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Dry Goods Sharing | An In-Depth Guide to High Pressure Homogenizers
01
Main Components of High-Pressure Homogenizers
➤ Transmission System – Provides the power source, converting electrical energy into mechanical energy to drive the plunger pump.
➤ Plunger Pump – Uses reciprocating plunger motion to generate high-pressure fluid, transporting material to the homogenization chamber.
➤ Homogenization Chamber – The area where material undergoes homogenization. High-pressure fluid applies shear, cavitation, and impact forces to disperse the material into a uniform state.
➤ Homogenizing Valve – A critical component for homogenization, consisting of a valve seat, valve core, and impact ring, made from high-pressure and corrosion-resistant materials such as ceramic, Stellite, or diamond. The valve interior features specific geometry to generate intense shear, cavitation, and impact. Homogenizers may be equipped with one (single-stage) or two (two-stage) homogenizing valves. For most applications, single-stage homogenization is sufficient. Two-stage homogenization is primarily used for emulsion systems, with secondary pressure typically ranging from 6% to 12% of the total pressure, aimed at dispersing particle size post-emulsification for a narrower distribution.
➤ Pressure Adjustment Device – Regulates the distance between the valve core and seat to control homogenization pressure, thereby adjusting the degree of homogenization. Laboratory equipment typically uses manual handle adjustment, while pilot and production-scale equipment employs pneumatic-oil methods controllable via knobs or PLC programs.
02
Working Process of High-Pressure Homogenizers
Material is pumped into the homogenization chamber and forced through the homogenizing valve under high pressure. Within the valve, the material undergoes high-speed shear, cavitation, and impact, breaking down large molecules and particles into smaller ones. The homogenized material is then discharged. The process is primarily influenced by three forces: impact, shear, and cavitation. Impact force occurs when material collides with the impact ring or other particles under high pressure. Shear force is generated as material passes through narrow passages in the valve, where velocity increases sharply. Cavitation arises when material flows through constricted areas at high pressure, causing a pressure drop that vaporizes dissolved gases, forming cavities. These cavities expand rapidly under high-pressure fluid impact, producing intense shock and shear forces that disrupt particles. These forces synergize to enhance homogenization efficiency.
03
Key Parameters of High-Pressure Homogenizers
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Pressure – One of the most critical parameters, determining the homogenization effect. Generally, higher pressure yields better results.
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Number of Homogenization Passes – Refers to how many times the material passes through the homogenizer. More passes typically improve homogenization.
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Homogenizing Valve Assembly Structure – Different material systems require varying energy inputs. Emulsion systems need strong shear forces to reduce particle size and ensure uniform distribution. ATS offers various valve types to suit different applications, such as emulsification and disruption.
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Temperature – Homogenization converts mechanical energy into kinetic and thermal energy, generating heat during emulsification and disruption. Prolonged operation can accumulate heat, affecting performance and lifespan. ATS homogenizers feature built-in temperature control modules to maintain material activity at the homogenization point. Production-scale models include oil pump air cooling, plunger cooling, and material heat exchange systems to ensure stable operation from the power end to the working end.
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Inlet Flow Rate – Determines production efficiency. Higher flow rates increase output.
04. Applications and Advantages of High-Pressure Homogenizers
High-pressure homogenizers are widely used in biopharmaceuticals, most commonly for disrupting various cells to release intracellular products. For example, when E. coli is used to express recombinant proteins such as insulin, the product often forms inclusion bodies inside the cells. High-pressure homogenizers are used to lyse the cells and release these inclusion bodies for subsequent purification. In the production of viral-based vaccines, since many virus particles are not effectively released into the extracellular culture medium during cultivation, high-pressure homogenizers are also required for cell lysis to release the viral particles. In the production of vaccines using virus-like particle technology with E. coli or yeast, high-pressure homogenizers are similarly used to lyse the cells and release the produced virus-like particles.
Secondly, they can be used for complex formulations such as liposomes, albumin nanoparticles, microspheres, emulsions, and suspensions to control particle size and ensure uniform size distribution.
High-pressure homogenizers also have various applications in cosmetics, spanning from raw materials to finished products:
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Emulsification: Cosmetics such as emulsions, creams, and ointments are emulsion systems. During emulsification, high-pressure homogenizers use intense shear and cavitation to uniformly disperse the oil and water phases, resulting in a stable emulsion.
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Dispersion: Substances like pigments, fragrances, and active ingredients play important roles in cosmetics but need to be uniformly dispersed to be effective. High-pressure homogenizers ensure even dispersion of these components, enhancing product performance.
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Cell Disruption: Often used in cosmetic ingredient production. Many active ingredients in cosmetics are produced via large-scale fermentation, and some of these are located inside cells, requiring cell disruption for release. High-pressure homogenizers can break open cells to release the active components.
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Encapsulation: Some cosmetic active ingredients are prone to oxidation or are light-sensitive, requiring encapsulation using liposomes or other materials. High-pressure homogenizers help achieve uniform particle size in liposomal encapsulation.
In the food industry, high-pressure homogenization is also a common technique. It is used to uniformly disperse fat globules in milk, improving stability and taste; to evenly distribute pulp particles in fruit juices, enhancing both flavor and nutritional value; and in applications such as enteral nutrition emulsions and microencapsulation.
Another application area is materials science, such as the preparation of nanomaterials. This includes producing nanocellulose, dispersing carbon nanomaterials like carbon black, carbon nanotubes, and graphene for conductive pastes, preparing Pt/C catalysts for electrocatalysis, and creating polishing slurries such as nano-alumina suspensions.
In summary, the main advantages of high-pressure homogenizers across various applications include:
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Effective Homogenization: High-pressure homogenizers generate powerful shear, impact, and cavitation forces, effectively reducing particle size or achieving uniform dispersion.
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Simple Operation: They are relatively straightforward to operate, easy to automate, and improve production efficiency.
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Cost-Effectiveness: Compared to technologies like ultrasonication, high-pressure homogenizers are relatively low-cost, enhancing the economic efficiency of production processes.
In the future, high-pressure homogenizers are expected to achieve even higher pressures and flow rates, with optimized homogenization chamber structures and control systems, enabling broader application areas.
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