A homogenizer is composed of a homogenization system, a transmission system, a lubrication and cooling system, and a frame. Working principle: During operation, the reciprocating motion of the plunger causes the one-way valve core and valve seat of the pump body to open and close, forming a high-pressure liquid flow inside. When the high-pressure liquid flow passes through the small gap of the homogenization valve, it is subjected to the combined forces of high-speed impact, squeezing, shearing, cavitation, and turbulence, achieving the effects of homogenization, emulsification, and crushing. High pressure homogenizer, as a modern new type of emulsification equipment, has been widely used in many industries such as food, pharmaceutical lightweighting, microbiology, and has achieved rapid development.
The factors that affect the homogenization effect include the product itself, homogenization pressure, degree of homogenization valve wear, homogenization temperature, and product air content. In production, we should strive to ensure the quality of materials as much as possible. However, due to the high-pressure state during operation, the components of the high-pressure homogenizer are prone to damage. Therefore, it is necessary to check whether they are correctly installed, tightened, or worn out and need to be replaced. In addition, some special conditions such as high-temperature SIP sterilization, frequent flushing, and abnormal operating procedures can affect the service life of the machine and its components. Below, the editor lists several fault situations of high-pressure homogenizers, analyzes their possible causes and troubleshooting methods:
(1) Homogenization valve leakage. The internal structure of the homogenization valve is complex, including homogenization head, homogenization ring, homogenization ring chamber, homogenization seat, O-ring, guide sleeve, etc. In response to phenomena such as leakage of the homogenization valve, insufficient homogenization total pressure, inability to achieve homogenization pressure, and homogenization valve noise, in addition to checking the O-ring, it may be caused by damage to the homogenization head and seat.
(2) The main motor is overloaded. Check if the homogenization pressure is too high, if the power transmission end is worn or damaged, if the belt tension is too tight, or if the main motor is faulty.
(3) The material flow rate slows down. Check if the main motor belt slips, if the main motor speed decreases, if there is any leakage in the plunger seal, or if there is air mixed in the material or if the valve spring breaks, all of which can cause the material flow rate to slow down or even no material flow.
(4) The one-way valve for incoming and outgoing materials is leaking. The three plunger high-pressure homogenizer includes six one-way valves, three of which are feed valves and three are discharge valves. Leakage is usually caused by wear of O-rings and anti extrusion rings.
In short, the frequency of faults in high-pressure homogenizers is closely related to whether daily maintenance is in place and whether operation is standardized. Therefore, in addition to routine inspections of high-pressure homogenizers, gaskets, plunger seals, transfer valves, valve seats and springs, homogenization valves, etc. should be replaced regularly according to the different materials being processed, and gear oil, water oil air filters, plungers, etc. should be replaced regularly for the machine.