Industrial Mixers
PerMix News & Updates
An inline emulsifier is a type of high-shear mixer specifically engineered for emulsion formation, where two immiscible liquids (e.g., oil and water) are finely dispersed into one another. It achieves this through a rotor-stator system, where high-velocity rotors force materials through precision stator slots, creating intense shear forces and hydraulic cavitation. This process reduces droplet size down to submicron or nano levels, stabilizing emulsions with or without emulsifiers/surfactants.
Applications:
An inline shear pump combines fluid conveyance and mechanical shear in one unit. It also utilizes a rotor-stator configuration but is designed primarily for viscous pumping with a secondary function of particle size reduction, dispersion, or homogenization. Unlike emulsifiers, shear pumps are optimized to transfer fluid under pressure while providing controlled shear energy, making them ideal for continuous processing systems with medium to high viscosities.
Applications:
| Feature | Inline Emulsifier | Inline Shear Pump |
|---|---|---|
| Primary Function | Emulsification of immiscible liquids | Pumping + shear for dispersion/homogenization |
| Shear Intensity | Extremely high (nano/submicron) | Moderate to high (depending on rotor-stator gap) |
| Flow Design | Mixing chamber optimized for droplet breakup | Pump housing optimized for flow & pressure |
| Droplet Size Control | Critical for emulsion stability | Less critical, more focused on flow & texture |
| Viscosity Range | Low to medium viscosity | Medium to high viscosity |
| Pump Pressure Capability | Typically low to moderate | High-pressure capable for pipeline transfer |
Here is a technical sales data sheet comparing the PerMix Inline Emulsifier vs. the PerMix Inline Shear Pump, designed to clearly differentiate both for customers and sales teams:
| Feature | PerMix Inline Emulsifier | PerMix Inline Shear Pump |
|---|---|---|
| Primary Function | Emulsification of immiscible liquids | Pumping while dispersing or homogenizing materials |
| Shear Mechanism | High-shear rotor-stator with ultra-fine slot tolerances | Rotor-stator configuration with integrated pumping geometry |
| Shear Intensity | Ultra-high shear (up to 40,000 rpm) for submicron droplet sizes | High shear (10,000–20,000 rpm) suitable for dispersions and homogenization |
| Particle/Droplet Size | Submicron to nanometer range (<1µm) | Fine to medium dispersions (5–50µm typical) |
| Mixing Type | Continuous high-energy emulsification | Continuous dispersion, homogenization, and pumping |
| Flow Capability | Moderate flow with emphasis on mixing | High flow and pressure for pipeline transfer |
| Viscosity Range | Low to medium viscosity (up to ~10,000 cP) | Medium to high viscosity (up to ~100,000 cP with feeding aid) |
| Pressure Rating | Typically lower pressure (<3 bar) | High-pressure capability (up to 10 bar or higher depending on model) |
| Pump Functionality | Limited to in-process recirculation or inline flow | Fully functional pump capable of transferring product over distance |
| Applications | – Cosmetic creams & lotions – Mayonnaise, dressings, sauces – Emulsified pharmaceuticals – Oil-water emulsions | – Powder-liquid dispersion – Breaking agglomerates – Homogenizing slurries – Viscous product pumping |
| Seal Options | Single mechanical seal, double mechanical seal, flushed seal | Mechanical seal, double seal with thermosyphon (for high-temp or pressure) |
| Construction | 304/316L SS, sanitary design available, CIP-ready | 304/316L SS, sanitary, CIP-ready, ATEX optional |
| Temperature Range | Up to 120°C standard (higher with custom design) | Up to 150°C standard (higher with thermal barrier) |
| Options | – Jacketed housing for heating/cooling – PLC control integration – Mobile skid version | – Hopper feed for powders – Pressure/flow sensors – Variable speed with load control |
| Model | Flow Rate (L/h) | Power (kW) | Max Viscosity (cP) |
|---|---|---|---|
| PC-1-50 (Emulsifier) | 500 – 2,000 | 3 – 7.5 | Up to 10,000 |
| PCH-75 (Shear Pump) | 1,000 – 5,000 | 5.5 – 15 | Up to 100,000 |
Custom designs available upon request. Full sanitary design, ATEX compliance, and automation integration options offered.
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