Sonic Corporation’s Sonolator high pressure homogenizers use no moving parts to create fine emulsions and dispersions with droplet sizes below 1 micron. 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.
- High pressure stresses the fluid
- Fluid is sheared along sharp edges of the Orifice
- Velocity change creates violent eddies spinning in the opposite direction of the flow
- Cavitation creates a turbulent counter current of vortices
- Droplets and particles are reduced to below 1 micron in diameter
Scalable High Pressure Homogenizers
Sonolator high pressure homogenizers achieve large-scale productions runs using PD pumps and electric motors as opposed to compressed air. Compressed-air homogenizers are limited in the flow rates they can achieve. Other conventional high pressure units use spring-loaded relief valves to create pressure. The pulsating valve assembly allows fluid to pass through unprocessed. These types of homogenization machines are difficult to scale up because compressed air pumps and partially closed valves only get you so far.
Our Sonolator systems do not use mechanical shear or moving parts to achieve particle size results. We don’t rely on compressed air pumps or pulsating valve assemblies either. Therefore, our results are repeatable and scalable over a wide range of flow rates and pressures. We can also garner better results at lower pressure because of our fixed Orifice design.
Equipment Features and Benefits
- Scalable flow rates for varying production volumes
- No compressed air operation
- Low power consumption
- Similar results at lower operating pressures
- Flow Rates from 0.5 GPM to 100 GPM
- Simple and inexpensive maintenance and repair
A typical Sonolator high pressure emulsification system consists of a PD pump, motor, instrumentation, safety valves, VFD inverter cabinets with operator controls, and in many instances, PLC automation.
Multiple-Feed Inline Production
Sonic is the only company that designs multiple-feed high pressure homogenizers. These custom designed systems use several PD pumps and mass flow meters to distribute water and liquid bulk materials at the proper ratio into the Sonolator high-pressure mixing chamber where very fine emulsions and dispersions are formed instantly. The system can process these incoming streams at differing temperatures as well which reduces heating and cooling time and costs. The system below features 3 PD pumps with mass flow meters, instrumentation and PLC automation. By metering water from its source, these mixers reduce the tank space typically required with batch mixing. In shampoo and body wash production, we can produce over 20 tons of shampoo and body wash from a 5 ton tank by metering 3 streams simultaneously into the Sonolator homogenizer mixer.
In lotions production, our processing skid can meter a hot oil phase with an ambient water phase and make a superb emulsion with a lower final temperature, which reduces a 8-10 hours process to under 2 hours. We have designed several SLES Dilution systems that meter and disperse SLES and water without any mixing tanks while transferring directly to a downstream process.
- Produces fine emulsions inline
- Bulk material metering from storage containers
- Eliminates need for bulk water transfers to a batch tank
- Eliminates huge and costly batch tanks
- Meters hot and ambient phases to reduce heating and cooling
- Produces more with less tank space
Processing Magazine ran an editorial about the huge benefits of multiple-feed homogenization. Please read this article as it is very informative and helpful in understanding how it works and the many benefits that go along with it.
Learn about more applications where the Sonolator has been a huge benefit to our customers and end users. Whether in single feed mode to make a superior emulsion at lower pressure, or in multiple-feed mode to save on precious tank space while reducing heating and cooling time.
Custom Design & Fabrication
Sonic Corporation specializes in complete system customization, offering in-house 3D design capabilities, panel building and electrical cabinet fabrication. We also write PLC and HMI hardware code. Unlike off-the-shelf systems, our homogenizer units can use a variety of PD pumps to meet flow and pressure requirements and are skid mounted, with no enclosures, which allows easy maintenance and access.
System Design Features
- Easily accessible and maintainable pumps and instrumentation
- Complete system customization designed to meet customer needs
- Motor horsepower chosen based on flow and pressure
- Custom pump selection
- In-house PLC and HMI programming
- Control and power cabinet design & fabrication