High Shear Mixer: Blending, Blending & Emulsifying

High Shear Mixers

High shear mixers are often used in rotor/stator mixers for solid-liquid dispersions and emulsions, and this function cannot be fully accomplished by ordinary high-speed dispersers.

Details of High Shear Mixer

Suitable for the material before the process
Small energy consumption
Large capacity
Certain self-suction and low lift transport function

Application: Paint, Adhesive, Battery, Pharmaceutical industry, Cosmetic

When the blade of the machine rotates, the material is continuously pumped into the stirring head, and the gas is discharged at high speed through the opening of the stator. The resulting hydraulic shear promotes rapid homogenization, deagglomeration, and emulsification.

Due to the limitation of the stator, high speed mixers provide higher shear rates but less pumping capacity than open-disk sawtooth-blade dispersers. For the same reason, the viscosity limit is also lower—about 10,000 to 20,000 centipoise.

Rotor/stator mixers for high shear mixers are available in both batch and in-line (continuous) production configurations. The performance of the online high shear mixer is similar to that of a centrifugal pump, it cannot automatically start the self-priming function, and needs to be added to the mixing tank by static pressure (gravity feeding) or positive pressure (pump feeding). In most cases, the product is delivered to the rotor/stator assembly by gravity when the agitator is usually located on the ground or on a platform below the recirculation tank level.

Standard in-line mixers easily move flowable products even up to about 10,000 cps, depending on the shear thinning properties of the formulation. Using an auxiliary pump, medium viscosity coatings, premixes, and intermediates can be processed in a high shear mixer. For large stirred tanks (> 500 gallons), an in-line configuration tends to be more practical compared to batch rotor/stator mixers or other high-speed mixers that require a high-power motor drive and relatively large blades to generate sufficient circulation to enter from the top.

Not only that, but the inline high shear mixer can circulate product through the 2500-gallon stirred tank as easily as in a 25-gallon stirred tank. In fact, with the right piping, one in-line mixer can serve multiple batch tanks of different sizes at the same time. Typical installation methods use simple valves to flow directly downstream to the finished product area or to switch from one feedstock source to another instantaneously.

When large batches of powder need to be added quickly to a liquid, or when hard-to-disperse solids take a long time to fully add, consider a high shear mixer with built-in means for subsurface addition of powder. Ejector-based powder injection systems, while effective at removing floating solids and providing more precise control during agitation and mixing, do often suffer from blockages and intensive equipment maintenance issues. Furthermore, these systems require an experienced operator to handle the often difficult task of balancing the performance of three separate devices in series: ejector, pump, and agitator. High shear mixers with powder injection monolithic construction are more reliable and easier to operate.

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Guidelines For High Shear Mixer

The mixing device of the high shear mixer is a rotor with four blades, which rotates at a high speed in a stationary stator to complete the entire stirring and mixing process.