In the industry of making emulsions the HSM (high-shear rotor/stator mixer) has become the most popular selection. They shorten the mixing process and have a broad range of functions they can perform. They may be used to make many different substances such as gums, drugs, cosmetics, pigments and flavors.
Since researchers have concentrated their studies on low-shear mixing the high shear mixers have been largely overlooked. Generally, it is the application that is the main focus of testing rather than the process of mixing. Because of this lack of information there have been many misconceptions about high speed mixers.
Scaling up in the laboratory is an important part of mixing properly. Yes the product quality is of course the number one concern. However, there are other serious considerations as well. Proper planning can help cut costs by enormous amounts. The goal is to spend the least amount of money and time while producing the same high quality product. Everything must be held under the microscope to find the best solutions. Even the floor plan must be taken under consideration. Operating procedures, net operating costs and equipment management all have an impact on the overall cost of operation.
For instance, if your lab can mix a batch in only 12 seconds but the machine is set to cycle for five minutes, you are wasting the other part of the time. Four minutes plus forty-eight seconds is time that can impact other expenditures since the batch reached its mixing equilibrium in the first twelve seconds. By overshooting even what seems like a small amount of time energy costs, labor, wear and tear on the machine and productivity factors are all affected and end up costing more in the long run. Careful planning can cut these extra lab costs.
One consideration that is worth looking into is using an inline mixer rather than a batch mixer. With the inline mixer the process is more easily controlled than with a batch mixer. Both solids and liquids monitored and easily mixed in. These are also easily adaptable to the pre set lab situations. This means that there does not have to be a lot of changes in existing floor plans. It can be positioned right beside the tank. Then the materials for the batch can be sent directly from the tank to be processed by the high-shear rotor and then returned to the tank.
There should be plenty of research and thought put into what will be most cost effective and productive for the lab. Which one is chosen will depend on the type of production line is in use. Consider whether the switch will be advantageous for your particular situation.
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More information about high shear mixer , please visit Marcel Miller's site: vacuum homogenizer blender
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