A Single Layer Homogenizer Mixing Tank is a versatile, high-performance industrial tank designed for blending, emulsifying, dispersing, and homogenizing a wide variety of liquid and semi-liquid products. It consists of a single-walled stainless steel tank integrated with a high-shear homogenizer, which delivers intense mixing and uniform particle size distribution. These tanks are widely used in industries requiring precise mixing without the need for thermal insulation or jacketed heating. The design ensures efficient mixing with minimal product wastage and is suitable for both batch and continuous processing. The tank may include features such as a bottom or side-mounted homogenizer, variable speed drive, control panel, and sanitary-grade fittings for CIP/SIP compatibility.
Working Principle
The working principle of a Single Layer Homogenizer Mixing Tank involves two main actions:
- Mechanical Agitation: The agitator (optional) ensures the bulk material is continuously stirred, preventing sedimentation or phase separation.
- High-Shear Homogenization: The integrated homogenizer uses a rotor-stator mechanism to create intense mechanical shear forces. As the product passes through the narrow gap between the rotor and stator, particles are broken down and dispersed uniformly.
This results in:
- Reduction of particle sizes
- Uniform blending of immiscible phases (e.g., oil and water)
- Elimination of agglomerates
- Enhanced product stability and texture
Application
Single Layer Homogenizer Mixing Tanks are used in a broad range of industries for producing high-quality emulsions, suspensions, and solutions. Typical applications include:
- Pharmaceutical Industry: Ointments, creams, syrups, suspensions
- Cosmetic Industry: Lotions, shampoos, conditioners, body wash
- Food & Beverage Industry: Sauces, dairy products, beverages, flavor emulsions
- Chemical Industry: Emulsions, resins, paints, inks, detergents
- Biotechnology: Cell lysis, culture media preparation
Material of Construction (MOC)
|
Component |
Material |
Grade |
Tank Body |
Stainless Steel |
SS 304 / SS 316 / SS 316L |
Homogenizer (Wetted Parts) |
Stainless Steel |
SS 316 / SS 316L |
Shaft & Impeller |
Stainless Steel |
SS 316L |
Seals & Gaskets |
Food Grade Silicone / PTFE |
FDA Approved |
Inlet/Outlet Valves |
Stainless Steel |
SS 316 / SS 316L |
Tank Legs / Support Frame |
Stainless Steel |
SS 304 / Powder Coated Mild Steel |
Control Panel Housing |
Stainless Steel or Mild Steel |
SS 304 / Powder Coated MS |
Key Components of a Single Layer Homogenizer Mixing Tank
|
Component |
Function / Description |
Tank Vessel (Shell) |
Main body of the tank, holds the product to be mixed. Made from SS 304/316 depending on application. |
Tank Top Cover / Lid |
Can be removable or fixed; often includes manhole, inlet/outlet ports, and instrument connections. |
Bottom Dish End / Cone |
Designed for complete discharge of the product and proper flow towards the outlet. |
Homogenizer (Bottom or Side Mounted) |
High shear rotor-stator unit used for emulsifying, dispersing, and homogenizing materials. |
Agitator / Stirrer (Optional) |
Helps in primary mixing and movement of materials within the tank (can be anchor, paddle, or propeller type). |
Motor & Gearbox |
Powers the agitator and/or homogenizer; variable speed drives (VFD) are often used for speed control. |
Shaft & Impeller (Agitator) |
Stainless steel rotating part connected to the motor for mixing contents in the tank. |
Baffles (Optional) |
Vertical strips inside the tank to prevent vortex formation and improve mixing efficiency. |
Sealing Mechanism |
Mechanical seal or lip seal to prevent leakage from rotating shafts. |
Inlet & Outlet Valves |
For feeding raw materials and discharging the final product. Can be butterfly, ball, or diaphragm valves. |
Sight Glass / Illumination (Optional) |
For observing the inside of the tank during operation. |
Pressure/Vacuum Relief Valve (Optional) |
To maintain safety in case of pressure/vacuum buildup. |
Instrument Ports |
For fitting temperature sensors, pressure gauges, pH probes, etc. |
Level Indicator (Optional) |
Shows the current liquid level inside the tank. |
CIP / SIP Spray Ball (Optional) |
For automated Cleaning-In-Place and Sterilization-In-Place systems. |
Control Panel |
Electrical cabinet for motor, speed control (VFD), temperature control, and safety interlocks. |
Support Legs / Skid Base |
Provides structural support and elevation to the tank. Often with adjustable feet or castors. |