Find a mixer for your application…

Homogenizing-Dispersing
A dispersion is simply the transport of one phase or ingredient (liquid, solid, gas) into a main continuous phase (typically liquid), with which it would normally be immiscible. The fluid is said to be homogenized when sufficient energy input results in a final product that resembles a mono-dispersion fluid, with no differentiation between separate components. The system is considered colloidal when one or more of the components has at least one dimension that is less than a micrometer (10-6 m). In liquid mixing, we can classify the various systems as Suspensions (Solid/Liquid), Emulsions (Liquid/Liquid) and Foams (Gas/Liquid).

High shear mixers create an intense, concentrated energy input that can produce a superior dispersion in significantly less time than traditional mixing methods. Below are a few common applications that IKA^® mixers are used to produce:

Products that are moderately difficult to homogenize can be produced with the Shear Pump SP, or Hi-Energy Disperser HED for continuous or semi-continuous processes, and with the Rototron RT or Turbotron RK/RF for batch processes. Difficult to homogenize products can be produced with the Ultra Turrax UTL or Dispax Reactor DR for continuous or semi-continuous processes, and with the Ultra Turrax for batch processes.

Suspending -Wet Milling (Solid-Liquid)
Suspending is dispersing of solid particles in a liquid. It is often desirable to reduce the particle size of the solids in conjunction with dispersing, and this is often referred to as wet milling. With the use of high shear mixers and sufficient energy input, the final product will become homogenized. Below is a list of some typical applications, and which IKA^® mixer provides the best solution:

Suspensions are easily accomplished with a Hi-Energy Disperser HED or Shear Pump SP for in-line processes, and the Ultra Turrax for batch or in-line processes. Wet milling requires more energy than suspending, and can vary widely, depending on the product. In order of increasing milling energy, IKA^® offers the Ultra Turrax UTL, Dispax Reactor DR, Super Dispax Reactor™ DRS, Colloid Mill MK and the Cone Mill MKO. Batch processing can be accomplished with the Ultra Turrax™.

Emulsifying (Liquid-Liquid Systems)
Emulsifying is the process of dispersing one liquid in a second immiscible liquid, such as oil dispersed in water. A colloidal suspension is a system comprising particles dispersed in a liquid that do not settle out of solution due to their extremely small size of less than one micrometer. In order to achieve the stable emulsion, a suitable amount of energy input is required to produce the droplet size that is necessary. A few examples of some common emulsions are:

Many emulsions are easily accomplished using moderate energy, and therefore, the Hi-Energy Disperser HED or Shear Pump SP is satisfactory for in-line processes, and the Rototron RT for batch processes. When the droplet size required is less then 10 microns, or sub-micron, higher energy input is required. In order to produce these smaller droplet sizes, or when the concentrations are high, IKA^® offers the following mixers Ultra Turrax™ UTL, Dispax Reactor DR, Super Dispax Reactor DRS and Colloid Mill MK. Batch processing can be accomplished with the Ultra Turrax.

Dissolving –Molecular/Colloidal
Below is a list of some typical dissolving applications, and which IKA^® mixer provides the best solution:

Most dissolving applications are easily accomplished with a Hi-Energy Disperser HED or Shear Pump SP for in-line processes, and the Ultra Turrax for batch or in-line processes. Difficult to dissolve materials may require a mixer with higher energy input. In addition, to reduce or eliminate re-circulating, one of the following IKA^® mixers may be required, in order of increasing energy, IKA^® offers the Ultra Turrax UTL, Dispax Reactor™ DR, Super Dispax Reactor DRS, Colloid Mill MK. Batch processing can be accomplished with the Ultra Turrax.

Powder-Liquid Incorporation
Incorporating powders into liquids offers many challenges to processors. The powders may be difficult to wet out, and may produce fish-eyes if not effectively dispersed into the liquid. The powders are often added to a vessel by dumping bags into the top, creating a plume of dust and creating a possible health hazard. Eductors, blenders, and other powder addition equipment will often clog, or not perform as well as desired, or the system is too complex to clean and maintain. IKA^® has developed unique, new technology that obsoletes many of these older technologies. IKA^® offers a complete line of powder-liquid mixers that offers more solutions than any other mixer manufacturer. Below is a list of some typical applications, and which IKA^® mixer provides the best solution:

Cosmetic Applications

2. Carbopol^®

Carbopol^® (Carbopol^® is a registered trademark of Noveon, Inc) is one of the most commonly used carbomers, a family of ingredients used in cosmetics to thicken, suspend, stabilize, and emulsify a wide range of recipes. Carbopol^® is a light, dusting powder, which will easily raft (float) on a liquid surface unless substantial agitation is applied. Once incorporated into the liquid, the powder often forms agglomerates or fish-eyes. The final viscosity is also sensitive to pH. Therefore, a base (high pH material) must often be added to achieve the finished viscosity. IKA^® Works range of high shear mixers offer cosmetics manufacturers solutions to all the above concerns.

ADVANTAGES OF IKA^® WORKS MIXERS FOR THE HYDRATION OF CARBOPOL^®

• Easy incorporation into liquid. IKA^® offers multiple mixer designs, both batch and inline, suitable for dispersing Carbopol^® . The CMS and MHD mixers allow the powder to be added directly to the liquid stream, without dusting or aeration.
• Smooth consistent product. The high shear rotor / stator action of an IKA^® Works Mixer ensures no agglomerates are present in the final product.
• Decreased operator input. IKA^® Mixers are not as sensitive to rates of ingredient addition as other devices. IKA^® Works also offers their customers the option of complete systems with automated powder feed and PLC controls.
• Decreased raw materials costs. The absence of agglomerates allows processors to avoid filtration and wasted powder. Also, the intimate dispersion achieved with an IKA^® Works rotor / stator mixer ensures full hydration of powders and rapid pH adjustment with tight control, avoiding excessive caustic usage.

IKA^® MIXERS SUITABLE FOR HYDRATING CARBOPOL^®

• Batch: RT, RKG, MSM, UTC, UTE, UTS
• Inline: HED, UTL, DR, DRS, CMS, MHD

Xanthan Gum
Pigments
Pectin
Clays

When adding solids in a batch process, the Rototron RT will quickly incorporate and disperse the solids in the vessel, for higher dispersing energy, the Ultra Turrax is recommended. To process in a re-circulating configuration, the CMS will rapidly wet out and disperse the solids. The CMS can also be used in a continuous system, and will handle large volumes of solids. IKA’s patented MHD is the best choice for continuous processes when aeration must be reduced to a minimum, accurate feed rates are required, or when the viscosity of the liquid is high. The MHD also has the widest variety of mixing tools available, and can provide enough energy to disperse even the most difficult products in one pass. The MHD is the only powder-liquid mixer in the industry that does not require vacuum to incorporate the solids, thus, eliminating the aeration that is inherent in other designs.