KFJ-1000 Vacuum Emusifier

Ⅱ. Description, exterior picture and introduction of the equipment

2.1 Description of the equipment

Model KFJ-1000 Vacuum Emulsifying Mixer(Emulsifier)

is a coaxial and triple type mixer, suitable to stable homogenizing and emulsifying. Relying on mixing of reversed impeller, under the condition of homogenizing turbine and vacuum status, you can get the high-quality effect of emulsifying and mixing.

Model KFJ-1000 Vacuum Emulsifying Mixer(Emulsifier) has very good performance in the aspect of insuring high quality of the finished material.

2.2 Product instruction

Model KFJ-1000 Vacuum Emulsifying Mixer(Emulsifier)

is specially designed by introducing foreign updated technology and on the basis of ointment-making technics for processing cosmetics and ointment. It is composed of emulsifying mixer, water and oil pretreatment boiler, vacuum system, electric control system and working platform, etc.

3. technical parameter

3.1 Emulsifying mixer：

Working volume: 1000L, total volume 1300L, material: SUS316L stainless steel, steam heating and water-cooling

Structure: With 3-layer structure, upper and lower end sockets. The upper end socket is connected to the tank body with flange between them. The internal layer of tank body is made of 8mm thick SUS316L stainless steel and interior polished in 300 MESH (sanitary level). The middle layer of tank body is made of 6mm thick SUS304 stainless steel and can stand max. working pressure 0.09MPa. The external layer of tank body is made of 2mm thick SUS304, and exterior polished in 300 MESH (sanitary level). All the welding seams shall be polished after rubdown, and as to the treatment interface, turned over edge arc transition is adopted. The heat preservation layer is made of PU polyurethane foaming. There is a mixing device in the tank.

3.11 Emulsify mixer:15kw, 1150-3500 rpm (frequency control)

3.12 Low-speed frame type scraping mixer: 3.7kw, 10-40 rpm (frequency control)

3.14 Attached units of the tank: Liquid feed inlet with stainless steel pipe filter, solid material inlet, vacuum inlet, compressed air inlet, breaking vacuum inlet, sight glass, temperature sensor, CIP cleaning head, discharging hole, dustproof asepsis respiratory device.

3.2 Pretreatment boiler:

Oil boiler of 600 L and water boiler of 800 L one each, material: SUS316L.

Structure: open (half-open) type, three feet with mixing.

Detailed Technical requirements:

Effective volumes: oil boiler of 600L, water boiler of 800L, material: SUS316L, 3 layers structure. The material of the inner of tank body is made of 6mm thick SUS316L and interior polished in 400MESH (sanitary level). The middle of the tank body is made of 4mm thick SUS304 and can stand max working pressure 0.09MPa. The external layer of tank body is made of 2mm thick SUS304 and exterior polished in 300MESH (sanitary level). All the welding seams shall be polished after rubdown, and as to the treatment interface, turned over edge arc transition is adopted. The heat preservation layer is made of PU polyurethane foaming. In the tank, there is a mixer, 1.5kw motor and 60rpm inlet rotary speed. Discharge hole is equipped with butterfly valve of sanitary level and pipeline of stainless steel 304.

3.3 Vacuum system

Adopting vacuum pump with feilitong or Zhuoxin, air extraction capacity 172M³/h and motor power 4kw.

3.5 Electric control system

A. Button control

Electric elements: Siemens products

Transducer: Siemens company

Button/switch: FUJI company

Instruments and sensor are home high quality products .

It is possible to adjust and vision mixing speed , temperature of each jar, set upper limit and lower limit of temperature, control automatic valve. It is possible to set the time control for slow speed emulsifies mixing and control performance of lift of hydraulic system.

B. Touch screen control

1. Adopting German SiemensS7-200 series.

2. Touch screen adopts Siemens Company Model: TP900

3. On the touch screen, it is possible to adjust and vision mixing speed , temperature of each jar, set upper limit and lower limit of temperature, control automatic valve. It is possible to set the time control for slow speed emulsifies mixing and control performance of lift of hydraulic system.

Electric elements: Siemens products

Transducer: Siemens company

Button/switch: FUJI company

4. Technical Parameters of whole machine

4.1 The whole volume of container:1300 L

4.2 Service volume of container: 1000L

4.3 Min. output: 500L

4.4 standard dimension : 3070 mm×3750 mm×3400mm/5000 mm

4.5 Net weight: 2800kg(only for standard equipment)

4.6 Container: connected with vertical and protruding flange with leading edge, equipped with double jackets.

4.7 Heating: by letting the steam into the double jacket. Cooling: by letting cool water into the double jacket.

4.8 Service modes of container: atmosphere / vacuum

4.9 Base of container: welded and high-grade mirror polish.

4.10 Upper cover: flanged and liftable.

4.11 The speed of slow-speed mixing system: 10-40 rpm, 3.7kw (frequency control).

4.12 The speed of high-speed homogenizing-mixing system: 1150-3500 rpm, 15kw (frequency control)

4.13 Installation power of vacuum pump:4kw

4.14 working pressure of container jacket:0.3Mpa

4.15 Main installation power: 29kw (only for standard equipment, no other option)

4.16 Electric power: 380V, 50 Hz.

4.17 Allowable fluctuation of voltage: ±5%.

4.18 Low voltage control: 24 V

4.19 protection: general

4.20 The water consumption of hydraulic ring vacuum pump:6L/min

4.21 Adjustable height of machine frame: ±10mm

4.22 The air suction device for ventilating motor

4.23 Security protection at low-voltage of 24 V

4.24 Equipment is made according to GMP standard.

4.25 The machine body is fully made of stainless steel SUS304.

4.26 All parts contacted with material are made of stainless steel SUS316L and mirror-polished.

Ⅲ. Application, characteristic and advantage

1. Application:

This unit can be used for production of ointments and creams in cosmetic and pharmaceutical factories.

2. Characteristic

This unit has such features as simple operation, stable performance, good homogenization, high production efficiency, convenient cleaning, reasonable structure, small floor space, and high automatization etc.

3. Advantage

This unit applies upper coaxial triple type mixer and hydraulic lifting mode to open the cover. The speed of rapid homogenizing mixer is 0-3500rpm (frequency control); the speed of slow-speed scraping mixer is 0-40rpm (frequency control); the homogenizing head applies high cutting eddy current type emulsifying mixer. The slow-speed scraping mixer automatically abuts closely to the bottom and wall of boiler. By applying vacuum sucking, this unit can suck in powder material by using vacuum to avoid powder flying upward. The whole process is performed under the vacuum condition in order to keep from the production of air bubble after the material is mixed at high speed and up to hygienic asepsis requirements. This system is equipped with CIP cleaning equipment. The parts of container, which contact the material, are made of SUS316L and inner surface mirror polish is up to 300MESH (sanitary level). In order to ensure stability of control part, the electric control parts apply the products from German Siemens, the press key from Japan FUJI company, frequency converter from Panasonic company, and vacuum pump from zhuoxin. The unit is made completely in conformity with GMP and is the most advanced, ideal ointment and cream production equipment currently in China.

Ⅳ. Description of whole machine

1. slow-speed mixing system

1.1 Low-speed mixing systems are composed of a hanging bracket full of scrapers as well as intermediate impeller.

1.2 The full automatic movable scraper's surface is made of PTFE, only working under the condition with material. It's easy for disassembly and cleaning.

1.3 Dynamic balancing coaxial shaft

1.4 Outer hanging brackets and inner impellers are made of stainless steel SUS316L.

1.5 The timing is controlled by PLC to facilitate the setting of working time. The mixer will not work if the time is not set.

1.6 The speed of the equipped reducer motor can be controlled directly by transducer to 0-40 rpm.

The low-speed mixing system produces two independent countercurrent flows inside the material.

1.7.1 One vertical fluid along the center can force material flow to the bottom of container. Its function is to convey the material to the bottom of homogenizing-turbine rapidly.

1.7.2 Another circle flow forces the material encircle the inner wall of the mixing container to facilitate the material to make heat-exchange during heating or cooling stage, which can prevent the material from being damaged due to overheat or overcooling.

2. Emulsifier

2.1 High-speed homogenizing activity is accomplished by one homogenizer installed on the center bottom of tank.

2.2 homogenize is composed of dentate stator and rotor with impeller.

2.3 homogenize is made of stainless steel SUS304 or SUS316L, rotating parts pass the dynamic balancing coaxial shaft.

2.4 The timing is controlled by PLC to facilitate the setting of working time. The mixer will not work if the time is not set.

2.5 Adjust speed by frequency control: 1150-3500 rpm

2.6 This kind of structure i.e. executing on the turbine not from the bottom can assure high cleanness of the process project. The reasons are as follows:

a. The material will not be polluted without the influence of motor flange connection.

b. Turbine is made easy for cleaning, maintenance, assembly and disassembly.

c. The bottom of tank is completely smooth without connection and is easy to clean.

d. The mixing and homogenizing motors are installed on the top of the tank, which is far from the processing area.

e. Strictly ensure the safety of the operators.

3. Heating/cooling system

3.1 Heated by the steam in the double jackets.

3.2 The temperature of material in the container may be controlled through temperature sensor signal from the control panel.

3.3 Temperature control is composed of PLC temperature module and temperature sensor installed at the bottom of the tank. Actual temperature of material may be read correctly.

3.4 Cooling is directly accomplished by the external cold water through the jacket.