20k ultrasonic homogenizer machine with mixing tank for extraction and emulsifier

20kHz Ultrasonic Oil and Graphene Mixing Machine for Motor Bike Gear Box

What is the ultrasonic mixing?

An ultrasonic homogenizer machine is a device that uses ultrasonic waves to mix, disperse, or emulsify liquids. It is widely used in various industries for its ability to produce uniform mixtures and fine particle sizes. Here’s an overview of its key features and applications:

How It Works

Ultrasonic Waves: The machine generates high-frequency sound waves (typically 20 kHz to several MHz) through a transducer.
Cavitations: These sound waves create rapid pressure changes in the liquid, leading to the formation and collapse of microbubbles (cavitation).
Mixing and Dispersing: The implosion of these bubbles produces intense shear forces, which effectively break down particles and mix different phases (liquid-liquid, liquid-solid).

When the ultrasonic waves pass through the liquid, they create alternating high-pressure and low-pressure cycles. This phenomenon is known as cavitation. During the low-pressure cycle, tiny bubbles or voids are formed in the liquid due to the rapid expansion of the liquid. These bubbles then collapse during the high-pressure cycle, creating intense local energy and generating microjets and shockwaves.

The collapse of these bubbles and the resulting shockwaves create strong shear forces and agitation within the liquid, leading to effective mixing, dispersion, and emulsification. The ultrasonic energy can break down agglomerates, disperse particles, and promote the uniform distribution of materials in the liquid. It is particularly useful for mixing materials that are difficult to blend using traditional mechanical mixing methods.

Ultrasonic mixing is utilized in various industries, including pharmaceuticals, food processing, cosmetics, paints and coatings, and research laboratories. It offers advantages such as increased mixing efficiency, reduced processing time, improved product quality, and the ability to work at a smaller scale.

Why is the ultrasonic important in the pigment processor?

Ultrasonic technology plays a crucial role in pigment processing for several reasons:

Efficient dispersion: Ultrasonic waves provide efficient dispersion of pigments by breaking down agglomerates or clusters of particles. The high-intensity pressure waves and cavitation generated by ultrasonic devices effectively disperse the pigment particles, resulting in a more uniform and consistent distribution throughout the liquid medium. 

Faster processing time: Ultrasonic pigment dispersion is generally a faster process compared to traditional methods such as milling or stirring. The intense shear forces and localized shock waves created by ultrasonic cavitation rapidly break down pigment agglomerates, reducing processing time and increasing productivity.

Higher pigment loading: Ultrasonic dispersion allows for higher pigment loading levels, which means a higher concentration of pigments can be incorporated into the liquid medium. This is particularly beneficial for industries that require intense and vibrant colors or high opacity, such as inks, paints, and coatings. 

Improved particle size control: Ultrasonic processing enables better control over particle size distribution. By adjusting the operating parameters of the ultrasonic device, such as intensity and duration, manufacturers can achieve the desired particle size range for their specific application. 

Reduced energy consumption: Ultrasonic pigment dispersion typically requires less energy compared to traditional dispersion methods. The efficient dispersion achieved through ultrasonic waves reduces the need for prolonged high-energy mechanical processes like milling. 

Preservation of pigment properties: Ultrasonic processing is a gentle method that minimizes the risk of pigment damage or degradation. The short processing time and absence of mechanical forces that can cause excessive heat or shear stress help preserve the integrity and functionality of the pigments. 

In summary, ultrasonic technology is important in the pigment processing industry due to its efficiency, speed, control over particle size, energy savings, and preservation of pigment properties. It enables manufacturers to achieve consistent and high-quality pigment dispersion, leading to improved product performance and cost-effectiveness.

Parameter:

Dispersion of Nanoparticles

Ultrasonic grinding and dispersing is often the only method to process nano-particles efficiently in order to obtain sinlge-dispersed primary particles. A small primary particle size results in a large surface area and correlates with the expression of unique particle characteristics and functionalities. At the same time, a smaller particle size is associated with a high surface energy for more severe aggregation and reactivity, so that the intense ultrasonic dispersing forces are required to disperse the nano particles homogeneously into the formulation. Furthermore, an ultrasonic surface treatment can modify the nano particles which leads to improved dispersibility, dispersion stability, hydrophobicity and other features. Researchers have recommended the ultrasonic dispersion method for nano particles as preferred solution, “because the material dispersed by the ultrasonic method is much purer than that produced by bead milling.”

When using an ultrasonic homogenizer machine, it’s important to follow safety precautions to ensure the safety of operators and the integrity of the equipment. Here are some key safety measures:

1. Personal Protective Equipment (PPE)

Eye Protection: Wear safety goggles to protect against splashes or debris.
Gloves: Use appropriate gloves to handle materials and equipment.
Lab Coat or Apron: Protect clothing and skin from hazardous substances.

2. Equipment Handling

Training: Only trained personnel should operate the ultrasonic homogenizer.
Read the Manual: Familiarize yourself with the operation manual and safety instructions specific to the machine.
Inspect Equipment: Check for any signs of damage or wear before use. Ensure that the probes and other components are securely attached.

3. Operational Safety

Avoid Direct Contact: Do not touch the probe while it is operating to prevent injury from vibrations or splashes.
Secure Work Area: Ensure that the work area is clean and free of clutter to avoid accidents.
Proper Setup: Make sure the machine is placed on a stable, secure surface to prevent tipping.

4. Handling Materials

Hazardous Materials: If using toxic or hazardous substances, follow proper handling and disposal procedures.
Vapor and Fume Control: Use in a well-ventilated area or fume hood, especially when working with volatile substances.

5. Electrical Safety

Check Connections: Ensure that all electrical connections are secure and that the machine is properly grounded.
Avoid Water Exposure: Keep the machine and its electrical components dry to prevent short circuits.

6. Noise Protection

Hearing Protection: Use earplugs or earmuffs, as ultrasonic homogenizers can produce high noise levels during operation.

7. Emergency Procedures

Know Emergency Stops: Familiarize yourself with the machine’s emergency shut-off procedures.
First Aid: Have a first aid kit accessible and know the location of emergency exits.

Working video for reference: