Triple shearing + vacuum degassing : The ultimate solution for emulsifying high-viscosity materials

In industries such as cosmetics, pharmaceuticals, food processing, and specialty chemicals, the emulsification of high-viscosity materials remains a critical challenge.        Achieving uniform particle size distribution, eliminating entrapped air, and ensuring long-term stability are essential for product quality. Traditional mixing technologies often fall short in these demands, leading to issues like phase separation, poor texture, and reduced shelf life.

Jiangsu GangBen Mixer Manufacturer, a leader in advanced mixing solutions, addresses these challenges with its Vacuum Emulsifying Mixer, which integrates triple shearing technology and vacuum degassing into a single, high-performance system.This innovation provides an unparalleled solution for processing high-viscosity emulsions efficiently and reliably.

The Challenges of High-Viscosity Emulsification

High-viscosity materials—such as creams, ointments, thick sauces, and polymer blends—require intense mechanical energy to break down agglomerates and achieve fine dispersion. Conventional mixers, including single-stage homogenizers and paddle mixers, struggle with:

Insufficient shear force, leading to coarse emulsions with unstable particle sizes.

Air entrapment during mixing, causing oxidation, microbial growth, and compromised product appearance.

Inefficient heat transfer, resulting in uneven temperature distribution and prolonged processing times.

These limitations not only degrade product quality but also increase production costs due to rework and waste.

Triple Shearing Technology: Precision at Every Stage

The Vacuum Emulsifying Mixer from Jiangsu GangBen employs a three-stage shearing system, each designed to target specific particle size ranges:

Coarse Shearing (Stage 1)

A high-speed rotor-stator assembly with wide gaps (1–2 mm) breaks down large aggregates into manageable chunks (50–200 µm).

Ideal for initial dispersion of waxes, thickeners, and solid particles.

Intermediate Shearing (Stage 2)

Narrower gaps (0.5–1 mm) and higher rotational speeds refine particles to 10–50 µm.

Enhances surface area for better surfactant adsorption, improving emulsion stability.

Fine Shearing (Stage 3)

Ultra-narrow gaps (0.1–0.5 mm) combined with ultra-high speeds (up to 5,000 rpm) achieve submicron dispersion (<10 µm).

Produces a smooth, homogeneous emulsion with exceptional long-term stability.

Benefits of Triple Shearing:

Reduces processing time by up to 50% compared to single-stage mixers.

Ensures consistent particle size distribution (D90 < 15 µm in most applications).

Minimizes energy consumption per unit volume.

Vacuum Degassing: Eliminating Air for Superior Quality

Air entrapment is a common issue in high-viscosity emulsions, leading to:

Oxidative degradation of sensitive ingredients (e.g., vitamins, essential oils).

Microbial contamination due to oxygen-dependent bacteria.

Aesthetic defects such as bubbles, uneven texture, and reduced gloss.

Jiangsu GangBen’s Vacuum Emulsifying Mixer incorporates a multi-stage vacuum degassing system that operates concurrently with shearing:

Deep Vacuum (-0.098 MPa): Removes dissolved and entrapped air by reducing atmospheric pressure.

Optimized Flow Path: Ensures uniform vacuum exposure across the entire batch.

Real-Time Monitoring: Sensors adjust vacuum levels based on material viscosity and temperature.

Results of Vacuum Degassing:

95%+ reduction in air content, preventing oxidation and extending shelf life.

Improved product appearance: Smooth, glossy finishes without surface defects.

Enhanced microbial stability: Reduced risk of spoilage in pharmaceutical and cosmetic formulations.

Why Choose Jiangsu GangBen’s Vacuum Emulsifying Mixer?

As a pioneer in mixing technology, Jiangsu GangBen Mixer Manufacturer delivers unmatched reliability and customization:

Material Compatibility: Constructed with 316L stainless steel for GMP/FDA compliance.

Scalability: Models range from 5 L laboratory units to 5,000 L industrial reactors.

Modular Design: Customizable shear head configurations, vacuum levels, and heating/cooling options.

Energy Efficiency: Reduced operational costs through optimized power consumption.

The combination of triple shearing and vacuum degassing in Jiangsu GangBen’s Vacuum Emulsifying Mixer represents a paradigm shift in emulsion technology. By addressing both mechanical and aerodynamic challenges, this system ensures superior product quality, shorter cycle times, and lower production costs.