This equipment is a standard workhorse for pilot-scale production and process validation. It bridges the gap between laboratory benchtop formulations (1–5L) and full-scale industrial manufacturing.
It is widely used in the cosmetic (creams, lotions), pharmaceutical (ointments), and food (sauces, dressings) industries to test viscosity, stability, and texture before mass production.
⚙️ Key Components & Structure
A typical 20L unit is a double-wall or triple-wall reactor system consisting of:
- Main Mixing Tank (20L Capacity):
- Material: High-grade SUS316L Stainless Steel.
- Jacket: Heating and cooling jackets (oil or water circulation) for precise temperature control.
- Surface Finish: Mirror polish (Ra ≤ 0.4μm) to prevent bacterial growth and ensure easy cleaning (CIP/SIP).
- Homogenizer (High-Shear Mixer):
- A high-speed rotor-stator system located at the bottom or top.
- Function: Reduces particle size to create a stable, uniform emulsion (e.g., mixing oil and water phases).
- Speed: Variable frequency drive (VFD) typically ranging from 0 to 3000 RPM.
- Anchor/Paddle Scraper:
- A slow-speed mixer that rotates along the vessel walls.
- Function: Scrapes viscous material off the walls to ensure total homogeneity and efficient heat transfer.
- Vacuum System:
- Function: Removes air bubbles entrapped during mixing (de-aeration) to ensure a glossy, dense final product.
- Pressure: Capable of reaching -0.09 MPa.
- Water/Oil Phase Tanks (Optional):
- Smaller auxiliary tanks (e.g., 5L–10L) connected to the main unit for pre-melting or heating specific ingredients before emulsification.
🚀 Key Features & Benefits
- Process Simulation: Allows R&D teams to replicate the exact conditions (shear force, temperature, vacuum) of a 1000L production tank on a smaller scale.
- De-aeration: The vacuum function is critical for high-viscosity products (like hair gels or thick creams) to remove air pockets that cause oxidation or inconsistent texture.
- Sanitary Design: Equipped with sanitary clamps, sight glasses, and spray balls for cleaning.
- Control System: Usually features a PLC Touch Screen to monitor and record:
- Mixing Speed (RPM)
- Temperature (°C)
- Vacuum Pressure
- Mixing Time
📋 Technical Specifications (Typical)
Parameter Specification
Total Capacity 20 Liters (Working volume approx. 16L–18L)
Material SUS316L (Contact parts) / SUS304 (Jacket/Frame)
Homogenizing Power 1.5 kW – 2.2 kW
Agitation Power 0.37 kW – 0.75 kW
Heating Method Electric / Steam / Thermal Oil
Cooling Method Tap Water / Chiller
Vacuum Level -0.09 MPa
Surface Finish Mirror Polish (Ra ≤ 0.4μm)
💡 Applications
- Cosmetics: Face creams, lotions, shampoos, serums.
- Pharmaceuticals: Antibiotic ointments, gels, suspensions.
- Food Industry: Mayonnaise, ketchup, salad dressings (requires food-grade certification).
- Chemicals: Adhesives, sealants, lubricants.
