PerMix Emulsifier

Step 1. When the rotor is driven by the motor, it rotates at a very high speed of several thousands rpm. A powerful suction is generated at its center and draws both solids and liquids from the inlet pipe into the working chamber.

Step 2.Centrifugal force leads the materials to the periphery. Materials are subjected to intensive squeezing and milling at the precision machined clearance between rotor and stator. High pressure is created there too due to the gathering of materials, which makes the impact between particles more remarkable.

Step 3. Followed is another intense hydraulic shear as the materials are forced out through the openings in the stator at very high velocity. When material particles arrive outside of the stator, they tend to explode into thousands of even smaller ones as the pressure drops down sharply.

Step 4. Fresh materials are continually drawn into the stator-rotor maintaining the circulation or single-pass flow

PerMix also designs two types of Stator & Rotor systems: K type and V type. Both have several sub-types. These designs of stator & rotor systems offers more selections for our customers to choose the most suitable one to deal with their specific liquids and solids.

Multi-stage & Multi-row Stator/Rotor
– Rows: Every stator and every rotor have one or several rows of “teeth” (K-type, stator and rotor), or “blades” (V-type, rotor), or “screens” (V-type, stator).

– Stages: PerMix supplies PC1 series Single-stage Inline Mixer, and PC3 series Multi-stage Inline Mixer. PC3 series Inline Mixers have three sets of stator & rotor.
Standard PC3 Mixer includes sets of coarse, intermediate and fine stator & rotor assemblies. PC3 Series Inline Mixer is applied to deal with difficult-to-disperse materials, or when customers require single-pass processing.

The multi-stage (usually 3-stage) inline mixer has 3 sets of stator/ rotor systems to enhance its shearing performance. This design dramatically reduce processing time, and in some cases only one pass through the mixer can lead to satisfied products.
Depending on the materials to be processed and customer requirements, for each stator/rotor, there can be only one row, or multi-row of teeth. Besides, PerMix provides coarse, medium and fine teeth to achieve different shearing intensity.

Special Design with Ultra-high Speed
PerMix designs the ultra-high speed inline mixer with the tip speed of about 40m/s. The ultra-high speed inline mixer is belt driven to increase the rotation speed of the rotor up to 12,000rpm (Model: PC-1/60, pilot size).

The thermosiphon is used to store and cool the buffer liquid for the double mechanical seals, operated as a closed circuit. It is able to compensate the leakage of the buffer liquid at the double mechanical seals to avoid drying running of the seals, thus improve the performance and duty life of the seals.

The buffer liquid flows to the thermosiphon from the double mechanical seals with the principle of Thermosiphon Effect (or by forced circulation), and returns to the seals being exchanged and cooled.

The thermosiphon is built in SS304 or SS316L, with pressure gauge, sight glass, all necessary connection nozzles and brackets for easy installation. The tank can be built with or without cooling coil with the purpose to cool the buffer liquid by cooling water.

• Food & Beverage
  Reconstituted milk, Salad dressing, Mayonnaise, Ice cream, Cheese, Yogurt, Fruit juice
• Pharmaceutics & Biology
  Drug synthesis, Vaccine, Fat emulsion, Injectable suspension, Veterinary medicine, Cell extraction
• Cosmetics & Daily Care
  Detergent, Body gel, Shampoo, Cream, Lotion, Toothpaste, Soap
• Chemicals & Oil Industry
  Synthetic rubber, Resin, Bitumen, Silicon oil, Dye, Pigment, Coating, Ink, Nanomaterial

If you want to manufacture wet wipes using only an Inline Mixer, the process can be streamlined for continuous operation while maintaining precision and consistency. Here’s how you can set up an automated system for dosing ingredients directly into an inline mixer:

1. Inline Mixer Setup

• Use a high-shear Inline Mixer designed for emulsifying, homogenizing, and dispersing.
  • Inline mixers work by pulling ingredients into the mixing chamber and processing them on the fly.
  • Choose a mixer with adjustable shear intensity to handle a variety of formulations.

2. Automated Ingredient Dosing System

A. Liquid Ingredients

• Metering Pumps:
  • Use metering pumps (e.g., peristaltic or diaphragm) to deliver precise volumes of liquid ingredients directly into the mixer’s inlet.
• Flow Meters:
  • Install flow meters to monitor and control the real-time flow rate for accurate dosing.
• Multi-Channel Manifolds:
  • Combine multiple liquid streams using a manifold that feeds into the mixer’s inlet port.

B. Powder Ingredients (if required)

• Powder Induction Systems:
  • Equip the inline mixer with a vacuum powder induction system to pull powders directly into the mixing chamber.
• Volumetric or Gravimetric Feeders:
  • Automate powder dosing by using feeders synchronized with the mixer’s flow rate.

3. Ingredient Introduction Options

• Direct Injection Ports:
  • Install multiple injection ports on the Inline Mixer for different ingredients. Each port can have an independent dosing pump.
• Pre-Mixing Tanks (Optional):
  • For ingredients requiring pre-dissolution or heating, use pre-mixing tanks to prepare solutions that are then pumped into the inline mixer.

4. Automation and Control

• PLC/HMI System:
  • Integrate the dosing and Inline Mixing system with a programmable logic controller (PLC) and human-machine interface (HMI).
  • Program recipes for different formulations, setting precise dosing times, rates, and sequences.
• Load Cells:
  • Place ingredient storage tanks on load cells to monitor usage and ensure accurate dosing.

5. Process Flow

1. Ingredient Storage:
   • Store liquid ingredients in stainless steel tanks, each equipped with level sensors and pumps.
2. Automated Dosing:
   • The PLC initiates dosing from the tanks or feeders into the inline mixer based on recipe requirements.
3. Inline Mixing:
   • The mixer homogenizes the ingredients as they flow through.
4. Final Dispersion:
   • The mixed solution is directly transferred to the wet wipe impregnating system.

6. Key Considerations

• Mixing Chamber Design:
  • Ensure the Inline Mixer is equipped with multiple mixing stages for high-shear processing.
• Sanitary Construction:
  • Use food- or pharmaceutical-grade materials (e.g., 316 stainless steel).
• Scalability:
  • Select an Inline Mixer that can handle varying flow rates to adapt to production needs.

7. Optional Enhancements

• Inline Heating & Cooling:
  • If temperature-sensitive ingredients are used, integrate a jacketed inline mixer for heating/cooling.
• CIP System:
  • Automate cleaning of the mixer and dosing lines with a clean-in-place system.

This setup ensures a fully automated and continuous manufacturing process for wet wipes using only an inline mixer. Would you like recommendations for specific PerMix Inline Mixers or additional customization options?