Working principle and structural composition of a homogenizing emulsifier.

A homogenizing emulsifier is a high-efficiency mixing equipment widely used in industries such as food, chemical, pharmaceutical, and cosmetics. It is designed to achieve homogenization, emulsification, dispersion, and refinement of materials. With its sophisticated and technologically advanced design, it can transform originally immiscible or difficult-to-mix solid, liquid, and gaseous components into uniform and fine emulsions or suspensions. Below, Jinzong Enterprise, with over 20 years of experience in the production, design, and R&D of emulsifiers, will elaborate in detail on the working principle and structural composition of the homogenizing emulsifier.

Working Principle of Homogenizing Emulsifier

The core working principle of the homogenizing emulsifier is based on powerful shear, impact, centrifugal extrusion, and inter-layer friction effects. The specific process is as follows:

• Pre-treatment Stage: Materials are first heated and preliminarily stirred separately in independent water and oil tanks to facilitate dissolution, mixing, or chemical reactions. Then, under vacuum conditions, the materials are drawn into the emulsification vessel.

• Mixing and Stirring Stage: Inside the emulsification vessel, a central stirring device and a wall-scraping device are typically installed. The central stirrer is responsible for thorough mixing of the materials and ensuring no residue remains on the inner wall of the vessel. Scrapers made of PTFE or other wear-resistant materials closely contact the vessel wall, effectively scraping off adhered materials for reintegration into the mix.

• High-Shear Homogenization Stage: The key component of the homogenizing emulsifier is the high-speed rotating homogenizing head (comprising the rotor and stator). The rotor spins steadily inside the stator at linear speeds up to 15-40 meters per second, creating a precisely fitted narrow gap between them. When materials pass through this gap, they experience intense shear forces, centrifugal forces, and violent collision and friction effects, resulting in effective refinement and dispersion of material particles down to micron or even nanometer levels.

• Vacuum System: The equipment is equipped with a vacuum system that removes air from the materials during emulsification, helping to eliminate bubbles, prevent oxidation, and promote rapid, uniform mixing, thereby improving product quality.

Structural Composition of Homogenizing Emulsifier

A typical vacuum homogenizing emulsifier generally consists of the following main components:

• Emulsification Vessel (Main Vessel): Features a liftable lid and a tiltable vessel design for easy cleaning, discharge, and maintenance. The inner wall is smooth for easy cleaning and often uses a jacketed structure to hold heating or cooling media.

• Stirring System: Includes the central stirrer and wall-scraping device, ensuring comprehensive mixing of materials and reducing build-up on the vessel walls.

• Homogenizing Mechanism: Also known as the homogenizing head or high-shear emulsifying head, located inside the emulsification vessel, typically containing one or multiple sets of rotor-stator assemblies driven by a high-speed motor.

• Vacuum System: Used to extract gases generated during the emulsification process, maintaining a vacuum environment inside the vessel to promote emulsification and de-aeration.

• Temperature Control System: Can utilize electric heating, steam heating, etc., to regulate material temperature and ensure process conditions.

• Electrical Control System: Includes functions for start, stop, speed adjustment, and display of working parameters, enabling automated and precise control of equipment operation.

• Auxiliary Devices: Such as feed ports, discharge valves, and safety protection devices, ensuring the safe and efficient operation of the entire emulsification process.

Through the effective synergistic work of the aforementioned principles and mechanisms, the homogenizing emulsifier can achieve a high degree of homogenization and emulsification of materials in a relatively short time, thereby producing high-quality products such as creams, ointments, lotions, and medicinal pastes.