Vacuum emulsifying mixer and homogenizers are essential emulsification tools used in the cosmetics, food, and pharmaceutical industries for combining immiscible liquids into stable emulsions or pastes.
This blog will thoroughly introduce the advantages, disadvantages, and applications of these equipment types to help you understand their features and select the best emulsification solution for your product needs and production requirements.
Vacuum emulsifying mxier
A vacuum emulsifying mixer is a device that uses a vacuum environment and stirring to achieve efficient emulsification. It creates negative pressure in the container to fully mix the raw materials under low oxygen conditions, and uses the shear force of the stirring paddle to continuously refine the droplet size, eventually forming a stable emulsion.
Working principle
The working principle of the vacuum emulsifier is to use negative pressure to remove bubbles in the raw materials, and at the same time disperse the immiscible liquids into the continuous phase through the shear force of the agitator to form a stable emulsion or paste. This process is usually carried out in a closed container, and the emulsification effect can be optimized by adjusting the vacuum degree and stirring speed.
Key Components of Vacuum Emulsifying Mixer
The vacuum emulsifying machine consists of the following key components, each of which performs its own duties and works in coordination to achieve efficient and stable emulsification effects.
Emulsifying mixing pot consists of a stainless steel cylinder, an insulation jacket, a feed port and a discharge valve. The inner surface of the cylinder is polished and equipped with an observation window; the insulation jacket is connected to hot and cold water or steam to control the temperature; the feed port is connected with a quick-release clamp; and the discharge valve is automatically controlled by a pneumatic butterfly valve.
Stirring system includes a ribbon stirrer, a vacuum homogenizing emulsifying head and a sealing device. The stirrer forms a two-way mixing flow field; the homogenizing head generates shear force through high-speed rotation, and the gap is adjustable; and a multi-stage mechanical seal prevents vacuum leakage.
Vacuum system consists of a water ring vacuum pump, a vacuum buffer tank, a vacuum regulating valve and a breaking valve. The vacuum pump is equipped with a gas-water separator; the buffer tank stabilizes the vacuum degree; the regulating valve controls the vacuum degree; and the breaking valve is used to restore normal pressure.
Electrical control system integrates touch screen interface, PLC controller, variable frequency speed regulation and recipe management functions. It realizes equipment operation monitoring, automatic execution of process steps, motor speed regulation and recipe switching.
Advantages
Low shear force, protect ingredients: Compared with high-speed homogenizers, the shear force of vacuum emulsifying mixers is relatively low. This is conducive to protecting heat-sensitive or shear-sensitive ingredients, reducing damage and maintaining their efficacy.
Vacuum environment, reduce oxidation: Under vacuum conditions, the raw materials are less exposed to air and the oxidation reaction is inhibited. This is especially important for easily oxidized raw materials, which can maximize their quality and stability.
High emulsification efficiency: Thanks to the dual effects of vacuum and stirring, the vacuum emulsifying mixer can achieve good emulsification effect in a relatively short time. Usually, an emulsification process only takes 30-60 minutes, which greatly improves production efficiency.
Scope of application
Cosmetics: vacuum emulsifying mixers are often used to prepare cosmetics such as creams, lotions, and essences. It can effectively blend the oil phase and the water phase to form a delicate and uniform texture, and enhance the product experience.
Food: In the food industry, vacuum emulsifying mixers can be used to produce salad dressings, chocolate sauces, jams, etc. It can fully mix raw materials such as oils, water, and emulsifiers to obtain products with rich taste and good stability.
Pharmaceuticals: Some pharmaceutical preparations, such as creams, suspensions, etc., also need to be prepared with the help of vacuum emulsifying mixers. By adjusting the vacuum degree and stirring speed, the particle size distribution and uniformity of the drug can be accurately controlled to ensure the efficacy.
Homogenizer
Homogenizer is another common emulsification equipment. Its principle is to use a high-pressure pump to pass the emulsion through a narrow gap, and withstand huge shear and impact forces in a very short time, so that the droplet size is reduced to the submicron level, forming a homogenous and stable emulsion.
Advantages
High shear force, fine particle size: The homogenizer can provide a shear force much higher than that of the vacuum emulsifying mixer, so that the droplet size is further refined, generally up to 0.1-1 micron. This is conducive to improving the stability and uniformity of the emulsion.
Continuous production, high efficiency: Homogenizers are mostly operated continuously, and the emulsion is driven by a high-pressure pump to continuously pass through the homogenization valve to achieve a continuous homogenization process. Compared with intermittent vacuum emulsifying mixers, it has higher production efficiency and is suitable for large-scale industrial production.
Scope of application
Dairy products: Dairy products such as milk, cream, and yogurt need to be homogenized to prevent fat globules from floating up and form a uniform and smooth taste. Homogenization can also improve the digestion and absorption rate of dairy products.
Juice drinks: Some natural juices and plant protein drinks also need to be homogenized to break up cellulose, reduce granularity, and improve taste and stability.
Biological products: Some biological products, such as vaccines and hormones, have strict requirements on particle size distribution. High-pressure homogenizers can fully emulsify ingredients such as antigens and adjuvants to ensure the immune effect of vaccines.
Difference Between Vacuum Emulsifying Mixer and Homogenizer
There are significant differences in the emulsification principle and scope of application between vacuum emulsifying mixers and homogenizers, and each has its own unique advantages and limitations.
Shear strength
The homogenizer uses a high-pressure pump and homogenization valve to generate extremely high shear force, which can reach tens to hundreds of thousands s-1. Under such strong shear force, even materials with high viscosity can be refined to submicron levels (usually 0.1-1μm) to form stable microemulsions or nanoemulsions.
The shear force of the vacuum emulsifying mixer is relatively mild and mainly comes from the mechanical action of the stirrer and homogenizing head. The shear force gradient can be optimized by adjusting parameters such as rotation speed, but is generally lower than that of a homogenizer. This moderate shear force is beneficial to protect heat-sensitive and shear-sensitive components, such as proteins, enzyme preparations, etc., from denaturation and inactivation.
Production method
Most homogenizers operate continuously, and the material continuously passes through the homogenization valve driven by a high-pressure pump to achieve single-pass or cycle homogenization. This continuous production method has the advantages of large production capacity, high efficiency, and low energy consumption, and is suitable for large-scale manufacturing of large-volume products, such as milk, juice and other standardized dairy products.
The vacuum emulsifying mixer adopts intermittent production, and the material undergoes multiple rounds of stirring, homogenization, and defoaming cycles in a closed container until the desired emulsification effect is achieved. Intermittent operation has greater flexibility and is suitable for small batches and multi-variety customized production, such as cosmetics, pharmaceuticals and other personalized products. By changing the formula and process parameters, the production of different products can be quickly switched.
Particle size control
With its ultra-high shear force, the homogenizer can refine the emulsion droplet size to the sub-micron level and achieve precise control by adjusting the homogenization pressure and times. For example, after two-stage homogenization (200/50bar) of milk, its fat globule diameter can be reduced to 0.1-0.5μm, significantly improving stability and taste.
The emulsion droplet size of a vacuum emulsifying mixer is usually at the micron level (1-100 μm), which can be optimized by adjusting parameters such as stirring time, speed, and vacuum degree. However, it is limited by its shear force level and is difficult to reach the nanometer level. But for many emulsified products, micron-level particle sizes are sufficient, such as skin care lotions, salad dressings, etc.
Applicable materials
The homogenizer has a wide range of applications and has relatively few restrictions on the viscosity, specific gravity, composition, etc. of the material. High shear force can effectively handle high viscosity systems and is not easily affected by differences in material specific gravity. But for some materials that are sensitive to shear and heat, high shear forces may lead to degradation or denaturation.
vacuum emulsifying mixer is more suitable for heat-sensitive and oxidation-sensitive materials, such as vitamins, unsaturated fatty acids, etc. The vacuum environment can effectively block oxygen and inhibit oxidation reactions. In addition, oil-in-water (W/O) emulsification systems and high viscosity systems are also the advantages of vacuum emulsifying mixers, which are often used to prepare creams, ointments, etc.
Quick overview of differences
| Equipment | Shear force | Production method | Particle size range | Applicable materials |
| vacuum emulsifying mixer | Low | Intermittent | Micron level | Heat-sensitive and oxidation-sensitive materials |
| Homogenizer | High | Continuous | Submicron level | Wide range |
How to Choose Between Vacuum Emulsifying Mixer and Homogenizer
When choosing between a vacuum emulsifying mixer and a homogenizer, in addition to the basic factors mentioned above such as product characteristics, production size and budget, companies need to thoroughly evaluate the following key aspects:
The Match of Process Requirements
vacuum emulsifying mixers are suitable for shear-sensitive, heat-sensitive, oxidation-sensitive materials, as well as high viscosity, difficult to emulsify systems. Their gentle shear, vacuum protection and precise temperature control help to maintain the efficacy of active ingredients and improve the texture and stability of creams, ointments and other products.
Homogenizer is suitable for products with strict requirements on the particle size of milk droplets and dispersion uniformly, such as dairy products, fruit juice drinks, etc.. Its high shear force can make the particle size distribution more uniform, significantly improve the sensory quality and shelf life of the product.
Convenience of cleaning verification
vacuum emulsifying mixer barrel and piping design needs to be easy to disassemble for cleaning and visual inspection to reduce dead space and risk of contamination. Quick-fit interface, surface polishing, automated cleaning system (CIP/SIP) and other designs can significantly improve cleaning efficiency and meet cGMP requirements.
Key components of homogenizers such as homogenizing valves need to be easy to disassemble and maintain, and the material must be resistant to high pressure and abrasion. All stainless steel shell, aseptic sealing and other designs are conducive to aseptic production. Integration with the pharmaceutical system should also be considered.
Flexibility of operation and level of automation
vacuum emulsifying mixer should be equipped with vacuum, stirring speed, homogenization speed and other parameters of independent control functions to match the process needs of different formulations. Intuitive touch screen interface, one key start and stop and other humanized design can reduce operational errors.
Homogenizer should be equipped with precise control and recording function of pressure and flow rate to realize the standardization and traceability of the process. Modularized PLC control system, intelligent fault diagnosis and alarm function can help improve production efficiency and product qualification rate.
Technical strength and service level of suppliers
High-quality emulsification equipment suppliers should have rich industry experience and strong R&D strength, and be able to provide personalized equipment customization and process optimization services according to customer needs.
Perfect after-sales service system, including installation and commissioning, operation training, spare parts supply, regular maintenance, etc., can ensure the long-term stable operation of the equipment.
The production workshop and quality management system of the supplier shall comply with the relevant certification standards (e.g. ISO, cGMP, etc.) and have the corresponding qualification certificates.
Return on Investment and Life Cycle Costs
The return on investment (ROI) of the equipment depends on its productivity, energy consumption, maintenance cost, service life and other factors. Choosing high cost-effective equipment can minimize the unit product cost while ensuring product quality.
The full life cycle cost (LCC) includes the acquisition cost, operation cost, maintenance cost and end-of-life disposal cost of the equipment. Evaluating the economics of equipment from a long-term perspective helps optimize capital budgets and cost control strategies.
Conclusion
Vacuum Emulsifying Mixers and homogenizers have their own strengths in the field of emulsification. When choosing equipment, companies need to comprehensively consider factors such as product characteristics, production scale, budget, etc., weigh the pros and cons, in order to achieve the best production effect and return on investment. In addition, it is also wise to find experienced and technologically advanced equipment manufacturers to obtain professional advice and customized solutions.
Wejing is a professional Vacuum Emulsifying Mixer manufacturer with many years of experience in equipment research and development and manufacturing. Our products cover various models of laboratory, pilot and production levels, and are widely used in cosmetics, food, pharmaceutical and other industries.
If you have any needs or questions about Vacuum Emulsifying Mixers, please contact us!
FAQs About Vacuum Emulsifying Mixer and Homogenizer
Q: What is the main difference between a Vacuum Emulsifying Mixer and a Homogenizer?
A: The main difference lies in their shear force and production methods. Vacuum Emulsifying Mixers use gentle shear force and operate intermittently in a vacuum environment, producing micron-level particles. Homogenizers utilize high-pressure pumps to generate intense shear force, operating continuously to achieve submicron-level particles.
Q: Which industries commonly use Vacuum Emulsifying Mixers?
A: Vacuum Emulsifying Mixers are widely used in cosmetics, pharmaceuticals, and food industries. They're particularly suitable for producing creams, lotions, ointments, and other high-viscosity products. These mixers are ideal for products containing heat-sensitive or oxidation-sensitive ingredients.
Q: What are the key advantages of using a Vacuum Emulsifying Mixer?
A: Vacuum Emulsifying Mixers offer three main advantages: low shear force that protects sensitive ingredients, a vacuum environment that reduces oxidation, and efficient emulsification that typically takes only 30-60 minutes. These features make them ideal for producing high-quality, stable emulsions.
Q: How does particle size control differ between Vacuum Emulsifying Mixers and Homogenizers?
A: Vacuum Emulsifying Mixers typically produce particles at the micron level (1-100 μm) through adjustable stirring parameters. In contrast, Homogenizers can achieve submicron-level particles (0.1-1 μm) through high-pressure homogenization, offering more precise particle size control.
Q: What factors should be considered when choosing between a Vacuum Emulsifying Mixer and a Homogenizer?
A: Key factors include product characteristics (heat sensitivity, viscosity), production scale (batch vs. continuous), and required particle size. Additionally, consider cleaning requirements, automation needs, and total lifecycle costs including maintenance and operation.
