1、 Core definition: What is an emulsion tank?
In short, the emulsification tank is an industrial cauldron specially used to manufacture "lotion".
For example, in daily life:
The milk we drink, the lotion we put on and the mayonnaise we eat every day are all systems of "oil" and "water" mixed together. But you will find that after standing for a period of time, oil and water usually separate (such as oil floating on the surface of the water). Why can milk and mayonnaise maintain uniformity and stability for a long time? Because they have undergone an "emulsification" process.
Emulsion tank is to disperse a liquid (usually oil) into extremely small droplets through strong mechanical shear force, and evenly and stably disperse into another incompatible liquid (usually water), finally forming a seemingly uniform and stable mixture, which is called "lotion".
2、 How does an emulsion tank work? (Core principle)
The core of achieving emulsification lies in "crushing" and "mixing", mainly relying on the following three systems:
1. Mixing system (core components)
The mixing system is usually not a regular mixing blade, but a combination of multiple mixers:
Frame/anchor agitator: located on the inner side of the tank wall, rotating at low speed. The main function is to scrape the wall, prevent materials from sticking to the tank wall, and achieve large-scale macroscopic mixing.
High speed homogenization head: It is located at the bottom of the tank and rotates at a high speed (several thousand revolutions per minute). Its precise stator and rotor structure generates enormous shear forces, instantly tearing and crushing the material into tiny particles/droplets at the micrometer level, thus achieving true "emulsification".
(Optional) Dispersion disk: For some processes that require the dispersion of solid powders, an additional dispersion disk will be provided for high-speed cutting and dispersion of powders.
The workflow can be understood as:
Low speed mixing (macro mixing) → high speed homogenization (micro emulsification) → formation of stable lotion
2. Heating and cooling system (temperature control system)
The tank usually has a jacket layer that can be filled with steam, hot water, or cold water to heat or cool the material.
Heating: Many materials have better emulsification effects at specific temperatures (such as 70-80 ℃), or require melting certain components (such as wax, grease).
Cooling: After emulsification is completed, it is necessary to quickly cool down to prevent product deterioration, volatile aroma, and improve production efficiency.
3. Vacuum and pressurization system (improving quality)
Vacuum system: Vacuum can be applied during the emulsification process for two main purposes:
Defoaming: Removing bubbles from the material during mixing to make the product more delicate.
Preventing oxidation: Operating in a vacuum environment can prevent materials from coming into contact with air and prevent oxidation and deterioration.
Pressurization system: After emulsification is completed, the finished materials in the tank can be quickly discharged by pressurization (usually using compressed air or nitrogen), reducing residue and waste.
3、 Main characteristics of emulsion tank
1. Good emulsification effect: thanks to the high-speed homogenizer, high-quality lotion with fine particles and uniform distribution can be obtained.
2. High mixing efficiency: Multiple mixing methods are combined, and there are no dead corners in the mixing process.
3. Easy to operate: Automated control can usually be achieved, with one click setting of mixing speed, time, temperature and other parameters.
4. High hygiene level: The inner wall of the tank is precision polished, smooth without dead corners, in compliance with GMP (Good Manufacturing Practice) standards, and easy to clean and disinfect.
5. Good sealing: Ensure that the material is operated in a sterile or anaerobic environment.
4、 Application areas of emulsion tanks
Cosmetics industry: face cream, lotion, essence, shampoo, shower gel, liquid foundation, etc.
Food industry: yogurt, ice cream, mayonnaise, salad dressing, beverages, seasoning sauce, etc.
Pharmaceutical industry: ointments, creams, suppositories, oral liquids, vaccine adjuvants, etc.
Chemical industry: paints, coatings, inks, pesticides, adhesives, etc.
Biotechnology: Preparation of nano drugs such as cell culture media and liposomes.