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Basic Working Principle and Common Structural Forms of Emulsifying Machines
Working Principle:
Utilizing the high-speed rotation of a specialized rotor within the stator cavity, a vacuum is created, continuously and rapidly drawing multi-phase fluid into the shear chamber. This process efficiently, quickly, and uniformly distributes one or multiple phases into another continuous phase (where the phases are normally immiscible), which is commonly referred to as homogeneous emulsification. During operation, the extremely high linear velocity generated by the rotor's high-speed rotation and the powerful kinetic energy from high-frequency mechanical effects subject the material in the precise gap between the rotor and stator to intense hydraulic shear, fluid layer friction, centrifugal extrusion, impact tearing, and turbulent flow. As a result, one or multiple phases are efficiently, uniformly, and rapidly dispersed into another continuous phase. Under the influence of appropriate mature processes and additives, immiscible solid, liquid, and gas phases are instantly, uniformly, and finely emulsified and dispersed. Through high-frequency cyclic repetition, a stable high-quality product is ultimately obtained.
Common Structures:
There are many structural forms of emulsifiers (homogenizing heads), with the most common including the following types:
High-Shear Dispersion Type (Radial Flow)
In-Line Type (Radial Flow)
Cone Mill Type (Axial Flow)
Axial Flow Type
Axial Flow Type
High-Efficiency Type (Radial Flow)
Emulsifiers come in various structural forms, but their fundamental working principles are largely similar. The operation can be illustrated using the working diagram of the most traditional and simple high-shear dispersion type (radial flow) emulsifier:
Process Illustration:
High-shear mixing emulsification technology has evolved into a distinct discipline from traditional mixing, continuously expanding its application fields and undergoing technological updates. It has been acclaimed by users as "the industrial revolution of mixers." The core structure of high-shear mixing emulsifiers is the stator and rotor system. Its structural forms include a claw-type structure suitable for lightweight, easily suspended materials and a blade-type structure suitable for heavier, easily sedimented materials.
Working Principle Breakdown
Driven by centrifugal force generated by the high-speed rotating rotor, the material in the diagram is simultaneously drawn into the work chamber from both the upper and lower feed zones of the work head in an axial direction.
The powerful centrifugal force propels the material radially through the narrow, precision gap between the stator and rotor, where it simultaneously undergoes centrifugal extrusion and impact forces, achieving preliminary dispersion and emulsification.
At the outer edge of the high-speed rotating rotor, a linear velocity of at least 15 m/s (up to 50 m/s) is generated, creating intense mechanical and hydraulic shear, fluid layer friction, and impact tearing. This thoroughly disperses, emulsifies, homogenizes, and breaks down the material, which is simultaneously ejected through the stator slots and continuously discharged at high speed in the radial direction.
Under the resistance of the material itself and the container wall, the flow direction changes. Simultaneously, under the effect of the upper and lower axial suction forces generated in the rotor area, two strong turbulent flows moving upward and downward are formed. After several cycles, the material ultimately completes the process of dispersion, emulsification, and homogenization.
Through the explanation of the process diagram above, we believe everyone has gained a preliminary understanding of homogeneous emulsification. We hope this has been helpful to you.
For over 20 years, Jinzong Enterprise has focused on the design and manufacturing of food and pharmaceutical machinery equipment, R&D of intelligent control systems, and engineering design and installation. With a design and marketing service center in Guangzhou and two production plants in Zhaoqing National High-Tech Zone, the company possesses special equipment manufacturing qualifications for pressure vessels and pressure pipeline installation (GC2) qualifications. It is recognized as a National High-Tech Enterprise and a Provincial Specialized, Refined, Distinctive, and New Enterprise. The company boasts two provincial famous brand products, dozens of product patents, software copyrights, and provincial high-tech products. It has passed the National Intellectual Property Management System Certification, ISO 9001-2015 International Quality System Certification, and EU CE Certification. For many consecutive years, it has been awarded the "Guangdong Province Contract-Honoring and Trustworthy Enterprise" by the Guangdong Administration for Industry and Commerce. Its users span over 50 countries and regions worldwide, receiving widespread recognition and support from more than 2,000 enterprises of various sizes.
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