Process Pilot

Process Pilot Pilots

PROCESS PILOT is the most versatile and highly reliable inline laboratory dispersing machine. It is designed for solid-liquid mixing, homogenizing, emulsifying, suspending and wet milling. The PROCESS-PILOT 2000/4 is suitable for a wide range of applications, particularly in the chemical, cosmetic, pharmaceutical, plastics, colors and food industries. It is uniquely designed with advance technology and is available with 8 interchangeable modules. It can be customized to fit particular process demands. Important process parameters such as circumferential speed, tools and mixing chamber geometry are structurally identical to those of the IKA 2000 inline production machines: UTL, DBI, DR, DRS, CMS, MHD, MK and MKO. Therefore, the PROCESS-PILOT ensures a reliable scale-up by offering the possibility to work with the same method from formulation development to mass production. The PROCESS-PILOT enables working under pressure/ vacuum as well as at elevated temperatures or with abrasive materials.

The basic inline machine is equipped with the single-stage dispersing module ULTRA-TURRAX® UTL. It is best suited for batch applications and can be adapted for the manufacturing of dispersions from coarse to fine. Compared to a conventional stirrer, the mixing time is reduced by up to 50%.

Depending on the application, the basic unit can be modified quickly with different working modules.

The module DBI is a two-stage high shear mixing and dispersing machine. It is best suited for batch operations with a recirculation loop and is directly mounted to the vessel bottom. The dispersing machine DBI enables suction, pumping, and self-cleaning under CIP conditions.

The module DISPAX-REACTOR® DR converts the PROCESS-PILOT into a multi-stage high capacity dispersing machine for fine particle size reduction. With just one pass, the module DR does typically achieve fine dispersions with an extremely narrow particle size distribution. It also guarantees an optimum homogeneity, which is an important pre-condition for the long-time stability of emulsions or suspensions.

The module CMS is used for solid/liquid mixing; ideally suited for enrichment of liquids by powders in a recirculation process. It creates a vacuum at the powder inlet, thus sucking the powder directly into the mixing chamber of the machine. It enables a quick, dust- and lump-free incorporation and energy-efficient homogeneous mixing.

The module MHD is designed for a fully continuous incorporation of powders into liquids. By use of this module, the mixing relation of solid and liquid will be volumetrically or gravimetrically controlled. Depending on the product characteristics, dispersions with viscosities up to 50 Pas or solid contents up to 80% can be achieved just after one pass.

The modules Colloid Mill MK and Cone Mill MKO are used for wet or fine milling of hard and granular raw materials or for the production of finest emulsions as well as for improving of quality of finished dispersions. The MK module consists of two cones with differently directed flow channels on their surfaces. The cones can be shifted against each other to a minimum distance, thus varying friction as well as flow capacity. By adjusting the milling gap, the achievable particle size can be controlled. The MKO module works on the same principle as the MK module except the outlet area of its cones is coated with abrasion-resistant tungsten-carbide. This results in an enlarged friction surface that enables to produce even finer suspensions at reduced flow.

The laboratory dispersing machine PROCESS-PILOT 2000/4 can be upgraded to a high-speed dispersing machine with the PROCESS-PILOT-CONTROLLER.

The laboratory dispersing machine PROCESS-PILOT 2000/4 differs from the alternative LABOR-PILOT 2000/4 machine due to the applied seal technology and two optional exchangeable modules for powder incorporation in the enrichment process ‒ DBI and CMS.

Advantages of the PROCESS-PILOT:

  • Flexibility and ease of use: one machine suits for many applications and variety of processes
  • Together with inline machines of 2000 series enables seamless transition of processes from laboratory to production while retaining the product quality
  • Easy and quick exchange of the modules as well as conversion to a complete working plant
  • Operates under pressure/vacuum
  • Works at elevated temperatures
  • Low maintenance mechanical seal
  • Suitable for dry-running
  • Available in Ex-protected design
Flow rate (max.)
(l/h)
Motor power
(kW)
Tip speed
(m/s)
Data Sheet Drawing
PROCESS-PILOT 2000/4 350 2.2 41

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If you have any further questions regarding our products and services, our team of advisers will be happy to help:
+1 910 452 7059