Common problems and solutions of vacuum emulsifier

The vacuum emulsifier is one of the commonly used equipment in industries such as cosmetics, pharmaceuticals, and food, capable of forming stable emulsions processes such as high-speed shearing, stirring, and homogenization. However, in the actual operation process, some common technical problems may arise due to improper use or lack timely maintenance. This paper aims to explore these issues and their corresponding solutions, and to deepen the understanding through specific application cases.

Common Issues and Solutions 1. Poor Emulsification Effect   Cause Analysis: Insufficient shear force leading to uneven dispersion; the material's high viscosity causing insufficient mixing.   Solution: Adjust the speed and time to ensure the desired shear force is achieved; for high-viscosity materials moderate heating can be applied to reduce viscosity, or a higher shear force emulsification head can be used. 2. Equipment Produces Loud Noise   Cause: Mechanical faults such as bearing wear, poor gear meshing, or loose couplings.   Solution: Regularly inspect and replace worn parts; ensure proper lubrication of transmission; tighten loose connections. 3. Product Degradation Due to Excessive Temperature   Cause Analysis: Uncontrolled heating system or failed cooling system. Solution: Check if the temperature control system is functioning correctly, and repair or replace if necessary; ensure the coolant water circulation is unobstructed. 4. U Mixing   Cause Analysis: Inadequate impeller design leading to poor fluid dynamics.   Solution: Optimize the impeller shape and layout to improve flow; choose the appropriate mixing method based on the material properties. 5. Leakage Issues   Cause Analysis: Aged or damaged seals; misaligned flange.   Solution: Regularly replace seals; check and adjust the parallelism and tightness of the flange faces.

Case Analysis Case One: Preparation of Lotion in Cosmetics Industry A cosmetics company encountered poor product stability when producing aizing lotion, despite using a high-shear force emulsification head. After an on-site investigation by the technical staff, it was discovered that the problem was due insufficient pre-mixing of raw materials before entering the emulsifier, resulting in uneven dispersion of some ingredients. The solution was to add a pre-mixing step and adjust operating parameters of the emulsifier. As a result, the product texture was significantly improved, and the emulsification effect was significantly enhanced. Case Two: Sauce in Food Processing A condiment manufacturer encountered serious mixing uniformity issues when producing a special-flavored sauce, with some of the spice particles failing to completely dissolve the matrix. After analysis, it was found that the problem was caused by the use of a mixing paddle type that was not suitable for handling this type of mixture containing solid particles. problem was effectively solved by switching to a screw paddle suitable for handling particulate materials. Conclusion Proper use and maintenance of the vacuum emulsifier is crucial for product quality. When faced with problems, it is necessary to analyze from multiple perspectives and take targeted measures to solve them. With the advancement of technology, future vacuum emulsifiers will more intelligent and efficient, better meeting the production needs of various industries.