Flavors are added to a wide variety of the foods we eat. Although they may take several forms, flavors are commonly concentrated in an oil based liquid. Food processors must often emulsify this oil in an aqueous system using high shear mixing technology coupled with gums or other stabilizing agents to improve product quality and shelf life.

IKA^® Works, Inc. has a wide range of solutions to improve product quality and process efficiency. The two steps to this process involve forming an emulsion (dispersing and reducing the droplet size of the liquids) and hydrating a stabilizer to help maintain the emulsion. Neglecting either of these steps will result in a reduced shelf life for the product.

Emulsions are formed when two immiscible liquids (oil and water) are dispersed within one another. Stability of the emulsion will depend on several characteristics of the product, most notably viscosity (thickness) and droplet size.

The higher the viscosity of the liquids, generally, the more stable the emulsion. This is because the phases cannot easily move within one another (picture an air bubble trying to rise in honey versus water). Therefore, the stabilizers often used in the manufacture of flavor emulsions include gums or other thickening agents. These ingredients, often a powder, act to increase the viscosity and thus keep the oil and water phases from separating. The challenge to the manufacturer is to effectively blend these often difficult to disperse powders. IKA^® Works range of high shear mixers can rapidly and efficiently disperse these stabilizers using rotor / stator technology. The intense mixing action breaks down the agglomerates (lumps) that often form when hydrating these powders and increases the surface area exposed to the liquid, improving functionality.

IKA^® Works’ value to the customer is not limited to dispersing a stabilizer. The shelf life of the product and stability of the emulsion will also depend on the droplet size of the liquids or how finely they are dispersed within one another. Illustrating this point, picture a small air bubble that sits in a glass of water for hours versus a large bubble which instantly rises to the surface. IKA^®Works’ customers utilize a range of interchangeable Generators (rotor / stator tools) to tailor a single mixer to achieve a very narrow droplet size distribution of the ideal size for maximum shelf life. The multiple rows of rotors and stators coupled with the ability to utilize up to three distinct rotor / stator sets allow IKA^® Mixers to overcome the forces (i.e. interfacial tension) that hinder the formation of stable emulsions. IKA^® has experience forming emulsions with droplet sizes as low as 0.25m m and very tight size distributions.

ADVANTAGES OF IKA^® WORKS MIXERS WHEN MIXING FLAVORS:

• Increased viscosity from a given amount of gum / stabilizer, due to increased functionality. This allows customers, in many cases, to decrease their raw materials usage.
• Less wasted product. Lumps of gum do not need to be filtered out.
• Decreased operator input. Operators must finely sift gums into a batch tank when using conventional methods, which takes a considerable amount of time. Also, filter changes / maintenance are common, as even the best operators cannot avoid some agglomeration when using these methods.
• Increased efficiency. Conventional methods take a considerable amount of time (often hours) to hydrate a gum or stabilizing agent. IKA® Works Mixers achieve almost instantaneous hydration.
• Fine droplet sizes / improved shelf life or stability. IKA^v Works Mixers produce the finest emulsions of any rotor / stator mixer with the tightest particle size distribution.
• Decreased process time. Alternate high shear devices will often require long process times or may not even be capable of forming the emulsion. IKA® Works’ innovative Generator designs ensure a tight, stable emulsion is quickly formed.

IKA^® MIXERS SUITABLE FOR FLAVOR APPLICATIONS:

• BATCH: UTC, UTS, UTE
• INLINE: CMS, DR, DRS,MHD, MK
• Master Plant
  

2. Dressings and Sauce

• Smooth, agglomerate free dispersion and hydration of gums without need for filtration.
• Reduced raw material costs through full hydration of gums and ability to wet grind spices on site.
• Stable emulsions and suspensions increase shelf life and improve visual appeal to consumers.
• Perfect grind and dispersion of spices or other additives allow manufacturers to produce a product with a fresher taste.

• Hydration of gums:
• Batch: UTC, UTE, UTS
• Inline: UTL , DR, DRS, CMS, MHD
• Emulsifying oil and water phases:
• Batch: UTC, UTE, UTS
• Master Plant

Jams and spreads are often fruit based products which also include some dispersed pectin (a fruit based gum). The challenges to the manufacturer include hydration of the pectin and achieving the proper product consistency and mouth-feel. IKA^® Works produces a range of mixers ideally suited to breaking down the agglomerates that often form when hydrating pectin as well as achieving the desired final product. Optimizing residence time in the mixer and utilizing the ideal Generator allows manufacturers to produce anything from a jam with plenty of fruit texture to a smooth jelly.

ADVANTAGES OF IKA^® WORKS MIXERS FOR PRODUCING JAMS AND SPREADS:

• Complete hydration of pectin decreases manufacturing costs through reduced process time, no wasted raw materials (no need for filtration), and full ingredient utilization.
• Ability to produce a wide range of products. Customers may use a single mixer to produce jams, jellies, or other materials by simply optimizing residence time and Generator selection.

IKA^® MIXERS SUITABLE FOR PRODUCTION OF JAMS AND SPREADS:

• Dispersion and hydration of pectin:
• Batch:UTC, UTE, UTS
• Inline: UTL, DR, DRS, CMS, MHD
• Achieving proper texture: UTL , DR, DRS, MK
• Master Plant

4. Fruit Juices, Concentrates, Pulps, and Soft Drinks

Beverage manufacturers are ideal candidates to benefit from IKA^® Works High Shear Mixing Technology. Applications include dispersion of nutritional supplements (i.e. calcium or other vitamins and minerals), dissolving sugar or other artificial sweeteners (i.e. base syrups for sodas), hydration of gums (improve mouth-feel, stabilize emulsions), hydrate flavoring or other additives (i.e. milk and cocoa powders in chocolate milk), and reduce particle size or pulp solids. This wide range of applications requires a mixer that can be adapted to a diverse range of processes, in other words the IKA^® Works 2000 Series.

ADVANTAGES OF IKA^® WORKS MIXERS FOR BEVERAGE MANUFACTURE:

• Nutritional Supplements:
• Improved product quality. These additives are often difficult to disperse and suspend. IKA^® Mixers input significant energy into the product, assuring a uniform, stable dispersion.
• Decreased process time. IKA^® Works equipment allows customers to quickly and effectively add solids including inline, single pass designs!
• Dissolving Sugar or Artificial Sweeteners:
• Reduced heat / cooling requirements. Manufacturers must often heat the liquid to adequately dissolve the sugar when using conventional methods. IKA® Mixers high shear action allow the sweeteners to be dissolved at ambient temperature.
• Reduced process time. Conventional methods often require hours of blending time to dissolve the sweeteners. IKA^® Works High Shear Mixers not only significantly reduce the dissolving time by increasing the surface area of the solids exposed to the liquid, but also reduce the time required for heating.
• Hydration of gums:
• Reduced raw materials requirements. Manufacturers must often add larger percentages of gums and filter the final product due to the poor hydration common with conventional mixing techniques. IKA^® Works Mixers ensure complete hydration / ingredient functionality and the high shear mixing action eliminates lumps, agglomerates, or fish-eyes. Thus, the percentage of gums may often be decreased and filtration eliminated, while maintaining product quality.
• Hydration of flavorings or other additives:
• Decreased production time. IKA® Works technology allows customers to blend powders into liquids inline, often in a single pass.
• Reduced aeration. IKA^® manufactures systems which allow rapid incorporation of solids into liquids without aeration or foaming.
• Reducing particle size / pulping solids:
• Improved product consistency. IKA^® Works Mixers can handle a wide range of initial particle sizes and through the use of various Generators produce the desired size reduction within a narrow distribution.
• Reduced capital costs. Due to the versatility of IKA^® Works Mixers, a single unit may perform the functions currently done with several other machines.

IKA MIXERS SUITABLE FOR BEVERAGE MANUFACTURE

• Nutritional supplements:
• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Dissolving sugar or artificial sweeteners:
• Batch: MSM, UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Hydration of gums:
• Batch: MSM, UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Hydration of flavorings or other additives:
• Batch: MSM, UTC, UTE, UTS
• Inline: HED, UTL , DR, CMS, MHD
• Reduction of particle size / pulping:
• Batch: MSM, UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, MHD, MK
• Master Plant

5. Seeds and Mustards

Various products, the most commonly known being mustard, are produced by grinding a seed and dispersing it into a liquid base. Traditional methods employ either dispersing a pre-ground powder into the liquid or dispersing the seeds and wet milling the product. IKA^® Works High Shear Mixers can be used to improve either process.

ADVANTAGES OF IKA^® WORKS MIXERS FOR SEEDS AND MUSTARDS

• Reduced process time. Mustard or seed powders are quickly and smoothly dispersed into liquids. Seeds may be ground in a fraction of the time required with other milling devices.
• Improved product quality / consistency. Powders are uniformly and smoothly dispersed. Seeds may be ground to any level of fineness with a tight particle size distribution.

IKA®MIXERS SUITABLE FOR PROCESSING SEEDS & MUSTARDS

• Powders
• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Whole seeds:
• Batch: UTC, UTE, UTS
• Inline: UTL , DR, DRS, MHD, MK
• Master Plant

7. Ice Cream

Ice cream has come a long way from milk, salt, and ice in the kitchen. Today’s manufacturers often blend a variety of powders into a liquid stream including gums (for freeze-thaw stability and proper texture), milk powder, and flavorings (i.e. cocoa powder). Some of the challenges include agglomeration (lumping) of the gums, bridging of cocoa powder in feed devices, and foaming of milk powder. IKA^® Works has developed solutions to all of these concerns.

ADVANTAGES OF IKA^® WORKS MIXERS FOR ICE CREAM MANUFACTURE

• Agglomeration of gums is eliminated. The intense high shear zones created by an IKA^® Mixer break down any agglomerates, exposing fresh powder to the liquid.
• Improved ingredient functionality. Subjecting the product to high shear ensures that all of the powder is exposed to the liquid and thus hydrated. This complete hydration eliminates waste and ensures full ingredient functionality.
• Elimination of foaming. IKA^® Works MHD powder / liquid mixer utilizes a positive powder feed, unlike the vacuum or venturi designs of competitive equipment. Vacuum or venturi systems can draw air into the system and cause foaming, especially with ingredients such as milk powder.
• Elimination of bridging. IKA^® Works MHD powder / liquid mixers employ an anti-bridging bar to ensure smooth powder feed.
• Single source responsibility. IKA® Works will work with your engineers to tailor anything from a single component to a complete system to your process.

IKA^® MIXERS SUITABLE FOR ICE CREAM MANUFACTURE

• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, CMS, MHD
• Master Plant

8. Cheese Spreads

Cheese spreads are often blends of oils, water, whey, milk solids, colors, flavors, and preservatives. Challenges to the manufacturer include emulsifying the oil and water phases, smoothly dispersing the whey powder (which often forms hard agglomerates), hydrating the milk solids without foaming, and uniformly dispersing all other ingredients. IKA^® Works offers cost effective solutions to all of these challenges.

ADVANTAGES OF IKA^® WORKS MIXERS FOR PRODUCTION OF CHEESE SPREADS

• Decreased production time. Traditional methods will require solids to be finely sifted into an agitated batch tank to avoid agglomeration or foaming. IKA® Works Mixers overcome these issues with innovative Generator and powder feed designs which rapidly disperse powders smoothly and without foaming.
• Improved product quality. The intense mixing action created by an IKA^® Works Mixer ensures a uniform dispersion of all additives and a stable emulsion with a tight droplet size distribution.

IKA^® MIXERS SUITABLE FOR PRODUCTION OF CHEESE SPREADS

• Batch:UTC, UTE, UTS
• Inline: UTL , DR, DRS, CMS, MHD
• Master Plant

9. Sugar

Sugar is a common ingredient in almost everything America consumes. This seemingly benign powder can often be a challenge for manufacturers to dissolve. The traditional process requires heat and long agitation times to accomplish. IKA^® Works has solutions that address both of these issues.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISSOLVING SUGAR

• Lower process temperatures. Sugar is traditionally processed at 180^oF or higher to increase solubility. However, the intense energy and shear imparted by an IKA^® Works Mixer allows customers to solubilize sugar at lower temperatures.
• Decreased process time. Traditional methods require a long agitation time coupled with the high temperature noted above to achieve solubilization. IKA^® Works Mixers can simultaneously reduce the temperature and process time required. Complete solubilization can often be achieved in a single pass through one of our high shear devices. We even offer systems to add and dissolve the sugar inline, eliminating the batch tank.

IKA^® MIXERS SUITABLE FOR DISSOLVING SUGAR

• Batch:UTC, UTE, UTS
• Inline: UTL , DR, DRS, MHD, MK
• Master Plant

10. Hydrocolloids

The family of ingredients known as hydrocolloids includes a number of gums or thickening agents which are found in a wide variety of foods, examples of hydrocolloids include: alginates, carrageenan, carboxymethylcellulose (CMC), gelatin, guar gum, gum arabic, locust bean gum, pectin, starch, and xanthan gum. Although these materials are derived from a variety of sources, the challenge of effectively hydrating them is common to all. Hydrocolloids have a propensity to form agglomerates (i.e. lumps, fish-eyes, etc) where a layer of partially hydrated material coats and protects the dry powder in the center. Conventional methods require an experienced operator, long process times, and often filtration to achieve a smooth product. Rarely is full hydration ever achieved with a conventional process. Users of IKA^® Works equipment have discovered that the solution to these challenges is to use a high shear mixer.

ADVANTAGES OF IKA^® WORKS MIXERS FOR HYDRATING HYDROCOLLOIDS

• Rapid process time. The intense shear exerted by an IKA^® rotor stator mixer ensures that any agglomerates that may form are rapidly broken down, exposing the full surface are of the powder to the liquid. Thus, operators may add powders faster and hydration occurs more rapidly.
• Decreased operator input. IKA^® Works CMS and MHD mixers will feed the powder into the liquid at a controlled rate, inline. Systems may be fully automated and include all ancillary equipment including pumps, powder feed systems, PLC controls, etc.
• Reduced production costs. Hydrocolloids are often one of the most expensive ingredients, per pound, added to a recipe. The complete hydration experienced with an IKA® Mixer reduces waste and often results in a reduction in raw material requirements. Gum manufacturers also offer "easy to disperse" versions of popular hydrocolloids at a price premium. IKA^® Works Mixers are capable of hydrating any gum, allowing manufacturers to purchase a less expensive grade of the hydrocolloid.

IKA^® MIXERS SUITABLE FOR HYDRATING HYDROCOLLOIDS

• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Master Plant

11. Milk Solids

Milk solids are derived from spray drying and separating the various solids found in liquid milk. Milk solids are used in a wide range of products and include whole milk powder, skim milk powder, non-fat dry milk (NFDM), caseinates, and other milk protein powders. Powdered milk solids offer producers advantages over liquid milk including decreased transportation costs, longer shelf life, and the ability to easily achieve a desired solids loading in a given product. The challenges with rehydrating milk solids involve foaming and agglomeration. IKA^® Works is able to help processors overcome these concerns in a cost effective manner.

ADVANTAGES OF IKA® WORKS MIXERS FOR HYDRATING MILK SOLIDS

• Elimination of foaming and aeration. Traditional methods involve adding the solids to the vortex of an agitated vessel or inline through a vacuum (venturi) device. These methods all allow air to enter the product and cause foaming. The IKA^® Works MHD powder / liquid mixer uses a positive powder feed design, which eliminates aeration and foaming.
• Improved product consistency. The high shear imparted on the product ensures a uniform dispersion while eliminating the agglomerates that often form when using conventional methods.
• Reduced operator input. IKA® Works CMS and MHD mixers allow inline addition of solids to the liquid stream and may be integrated with existing plant controls.

IKA^® MIXERS SUITABLE FOR HYDRATING MILK SOLIDS

• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Master Plant

12. Salts

Salt is added to a wide range of products, generally to intensify flavor. Depending on the base liquid, salt will either be dissolved (water based products) or dispersed (oil based products). Traditional mixing techniques will require batch tanks and long process times to dissolve the salt. Oil based dispersions may suffer from settling or poor uniformity. Further, concentration is often limited (dispersed or dissolved) when compared to products made with an IKA® Works Mixer.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISSOLVING OR DISPERSING SALTS

• Decreased process time
• Dissolving (water based). Traditional methods often require long process times to dissolve salts. IKA® Works Mixers utilize a high shear action which rapidly breaks down the solid particles, exposing a large surface area to the liquid and speeding solubilization.
• Dispersing (oil based). Traditional methods require batch tanks and adequate residence time to ensure a uniform dispersion. The intense shearing action of an IKA^® Mixer ensures an instantaneous dispersion.
• Higher concentrations of solids
• Dissolving. Traditional methods are limited on the percentage of solids that can be dissolved. However, the intense energy input from an IKA^® Works Mixer allows higher solids loading. We have accomplished over 60% solids in a single pass!
• Dispersing. Traditional methods will suffer from settling / sedimentation when a certain solids loading is reached. Utilizing an IKA® Works mixer allows intimate contact between the salts and oil, forming a more stable dispersion even at higher concentrations.

IKA^® MIXERS SUITABLE FOR DISSOLVING OR DISPERSING SALTS

• Batch: MSM, UTC, UTE, UTS
• Inline: HED, UTC, DR, DRS, CMS, MHD
• Master Plant

13. Edible Oils

Edible oils may be extracted from a variety of plant or animal sources and are commonly found in the foods we eat. This report will focus on plant derived oils. These oils include the following examples: cottonseed oil, palm oil, peanut oil, soybean oil, sunflower oil, and linseed oil. These oils are usually obtained through solvent extraction and then purified. The purification process generally involves the following steps:

1. Degumming. This involves treating the crude oil with water and / or acid (typically phosphoric acid) to hydrate phosphatides and allow separation through centrifugation.
2. Alkali refining. The degummed oil is then treated with an alkali solution (i.e. NaOH) to reduce the free fatty acid content and remove other impurities through conversion to water soluble soaps. These soaps are removed from the oil with a water wash.
3. Bleaching. The oil is purified further and colors removed through bleaching. Typically, diotomaceous earth or clay is used to absorb color affecting substances. The clay and absorbed impurities are then filtered out.
4. Deodorization. Vacuum steam distillation is then used to remove volatile compounds that may affect taste, color, or odor.
5. The oil can then be either subjected to fractionation, hydrogenation, interesterification, esterification, or simply packaged depending on the properties desired in the final product.

IKA^® Works has become a world leader in the supply of high shear mixing equipment for use in the purification of edible oils.

ADVANTAGES OF IKA® WORKS MIXERS WHEN PURIFYING EDIBLE OILS

• Reduced additive quantities. The intense high shear mixing action (see Tech Info for more details) of an IKA® Mixer ensures intimate contact between the oil and any additives (i.e. phosphoric acid, caustic soda) allowing a smaller quantity of additive to treat a larger quantity of oil.
• Decreased processing times. Utilizing innovative Generator designs and up to three distinct stages of rotors and stators, IKA®Mixers ensure that all components are intimately blended together. This allows additives to work more rapidly and a higher purity oil is produced more quickly.
• Improved filtration efficiency. The IKA^® CMS and MHD mixers are capable of rapidly and effectively dispersing the clay or diatomaceous earth throughout the oil. This allows a more effective bleaching process and lowers the occurrence of clogged filters.
• Versatility. The modular concept of the IKA® Works 2000 Series Mixers allows a single unit to be adapted to a wide range process requirements.

IKA^® MIXERS SUITABLE FOR EDIBLE OIL REFINING

• Degumming: UTL , DR, DRS
• Alkali refining: UTL , DR, DRS
• Bleaching: UTL , DR, DRS, CMS, MHD
• Master Plant

 

Chemical

1. Fumed Silica

Fumed silica is a very light, dusting powder used in a wide range of products from cosmetics to agro-chemicals. Fumed silica, also referred to as Aerosil® (Aerosil® is a registered trademark of Degussa) or Cabosil® (Cabosil® is a registered trademark of Cabot Corp.), is often used as a filler, stabilizer, or viscosity control agent. The main challenges to processing fumed silica are to wet it out and achieve full viscosity. IKA^® Works has extensive experience processing fumed silica and a number of solutions to meet any manufacturer’s needs.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISPERSING FUMED SILICA

• Dusting eliminated. IKA^® offers several designs to incorporate fumed silica directly into the liquid. The powder can be vacuumed directly from a bag, conveyed from a super-sac, or we can work with your engineers to devise a system tailored to your individual process.
• Improved vessel cleanliness. Utilizing an IKA^® Works inline powder liquid mixing system will eliminate scum lines on vessel walls, improving cleanliness and eliminating wasted raw materials.
• Complete ingredient functionality. Many companies claim to wet out fumed silica, but often, substantial shear is required to achieve full activation and viscosity. Only IKA^® Works offers mixers capable of dispersing fumed silica and incorporating this level of shear.

IKA® MIXERS SUITABLE FOR DISPERSING FUMED SILICA

2. Inks and Lacquers

Inks and lacquers cover a broad range of products used for marking or coating an object. The ink or lacquer can be either water or solvent based, with addition of pigments and / or resins. Utilizing traditional methods, it often takes a substantial period of time to dissolve any resins, solids may settle out, and pigment agglomerates may form. Utilizing an IKA® Works Mixer allows manufacturers to produce a higher quality product more quickly.

ADVANTAGES OF IKA^® WORKS MIXERS FOR MANUFACTURING INKS & LACQUERS

• Decreased process time. The high shear imparted on the product by an IKA® Mixer ensures that resin particles are constantly being broken down, exposing fresh surface area to the solvent, and speeding the dissolving process.
• Reduced settling. The intense mixing action of an IKA® Works high shear mixer provides intimate contact between liquid and solids, impeding settling.
• Improved product quality. Depending on the level of pigment grind required and condition of raw materials (i.e. pre-micronized pigment) IKA® Works offers solutions to either wet grind the pigments and / or ensure the final product is agglomerate free. The wide selection of IKA^® Generators ensures an ideal fit for the application.

IKA® MIXERS SUITABLE FOR MANUFACTURING INKS & LACQUERS

• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, MK, MKO
• Master Plant

3. Carbon Black

Carbon black is, as the name implies, a black pigment. The powder must often be incorporated into a liquid and then ground to a required particle size. The powder addition is commonly done in a dedicated area to avoid coloring everything in the main production area. IKA^® Works offers equipment capable of grinding carbon black down to <1m m, while sealing the powder from the remainder of the production area.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISPERSING / GRINDING CARBON BLACK

• Improved cleanliness. Utilizing an IKA^® Works MHD powder / liquid mixer allows customers to disperse the powder directly from storage into the liquid without handling.
• Improved product quality. Carbon black can be ground to 8 Hegman with an IKA^® Works Mixer, beyond the level of other high shear manufacturers. Also, IKA^® Mixers are known for their extremely tight particle size distribution.
• Reduced process time. Customers are able to produce results traditionally requiring low throughput media mills in a fraction of the time with an IKA^® Works Mixer.

IKA® MIXERS SUITABLE FOR DISPERSING / GRINDING CARBON BLACK

• Batch: UTC, UTE, UTS
• Inline: DR, DRS, MHD, MK, MKO
• Master Plant

4. Titanium Dioxide

Titanium dioxide is a white pigment used in a range of products from paint to sun tan lotion to tablet coatings. It is generally supplied as a pre-micronized powder, but some particle size reduction may be required. Also, the powder will often reagglomerate when added to a liquid through conventional methods. The IKA^® range of mixers are designed to ensure a rapid dispersion, tight particle size distribution, and agglomerate free end product.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISPERSING & GRINDING TiO₂

• Decreased process time. The high speed, high shear mixing of an IKA® Works Mixer ensures rapid, agglomerate free dispersion of the TiO₂ powder. IKA^® also offers the CMS and MHD powder / liquid mixers to add the powder directly to a liquid stream, often in a single pass.
• Improved product quality. The high shear mixing action (see Tech Info for more details) of an IKA® Works Mixer ensures that any agglomerates are rapidly broken down and the powder evenly dispersed throughout the liquid. The result is improved gloss and opacity properties, which are directly related to the quality of the dispersion.
• Reduced capital costs. IKA^® Works Mills offer excellent particle size reduction and tight particle size distributions when grinding TiO₂. The throughput of an IKA^® Works Mill is often much higher than alternate devices, while still achieving a similar grind. High throughputs coupled with the modular concept of the IKA^® Works 2000 Series equates to reduced capital costs to the customer.

IKA^® MIXERS SUITABLE FOR DISPERSING & GRINDING TiO₂

• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD, MK, MKO
• Master Plant

5. Clays

Clays cover a range of naturally occurring products, the most common in industry being bentonite and kaolin (also known as "China Clay"). Clays are generally used as thickeners in products from cosmetics to drilling muds to pesticides to paper coatings. The viscosity increase comes from the clay "swelling" on addition to water, which often takes several hours with traditional mixing techniques. IKA® Works offers mixers to quickly disperse the clay powder while ensuring maximum functionality.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISPERSING CLAYS

• Reduced process time. Traditional methods often take hours for the clay slurry to thicken. The use of an IKA^® Works Mixer ensures that the maximum surface area of powder is exposed to the liquid, speeding the gelling process.
• Decreased raw materials costs. The efficient dispersion achieved with an IKA^® Mixer ensures that the maximum viscosity is achieved, eliminating wasted product. Customers often find a substantial raw material savings ( up to 33%) when switching to an IKA^® Mixer from alternate devices.
• Improved product quality. The high shear mixing action of an IKA^® Works Mixer (see Tech Info for more information) ensures no agglomerates are present in the final product, improving product quality.

IKA^® MIXERS SUITABLE FOR DISPERSING CLAYS

• Batch: MSM,UTC, UTE, UTS
• Inline: HED, UTL , DR, DRS, CMS, MHD
• Master Plant

6. Pesticides and Herbicides

Pesticides and herbicides are familiar to any home owner and although the application may vary considerably, the manufacturing process is often similar from one product to the next. The material often consists of a liquid base with an active ingredient suspended in it. The formulation may also contain a number of other additives including wetting agents, suspending agents, anti-foam, etc. The solids are dispersed into the base liquid and the mixture is then milled until a desired particle size is achieved (this is often <5m m for spraying applications). The product is then either sent directly to packaging or to a spray dryer. The challenges to the manufacturer are to produce a consistent product with the appropriate particle size distribution, while maintaining safety for employees (the active ingredients are often toxic to humans). IKA^® Works’ experience in this industry allows customers to partner with a company capable of addressing all of the above concerns.

ADVANTAGES OF IKA^® WORKS MIXERS FOR MANUFACTURING PESTICIDES & HERBICIDES

• Reduced employee exposure to toxins. IKA^® Works manufactures sealed systems, which allow customers to add toxic materials directly to their product without any operator contact.
• Reduced process time. Traditional methods often require long agitation times to ensure a complete and uniform dispersion of all ingredients and reduction of any agglomerates. IKA^® Mixers utilize rotor / stator technology (see Tech Info) to ensure an instantaneous and uniform dispersion, while breaking down any agglomerates that may form. Further, plants traditionally utilized media mills to ensure proper particle size reduction of the finished product. This process was energy intensive and time consuming. IKA^® Mixers are capable of milling solids to <5m m in a fraction of the time required by traditional techniques.
• Reduced capital costs. The modular design of the IKA^® Works 2000 Series allows customers to tailor the mixer to their process, while enjoying the cost benefits of economies of scale.

IKA^® MIXERS SUITABLE FOR MANUFACTURING PESTICIDES AND HERBICIDES

• Batch:UTC, UTE, UTS
• Inline: UTL , DR, DRS, CMS, MHD, MK, MKO
• Master Plant

7. Detergents

Detergents include the products we use to clean most everything we own. The applications for high shear mixers in the manufacturing process commonly involve the dilution of a high active surfactant (the compound that "does the cleaning") and the following neutralization step. A high shear mixer can speed process time and greatly improve process efficiency when compared to conventional methods. IKA^® Works, the world leader in high shear mixing technology, has the experience to assist customers with either of the applications noted above.

ADVANTAGES OF IKA^® WORKS MIXERS FOR MANUFACTURING DETERGENTS

• Decreased process time. High active surfactants are often difficult and time consuming to disperse. Using an IKA^® High Shear Mixer allows customers to rapidly disperse their high active surfactants in a fraction of the time required by conventional methods.
• Reduced aeration. Aeration can cause a number of issues for manufacturers including foaming and excessive viscosity. IKA^® Works offers aeration free designs, including a non-vacuum or venturi based powder / liquid mixer (MHD), to address this concern.
• Improved ingredient functionality. The neutralization step often requires substantial energy / shear input to achieve the required pH. The application of a lower shear device will result in long process times and wasted raw materials from over addition of pH adjusting chemicals. IKA^® Works Mixers utilize innovative Generator designs to ensure rapid mixing and full utilization of pH adjusting agents. Thus, customers see process times are reduced, pH control is improved, and raw materials usage is decreased.

IKA^® MIXERS SUITABLE FOR MANUFACTURING DETERGENTS

• Batch:UTC, UTE, UTS
• Inline: UTL , DR, DRS, CMS, MHD
• Master Plant

8. Resins

Resins are materials commonly used in the manufacture of lacquers, glues, plastics, and a wide range of other items. They are typically hard solids, which must be dissolved in a solvent base or wet milled (wet milling is desired to avoid the heat and dust issues inherent in dry milling) in an aqueous system. This process is often time consuming and operator exposure to solvent fumes must be limited. IKA^® Works’ line of high shear mixers offer customers a safe, efficient means to dissolve or grind any resin.

ADVANTAGES OF IKA^® WORKS MIXERS FOR DISSOLVING OR WET MILLING RESINS

• Reduced process time. Conventional methods may take hours to dissolve a resin into a solvent, tying up valuable production resources. IKA^® Mixers, through their use of innovative Generator designs and rotor / stator technology (see Tech Info), rapidly reduce solid particles, exposing a large surface area of the resin to solvent. This high speed, high shear action rapidly dissolves the solids, reducing process times.
• Single source responsibility. IKA^® Works is capable of supplying complete systems including tanks, scrape surface agitation (for high viscosity blends), high shear mixers, and controls.
• Improved operator safety. Solvent emissions and fumes are often a hazard to operators and an environmental concern. IKA^® Works Inline Mixers are supplied with double mechanical seals as standard. We also offer a range of options to feed liquid or solid materials directly into the product, without operator exposure.
• Improved product quality. Manufacturers wet milling a resin must often choose between a tight particle size distribution or rapid process time. IKA^® Works offers customers both a tight particle size distribution and rapid process time, while maintaining competitive costs. This is possible due to the economies of scale present with the modular concept of IKA^® Works’ innovative 2000 Series Mixers.

IKA^® MIXERS SUITABLE FOR DISSOLVING OR WET MILLING RESINS

• Batch: UTC, UTE, UTS , RFG,
• Inline: UTL , DR, DRS, CMS, MHD, MK, MKO
• Master Plant

9. Pigments and Dyes

Pigments and dyes cover the wide range of materials used to change the color of a product from its natural tint (see reports on TiO₂ and Carbon Black for more information on these particular pigments). Pigments and dyes are commonly inorganic solids (i.e. PbO, TiO₂, etc) which must be purchased as a pre-micronized powder or finely ground in order to be used. The challenges to the processor include adequately dispersing the pigment or dye, breaking down any agglomerates and / or obtaining the desired particle size. IKA^® Works’ line of high shear mixers can be used to accomplish any of the above goals with a product quality and process efficiency second to none.

ADVANTAGES OF IKA^® WORKS MIXERS FOR GRINDING / DISPERSING PIGMENTS AND DYES

• Improved product consistency. The color of a given product is often a direct result of the pigment / dye dispersion. A better dispersion will yield more vibrant colors. IKA^® Works’ range of high shear mixers utilize innovative Generator designs to ensure an agglomerate free product and excellent dispersion of any pigment or dye.
• Improved product quality. Product quality has a direct relationship to the pigment grind. Products such as gloss paint require fine particle sizes with a tight distribution to achieve the proper shine. The small particle sizes (7-8 hegman is common) and tight size distribution achieved with an IKA^® Mixer ensure a high quality product.
• Reduced capital costs. Dispersion and milling equipment often require a substantial capital oUTL ay. IKA^® Works revolutionary 2000 Series Mixers utilize a modular design allowing customers to enjoy the savings associated with economies of scale. Further, a single base unit can be quickly and easily adapted to a wide range of products and processes.

IKA^® MIXERS SUITABLE FOR GRINDING / DISPERSING PIGMENTS AND DYES

• Batch: UTC, UTE, UTS
• Inline: UTL , DR, DRS, CMS, MHD, MK, MKO
• Master Plant

10. Catalytic Agents

Catalysts are used widely in the chemical industry to promote and accelerate reactions. Catalysts are often expensive, used in relatively small quantities, and derived from inorganic chemicals (i.e. heavy metals). Catalysts may be used to simply provide an acceptable site for the chemical reaction to take place or may themselves be an integral part of the reaction (one of the reactants). In either case, the maximum yield will depend on effectively bringing the catalyst into contact with the reactants (effective dispersion) and / or constantly renewing the catalyst’s surface area (de-agglomeration, particle size reduction, etc). IKA^® Works proven experience in the chemical industry allows customers to rest assured that they will receive the maximum yield from their catalyst(s).

ADVANTAGES OF IKA^® WORKS MIXERS WHEN PROMOTING REACTIONS WITH CATALYSTS

• Increased yields. IKA^® Works Generators are specifically designed to ensure complete dispersion, bringing the catalyst into contact with the other reactants. Further, the high shear rotor / stator action (see Tech Info for more details) ensures that agglomerates are broken down, surface areas refreshed, and reaction yields are maximized.
• Decreased production time. The high speed, high shear mixing action of an IKA^® Works Mixer ensures that catalyst(s) and reactants are rapidly dispersed within one another, speeding reactions. The high energy input of an IKA^® also helps accelerate the reaction process.

IKA^® MIXERS SUITABLE FOR PROMOTING REACTIONS WITH CATALYSTS

• Batch: MSM,UTC, UTE, UTS, RT
• Master Plant

11. Waxes and Polishes

Waxes and polishes encompass a range of products including solid car waxes, liquid waxes, and shoe polishes. The manufacturing process for these products generally includes melting a solid wax, adding any suspending agents or minor ingredients, emulsifying the liquid wax with either a water or oil phase, cooling the product, and packaging. IKA^® Works experience with these products allow us to supply customers with solutions ranging from an individual mixer to a complete plant.

ADVANTAGES OF IKA^® WORKS MIXERS FOR MANUFACTURING WAXES AND POLISHES

• Decreased heating / melting time. The high shear mixing action of an IKA^® Works rotor / stator mixer rapidly reduces the particle size of solids, improving heat transfer and speeding the heating and melting process.
• Improved product quality. IKA^® Mixers provide a uniform dispersion of minor components and sub micron emulsions, with tight droplet size distributions.
• Turn key systems. IKA^® Works has experience and designs for complete systems including process vessels, heat transfer equipment, low and high shear mixers, and plant controls.

IKA^® MIXERS SUITABLE FOR MANUFACTURING WAXES AND POLISHES

• Batch: UTC, UTE, UTS, RKG, RFG
• Inline: UTL , DR, DRS, MK, MKO
• Master Plant

12. Sulfur

Although most of us are familiar with sulfur as a solid, it is often processed as a liquid at elevated temperatures. It can then be emulsified to produce fine particle sizes when cooled. IKA^® Works line of high shear rotor / stator mixers are ideal for creating these emulsions.

ADVANTAGES OF IKA^® WORKS MIXERS FOR EMULSIFYING SULFUR

• Reduced capital costs. IKA^® Works revolutionary 2000 Series utilizes a modular concept to allow all customers to benefit from economies of scale. These mixers also come with heating jackets and seals capable of high temperature operation* (*care must be taken with elastomer selection), as standard.
• Improved product consistency. IKA^® Works selection of innovative Generators allow the customer to rapidly achieve the desired particle size with a tight size distribution.
• Improved product quality. The high shear action and multiple Generators of an IKA^® Works Mixer allow customers to produce particle sizes down to 1m m or less.

IKA^® MIXERS SUITABLE FOR EMULSIFYING SULFUR

• Batch: UTC, UTE, UTS
• Inline: DR, DRS, MK, MKO
• Master Plant

13. Edible Oils

Edible oils may be extracted from a variety of plant or animal sources and are commonly found in the foods we eat. This report will focus on plant derived oils. These oils include the following examples: cottonseed oil, palm oil, peanut oil, soybean oil, sunflower oil, and linseed oil. These oils are usually obtained through solvent extraction and then purified. The purification process generally involves the following steps:

1. Degumming. This involves treating the crude oil with water and / or acid (typically phosphoric acid) to hydrate phosphatides and allow separation through centrifugation.
2. Alkali refining. The degummed oil is then treated with an alkali solution (i.e. NaOH) to reduce the free fatty acid content and remove other impurities through conversion to water soluble soaps. These soaps are removed from the oil with a water wash.
3. Bleaching. The oil is purified further and colors removed through bleaching. Typically, diotomaceous earth or clay is used to absorb color affecting substances. The clay and absorbed impurities are then filtered out.
4. Deodorization. Vacuum steam distillation is then used to remove volatile compounds that may affect taste, color, or odor.
5. The oil can then be either subjected to fractionation, hydrogenation, interesterification, esterification, or simply packaged depending on the properties desired in the final product.

IKA^® Works has become a world leader in the supply of high shear mixing equipment for use in the purification of edible oils.

ADVANTAGES OF IKA^® WORKS MIXERS WHEN PURIFYING EDIBLE OILS

• Reduced additive quantities. The intense high shear mixing action (see Tech Info for more details) of an IKA^® Mixer ensures intimate contact between the oil and any additives (i.e. phosphoric acid, caustic soda) allowing a smaller quantity of additive to treat a larger quantity of oil.
• Decreased processing times. Utilizing innovative Generator designs and up to three distinct stages of rotors and stators, IKA^® Mixers ensure that all components are intimately blended together. This allows additives to work more rapidly and a higher purity oil is produced more quickly.
• Improved filtration efficiency. The IKA^® CMS and MHD mixers are capable of rapidly and effectively dispersing the clay or diatomaceous earth throughout the oil. This allows a more effective bleaching process and lowers the occurrence of clogged filters.
• Versatility. The modular concept of the IKA^® Works 2000 Series Mixers allows a single unit to be adapted to a wide range process requirements.

IKA^® MIXERS SUITABLE FOR EDIBLE OIL REFINING

• Degumming: UTL , DR, DRS
• Alkali refining: UTL , DR, DRS
• Bleaching: UTL , DR, DRS, CMS,
• Master Plant