Immiscible mixtures with components of the same or distinct phases can be emulsified, homogenized, dispersed, ground, and dissolved using high-shear mixers, sometimes referred to as high shear reactors (HSRs), rotor-stator mixers, and high-shear homogenizers. These machines differ from standard mixers because they have greater rotor tip speeds, higher shear rates, localized energy dissipation, and higher power consumption. Emulsions, suspensions, and granular products can all be made using a high-shear mixer. Read More…
High Shear MixersHigh shear mixers are high-speed machines that offer homogenization, emulsification, disintegration, particle size reduction and dispersion for many different solid and liquid materials. Because of high powered mixing blades, called shears, the mixing time is much shorter than other standard mixers.
As a world leader in industrial mixer manufacturing, KADY International offers high-performance industrial mixing machinery including top and bottom entry batch mixers, high shear mixers and chemical mixers.
Ross manufactures the world’s broadest line of High Shear Mixers – from traditional
High Speed Dispersers and single-stage Rotor/Stator Mixers to new generation ultra-
high shear patented mixing technologies. Our high performance rotor/stator mixers are
available in sizes from benchtop through full-scale production, in batch and in-line
configurations, with a multitude of options to help...
Admix, Inc. manufactures stainless steel mixing technologies & assists with tough mixing issues for a variety of markets. Choose from products such as basic mixers, Rotomaxx™ high torque mixers, BenchMix™ programmable lab mixers and more.
PerMix has been manufacturing mixing and blending equipment since 1954 for the pharmaceutical, nutraceutical, cosmeceutical, food, and chemical industry. PerMix leads the industry in innovative, performance driven, Value Added Engineering mixing solutions of all types for all industries. With over 28 types of mixers, we lead the industry in mixing solutions when it comes to mixing powders,...
At ARDE Barinco, our goal is to help our clients mix, disperse, deagglomerate, grind and compound their high quality products in the shortest amount of time with the lowest operating and capital cost. Complete, up to date pricing for all standard mixers and spare parts is shown on our website.
High shear mixers are also used for emulsification, homogenization, particle size reduction, and dispersion in the adhesives, chemical, cosmetic, food, pharmaceutical, and plastics industries.
Principle Of Operation Of High Shear Mixers
Shear is caused when one fluid region moves at a different speed than an adjacent region. A high shear mixer "works" the fluid to produce flow and shear using a rotating impeller, high-speed rotor, or a succession of such impellers or inline rotors, typically driven by an electric motor. Shear results from a velocity differential between the fluid at the center and the outside diameter of the rotor. This velocity difference is known as the tip velocity.
The stator is a stationary component that may be utilized in conjunction with the rotor. As the material leaves the rotor, the stator generates an exceptionally high-shear zone by forming a small clearance gap between the rotor and itself. The mixing head, or generator, is the collective term for the rotor and stator. There may be several generators inside a sizable high-shear rotor-stator mixer.
The main design considerations are the rotor's diameter and rotating speed, the separation between it and the stator, the amount of time spent inside the mixer, and the number of generators used. In addition, the number of rows, angle, and width of the spaces between the teeth are all variables.
Types of High Shear Mixers
High shear mixers are categorized based on their setup.
Batch High Shear Mixers
This kind uses a tank or vessel to batch-mix all the ingredients in large quantities. The top of the vessel is often where the components are charged. The mixing head that can be lifted and suspended to serve many vessels can also be set for batch high shear mixers. With the same power rating, batch mixing is believed to process faster than inline high shear mixers. The cleaning procedure between batches with different formulas is one issue with this technology. Viscous mixes are where this issue is most obvious. As a result, the next batch of products may contaminate the initial batch's leftovers. Clean-in-place (CIP) systems are used to address this issue.
In-line High Shear Mixers
The components are mixed in a chamber with an entrance and an output in this form. Centrifugal force is produced by high-shear mixers, which subsequently function as a pump to move the mixture through the chamber. In contrast to the batch type, the chamber is closed at all times, making it less prone to contamination. The inline mixer is also better regulated than batch mixers because it is a component of the product stream. Continuous monitoring of the product flowing from the mixer enables process operators to make real-time parameter changes.
In a typical configuration for an inline high shear mixer, all raw materials are gathered and combined in a mixing pot or other vessel. This container could be a batch mixer or a straightforward mixing chamber.
An inlet and an outlet are located in a chamber where the components are mixed in this type. The mixture is pumped through the chamber by the centrifugal force produced by high shear mixers. Compared to the batch type, the chamber is less likely to be contaminated because it is always closed. It is also more regulated than batch mixers because the inline mixer is a component of the product stream. Process operators can change parameters in real time by continuously monitoring the product pouring from the mixer.
A mixing pot or other vessel is typically used to gather and integrate all raw materials in an inline high shear mixer arrangement. For example, this vessel could be a batch mixer or a straightforward mixing chamber.
Powder Induction High Shear Mixers
Vacuum systems are used in these high shear mixers to suck powdered ingredients right into the mixing head. The rotor-stator assembly draws the powder from a hopper by creating a vacuum. Working with powders that are challenging to process resolves several issues.
Ultra-High Shear Mixers
These kinds are made to operate at extremely high speeds to generate a very tiny particle size distribution. As a result, the homogenization of scattered particles and liquids into a continuous phase happens more quickly. In addition, the rotor is precisely shaped to produce a high pumping capacity and shear intensity. As a result, vortices are produced at the bottom of the mixing head. These vortices extract the mixture into the mixing head and then release it radially through the stator slots. Additionally, agglomerates floating on the surface can be drawn into the vortex.
Choosing the Right High Shear Mixer Supplier
To ensure you have the most positive outcome when purchasing a high shear mixer from a high shear mixer supplier, it is important to compare several companies using our directory of high shear mixer suppliers. Each high shear mixer supplier has a business profile page highlighting their areas of experience and capabilities, along with a contact form to directly communicate with the supplier for more information or request a quote. Review each high shear mixer business website using our proprietary website previewer to quickly learn what each company specializes in. Then, use our simple RFQ form to contact multiple high shear mixer companies with the same form.
High Shear Mixers Informational Video
Industrial Mixers Power Pages
Agitators are equipment used in homogenizing media inside a tank. It works by rotating the impeller at its immersed end at a controlled speed or revolutions per minute (rpm). The work exerted by...
High Shear Mixers
High shear mixers, also known as high shear reactors (HSRs), rotor-stator mixers, and high shear homogenizers, are used to emulsify, homogenize, disperse, grind and/or dissolve immiscible mixtures with components of the same or different phases...
A homogenizer is a type of mixing equipment used to create a uniform and consistent mixture. It works by breaking the components and evenly distributing them throughout the solution. The components are either immiscible, have varying sizes, or are in different phases from each other...
An industrial blender is a machine for large-scale production that consists of a large tank capable of mixing and blending batches of manufacturing materials to create a reaction between the materials. The many uses for industrial blenders are due to their capacity and...
A mill is a mechanical device that is often a structure, appliance, or machine that is used to break down solid materials into smaller pieces by cutting, grinding, or crushing them. Many industrial processes involve...
A tank mixer is a mixing device that blends several different ingredients in a single tank to make a single solution. It is a mixing process capable of mixing wettable powders, liquids, emulsifiable concentrates, and surfactants...
Types of Mixers
A mixer is a complex and precise tool that is used in combining and mixing of substances and chemicals for manufacturing, production, and industrial use. There are many types of industrial mixers including...
A plastic tank is a large capacity liquid or granular storage unit that can be vertical, horizontal, below or above ground, and permanent in place or movable. They are designed to hold several gallons of a variety of substances...
Pressure tanks are vessels that are used to store, hold, and/or convey gasses, vapors and fluids at pressures greater than atmospheric pressure, also known as high pressures...