High Shear Mixer

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The high shear mixer is widely used in the experimental fields of liquid mixing, emulsification, liquid/solid powder dispersion, and slurrying in biology, physics, chemistry, cosmetics, health care products, food, paint, coatings, and chemicals. It is ideal laboratory equipment for scientific research, product development, quality control, and production process applications in scientific research institutions, colleges and universities, health and epidemic prevention, product manufacturing, and pharmaceutical and medical units.

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The dispersion process of the high shear mixer is based on the cutting principle of the rotor and the stator. The experimental equipment is driven by a high-speed motor to drive the shearing and emulsifying working head, which promotes the rotor to make a high-speed circular motion. The high-speed rotating rotor and the precision stator form high-frequency, strong circumferential tangential velocity, angular velocity, and other comprehensive kinetic energy, which encourages the experimental materials to be sucked into the rotor area from the bottom of the experimental container, and the stator hole under the action of huge centrifugal force throw out.

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High Shear Emulsifier

The high shear Emulsifier is widely used in the experimental fields of liquid mixing, emulsification, liquid/solid powder dispersion, and slurrying in biology, physics, chemistry, cosmetics, health care products, food, paint, coatings, and chemicals.

High Shear Mixer

High Shear Mixer is to disperse one or more phases into another continuous phase through efficient, fast, uniform and other processes, and under normal circumstances each phase is insoluble.

Inline Homogenizer

The Inline homogenizer is mainly used for mixing and homogenizing materials, dispersing, and emulsifying, and it is versatile and versatile. The inline homogenizer is generally used as a primary and intermediate material for mixing, and homogenizing.

Inline Emulsifier

The inline emulsifier is composed of three sets of stators (two layers, four layers, and six layers) in the working cavity, which has higher processing accuracy, large processing capacity, and wide processing viscosity range.

Guidelines For High Shear Mixer

High Shear Mixer is to disperse one or more phases into another continuous phase through efficient, fast, uniform, and other processes, and under normal circumstances each phase is insoluble. Because of the high rotor high-speed rotation of the tangent velocity and kinetic energy of high frequency mechanical effect brings strong, make the material in the narrow gap, rotor fierce mechanical and hydraulic shear, centrifugal extrusion, tearing and turbulent liquid layer friction, lighting strike, etc inductive effect, so that the miscibility of the solid phase, liquid phase, and gas phase in the corresponding mature technology and with a moderate amount of additive effect, Disperse and emulsify evenly and finely in an instant, and get stable and high-quality products after high frequency cycles.

Daily operation guide for high shear mixer

The stator and rotor form strong, reciprocating hydraulic shear, friction, centrifugal extrusion, and fluid collision in a reasonably narrow gap. The experimental materials cyclically reciprocate in the container, and withstand tens of thousands of times per minute of shearing, tearing, impact and mixing, to achieve the effect of shearing and emulsification, and the efficiency of high shear mixer is about a thousand times higher than that of ordinary mixing.

The high-shear mixer is a multi-functional integrated complex emulsification equipment. Because of its multi-functionality, it must be operated by the manufacturer before using it.

The components of our equipment operation are the mixing system of the main emulsification tank, the homogenization system, the lifting system of the main tank, the mixing system of the water-oil tank, and the vacuum system. The equipment can be controlled according to the buttons on the control panel, including lighting and extinguishing the lights, controlling the mixing operation of the mixing bowl, homogenizing mixing operation of the mixing bowl, mixing operation of the water and oil boiler, controlling the operation of the vacuum system and the main Heating of pot and water and oil pot. The various controls of the equipment are carried out on the control panel.

Daily operation guide for high shear mixer

①Turn on the power →②Feeding in the oil-water pot →③Close the lid of the oil-water pot →④heat and stir the oil-water pot →⑤Close the lid of the homogenizer pot, close other valves on the lid, and open the vacuum valve to vacuum (suction) →⑥Homogenizer pot Heating (adjustable temperature)→⑦Homogeneous mixing and emulsification of the poor material (time is up) stop heating→⑧open the discharge valve again to discharge the material→⑨(after cleaning, the lid can be lifted, dumped, drained and closed)→⑩circulation.

What is a high shear mixer？

High shear mixers are designed to provide intense agitation and shear forces, ensuring thorough mixing and dispersion of even the most challenging ingredients. These powerful machines are capable of handling a wide range of viscosities, from low-viscosity liquids to highly viscous pastes and semi-solids. Whether you’re blending, emulsifying, homogenizing, or dispersing, a high shear mixer can deliver exceptional results with unparalleled efficiency.

At the heart of a high shear mixer lies a robust rotor-stator assembly. The rotor, driven by a powerful motor, spins at high speeds, creating a powerful suction that draws the materials into the mixing head. As the ingredients pass through the narrow clearance between the rotor and the stationary stator, they experience intense shear forces that break down agglomerates, disperse particles, and create a homogeneous mixture.

The shear rate generated by these mixers can reach up to several hundred thousand reciprocal seconds, ensuring thorough mixing and particle size reduction in a matter of minutes. This high-energy input not only accelerates the mixing process but also facilitates chemical reactions, enabling faster and more efficient processing.

High shear mixers can be categorized into several types based on their design and flow patterns:

Axial Flow Mixers

Propeller Mixers
Three-Blade Pitched Turbine
Four/Three-Blade Turbine
Two-Blade Curved Impeller
Four-Blade Curved Impeller

Radial Flow Mixers

Four-Blade Straight Impeller
Six-Blade Straight Impeller
Six-Straight Blade Disk Turbine
Six-Parabolic Blade Disk Turbine
Six-Backward Curved Blade Disk Turbine
Closed Disk Turbine Impeller
Anchor Agitator

Mixed Flow Mixers

Four-Blade Pitched Impeller
Six-Blade Pitched Impeller
Three-Blade Retreat Curve Impeller
Six-Pitched Blade Disk Turbine

Other Types

Screw Mixers
Screw and Auger Mixers
Batch High Shear Mixer/Emulsifier

The main differences among these types lie in their impeller designs, flow patterns, and shear rates generated, making them suitable for different applications and material viscosities. For example, axial flow mixers are efficient for low to medium-viscosity liquids, while radial flow mixers are better suited for high-viscosity materials. Mixed-flow impellers combine axial and radial flow patterns for versatile performance.

Versatility and Applications

High shear mixers are versatile machines that can be adapted to a wide range of applications across various industries. In the food and beverage sector, they are commonly used for emulsifying, homogenizing, and dispersing ingredients in the production of sauces, dressings, mayonnaise, and beverages. Pharmaceutical companies rely on these mixers for the efficient blending of active ingredients, excipients, and suspensions, ensuring consistent drug delivery and bioavailability.

The cosmetics industry benefits from high shear mixers in the production of creams, lotions, and other personal care products, where a smooth and homogeneous texture is essential. Additionally, these mixers find applications in the chemical industry for dispersing pigments, resins, and other additives, as well as in the production of paints, coatings, and inks.

Benefits of High Shear Mixing

1. Improved Product Quality: High shear mixers ensure thorough mixing and dispersion, resulting in consistent and uniform products with superior quality.

2. Increased Efficiency: The intense shear forces generated by these mixers accelerate the mixing process, reducing processing times and increasing overall efficiency.

3. Particle Size Reduction: The high shear rates facilitate particle size reduction, enabling the creation of stable emulsions, suspensions, and dispersions.

4. Versatility: High shear mixers can handle a wide range of viscosities and materials, making them suitable for various applications across multiple industries.

5. Scalability: These mixers are available in different sizes and configurations, allowing for easy scaling from laboratory to industrial production levels.

6. Sanitary Design: Many high shear mixers are designed with sanitary features, making them suitable for use in industries with stringent hygiene requirements, such as food, pharmaceuticals, and cosmetics.

Choosing the Right High Shear Mixer

With a variety of high shear mixer models available on the market, selecting the right one for your specific application is crucial. Factors to consider include the viscosity range of the materials, the desired particle size reduction, the required batch size, and the level of sanitation required.

FRANLI manufacturers offer a range of high shear mixer models, each designed to meet specific needs. From batch mixers to inline mixers, and from laboratory-scale to industrial-scale units, there is a solution tailored to your unique requirements.