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Effective ways of using high speed shear mixers

January 13, 2014

A high speed shear mixer disperses an ingredient into the main ingredient or continuous phase, with which it is normally not mixable. The mixer’s rotor, together with a vital stationary part called a stator, works hand in hand to mix the solution placed inside the tank. The solution may also be made to pass through a pipe in order to create a shear.

High shear mixers are used to form suspensions, emulsions, lyosols, and many forms of granular products. It is a main tool in the production of various adhesives, cosmetics, chemical, drug, food, and plastics. The processes that it performs are homogenization, particle reduction, dispersion, and emulsification.

Mixing tips when using high shear mixers:

A high shear mixer is a top notch industrial mixing tool. It is a superior tool compared to traditional mixers. Here are advices on how to properly mix various ingredients using this device:

1. Dispersing Powder

High shear mixers are often used to achieve the smallest particle size possible. In order to do this, the mixer disperses the powder into the smallest amount of liquid. This allows the mixer to disperse the substance and mill it, instead of blending the whole batch all at once.

The greater powder concentration means higher reduction in the size of the particle. As soon as the desired size of particle is achieved, the remaining liquid can be mixed with the solution inside the mixer.

2. Gum / thickener

Mixing gum and thicker using traditional mixer is not possible since the latter tends to clump it. Likewise, mixing can be a tedious and slow process since this type of mixer should be operated slowly in order to lessen the formation of fisheyes and lumps. This is not the case when it comes to high shear mixer, since it is advised to perform mixing in a fast manner, with all the liquid quickly mixed into the gum.

The fast shearing action of the high shear mixer’s rotor head are efficient in breaking up and hydrating the powder even before the thickness begins to occur. In other words, the mixture is free of lump and has a consistently thick texture.

3. Viscous liquid

When mixing fluids of various thicknesses using an inline mixer, the process must start with the thinnest liquid, gradually adding the thicker liquid to the mix. Doing so effectively mixes the solution at a short period of time. High shear mixers are known to successfully mix fluids of any type of viscosity.

4. Emulsion formation

One of the most common issues when increasing the level up from laboratory scale blending to larger production is creating an emulsion. Emulsion formation is an easy task when done on a small, lab scale. However, large volumes of substance being mixed to produce emulsion can be very critical. So, it is important to use the high speed shear mixer properly. In order to form a quick and good quality emulsion, the operator must see to it that the dispersed substance is added to the high shear mixer just before any other phase.

high speed shear mixer

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