High Pressure
Homogenizers

Create fine emulsions and dispersions
with droplet sizes below 1 micron.
No moving parts.

High Pressure Homogenizer

HIGH PRESSURE HOMOGENIZERS

Create fine emulsions and dispersions with droplet sizes below 1 micron. No moving parts.

Sonic’s High Pressure Homogenizers are incorporated into standard and custom systems that emulsify liquid solutions and disperse & deagglomerate solids within liquid slurries. The Sonolator uses no moving parts or mechanical shear to generate fine particles and droplet sizes. No partially closed mixing valves or compressed air pumps are used either. Because of this, results are directly scalable to high flow rates!

Sonolator

OVERVIEW

Our Sonolator High Pressure Homogenizers achieve droplet size reduction inline using fluid acceleration, inline cavitation and turbulent flow. The device is included in a complete system featuring a positive displacement pump, electric motor, instrumentation and PLC controls. This homogenizer features a fixed orifice and blade which create extreme turbulence inline and break down oil phase droplets or deagglomerate solids within a liquid medium. Our Sonolator systems are then custom designed to meet factory needs and operate at required flow and pressures. Inline multiple-feed homogenization at high pressures is unique to Sonic.  We are the only homogenizer manufacturer to create systems where bulk materials and water are metered simultaneously and emulsified inline on a continuous or semi-continuous basis at high pressure.

HOW IT WORKS

A high-pressure positive displacement pump connected to the Sonolator forces liquid through a specially engineered orifice at pressures to 6,500 PSI. The fluid changes velocity dramatically over a very short distance and accelerates to over 300 ft/sec, creating high shear and turbulence within the process material. Immediately thereafter, the solution impacts on a blade set in its path. Extreme hydrodynamic cavitation occurs as the solution flows over the blade where aggressive and turbulent counter currents are formed. These reverse eddies are violently reintroduced to the liquid stream creating additional turbulence.

HOW IT WORKS

A high-pressure positive displacement pump connected to the Sonolator forces liquid through a specially engineered orifice at pressures to 6,500 PSI. The fluid changes velocity dramatically over a very short distance and accelerates to over 300 ft/sec, creating high shear and turbulence within the process material. Immediately thereafter, the solution impacts on a blade set in its path. Extreme hydrodynamic cavitation occurs as the solution flows over the blade where aggressive and turbulent counter currents are formed. These reverse eddies are violently reintroduced to the liquid stream creating additional turbulence.

Sonic designs and builds high pressure homogenizers in both single-feed and multi-feed configurations based on your specific needs.

SINGLE FEED SYSTEM

Sonic manufactures standard single-feed HP Homogenizer units that can be installed under a batch tank and operate as an inline emulsification or homogenization system while transferring product to hold tank or filling lines.

Our basic single-feed Sonolator HP Homogenizer units are complete with PD pump, electric motor, Sonolator and related instrumentation.
  • 6000 PSI Operating Pressures
  • 1 – 100 GPM Pilot scale to full production
  • Skid mounted system w/ instrumentation and PRV
  • Electrical control box w/ VFD and safety shutoffs
  • Customization available for layout and component selection
Basic High Pressure Homogenizer

15 GPM – 2000 PSI Sonolator System

FEATURES

  • Homogenization achieved with no moving parts
  • Fixed orifice generates acceleration and cavitation
  • Fluid velocity change shears product inline
  • No partially closed mixing valve
  • Droplets reduced to below 1 micron

BENEFITS

  • Scalable from 0.5 GPM to 100 GPM
  • Fixed orifice means better droplet distribution
  • No mechanical shear means repeatability and scalability
  • No mixing valve means better results at lower pressure
  • All systems customizable
  • Multiple-Feed homogenizing reduces tank requirements

FEATURES

  • Homogenization achieved with no moving parts
  • Fixed Orifice generates acceleration and cavitation
  • Fluid velocity change shears product inline
  • No partially closed mixing valve
  • Droplets reduced to below 1 micron

BENEFITS

  • Scalable from 0.5 GPM to 100 GPM
  • Fixed Orifice means better droplet distribution
  • No mechanical shear means repeatability and scalability
  • No mixing valve means better results at lower pressure
  • All systems customizable
  • Multiple-Feed homogenizing reduces tank requirements

MULTI-FEED HIGH PRESSURE HOMOGENIZERS

Sonic is the only company that designs and manufacturers multiple-feed high pressure homogenizers. The multi-feed process approach uses several high-pressure PD pumps with flow meter technology and our patented Sonolator to simultaneously meter at ratio and mix, homogenize and transfer product. No other company offers such systems at pressures exceeding typically 100-200 psi. Our industrial or complete sanitary systems meter various liquid streams and homogenize at pressures as low as 200 psi to as high as 5000 psi.

Each of Sonic’s custom-engineered multiple-feed systems contain several PD pumps and flow meters for the various liquid streams. In many cases, the goal is to draw bulk material from their storage locations to eliminate or reduce any tanks used in the process. Transferring bulk liquids or water and allowing it to consume valuable tank space is wasteful. The various pump flow rates are tightly controlled by the onboard PLC and VFD hardware to deliver ratios at pressures to 5000 psi.
Sonolator

Processing Magazine ran an editorial about the immense benefits of multiple-feed homogenization.

BENEFITS OF A MULTI-FEED SONOLATOR SYSTEM

Reduced Heating/Cooling

Hot phase can be metered along side an ambient phase to create a finish product that requires much less cooling.

Increase Product Yield

Product yield per given tank space can be increased significantly when water can be metered from its own source without being held in a tank.

Reduced Compounding

Compounding might be required if there are pre-blends and pre-blends are much easier to make than full batches.

Reduced Process Times

In-line continuous and semi-continuous homogenization, where material material is drawn from bulk, will always be faster than making giant bulky batches that require multiple transfers.

What’s your application?

Contact us to discuss innovative multiple-feed High Pressure Homogenizer systems, like this Tri-Feed Sonolator System rated to
30 GPM at 300 PSI for making lotions, shampoos, body wash and more personal care products.

Full Homogenizer System

Question? Ask Our Experts.