Welding: TIG argon welding with smooth internal surfaces

● Piping: Seamless sanitary stainless steel

● Compliance: FDA, 3A, GMP

● Design standards: ASME, DIN, GB

The system is designed for high hygiene, smooth surfaces, and CIP compatibility, ensuring easy cleaning and preventing contamination.

Advantages

● Combines mixing, heating, cooling, and high-shear emulsification in one unit

● Capable of processing materials with high viscosity and poor solubility

● Produces fine, stable emulsions with uniform particle size

● Hygienic structure, easy to clean and sterilize

● Highly efficient and energy-saving for batch production

● Customizable to meet specific process and material requirements

Applications

● Dairy & Beverage: Milk drinks, protein beverages, flavored milk, fruit sauces

● Food Industry: Dressings, mayonnaise, condiments, creams, syrups

● Cosmetic Industry: Creams, lotions, gels, shampoos, emulsions

● Pharmaceutical: Suspensions, nutrient solutions, emulsified preparations

● Chemical: Emulsions, dispersions, and fine chemical blending

Optional Configurations

● VFD speed control for rotor and secondary agitator

● High-shear emulsifier or homogenizer upgrade

● Jacketed heating/cooling with temperature control

● CIP spray ball & pipeline

● Load cells for weighing

● Level gauge (magnetic or electronic)

● Sight glass with LED illumination

● Vacuum or pressure relief valves

● Skid-mounted mixing platform