How to get Emulsification Tanks?

What is Emulsification Tank?

The function of an emulsification tank is to dissolve one or more materials (water-soluble solid phase, liquid phase or gel, etc.) in another liquid phase and to make it water into a relatively stable emulsion. It is widely used in the emulsification and mixing of edible oils, powders, sugars and other raw materials. Some emulsifying and dispersing paints and emulsifiers are also used in emulsification tanks, especially for some difficult sol-like additives such as CMC and xanthan gum.

The application range of emulsification tank
The emulsification tank is suitable for the production of industrial products such as make-up, medicine, food, chemical, dyeing, printing ink, etc., especially for the viscosity of the matrix, the solid content ratio
 Higher formulae emulsify more effective.
(1) Make-up industrial products: creams, lotions, lipsticks, shampoos, etc.
(2) Pharmaceutical industrial products: ointments, syrups, eye drops, antibiotics, etc.
(3) Food industry products: jam, butter, margarine, etc.
(4) Chemical industrial products: chemicals, synthetic adhesives, etc.
(5) Dyeing industrial products: pigments, titanium oxide, etc.
(6) Printing inks: color inks, resin inks, newspaper inks, etc.
(7) Others: pigments, waxes, coatings, etc.

Emulsification tank features
The unit is characterized by a simple operation, stable performance, good homogeneity, high production efficiency, convenient cleaning, reasonable structure, less floor space and a high degree of automation.
Emulsion tank advantages
The unit adopts the upper coaxial three heavy-duty stirrer, hydraulic lifting, and opening, quick homogenizer speed: 0-3000r/min (frequency control), slow speed scraper stirrer will automatically cling to the tank bottom and tank wall. The use of vacuum suction, especially for powder materials using vacuum suction to avoid dust flying. The whole process is carried out under vacuum conditions to prevent the material from generating bubbles after high-speed stirring, which can meet the requirements of hygienic asepsis. The system is equipped with a CIP cleaning system, and the contact part between the container and the material is made of SUS316L material and the inner surface is mirror polished (sanitary grade).

Emulsification tank description
Emulsification tank is a three-coaxial mixing mixer, suitable for stable homogeneous emulsification, the particles produced are very small, the emulsification quality depends on how the particles are dispersed in the preparation phase, the smaller the particles, the tendency to collect on the surface The weaker, the less chance of emulsification being destroyed.
Reliance on the mixing action of the reversed vanes, homogenous turbines, and vacuum conditions to obtain high-quality emulsifying mixing.

Emulsion tank system composition

A slow mixing system
The structure of the stirring paddle is frame type and double stirring type. The middle paddle and the frame type wall rotating paddle are used for convection stirring. The rotation speed of the rotating paddle is preferably in the range of 15-60 r/min.
The speed is too slow: The reducer has a serious heat.
Excessive speed: Reducer damage is accelerated. The plate is made of polytetrafluoroethylene, and the heat exchange is adjusted to flatten the pot wall.
1 Two reverse rotating low-speed stirring systems. It consists of a hanger and blades covered with a scraper.
2 The fully automatic movable scraper is made of PTFE material. It can work only when there is material and it is easy to disassemble and clean.
3 Dynamically balanced concentric shafts.
4 The outer hanger and inner blades are made of stainless steel SUS316L.
5 The electronic timer is installed on the PLC to facilitate adjustment of working time.
6 equipped with geared motor – ABB company, the speed can be adjusted directly by the inverter, speed 0-80rpm/min.
The slow mixing system creates two separate counterflows inside the material.
(1) A vertical flow along the center forces the material to flow toward the bottom of the volume, which acts to quickly feed the material to the bottom of the homogeneous turbine.
(2) A circumferential annular flow forces the material around the inner wall of the mixing vessel for heat exchange during the heating and cooling phases and avoids damage to the material caused by overheating or undercooling.

Second, the rapid and homogeneous mixing system
1 The rapid homogenous mixing action is performed by a turbine installed in the center of the tank bottom.
2 The turbine consists of a toothed stator and a rotor with a blade.
3 The turbine is made of SUS316L stainless steel and the rotating part is made of a balanced coaxial shaft.
4 Electronic timer mounted on the PLC to adjust the processing time.
5 equipped with geared motor – ABB company, using frequency control, speed 0-3000r/min
This structural feature guarantees a high degree of cleanliness of the process, for the following reasons:
Because there is no influence of the motor flange connection, there will be no pollution to the material.
Turbine settings are easy to clean, maintain and handle.
The bottom of the tank is completely smooth and unconnected and easy to clean.
A central valve (option) can be installed to discharge.
The mixing and homogenizing motor are mounted on the upper part of the tank away from the processing area.
Strictly protect the safety of operators.

Third, heating/cooling system
1 Heat is transferred from the external steam through the jacket to the inner tank.
2 Control the water temperature in the jacket from the PLC via the temperature controller.
3 Temperature control consists of an electronic thermostat controller and a galvanic couple installed at the bottom of the tank to accurately read the actual temperature of the material.
4 Cooling is done directly by the external cold water through the jacket.

IV. Vacuum system
1 water ring vacuum pump.
2 The vacuum gauge indicates the vacuum inside the container.
3 The vacuum safety switch is designed to avoid opening the cover when there is a vacuum.
4 The airtightness of the upper cover is guaranteed by the silicon packing on the flange.
5 The theoretical maximum vacuum is 730mm/hg at 20°C. For perfect emulsification, air must be prevented from entering the material. Processing in a vacuum allows direct injection of liquid or powder into the volume.

V. Cover lifting system
The lifting and lowering of the upper cover are accomplished by a set of hydraulic devices with a safety limit system that can keep the upper cover in any desired position.

Six, volume dumping system
The volume dump system is used for unloading and is completed by a manual wheel and stays at any angle.

Seven, processing control
The observation window is equipped with a washer and a light and has good internal visibility.

Eight, security system
1. The safety lock must not be opened by accident under vacuum.
2. The upper cover and the volume are not well aligned and the airtightness is not enough.
3. If the top cover is not completely raised, the dumping function is disabled.
4. When the cover is opened, mixing and homogenizing motor, the vacuum pump is disabled.
5. Limit the microswitch to automatically open/close the cover.
6. The parameters can be changed according to user requirements and achieve the best performance.

Emulsion tank use matters needing attention
1 This system must be used to ensure that all individual pieces of equipment are operational.
 
2 When sterilizing the filter, the pressure of the steam flowing through the air filter must not exceed 0.17 MPa, otherwise, the filter element will be damaged and the filter capacity will be lost.
 
3 During the fermentation process, it should be ensured that the tank pressure does not exceed 0.17 MPa.
 
4 In the actual elimination process, when the jacket is steam-heated, the inlet steam pressure must be controlled within the working pressure range of the equipment (should not exceed 0.2MPa), otherwise, it will cause damage to the emulsification tank.
 
5 When empty and actual consumption, be sure to drain the remaining water in the emulsified tank jacket. Failure to do so may result in flattening of the cylinder in the emulsification tank and damage to the equipment. When it is actually consumed, too much-condensed water will cause the culture fluid to be diluted, thus failing to meet the process requirements.
 
6 In the process of cooling after emptying and dehydrating, it is forbidden to produce negative pressure inside the emulsification tank to avoid causing pollution or even damage the equipment.
 
7 During the fermentation process, the tank pressure should be maintained between 0.03 and 0.05 MPa to avoid contamination.
 
8 During each operation, the pressure in the airline must be kept higher than the tank pressure of the emulsification tank. Failure to do so may cause the liquid in the emulsification tank to flow back into the filter, clogging the filter element or invalidating the filter.
 
9 If you have problems that you cannot solve yourself, please contact the company’s after-sales service department directly. Do not forcibly disassemble or repair.
Mixing and Emulsification Double Head Type Emulsification Tank

mixing emulsification double head type emulsification tank - How to get Emulsification Tanks?

The Emulsification Tank adopts Vertical circular tanks, both of top and bottom are standard oval and torispherical head. Transition section in tank using circular arc transition, without dead corner, easy to clean. Heating mode with steam, electric heating, heat conduction oil, equipped with mechanical stirring according to customers’ requirement.

The Emulsification Tank be designed, manufactured and inspected in accordance with the pressure vessel standard(GB150-2011) and the steel welded atmospheric pressure vessel standard(NB/T 47003.1-2009) , strictly meet to GMP.

Tank Optional Configuration

The Crystallizing Tank can select 0.2μm hydrophobic sterile air filter, thermometer(Digital display or Dial type), 2 sight glasses, steam sterilization hole, sanitary manhole, liquid in-outlet, CIP rotating cleaning ball, liquidometer and Liquid level control system(Bearing module, non-contact ultrasonic, static pressure transmitting device) and so on, also can configure as customers’s requirement.

Application 
• Suitable for cosmetic, medicine, food, chemical, dyeing, printing ink and other industrial production, especially for high matrix viscosity, solid material content higher material preparation emulsion will be more efficacy.

Feature
• Volume:600L~20000L and multiple specification, also can design and manufacture according to customers’ requirement.
Jacket can pass steam (or hot water), can also pass the cooling water. Jacket has disk tubular, full jacketed and Maitreya plate. Jacketed outside covered with insulation, thermal insulation material for rock wool (warm) or PU (cold).
• The connection adopts Tri-clamp, the tanks’ inner use 304 or 316L. The inner surface mirror polishing Ra≤0.28μm~0.6μm, outer surface can polishing, wire drawing and sandblasting according to customers’ requirement.
• Agitation adopts top mechanical agitation. Stirring methods(Push type, screw, anchor, etc) can be selected.
• The sealing of agitating shaft and emulsification shaft adopt sanitary mechanical seal. The mixing motor can use Cycloidal reducer, stepless speed reducer. These items can be selected according to customers’ requirement. (Frequency control is widely used) Emulsion motor adopts frequency control of motor speed reducer.

Design Parameter

Design pressure

-0.1MPa~0.6MPa
Design temperature According to the customers’ requirements(0℃~160℃)

Material

Inner tank 304、316L
Jacket 304
Insulation layer Rock wool ( keep warm ) or PU ( keep cool )
Feet 304

Surface Finish

Finish type Mechanical polishing, electrolytic polishing,
Sand blasting , pickling
Polishing precision Inner surface Ra≤0.3μm, 
Outer surface Ra≤0.6μm

Connection

In-outlet Tri-clamp , Flange

Normal Model And Main Technical Parameters

Parameters Model SECRRG—600 SECRRG—1000 SECRRG—2000 SECRRG—3000 SECRRG—4000 SECRRG—5000
Effective volume:L 600 1000 2000 3000 4000 5000

Barrel

Diameter:mm Φ900 Φ1100 Φ1300 Φ1600 Φ1700 Φ1800
Height:mm 900 1000 1500 1500 1800 1800

Emulsification

Motor power :KW 4 7.5 7.5 11 11 15
Emulsification RPM 4P(The design can be adjusted according to customer usage)

Mixing

Motor power:KW 1.1 1.5 2.2 2.2 3 4
Mixing RPM:r/min 22(The design can be adjusted according to customer usage)
JTRRG—6000 SECRRG—8000 SECRRG—10000 SECRRG—12000 SECRRG—15000 SECRRG—20000
6000 8000 10000 12000 15000 20000
Φ1900 Φ2000 Φ2200 Φ2400 Φ2600 Φ2800
2000 2200 2400 2500 2700 3000
18.5 22 30 37 45 55
4P(The design can be adjusted according to customer usage)
4 5.5 5.5 7.5 7.5 9.2
22(The design can be adjusted according to customer usage)
The above-mentioned data is the standard mixing and emulsification double head type emulsification tank,, for reference only. it can customize according to customer’s requirements.

Stainless Steel High Shear Emulsification Tank

The High Shear Emulsification Tank be designed, manufactured and inspected in accordance with the pressure vessel standard (GB150-2011) and the steel welded atmospheric pressure vessel standard (NB/T 47003.1-2009) , strictly meet to GMP certificate requirements.
Square High Shear Emulsification Tank use square single layer stainless steel,and the inner wall of the tank body is made of circular transition, , no dead corner, easy to clean;and the bottom with mechanical emulsification.
Tank body and bottom head of Square High Shear Emulsification Tank can be equiped with an insulation layer according to the customers’ requirements.

Tank optional configuration

Square High Shear Emulsification Tank optional configuration: sterile air filter, thermometer (digital display type or dial), sight glasses, sanitary manhole, in-outlet, CIP universal rotating cleaning ball, sterile sampling valve (stainless steel tank bottom), the liquid level meter and liquid level self-control system (bearing module, non-contact ultrasonic, static pressure transmitting device), etc., or configured according to customers’ requirements.

20171227043226 22327 - How to get Emulsification Tanks?

Application: 
• Suitable for food (milk), beverage, biotechnology, pharmaceutical, fine chemicals, pigment etc . mixed liquid and mixture in the tank is full and rapid mixing, dispersion, emulsification, homogenization.

Feature
• There are 600L~5000L varietys of specifications, it can be designed, customized according to the customers’ requirements.
• Connector use fast installation chuck (clamp), inner tank use SS304 or SS316L, the inner surface mirror polishing Ra≤0.28μm~0.6μm, outer surface can be polishing, wiredrawing ,sandblasting according to customer’s requirement.
• Square High Shear Emulsification Tank use mechanical emulsification at bottom, adopt claw type occlusion, double suck material structure; high speed mixing and emulsification, can be suitable for different mixture, mixing, dispersion, emulsification, homogenization.
• Emulsification shaft seal use sanitary mechanical seal, emulsification motor can use planet-cycloid retarder, stepless reducer according to the customers’ requirements .

Design Parameter

Design pressure

ATM

Design temperature

According to the customers’ requirements(0℃~160℃)

Material

Inner tank

304、316L

Insulation layer

Rock wool ( keep warm ) or PU ( keep cool )

Feet

304

Surface Finish

Finish type

Mechanical polishing, electrolytic polishing,
Sand blasting

Polishing precision

Inner surface Ra≤0.4μm, 
Outer surface Ra≤0.6μm

Connection

In-outlet

Tri-clamp , flange

Normal Model And Main Technical Parameters

Parameters

Model

SECRGR—1000

SECRGR—2000

SECRGR—3000

SECRGR—4000

Effective volume:L

1000

2000

3000

4000

Barrel

Length and width:mm

1100

1300

1450

1600

height:mm

800

1200

1400

1500

Emulsification

Motor power:kW

18.5

22

30

37

Emulsification RPM

1500

The above-mentioned data is the standard ,for reference only. it can customize according to customer’s requirements.

Source: China Emulsification Tanks Manufacturer  www.secmachinery.com

www.secmachinery.com is one of the leading China filtration equipment & sanitary stainless steel pressure vessels manufacturer, with a professional factory. We focus on the sanitary pressure vessels, filtration equipment research, and development, manufacturing, sales and service since the company been established. Our products are widely used in biopharmaceutical, food and beverage, fine chemical industry. 

If you want to have more information about the article or you want to share your opinion with us, contact us at sales@secmachinery.com
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