100L GMP Grade Vacuum Emulsifying Homogenizer with Dual Phase Vessel System

High-Shear Vacuum Emulsification System for Creams, Ointments & Fine Emulsions Under GMP Standards

What Is a Vacuum Emulsifying Homogenizer

Vacuum emulsifying homogenizers utilize high-shear emulsification technology to create stable, fine, and uniform emulsions in a completely enclosed environment. When the vacuum pump activates, a negative-pressure atmosphere is established within the sealed tank, reaching an ultimate vacuum of -0.092 MPa. Under these oxygen-free conditions, no air bubbles form during the stirring and homogenizing process. Any residual microbubbles in the raw materials rapidly expand and collapse under vacuum, yielding a smooth, glossy, and shelf-stable final product.

Our HY-LM100P model is engineered specifically for GMP-compliant production environments. The complete system integrates two independent dual phase pre-treatment vessels (for oil phase and water phase respectively), a main vacuum emulsifying and blending chamber, a vacuum pump unit, a hydraulic lifting mechanism, a tilting discharge assembly, and a PLC intelligent control panel. The modular design ensures straightforward operation, reliable performance, superior homogenization results, high throughput efficiency, and rapid clean-in-place (CIP) capability.

Key Technical Features

• Integrated Vacuum Transfer Network — Automatically draws oil phase and water phase materials from their respective dual phase vessels into the main chamber while simultaneously degassing the emulsion throughout the entire batch cycle.
• Hydraulic Vessel Lifting Mechanism — Delivers fail-safe vertical positioning for thorough cleaning access to agitators, scrapers, and the homogenizer head assembly. Offers superior stability and lower maintenance compared to pneumatic alternatives.
• Programmable Multi-Zone Thermal Control — Triple-layer jacketed vessel with electric heating/cooling circuits and optional steam-heating compatibility for precise, recipe-driven temperature management across all production phases.
• Dual-Axis Homogenization Architecture — Combines a bidirectional frame scraper blending system with an independent high-shear rotor/stator homogenizer, achieving pharmaceutical-grade dispersion efficiency and particle size reduction.
• Fully Enclosed GMP Structure — Dust-free, sterile, and leak-free operation with food-grade silicone seals at all interfaces. Every unit passes a factory air-tightness pressure test before shipment.
• PLC Intelligent Control Center — 7-inch touch-screen HMI with variable frequency speed regulation, multi-recipe storage, and real-time monitoring of temperature, vacuum level, homogenizer RPM, and mixing speed.
• High-Gloss Finished Product Output — The vacuum environment eliminates microbubbles, producing creams and lotions with exceptional glossiness, uniform texture, and extended shelf stability.

Industry Applications

This vacuum emulsifying homogenizer serves a broad spectrum of industries requiring high-viscosity emulsions, suspensions, and homogeneous mixtures:

Technical Specifications

Core Component Breakdown

1. Hermetically Sealed Main Vessel

The main vessel is the foundational element of the entire system, directly determining batch quality and process reliability. An imperfect seal compromises vacuum integrity and causes leakage during emulsification. We employ food-grade silicone gaskets at every interface including the charging port, sight glass, temperature probe, and CIP connections. Each vessel undergoes a rigorous helium leak test before shipment. All material-contact surfaces are fabricated from SUS316L stainless steel with electropolished finish (Ra ≤ 0.4μm) to eliminate microbial harborage points.

2. High-Shear Rotor/Stator Homogenizer Assembly

The homogenizer is the process-critical component consisting of a precision-machined stator, multi-tooth rotor, and optimized working chamber geometry. At 2990 rpm, the rotor generates intense negative pressure in the chamber, instantly drawing material into the narrow shear gap (0.3-0.5mm) between rotor and stator where it undergoes micro-second shearing. The resulting centrifugal acceleration drives multi-directional particle collisions for further dispersion, while instantaneous pressure differentials disrupt droplet structures at the micron level. This assembly is the core determinant of final product uniformity, stability, and particle size distribution.

3. PTFE Frame Scraper Agitator System

The agitator features an optimized frame geometry fitted with spring-loaded PTFE scraper blades that maintain constant contact with the vessel wall. Operating at 0-60 rpm via a frequency inverter with stepless speed adjustment, the scraper ensures continuous bulk turnover of the product mass, prevents material adhesion and scorching on the heated wall, and promotes uniform thermal distribution throughout the batch. The drive shaft is equipped with a double mechanical seal arrangement and a pressurized barrier fluid system to guarantee zero-leak vacuum integrity during extended production runs.

Production Process Workflow

Phase 1 — Vacuum Establishment: The vacuum pump evacuates air from the sealed main vessel to achieve -0.092 MPa. This oxygen-free environment prevents bubble entrapment and protects oxidation-sensitive active ingredients from degradation.

Phase 2 — Dual Phase Transfer: The oil phase and water phase materials are independently drawn from their respective dual phase pre-treatment vessels into the main chamber through the vacuum transfer network. All liquid additions occur under vacuum to prevent air re-introduction.

Phase 3 — High-Shear Emulsification: The rotor/stator homogenizer engages at the programmed speed, generating intense shear forces that rapidly blend the oil and water phases into a stable, sub-micron emulsion. Simultaneously, the frame scraper agitator provides bulk mixing to ensure homogeneity throughout the entire vessel volume.

Phase 4 — Precision Thermal Processing: The triple-layer jacket circulates heating or cooling media based on the programmed recipe. Electric heating elements raise the product to target temperature with ±1°C accuracy. For heat-labile formulations, chilled water circulation through the jacket provides rapid cooling to preserve active ingredient potency.

Phase 5 — Controlled Discharge: Upon batch completion, the hydraulic tilting system tips the vessel for complete product discharge. Both automated (PLC-timed) and manual discharge modes are available. The tilting angle and speed are programmable for seamless integration with downstream filling or packaging equipment.