Homogenizer - Multi-Feed Systems

As illustrated above, individual phase tanks (to the left) hold either prepared phases, bulk storage liquids, etc. These phase tanks, bulk storage tanks, totes, etc. are piped to the Sonolator integrated skid. Our pumps then meter, via mass flow meters at 0.1% accuracy, each item into the Sonolator Orifice/Blade mixing chamber where and emulsion, mix, blend, etc. is formed instantly. The system acts as a material transfer unit and pumps finished product straight away to hold/finish tanks (to the right). The concept can be tested and approved using Bench and Pilot scale systems, as seen to the right.

Sanitary Pilot Tri-Feed Sonolator
The pilot plant scale multiple-feed Sonolator system takes the idea to the next level by incorporating viable plant scale controls and instrumentation, making the transition to full scale seamless. Such systems include coriolis mass flow meters by E&H, MicroMotion, Foxboro; pressure transmitters and switches; VFD controllers and PLC by Allen Bradley, Siemens, Mitsubishi and others; valves by Tuchenhagen, Jensen.
Such systems are delivered out of the box with touch screen Op Panel and PLC that allow the operator to connect power, enter phase ratios and start processing. Data logging units and recipr management can be included, or use a full Panel PC with hard drive, ethernet, modem and more.

As mentioned, the Multiple-Feed Sonolator approach provides incredible benefits that help our customers meet production goals, streamline processing, save money and time, and produce more with less tank space:

DI or soft water can be metered separately without consuming tank space, thereby providing critical finished product yields for existing tank space. This often helps customers get an edge, increase plant capacities and bring manufacturing back in-house from outside tollers.
Being able to remove water from the tank and meter on its own also allows the customer to reduce cycle times as compounding frequency is reduced. Example: if 50% water can be metered, then finished product yield for given tanks is doubled, from say 10,000 gallons to 20,000, for only a single round of compounding.
Various phases can be metered at various temperatures while still forming a superior emulsion; this means that final temps are lower resulting in tremendous savings via cooling time and energy reductions.
Breaking out into phases allows the customer to heat only that phase, traditionally an oil/wax type phase, which requires heating. This means that some percentage, usually 50% or more, is not heated to such high temps and a great savings is realized by reduction in heating costs, energy and time.
Compounding phases is much easier and much faster than compounding a complete batch where order of addition rules and heating/cooling cycles cost time and money.
Each Multiple-Feed Sonolator system is custom designed to meet your plant needs and requirements. Our long history and experience in system design and engineering means our customers benefit from our knowledge and expertise concerning pumps, valves, motors, drives, PLC and automation hardware, electrical design and implementation, high pressure pipe works, sanitary pipe works and more.

Plant Tri-Feed Sonolator
Our production scale multiple-feed Sonolator systems range from very simple to more complex. As indicated all along, each system is designed to meet your requirements. We work with you providing mechanical layout drawings and electrical schematics to ensure we do the job right!
This system was designed to meet stringent hygiene needs and meets all necessary 3A requirements being CIP and sanitary. The system employs progressing cavity pumps to handle varying viscosities ranging from water to 25,000 cps phases and materials. Tuchenhagen valves were used for pressure relief, Sonolator tuning, to divert discharge material and as low point drains. Endress & Hauser mass flow meters were used to establish 0.1% metering accuracy for each pump.

High Pressure Homogenizers and Homogenizing Systems